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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of Provisional Patent Application No. 61/004,265 by the present inventors, filed on Nov. 26, 2007, the entire disclosure of which is incorporated herein by reference.
[0002] This application contains material disclosed in part in U.S. patent application Ser. No. ______ filed by the present inventors on even date herewith, the entire disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] The invention pertains to apparatus and methods related to the movement of international cargo in containerized structures. More particularly, the invention relates to tracking and security of ISO compliant intermodal shipping containers.
[0005] 2. Description of Related Art
[0006] There are an estimated 15 million intermodal shipping containers moving throughout the world on a daily basis. Nine million of these containers arrive at U.S. ports annually, raising significant security issues. If a weapon of mass destruction were delivered to a port in the U.S., the cost to the domestic economy could reach $1 trillion.
[0007] Security applications, such as cargo tracking are growing in importance. The worldwide ocean-going freight transportation infrastructure is the cornerstone of the global economic well-being and has been in crisis since Sep. 11, 2001. Domestic shipping via the Marine Transportation System (MTS) totals over $850 B in cargo annually and contributes $2 T to the U.S. gross domestic product. The current volume of domestic maritime shipping is expected to double over the next 20 years. International maritime shipping is expected to triple over the same time period. Many port facilities are under economic stress from several fronts, including antiquated technology, environmental restrictions, just-in-time manufacturing practices, overlapping federal/state/local jurisdictions, and the lack of basic technological infrastructure to orchestrate a global network for intermodal asset security monitoring and tracking. Land competition and environmental regulations will further restrict the geographic expansion of current port facilities. Further, the information systems for managing the supply chain still largely depend on manual data entry processes.
[0008] In addition to concerns about MTS economic inefficiencies, a renewed emphasis on homeland security in the U.S. is evident. Terrorist threats have brought about a new reality in the MTS. Attacks will likely focus on economic means to effect change in the modern world. One need only look to the open movement of containerized cargo to find simple, effective, and efficient means of large-scale economic damage. The destruction of a few key ports could bring our economy to a complete halt and cripple the nation in a matter of weeks. The result is a conflict between efficiency and security in the port system that supports the MTS.
[0009] A well-documented need exists for technology solutions to increase efficiency and security in the MTS. In 2004, 9 million containers entered the U.S. via the MTS. U.S. Customs inspects less than 5 percent of these containers manually, relying on intelligence to “profile” containers. The Coast Guard and U.S. Customs do not have the resources to inspect each container entering the U.S. Therefore, investment in appropriate tracking and monitoring technology will be needed to increase security and economic efficiency. Neither efficiency nor security can be sacrificed. Therefore, tracking and monitoring technologies must be developed to provide greater efficiency and at the same time secure the global supply chain.
[0010] The ability to monitor conditions and location in real-time has a number of insurance ramifications. The insurers of ships and cargo are critically interested in loss and theft of cargo via security breaches and fraud. For the 12 months prior to November 30, 2004, $700 billion in cargo was shipped via the MTS. Some private industry estimates of losses overboard, damage, or outright theft are as high as seven to ten percent of all containers annually, as high as $40 billion per year losses in the supply chain. Insurance companies finance a great deal of this expense, and in turn, pass along these losses as premiums and retained losses to cargo owners, carriers, and ultimately the consumer. Carriers, cargo owners and the manufacturers absorb the remaining losses that are again ultimately passed along to end consumers. Entities in the distribution chain would be expected to receive a lower insurance premium for shipping through a more secure service provider.
[0011] Current products on the commercial market for logistics applications and container security offer little security. Electronic seals, which are wireless enabled versions of mechanical seals that have been used for decades, do not provide the means to secure the container.
[0012] Various types of seals have been described including: Swift U.S. Pat. No. 5,116,091; Tuttle U.S. Pat. Nos. 5,406,263 and 5,831,531; Wilk U.S. Pat. No. 5,528,228; White U.S. Pat. No. 5,755,175; Gagnon U.S. Pat. No. 5,939,982; Kadner U.S. Pat. No. 6,069,563; Wilhelm U.S. Pat. No. 6,464,269; Fuehrer U.S. Pat. No. 6,513,842; Palzkill U.S. Pat. No. 6,846,024; Pirnie U.S. Pat. No. 6,928,843; and Moreno U.S. Pat. Nos. 7,044,512 and 7,178,841. Generally seals focus on detecting tampering rather than providing true locking mechanisms. At best the seal serves as a deterrent and at worst it potentially conveys a false sense of security. Several studies have examined seals and found they offer little or no security in their current forms, only serving a deterrent function.
[0013] Various types of locks have been described, including: VanderWyde U. S. Pat. No. 4,422,313; Yulkowski U.S. Pat. No. 6,259,352; Strodtman U.S. Pat. No. 6,581,419; and Brown U.S. Pat. No. 6,581,425. These solutions tend to focus on permanent retrofit/installation of hardware to ISO standard containers but raise expensive and substantial installation and maintenance issues. Containers are leased; shippers have little or no ability to implement these solutions. Container owners/lessors have little or no incentive to implement them because it represents a net cost to operations.
[0014] In U.S. Pat. No. 6,364,584, Access Bar for a Shipping Container, Taylor describes a system that secures both doors at the same time and uses the corner posts as a “gravity” locking mechanism.
[0015] A locking and tracking system as taught by Galley in U.S. Pat. No. 6,975,224, Reusable Self Container Electronic Device Providing In-Transit Cargo Visibility, attaches to the door latch and would require two devices (one for each door) to work.
[0016] Various types of tracking systems have been described, including the following: Camhi, in U.S. Pat. No. 5,825,283, System for the Security and Auditing of Persons and Property, discloses a vehicle and personnel tracking system and geofence applications but does not mention shipping containers or the locking of such. Radican, in U.S. Pat. No. 6,148,291, Container Inventory Monitoring Methods and Systems, discloses an inventory system for shipping containers but does not mention security or the locking of such containers. Carson, in U.S. Pat. No. 6,577,921, Container Tracking System, discloses localized tracking within storage and transfer yards without mention of security or the locking of such containers. Ghaffari, in U.S. Pat. No. 6,662,068, Real Time Total Asset Visibility System, discloses a tracking system for cargo but does not mention shipping containers, or security or locking of such containers. Lareau, in U.S. Pat. No. 6,972,682, Monitoring and Tracking of Assets by Utilizing Wireless Communications, discloses wireless tracking and triangulation of container location but does not mention security or locking of shipping containers. Shafer, in U.S. Pat. No. 7,165,722, Method and System for Communicating with Identification Tags discloses IP addressing of RFID tags without mention of securing or locking of such containers. Twitchell, in U.S. Pat. No. 7,221,668, Communications within Population of Wireless Transceivers Based on Common Designation, discloses the ad hoc network formation within shipping containers to provide location and condition without mention of container security or locking. Neher, in U.S. Pat. No. 7,242,322, Security Tracker, discloses a covert tracking system for monitoring location and condition for later download, without mention of security or locking of the container.
OBJECTS AND ADVANTAGES
[0017] Objects of the present invention include the following: providing a secure locking device for cargo containers that simultaneously monitors at least one condition affecting the container; providing a combined container lock and container monitor capable of transmitting monitored data to a central administrator; providing a locking device for cargo containers that simultaneously monitors a condition of the container and the container's location within a GPS system; providing a locking, monitoring, and display device for cargo containers that is capable of displaying selected messages on an outside surface of the container; providing a locking device for cargo containers that can display messages received from a remote system administrator; and, providing a locking device for cargo containers that can display selected messages when the container is in selected geographic locations. These and other objects and advantages of the invention will become apparent from consideration of the following specification, read in conjunction with the drawings.
SUMMARY OF THE INVENTION
[0018] According to one aspect of the invention, a security system for freight containers comprises: a locking device configured to reliably attach to the container and prevent unauthorized opening of the container doors; a sensing device configured to sense at least one condition affecting the container; and, a communication system configured to transmit the output of the sensing device to a system monitor located remotely from the container.
[0019] According to another aspect of the invention, a security system for freight containers comprises: a locking device configured to reliably attach to the container and prevent unauthorized opening of the container doors; a sensing device including a two-way communication system, the sensing device configured to sense at least one condition affecting the container, the sensing device further containing a GPS receiver; and, a system monitor located remotely from the container, the system monitor configured to receive data from the sensing device at selected times and to communicate with the sensing device at selected times.
[0020] According to another aspect of the invention, a security system for freight containers comprises: a locking device configured to reliably attach to the container and prevent unauthorized opening of the container doors; a sensing device configured to sense at least one condition affecting the container; a communication system configured to transmit the output of the sensing device to a system monitor located remotely from the container; a visual display device on the outside of the container, capable of displaying selected information; and, a system monitor configured to receive selected data from the sensing device and to transmit selected messages to the visual display device.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] The drawings accompanying and forming part of this specification are included to depict certain aspects of the invention. A clearer conception of the invention, and of the components and operation of systems provided with the invention, will become more readily apparent by referring to the exemplary, and therefore non-limiting embodiments illustrated in the drawing figures, wherein like numerals (if they occur in more than one view) designate the same elements. The features in the drawings are not necessarily drawn to scale.
[0022] FIG. 1 is a schematic illustration of one embodiment of the invention, in which a locking assembly or Access Bar is deployed on a shipping container to secure the doors.
[0023] FIG. 2 is a schematic illustration of one embodiment of the invention, separated from the shipping container.
[0024] FIG. 3A illustrates a block diagram of the functional components in an Access Bar according to one aspect of the present invention.
[0025] FIG. 3B illustrates a block diagram of the functional components in an Access Bar according to another aspect of the present invention.
[0026] FIG. 4 illustrates several aspects of local and global communications according to one aspect of the invention.
[0027] FIG. 5 illustrates a method for securing cargo in accordance with one aspect of the invention.
[0028] FIG. 6 illustrates a method for securing cargo in accordance with another aspect of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0029] The invention combines an access bar for a shipping container with a variety of wireless communications technologies (including, but not limited to: Radio Frequency Identification, cellular communications, and satellite communications) and a sensor interface to allow the detection of selected events or environmental factors (including but not limited to: tilting, vibration, and tamper switches, air pressure, temperature and humidity sensors, and detectors for hazardous conditions such as the presence of chemical, biological, radiological, nuclear, and explosive agents). It further incorporates a geographically-based lock that prevents unauthorized opening of the container until the container has reached a selected destination, as described more fully in Applicants' co-pending application.
[0030] In the examples that follow, it will become apparent that a trackable, removable, and secure device to secure both doors simultaneously provides a unique solution to many of the known concerns of the intermodal shipping industry. Some of the noteworthy benefits include: 1. Only one device is required to secure both the doors. 2. Tracking the lock is a convenient proxy for tracking the container. 3. The inventive device is reusuable by shipper or carrier and because it is a small, high-value component (compared to the empty container) it is more convenient to store when not in use than a similar component integrated permanently onto a container. 4. It does not interrupt the normal flow of cargo or impede legitimate access to the cargo. 5. It allows access to be granted according to a selected hierarchy of communications and information.
EXAMPLE
[0031] Applicants' co-pending application describes a removable Access Bar configured to securely lock a shipping container, as shown generally in FIGS. 1 and 2 . Applicants contemplate that in many applications, the Access Bar will be configured with a form factor that is compatible with certain characteristic dimensions of standard shipping containers, as shown in the figures. It can be seen that in the embodiment shown in the drawings, the Access Bar may take advantage of depressions in the doors so that much of the electronics may be afforded somewhat more protection while at the same time the Access Bar lies flat against the container and thus minimizes protrusions or other deviations from normal container dimensions that might interfere with automated container handling. Although not shown in the drawings, it will be appreciated that the inventive concept may equally well be adapted to containers of other geometries with only routine engineering modifications. For example, the Access bar may be configured with a ring-like locking mechanism to grasp the rim of a standard drum or barrel, thereby preventing the barrel from being opened during transit.
EXAMPLE
[0032] As shown generally in FIG. 3A , the Access Bar 10 contains, among other things, a GPS circuit 18 that operates to prevent the Access Bar from being unlocked before the container has reached a selected destination. The Access Bar 10 optionally includes the provision of at least the following: one or more selected sensor packages 19 ; one or more wireless communication systems 16 that may include Radio Frequency Identification, data radios, cellular, and satellite communications. A suitable antenna 21 is preferably disposed integrally with the device to minimize protrusions and protect the system from mechanical damage. Additional RFID components may be located on the side of the device.
EXAMPLE
[0033] Although some elements of the device (notably RFID tags) may be substantially passive devices, it is contemplated that in many applications it will be preferable to have an on-board power supply 15 . This may be accomplished with batteries, fuel cells, and the like, and provision may also be made for recharging or maintaining charge via a cradle or an umbilical configured to accept power from a shipboard generator during ocean transit, for example.
EXAMPLE
[0034] The sensor package 19 may include a number of devices performing various security and tracking functions. The device may allow for wireless communication with a variety of sensor (chemical, biological, radiological, nuclear, explosive, temperature, humidity, vibration, accelerometry, etc.) and information sources (camera, keypad, PDA, cell phone, satellite phone, hand-held interrogator, RFID reader, etc.). Sensor package 19 may contain a load cell, strain gage, or other means of monitoring tension on locking bar 12 so that an alarm condition will be triggered if bar 12 is cut or even if the bars on the container door are cut. The device will communicate wirelessly with a sensor node, which detects a variety of constituents and conditions, either permanently or temporarily installed in an intermodal container, over the road trailer, or enclosed conveyance.
[0035] It will be appreciated that wireless communication may include such familiar protocols as serial radio, cellular radio, satellite radio, etc. The wireless device(s) will preferably be utilized in order of cost of communications beginning with the serial radio, which, with the Reader within range, represents the least cost. Failing to identify a valid serial radio link, the cellular radio may be activated. Failing to identify a valid cellular link, satellite communication to one of multiple low earth orbit satellite systems may be activated. This process optimizes the cost of data communications on a global basis.
EXAMPLE
[0036] As noted above, the inventive Access Bar may contain various sensing elements such as chemical, biological, or radiation sensors, or it may be in wireless communication with sensors deployed elsewhere in or on the container. Such sensors may be used to alert the shipper that unauthorized materials have been packed in the container. It will be appreciated, however, that a modern container ship might carry as many as 6000 containers. Thus, the Access Bar may detect a source of radiation in an adjacent container and serve as a warning that hazardous material is present somewhere else on the ship. If a source of radioactivity were somewhere on board, it is possible that data from perhaps a dozen widely distributed sensors could be triangulated and the resulting data used to alert authorities before the ship arrived at port, and even give an indication of the approximate location of the suspicious container before the ship is unloaded or even close to populated areas.
[0037] The foregoing example illustrates an important aspect of the invention, viz., that the system administrator, by having access to reports from a plurality of Access Bars, inherently derives a higher level of situational awareness, and that the resulting information can therefore have significant added value to various clients.
[0038] It will further be appreciated that the general level of background radiation varies from place to place around the earth. Because the invention includes GPS location data, corrections can be made for fluctuations in background that are due to known local geophysical effects. Further, by having a plurality of Access Bars in a given geographical area, the background radiation can be identified through mathematical averaging and either reported to the system administrator or used to analyze local radiological patterns to determine threats.
EXAMPLE
[0039] The Access Bar may be provided with one or more components 22 for local data input/output. A ruggedized keypad may be used to enter certain functions and commands, such as arm/disarm, lock/unlock, etc. Alternatively, for entering more detailed information, such as a shipping manifest, a USB port or other standard data bus such as a Bluetooth wireless link may be provided.
EXAMPLE
[0040] In one embodiment, the device uses two electronically controlled mechanical devices: one mechanism 13 holds the device to one of the container doors (install/uninstall), and the other mechanism 12 locks the container doors closed (lock/unlock) by means of a mechanical latch 14 that may be secured in the locked position by an internally mounted electromechanical latch. Each device 12 , 13 can be engaged or disengaged separately based on rectangular geofences. The install/uninstall geofences are defined and evaluated locally by the invention, and the lock/unlock geofences are defined and evaluated remotely by the server based tracking system. The install/uninstall mechanism 13 can also be engaged or disengaged for unscheduled inspections by a single use code either sent from the tracking and system or entered through a ruggedized keypad or other I/O device 22 on the exterior of Access Bar 10 .
EXAMPLE
[0041] In general, Applicants contemplate that the locking bar 12 has a series of teeth that engage a ratcheting mechanism, and in the unlocked condition bar 12 may be free to slide completely out of the device. Those skilled in the art will appreciate that this configuration lends itself to being implemented as a somewhat smaller device that can operate like a padlock and thereby secure any closure that is designed to have a bolt-type lock.
EXAMPLE
[0042] In its simplest form, the geolock comprises the following components, as shown schematically in FIG. 3A : an electromechanical lock actuator or latching mechanism 14 ′, a GPS receiver 18 including a suitable antenna 21 , a CPU or other logic device configured to allow the operation of lock actuator 14 ′ when certain GPS location requirements are satisfied, and a power supply 15 capable of providing sufficient power to operate all components for a suitable period of time.
EXAMPLE
[0043] As noted above, a key element of the inventive Access Bar is a “geolock” that is designed to allow the lock to be opened only if some geographic condition is met (typically indicating that the container has reached a selected destination). Applicants contemplate that under normal operating conditions, the geolock will be governed primarily by GPS data. Applicants recognize, however, that means are available to spoof a GPS receiver if an adversary has sufficient resources and is able to position sophisticated RF equipment close enough to the GPS unit. The inventive Access Bar may therefore be optionally equipped with redundant means of cross-checking the GPS data. Some preferred means include the following:
[0044] 1. Small accelerometers may be used along with a clock to compute the approximate location by dead reckoning; if the GPS location differs from the dead reckoning location by some selected margin of error, the lock will not open without additional authorization. Accelerometers may be incorporated in sensor package 19 .
[0045] 2. A clock circuit may be used to prevent unlocking at any time prior to the approximate scheduled time of arrival, in a manner analogous to a lock on a bank vault that prevents it from being unlocked at night even if one has the combination.
[0046] 3. The system administrator (or the internal memory in the Access Bar itself) may receive periodic updates on the container's location. If the indicated location is greatly different from the previously updated location, in such a way as to suggest a physically impossible movement, an alarm condition may be indicated and the lock will not be opened.
[0047] 4. An access code may be required in addition to satisfying the GPS location required by the geolock.
[0048] 5. It is contemplated that several (or many) containers on a given ship (or train) may be equipped with the inventive Access Bar. The system administrator may therefore be alerted if the indicated GPS location of one container abruptly differs from that of other containers that are supposed to be traveling together.
[0049] Some examples of commercial available wireless communications modules include the following: 1. Serial Mesh Radio (e.g., ZMN2405HP manufactured by RF Monolithics, Inc. 4441 Sigma Road, Dallas, Tex. 75244), 2. Quadband GSM Cellular (e.g., GM862-GPS manufactured by Telit Wireless Solutions, Inc. 3131 RDU Center Drive, Suite 135, Morrisville, N.C. 27560), 3. LEO Satellite (e.g., DS100 manufactured by Stellar Satellite Communications Ltd., 46050 Manekin Plaza, Suite 100, Dulles Va. 20166). All of the foregoing are suitable in for inclusion in the inventive device in terms of form factor, data conditioning, and power conditioning characteristics.
[0050] Some examples of commercial available sensor packages include the following: 1. Angular rate sensors and gyroscopes, (e.g., ADXRS manufactured by Analog Devices, 3 Technology Way, Norwood, Mass. 02062), 2. Pressure sensors (e.g., Flexiforce manufactured by Tekscan, Inc., 307 West First Street, South Boston, Mass. 02127-1309), 3. Magnetometers (e.g., MicroMag manufactured by PNI Sensor Corporation, 133 Aviation Blvd., Suite 101, Santa Rosa, Calif. 95403), 4. Accelerometry (e.g., ADXL manufactured by Analog Devices, 3 Technology Way, Norwood, Mass. 02062). Other sensors such as temperature and humidity sensors, tamper switches, etc. are well known in the art. All of the foregoing are likewise suitable in for inclusion in the inventive device in terms of form factor, data conditioning, antenna configuration, and power conditioning characteristics. Systems known in the art to detect and measure chemical, biological radiological, nuclear, and explosive agents are also suitable for inclusion in the inventive access bar.
[0051] There are many suitable commercially available central processing units and microcontrollers; for example, Applicants have found the following device to be suitable for carrying out the invention: ARM9, manufactured by ARM Ltd., 110 Fulbourn Road, Cambridge, UK. This and many similar devices are all suitable for inclusion in the inventive device in terms of form factor, data conditioning, and power conditioning characteristics.
EXAMPLE
[0052] The inventive Access Bar may further be adapted to a less-than-load tracking application via the wireless serial mesh radio. Individual cargo constituents in the container (individual packages, individual pallets, or the like) may be affixed with a compatible serial radio, which may be a meshing radio, in order to report to the Access Bar. The inventive Access Bar can aggregate these devices to provide the ability to perform real-time inventory on a suitably equipped container at any point in its journey.
EXAMPLE
[0053] Another aspect of the Access Bar is to serve as a remote aggregation point for terminals, yards, depots, warehouses, and the like. The aggregation point includes a combination of a serial mesh radio and a satellite uplink or direct access to the internet in order to transmit information on the status, condition, and location of the Access Bar. The remote uplink can aggregate these devices to provide the ability to perform real-time inventory of the containers in any geographic location.
EXAMPLE
[0054] Another important aspect of the inventive method is a network operation center 44 including a system administration with automated and/or manual systems for aggregating Access Bar information, distributing client information, and performing advanced value-added logistics and risk or threat analysis. As noted above, those skilled in the art will appreciate that this system provides a higher level of situational awareness and a common operational picture from the container, to the community, to the region, to the world. This situational awareness not only improves the overall logistics operation, but also can provide key elements of an early warning security system for a variety of chemical, biological, radiological, nuclear, and explosive threats.
EXAMPLE
[0055] The locking bar 12 may be manufactured by various conventional methods, provided that the resulting structure has adequate strength both to withstand normal stresses in service and to provide adequate resistance to tampering or intrusion attempts. The bar is preferably metal, such as stamped, bent, and machined/punched steel, extruded aluminum, titanium, or other suitable structural alloy. It may further be provided with selected coatings such as chrome plating, polymer dips, paints, diamond films, etc. for corrosion resistance and may be heat treated to harden it against cutting or sawing. Decorative paints, decals, etc. may be provided to the protective housing 11 identify the owner of the device or for branding, advertising, or other desired purposes. Housing 11 may be constructed of any suitable material having adequate strength; in many cases it will be cast, stamped, deep drawn, machined, or formed metal, metal alloy, or metal-matrix composite. Alternatively, it may be a polymer- or ceramic-matrix composite. Depending on the dielectric properties of housing 11 RF-transparent windows or antenna feedthroughs as are well known in the art may be provided in order to allow one- or two-way communication signals to enter or exit housing 11 .
[0056] In addition to the particular exemplary, and therefore non-limiting, configurations shown in the drawings, it will be appreciated that the invention may also be advantageously implemented with gravity-type locking systems such as that generally disclosed by Asher in U.S. Pat. No. 6,364,584.
[0057] In addition to the passive display of logos or other advertising as described above, the inventive device may further be provided with visual display means, whereby messages may be displayed to passersby or trailing vehicles. It will be appreciated that the device has several characteristics that make it especially useful for dynamic advertising, viz., it has the capability of communicating with a system administrator, and its geographic position is known. Thus, the system administrator may interact with the device to cause it to display particular messages or advertisements in particular locations, whereby the value of such advertising may be maximized. Alternatively, the visual display means may be used to alert workers at the point of arrival that the container has experienced some off-normal condition as well as to provide visual confirmation that the system is working normally.
EXAMPLE
[0058] One aspect of the inventive method is shown generally at 50 in FIG. 6 , wherein the individual operations are:
51 Load container 52 Install Access Bar 10 on first door 53 Install locking bar 12 on second door and tension locking bar using latch mechanism 14 54 Monitor status and location en route, preferably via GPS 18 55 Communicate with system administrator/server
55 A Report to server at selected intervals 55 B Report to server on alarms, warnings, or deviations 55 C Receive acknowledgments/updates/ authorizations from server 56 Arrive at waypoint 57 Unlock based on time, location, and/or access code 58 Last waypoint? 59 Uninstall based on time, location, and/or access code.
EXAMPLE
[0071] Another aspect of the inventive method is shown generally at 60 in FIG. 6 , wherein the individual operations are:
61 Itinerary programmed; alarm on disparity with geography/schedule 62 At startpoint? 63 Maintain unlatched/unlocked status 64 Properly installed? 65 Report status to server 66 Properly locked? 67 Report status to server 68 Report status to server 69 Run “itinerary” 70 Report to server on alarms, warnings, or deviations 71 Receive acknowledgments/updates from server 72 Wait for keypad input 73 Valid code? 74 Report event to server 75 Valid location for code? 76 Report event to server 77 Valid time for location and code? 78 Report event to server 79 Unlock 80 End of itinerary? 81 Wait for keypad input 82 Valid code? 83 Report event to server 84 Unlatch (uninstall) and sleep
[0096] The foregoing example illustrates some ways in which the invention provides redundant validation to GPS data to prevent unauthorized opening if the GPS is tampered with or spoofed electronically.
EXAMPLE
[0097] The general method of using the invention according to one aspect of the invention may be described as follows: The Access Bar with its on-board electronics package is attached to the container at some point in the supply chain, which is preferably the point of its packing. The on-board package notes the installation, reports Global Positioning Systems (GPS) location, time stamp, and condition of any sensors. The system remains in place (relative to the container) for the length of the intermodal journey. If, during the trip, a variety of sensor conditions occurs, the mechanism may either report through the wireless medium of choice an alert condition, or it may simply record the condition in on-board memory for later downloading at the time of arrival. Reportable sensor conditions may include low battery, tampering, removal, temperature out of range, humidity out of range, or the presence of chemical, biological, radiological, nuclear, or explosives of interest. The device may further report to the system administrator on request or upon a predetermined time interval through the wireless medium of choice. Reports may include such parameters as GPS coordinates, battery condition, switch positions, and readings from sensors configured to respond to temperature, humidity, or chemical, biological, radiological, nuclear, and explosive agents, etc. The device may be programmed to report certain conditions immediately to the system administrator, such as large deviations in GPS coordinates or the presence of radioactivity, whereas other, less critical sensor conditions such as tip/tilt or impact/acceleration readings may be reported at the time of arrival so that the cargo can be immediately inspected for damage.
[0098] The inventive system may exploit so-called ad-hoc wireless networking (serial mesh radio). Some characteristics of Ad Hoc Serial Network Radio include: 1. Secure hand-shaking using a variety of information security, encryption, and validation protocols; 2. Scalable to Hybridized Spread Spectrum (HSS) radio format; 3. Automatically finds other related devices within range; 4. Automatically forms communities if two or more related devices are present; 5. “Elects” a spokesman to collect and send Tracking and Security Information (TSI) for whole community based on the minimum period settings of each individual of the community
EXAMPLE
[0099] The invention may further use a protocol that is an anti “spoofing” system for Intelligent RFID Tags that prevents malicious attacks from interfering with the normal operation of the invention. The protocol makes use of an on-board circuit to generate a universally unique identification code based on the collected history, geography, and condition of the device. This code becomes part of the distributed intelligence provided by the inventive solution.
[0100] Those skilled in the art will appreciate that the inventive system provides a removable, but secure platform for intermodal assets. The modular nature combines tracking, sensing, and security in an interchangeable/mix-and-match building block architecture in which particular users may select the sensor package of interest, the identification and reporting protocols to be used, and the communication methods that are most suitable to the user and asset being shipped.
[0101] The inventive system is contemplated to be used within a global intermodal transportation management system consisting of facilities for the capture, storage, retrieval, analysis, and action (alerts, alarms, etc.) of geographic location and condition information in a web-ready/web-friendly data visualization and reporting application. As such, it forms a fully enabled Geographic Information System (GIS) with customized industry specific applications build around the GIS core/platform. A web-based tracking service may provide real-time access to asset location and condition, automated customized alerts, and content for client needs accessible from any internet-enabled terminal globally. Logistics information can be pulled or pushed directly from the site into the user's internal resource management system. The inventive system may be further enhanced with custom, value-added client services to augment the functionality of the basic tracking system.
[0102] The general characteristics of the inventive method as applied to marine transportation is illustrated schematically in FIG. 4 .
EXAMPLE
[0103] Some aspects of the communication links that may be employed in the inventive method are shown schematically in FIG. 4 . A container ship 41 carries a plurality of containers, at least one of which is fitted with the inventive Access Bar 10 . Local communication 42 may be established with a transceiver on board ship 41 . Satellite communications 43 carry data between ship 41 and the system administrator 44 . The system administrator may in turn forward selected data reports to one or more clients indicated generally at 45 . The clients 45 may include the shipper or owner of the cargo; the shipping line or ship owner; and various government agencies.
[0104] The inventive system is designed to address the following critical attributes of a global asset tracking and control solution in the following ways:
[0105] The system includes the following components: 1. Rigid ISO compliant container locking devices—a physical locking system using the inherent characteristics of the container to protect the container from violation. 2. Robust active RFID technology—assets must be visible under extremely harsh wireless multipath interference conditions (e.g. local area networking of container-based and sub-container assets in stacks in a port, on a ship's deck, in the hold of a ship, and in warehouses). 3. Satellite and/or cellular communications—the ability to utilize wide area communication networks in remote areas to validate security and fulfill logistics optimization operational needs. 4. Smart Sensor networks—“plug and play” smart sensors with a universal addressing scheme to determine the integrity and condition of containers and cargo. 5. Intelligent information systems—capable of analyzing geostatistical and geospatial information and patterns (e.g. Geographic Information Systems) to create Strategic Asset Intelligence. 6. Advanced battery technology—battery life exceeding three years.
[0106] The preferred capabilities of the inventive system include the following: 1. Secure wireless communications system—the information transmitted via wireless and wired networks must be protected to prevent eavesdropping (e.g. physical layer security, data scrambling, encryption, authentication, etc.). 2. Real-time location—GPS, advanced television signal processing, dead reckoning, or other location based technologies providing the ability to pinpoint assets in real-time under harsh multipath conditions represents a substantial increase in efficiency for port, ship, and warehouse management justifying rapid return on investment. 3. Intelligence fusion—a Common Operational Picture (COP) with real-time alert capability. 4. Network security—multi-layer security scheme for asset tracking and analysis. 5. Multi-user access scheme—wireless devices must have the ability to communicate simultaneously with large numbers of tags per reader (>5000) in a given area to accommodate the numbers of containers in close proximity in modern shipping terminals. 6. Globally available unlicensed radio frequency—need for a single unlicensed RF band to insure interoperability in local area networking and RFID applications or frequency and protocol agile RFID systems.
[0107] It will be appreciated that the system relies on wireless communications in various ways. There are three basic approaches to robust wireless RFID communications under harsh multipath environments, viz., Peer-to-peer (mesh networking) solutions, Ultra Wideband solutions; and, Hybridized Spread Spectrum solutions. Applicants prefer the Hybridized Spread Spectrum (HSS) solution because it best stands to holistically address the performance specifications of a global asset tracking and control system: The HSS approach allows for a narrow-spectrum, broad band solution to be engineered to, e.g., a 2.45 GHz frequency (high data rates and higher resistance to environmental conditions), which is the only emerging globally available unlicensed band at the moment providing for robust wireless communications under harsh multipath interference conditions, the traditional barrier to wireless communications. The state-of-the-art in HSS technology constitutes a superior anti-collision wireless communications solution based on the utilization of time sequencing (increased volume for multi-user access), fast frequency hopping (superior resistance to multipath interference), and direct sequence spread spectrum (superior resistance to interference from and two other RF applications in the same geographic area) protocols combined in a unique way and incorporating advanced signal processing concepts.
[0108] In essence, the HSS system is able to distinguish the original signal from short-range multipath reflections. The statistical probability of successful communication on the first attempt is 99.99 percent at the bit level with the HSS approach. This network reliability level reduces the need for redundant transmission thereby increasing battery life over currently available commercial technologies. Based on the narrow band solution that is virtually immune to multipath interference, the system will support radiolocation (1 meter 3 dimensional accuracy in real-time) to be performed on individual tags in the standard stacking conditions of shipping containers in a port, on a ship, in the hold of a ship, and in warehouses. The HSS solution can create a geo-optimized mesh networking capability intelligently switching modes depending on the nature of the environment based on the radiolocation and transceiver architecture (each tag is a reader and a transmitter). The time sequencing aspects of the HSS solution has the potential to support two-way communication with up to 10,000 individual tags per Reader unit in every 100-second window, which is critical in the maritime ship and port environment. The end result is a robust multi-user active RFID wireless tracking and communication solution with inherent security at the physical layer (based on the way the waveform is generated) upon which encryption, data scrambling, and authentication security can be layered. For these reasons, the HSS approach appears to be the most logical and tenable solution to a globally deployed RFID total asset visibility solution.
[0109] In studies conducted in February, 2004, the HSS solution was first demonstrated at the Port of Charleston, Wando Terminal at the APM Terminals North American facility and again in June of 2004 for the Department of Homeland Security, Homeland Security Advanced Research Projects Agency. The HSS technology proved the ability to communicate from with a standard stack of refrigerated containers in real-time using a 2.45 GHz RFID solution with near-perfect accuracy. Additional testing was completed in August of 2004 demonstrating the ability to communicate under standard stacking conditions (10 long×3 high) of “dry box” shipping containers.
[0110] The inventive system provides real-time asset tracking for both commercial intermodal asset management and homeland security needs: 1. Real-time, global ship location tracking with detailed history of passage to provide a comprehensive “view” of all maritime shipping vessels. 2. Remote aggregation and uplink point for depots, terminals, yards, etc., which is a combination of a remote satellite uplink and a serial mesh radio. 3. Track container location and condition with tampering notification and internal environmental, biological, chemical, and radiation status. 4. Early warning/threat identification of ships and containers arrival in US waters and ports with an audit trail. 5. Detect and monitor suspicious shipping activities (unscheduled port calls, etc.). 6. Secure data feed to clients and stakeholders on a need-to-know basis. 7. Identify long-term patterns of activity at both container and cargo level. 8. Foster “low risk,” fast-track passage protocols through ports, canals, and inspection points. 9. Intermodal inventory management, combining tracking by ship, rail, and truck lines for order management, space allocation, scheduling, load balancing, supply chain management, harbor management, and port/container management.
[0111] Satellite and cellular networks provide the Wide Area Network (WAN) ability to track and monitor assets globally in real-time with the ability to concentrate all the information effectively in one location. This provides advantages for security, fault-tolerance, data back-up/archiving, and database maintenance. A central network operations center will integrate a variety of information sources with the transmitted inventive access bar status, location, and condition to support client date needs, advanced value-added commercial logistics, and risk and threat analysis. Both are combined with commercially available technologies in GIS, GPS, real-time alert systems, high performance cluster computing (HPCC), and the Internet in open systems architecture to create a real-time tracking and asset management system. The center provides one single location for real-time logistical support for the global management of mobile assets. The inventive system may further include a web-based tracking system that allows individuals or organizations to manage assets in real-time via the Internet with strict information protection protocols. The information will be distributed to relevant parties through secure transactions on a need-to-know basis thus precluding the use of the system to target assets for theft.
[0112] As noted earlier, the Access Bar is small and of generally higher value than an empty shipping container. It is therefore likely that in some applications, it will be desirable to return a number of Access Bars to their original point of origin without necessarily returning the empty containers. It will be appreciated that a metal rack may be constructed that fits into a standard container and has a number of parallel bars spaced comparably to the spacing of the bars on a container door (see, e.g., FIG. 1 ). A large number of Access Bars may be secured onto the rack and programmed so that they cannot be removed from the rack until they have reached the desired location. The rack in turn holds the Access Bars more securely during transit than if they were simply stacked in an empty container for the voyage.
[0113] It will further be appreciated that the invention may usefully be employed in logistical settings other than maritime transportation. Such other settings may include: over-the-road trailers, freight trains, enclosed conveyances of all types, as well as other sizes and constructions of containers used in a variety of industries. Thus, the invention is not limited to use on “standard” maritime shipping containers but may be easily adapted to other sizes and geometries.
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A security system for freight containers comprises: a locking device to reliably attach to the container and prevent unauthorized opening of the container doors; a sensing device to sense conditions affecting the container; and, a communication system configured to transmit the output of the sensing device to a system administrator located remotely from the container. The locking and sensing devices may be capable of two-way communication with the system administrator, whereby the administrator may interrogate the locking/sensing device at selected times. The locking device may contain a GPS receiver whereby its geographic location at various times may be monitored either continuously, periodically, or after a trip is completed. The system may include a visual display on the exterior of the container capable of displaying selected messages. The messages may be preprogrammed or may be changed as the container moves from one geographic location to another.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
TECHNICAL FIELD
[0001] This invention relates to cable for use in strata control, especially to reinforce the roof and/or walls of underground mines and tunnels, to methods of manufacturing cable bolts and to manufacturing components and systems used in such methods.
BACKGROUND
[0002] Cable bolts are usually made from cable comprising a plurality of steel filaments wound together around a central wire to form a tendon. Resin and/or cement grout is used to fix the cable bolt to a borehole. To increase the effective bond strength between the cable bolt and resin or grout the bolts are often provided with spaced protuberances along the length of the cable. These protuberances are often known as bulbs or cages. The protuberances assist in preventing cable bolts from being pulled through the resin or grout, thus providing improved anchorage and load transfer between the cable, resin/grout and the surrounding strata.
[0003] It is known that tensioning of the cable prior to cement grouting can cause the protuberance to collapse thus reducing the cable's effectiveness. In Australian patent 2004260817 there is a proposal to insert ball bearings into the cavities defined by the protuberances to reduce the likelihood of the protuberances collapsing when the cable is tensioned. This proposal has proved expensive to manufacture and unreliable due to the ball bearings being pushed out of the protuberances. There is also a need to displace the central wire to locate each ball bearing. In some cable bolts the central wire is replaced by a hollow tube which extends along the centre of the cable. Other disadvantages relate to the difficulty in automating the placement of the ball bearings and the ball bearing creates a stress concentration on the strands of the cable creating loads that lead to failure loads up to 25% less than the original strands ultimate tensile strength.
[0004] In our earlier Australian patent application 2008200918 we disclose a cable bolt having a hollow strand which facilitates the passage of grout along the cable. It is important that the hollow strand does not get crushed by radial loads in non collapsible protrusions.
[0005] It is these issues that have brought about the present invention.
SUMMARY
[0006] According to one aspect of the present invention there is provided a cable bolt comprising a plurality of flexible steel filaments formed around a central member, the cable bolt having spaced bulbous portions along the length of the bolt each bulbous portion defining a cavity containing a segmented ring that surrounds the central member to engage the filaments of the bulbous portion.
[0007] In accordance with a further aspect of the present invention there is provided a method of manufacturing a cable having twisted flexible steel filaments over a central member, the method comprising forcing the filaments apart without plastically deforming the filaments, inserting a spacer through the parted filaments to sit between the filaments and the central member, and releasing the parted filaments to return against the spacer to form a bulbous portion.
[0008] In one form, the filaments are forced apart by applying torsion to the filaments. In one form, the torsion is applied over a length of the cable to form bulbous portions spaced along the cable.
[0009] In one form, in addition to or instead of, the filaments are forced apart by inserting a spreading tool between the filaments.
[0010] In one form, the spacer extends around the central member. In a particular form, the spacer is a segmented ring that is placed in pieces through the parted filaments and formed into a ring surrounding the central member. In another form, the spacer may be a unitary element, such as helical wound member that is rotated onto the inner member through the parted filaments.
[0011] In one form the torsion and/or spreading is applied over a section of the pre-wound cable to open the outer filaments over a set length to allow insertion of the ring segments around the central member before releasing the filaments forming a permanent non-collapsible single protrusion. The process may be repeated further along the pre-wound cable.
[0012] In a further aspect of the present invention, there is provided an apparatus for forming bulbs in a cable having twisted flexible steel filaments over a central member, the apparatus comprising:
[0013] a bulbing assembly releasably engagable with said cable, said assembly being operative to force the filaments apart without plastically deforming the filaments; and
[0014] an inserting device operative to insert a spacer through the parted filaments to sit between the filaments and the central member.
[0015] In use on releasing the parted filaments they return against the spacer to form a bulbous portion in the cable.
[0016] In one form, the apparatus further comprises a frame; and a securing device for holding at least a portion of a cable with respect to frame.
[0017] In one form the cable is fed through the bulbing assembly so that a plurality of bulbing portions are able to be formed along the cable.
[0018] In another form, the bulbing assembly is movable relative to the apparatus frame to form spaced apart bulbing portions in the cable. Typically in this latter arrangement the cable remains stationary during forming of the plurality of bulbs but in another form, the cable may be moved so that both the cable and the bulbing apparatus move during bulb forming.
[0019] In one form, the apparatus includes a feed assembly to feed the cable from a coil into the apparatus. In one form the cable, with bulbs formed therein, is progressed to a table and the apparatus further includes a cutting device to cut the cable to length as required in formation of cable bolts.
BRIEF DESCRIPTION OF DRAWINGS
[0020] An embodiment of the present invention will now be described by way of example only with reference to the accompanying drawings in which:
[0021] FIG. 1 is a part sectioned side view of a typical cable bolt,
[0022] FIG. 2 is a cross sectional view of the cable bolt,
[0023] FIG. 3 is a schematic view of an apparatus for forming bulbs in a cable in accordance with an embodiment of this invention,
[0024] FIG. 4 is a plan view of a bulbing apparatus of the apparatus of FIG. 3 ,
[0025] FIG. 5 is a detailed view of the bulbing apparatus of FIG. 4 ,
[0026] FIG. 6 is a perspective view of the bulb illustrating insertion of a segmented ring. For convenience components of the bulbing apparatus are not shown; and
[0027] FIG. 7 is a perspective view illustrating the location of the segmented ring on a central strand of the cable bolt.
DETAILED DESCRIPTION
[0028] FIGS. 1 and 2 illustrate a cable bolt 10 . These drawings are taken from our earlier Australian patent application 2008200918, corresponding to U.S. Pat. No. 8,322,950, incorporated herein by reference.
[0029] As illustrated in FIG. 1 , an embodiment of a resin anchorable cable bolt 10 comprises a flexible cable 11 formed from a plurality of wound co-extending strands in the form of wound co-extending steel filaments that extends along an axis C between opposite ends (being, relative to the direction the bolt 10 is installed in a bore in a substrate, such as a mine shaft roof, a distal end 13 and a proximal end 14 ). The cable 11 has a first portion 15 adapted primarily for resin point anchoring, and a second portion 16 adapted predominantly for cement grouting.
[0030] As illustrated in FIG. 2 , the filaments comprise nine outer steel filaments 12 a spiral wound about a central hollow filament, or strand 12 b , located axially within the cable 11 . In one form, the hollow strand 12 b may comprise at least one region for resisting radial compression, in particular of a tensioning assembly which is discussed in more detail below. In alternative arrangements, the hollow strand 12 b may be plain, and/or more or fewer outer steel filaments 12 a may be used, in which case their relative diameter with respect to the hollow strand 12 b would be adjusted accordingly such that they are close fitting about the hollow strand 12 b . The outer steel filaments, or strands, 12 a are typically solid and of the type used for cable bolt or pre-stressed concrete applications. The hollow strand 12 b extends in the second portion 16 and not in the first portion 15 , however in alternative embodiments, the hollow strand may extend into the first portion 15 also.
[0031] In the embodiment of FIG. 1 , the central hollow strand 12 b comprises profiling allowing flexibility of the cable 11 , while providing strength to resist crushing of the strand (i.e. radial compression of the cable). The hollow strand 12 b is flexible to allow coiling of the cable 11 such that the coil has a minimum diameter of 1 . 2 m without kinking the hollow strand 12 b . In alternative embodiments, the minimum coiling diameter without kinking the hollow strand may fall within the range of 0.8 m to 2.5 m, or 1 m to 2 m. In the embodiment illustrated in FIG. 1 , the profiling is in the form of a helical or spiral ribs 17 (see FIG. 7 ) along its entire length. The hollow strand 12 b is formed from a metal material, in this embodiment steel, but may be formed from a polymeric material, such as polypropylene, a polyethylene, or other appropriate polymer.
[0032] Referring again to FIG. 1 , the cable bolt 10 further comprises a resin retainer 22 disposed between the first and second portions 15 , 16 of the cable 11 . The resin retainer 22 is affixed to the cable 11 and extends radially outwardly from the cable so as to substantially reduce the migration of resin from the first portion to the second portion within the bore during point anchoring of the bolt 10 . The resin retainer is typically formed from metal, however may be formed from any suitable polymer such as polypropylene or a polyethylene.
[0033] The hollow strand 12 b is located in the second portion 16 of the cable bolt 10 and extends from the proximal end 14 of the cable 11 to a location 24 in the second portion 16 at or adjacent the retainer 22 . As illustrated in FIG. 1 , a nut 26 is located on or near the hollow strand 12 b at location 24 within the outer filaments 12 a , forming a bulb, or “nut cage” 28 . The nut cage is formed by spacing apart and forcing outwardly all of the steel filaments 12 along a discrete section of the cable 11 and placing the nut 26 about the hollow strand end 24 .
[0034] The first portion 15 includes an end collar 31 for holding together the strands 12 a at the distal end 13 , and a plurality (three in the illustrated case) of radially outwardly extending resin mixing protrusions in the form of “bird cages” 32 , where a ball bearing (or other rigid object) is inserted in a partially unwound portion of strands 12 a.
[0035] It is desirable in some instances to form bulbs along the second portion 16 (in addition to the first portion 15 ) and/or to extend the hollow strand 12 b into the first portion 16 . As such it is desirable to be able to form bulbs about the hollow strand 12 b . Further to facilitate manufacturing processes, it is desirable that the bulbs are formed without unwinding of the steel filaments.
[0036] FIGS. 3 to 6 illustrate an apparatus for forming non collapsible spaced protrusions (or bulbs) 18 about the hollow strand 12 b of the flexible cable 11 . These bulbs 18 incorporate a segmented ring 40 ( FIG. 7 ) that prevents collapse of the bulb 18 whilst ensuring against radial compression of the hollow strand 12 b.
[0037] The method of forming the bulbs 18 and locating the segmenting ring 20 is discussed with particular reference to the bulbing apparatus 100 shown FIGS. 3 to 5 .
[0038] As best shown in FIG. 3 , the apparatus 100 includes a bulbing assembly 102 mounted on a frame 104 . A cable 11 is arranged to be fed from a coil (not shown) mounted within a coil handler 106 . Once bulbs are formed in the cable 11 (as discussed in more detail below) by the bulbing assembly 102 , the cable is progressed to a payout table 108 . A cutting device 110 is disposed between the frame 104 and the payout table 108 and is arranged to cut the cable once a desired length (typically of 8 m but it may be more or less depending on requirements) is passed onto to the table. The cut lengths of cable can then be further processed to form the final cable bolts as required. The bulbing process is preferably fully automated and controlled by a control system 112 which may include, as illustrated, a control cabinet 114 and operator interface 116 .
[0039] As best shown in FIGS. 4 and 5 , bulbing assembly 102 includes three components; namely torsioning device 118 , spreader 120 , and inserter 122 . In general, the torsioning device 118 is designed to twist the cable bolt 10 to force the filaments 12 a apart to define a gap. The spreader 120 (shown in the form as a pair of plates or knives 56 , 57 ) is designed to further spread adjacent filaments that allows the inserter 122 adequate space to enable the segmented ring 40 to pass through the parted filaments 12 a to be located in an interfitting arrangement on the central strand 12 b.
[0040] In the illustrated embodiment, the torsioning device 118 discloses the use of mandrels 51 , 52 positioned around the cable 11 at spaced intervals to define a length of cableas shown in FIGS. 4 and 5 . Each mandrel 51 or 52 includes a three jaw chuck 53 , 54 which can be brought into clamped engagement with the periphery of the cable 11 . The chucks 53 , 54 are clamped to the cable and are either rotated in opposite directions or one is rotated relative to the other to place the filaments 12 a of the cable into torsion which has the effect of parting the filaments 12 a and forming a protrusion 18 at the mid span of cable between the chucks 53 , 54 . With the chucks 53 , 54 held in position to maintain the torsion, spreader knives 56 , 57 are pushed between selected parted filaments 12 a and rotated to further move the filaments apart. This provides access to the inserter 122 (in the form of robotic arms 59 , 60 ) which place segments 41 , 42 of the ring 40 on opposite sides of the hollow strand 12 b and then fitted together as shown in FIGS. 6 and 7 .
[0041] As shown in FIG. 7 , each ring segment 41 , 42 has a projection 43 that is a snug fit within a similarly profiled recess 44 on the other segment 42 of the ring to allow the segments 41 , 42 to form a circular one piece ring 40 as shown in the left hand side of FIG. 6 . Once the ring 40 has been placed on the central strand 12 b the knives 56 , 57 can be removed and, the torsion applied by the mandrels 51 , 52 can be released causing the parted filaments 12 a to close onto the periphery of the ring 40 thereby locating the ring 40 in the cavity of each protrusion 18 on the central strand 12 b . By a steady release of the torsional load the parted gap between the filaments closes and the filaments 12 a contact the ring 40 to form an expanded non-collapsible bulb 18 .
[0042] The location of the ring 40 on the hollow central strand 12 b ensures that when the cable bolt is tensioned the protrusion 18 does not collapse. The segmented ring 40 , by forming a single annular ring ensures that there is no danger of the segments 41 , 42 crushing the central strand 12 b . The dovetailed inter fitting of the segments 41 , 42 ensure that radial forces on the ring 40 are evenly distributed around the periphery of the strand 12 b . The segmented ring 40 whilst preventing radial collapse of the strand 12 b can also allow a degree of movement between the strand 12 b and ring 40 thus maintaining the flexibility of the final cable.
[0043] In the form illustrated, the torsional and spreading forces that are placed on the cable bolt as it is twisted through use of the mandrels 51 , 52 and spreader 120 is insufficient to cause plastic deformation of the wire filaments 12 a.
[0044] Once the bulb 18 is formed, the cable 11 can then be fed through the bulbing assembly 102 (in a direction towards the payout table 108 ) such a subsequent portion of the cable 11 aligns with the bulbing assembly. The bulbing assembly is then able to form a further bulb 18 in the cable allowing separate spaced bulbs 18 to be formed in the cable 11 .
[0045] In an alternative form, the bulbing assembly may be designed to move along the length of the cable 11 to form spaced apart bulbs in the cable 11 . In either process, in this manner the cable 11 can have non collapsible grouting protrusions (in the form of bulbs 18 ) at desired intervals along the length of the cable 11 .
[0046] This process can be completed off a reel and wound back into smaller reels; or to cut to lengths. Alternatively, the process can use precut lengths.
[0047] It is also envisaged that the mandrels 51 , 52 and chucks 53 , 54 may be split to facilitate attachment to the cable 10 without the need to pass the cable through the mandrels and chucks.
[0048] It is to be understood that, if any prior art publication is referred to herein, such reference does not constitute an admission that the publication forms a part of the common general knowledge in the art, in Australia or any other country.
[0049] In the claims which follow and in the preceding description of the invention, except where the context requires otherwise due to express language or necessary implication, the word “comprise” or variations such as “comprises” or “comprising” is used in an inclusive sense, i.e. to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the invention.
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A cable bolt comprising a plurality of flexible steel filaments formed around a central member, the cable bolt having spaced bulbous portions along the length of the bolt each bulbous portion defining a cavity containing a segmented ring that surrounds the central member to engage the filaments of the bulbous portion.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
[0001] This invention relates to gutter systems for houses, and more particularly to an apparatus for protecting a gutter while providing support for a ladder.
[0002] Numerous drain systems for roofs have been provided in the prior art that include gutters that catch rainwater from roofs and carry it to leaders extending to the ground. Most houses built in the United States today include gutters which are secured to the fascia board of a house structure, just below the roof line. These gutters are necessary to protect siding or paint on the house front, back and side structures from damage from rain, snow and the like by catching the rain, snow and the like and causing it to flow to down spouts and away from the house structures with minimal contact with the house structures.
[0003] The construction of gutters and the placement thereof against the fascia board of a structure is well known in the art. The gutters are generally made of a thin sheet of aluminum, vinyl, plastic or wood, which are light in weight. The presence of thin aluminum or plastic gutters along the fascia board of a structure is a source of difficulty when one needs to access the roof or upper portion of the structure. Usually, a ladder is placed and supported against the structure, and the worker or home owner climbs the ladder to access, for example, the roof. However, since the gutters must stick out beyond the lower roof line to be effective in trapping rain and the like, the ladder must be placed against the gutters. The thin gutters of modern construction cannot withstand much pressure before bending. When a ladder is placed against the front of a gutter it will tend to crush the gutter and slide along it. This often results in a structure's gutter having to be replaced, although the initial work task had nothing to do with the gutters. Regardless of the method used in attaching a gutter to a building, e.g., hangers, straps, spikes, ferrules, etc., the gutter is very susceptible to scratching, denting, and crushing from prolonged ladder contact or from a weight overload from a ladder.
[0004] One of the common attempts to avoid gutter problems is the use of double-pronged ladder stabilizers. One of the real limitations with ladder stabilizers is that they are not very strong. Ladder stabilizers also tend to become unsquare with the ladder until a ladder's upper portion inside edges crushes the gutter, roof edge and flashing. Ladder stabilizers are especially a problem for ladder staging. Since stabilizers are firmly secured to the ladder, they need to be adjusted frequently and mechanically in relationship to where they would rest on the building for proper ladder staging bracket and plank placement. Furthermore, the ladder cannot be set under the eave since the projection of eave and gutter is almost equal to the width of the staging plank, thus providing minimal work space and a dangerous environment for a staging worker. Fastening any material to the eaves to prevent gutter damage only causes the need for repairs of another kind.
SUMMARY OF THE INVENTION
[0005] The present invention provides an apparatus for protecting a gutter while at the same time providing support for a ladder placed against the gutter. The present invention supports the weight of ladders, ladder brackets, staging planks, material and men by diffusing weight around a gutter directly to the fascia.
[0006] The present invention accomplishes this by providing a U-shaped channel member fitted horizontally over the gutter, with each protruding channel member engaging the fascia board to which the gutter is attached. Ladder legs rest against the channel member between invention brackets. A strap attached to the channel member is adapted to engage a ladder rung with the gutter, thereby holding the ladder in engagement with the channel member and further preventing the ladder from sliding laterally or diagonal movement, i.e., ladder bottom kick out. The present invention also provides a means for speedy set up of ladder and staging.
[0007] These together with other objects of the invention, along with various features of novelty which characterize the invention, are pointed out with particularity in the claims annexed hereto 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 had to the accompanying drawings and descriptive matter in which there is illustrated a preferred embodiment of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] [0008]FIG. 1 is a side view of the invention.
[0009] [0009]FIG. 2 is a front view of the invention.
[0010] [0010]FIG. 3 is a front, perspective view of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0011] Referring to the drawings in detail wherein like elements are indicated by like numerals, there is shown an external, vertical building wall structure 10 , such as a front, rear or side wall, an eave 14 , a fascia board 13 , a lower roof line edge 11 extending over the fascia board 13 , and a rain gutter 20 attached to the fascia board 13 , said gutter 20 extending out beyond the lower roof line 11 .
[0012] The rain gutter 20 has a top 21 , a bottom 22 , a rear 23 , a front 24 , and two sides 25 . The gutter sides 25 define a longitudinal axis which lies in a horizontal plane. The rain gutter rear 23 abuts the fascia board 13 and may be connected by means of hangers, straps, or spikes and ferrules.
[0013] The present invention 1 provides a horizontal, U-shaped channel member 30 comprised of a flat top 31 , a flat bottom 32 , an open rear 33 , a closed, flat front 34 , and two open sides 35 , said front 34 being connected to said top 31 and said bottom 32 . The channel member sides 35 define a longitudinal axis which lies in a horizontal plane. In this embodiment of the invention 1 , the channel member's top 31 and bottom 32 lie in planes perpendicular to the channel member's front 34 . The channel member's front 34 , top 31 and bottom 32 define a channel member interior 36 . The top rear 31 , 33 and bottom rear 32 , 33 terminate in strips 37 made from a non-skid, non-abrasive, resilient material, such as plastic or rubber.
[0014] The channel member top 31 and bottom 32 are attached to the channel member front 34 by means of external brackets or bands 40 . In this embodiment of the invention 1 , there are two brackets 40 , each extending vertically across the front 34 and horizontally rearward across a portion of the top 31 and bottom 32 , and fixedly attached thereto. The portion 41 of each bracket 40 extending across the channel member front 34 has a horizontal hole 42 formed therein, each said hole 42 having a central axis parallel to the plane of the channel member top 31 . An elasticized cord 50 with two ends 51 , each end 51 terminating in a hook 52 , is threaded through the bracket front portion holes 42 . The junction 44 of each bracket front portion 41 and the bracket portion 43 extending across the channel member top 31 is vertically raised as much as two inches to provide lateral stops for ladder legs 3 resting against the channel member 30 .
[0015] In this embodiment of the invention 1 , the channel member 30 has a side-to-side length of twenty-seven inches with the brackets 40 being positioned equidistantly nineteen and one-half inches apart. For residential applications the channel member inside depth is preferably six inches and inside height is preferably four inches. Commercial applications usually require an additional inch in height and depth. The channel member 30 is preferable made from perforated aluminum, thereby providing strength and light weight. However, comparable materials, including wood, may be used. The perforations 39 are optional, but are particularly effective when using metallic materials.
[0016] In operation, the channel member 30 is fitted horizontally over the gutter 20 , with the channel member top and bottom strips 37 engaging the fascia board 13 to which the gutter 20 is attached. The gutter 20 snugly fits within the channel member interior 36 . The channel member top 31 rests on the gutter top 7 21 . The strips 37 prevent damage to the fascia 13 . A ladder 2 is set at a desired location. The ladder 2 is raised to a position on the wall top 12 just under the gutter 20 . The channel member 30 is placed over the gutter 20 . Because of the channel member's snug fit over the gutter 20 , the channel member 30 will stay in place without further attachment. The ladder 2 is then raised so that the ladder upper legs 3 rest against the channel member 20 , typically against the channel member front top 34 , 31 between the bracket junctions 43 . The cord 50 is then wrapped about the ladder 2 , preferably an upper rung 4 , and the cord end hooks 52 attached to the gutter 20 on either side of the channel member 30 . The engagement of the cord 50 with the ladder 2 prevents the ladder upper portion legs 3 from “bouncing” over the bracket junctions 43 and sliding laterally. This engagement also retards the ladder bottom (not shown) from kicking out.
[0017] The present invention 1 is used extensively under the following situations where a gutter 20 is present: (i) when ladder staging is required for reroofing, dormer accessibility, skylight accessibility, roof repairs; (ii) general roof access for painting, siding, and the like; (iii) extended ladder stay at one point; (iv) heavy load required on ladder; (v) any need to access a non-walk roof; and (vi) numerous round trips on ladder. The present invention permits simplified installation of roofing systems. The inside edges of the upper ladder legs 3 are kept away from sheathing/top of fascia intersection. Drip edge 8 flashing and roofing material can be applied and remain undamaged.
[0018] It is understood that the above-described embodiment is merely illustrative of the application. Other embodiments may be readily devised by those skilled in the art which will embody the principles of the invention and fall within the spirit and scope thereof.
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A U-shaped channel member fitted horizontally over a gutter, with each protruding channel member engaging the fascia board to which the gutter is attached. Ladder legs rest against the channel member between invention brackets. A strap attached to the channel member is adapted to engage a ladder rung with the gutter, thereby holding the ladder in engagement with the channel member and further preventing the ladder from sliding laterally or diagonal movement, i.e., ladder bottom kick out.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a control technique for the injection of fluids into a subterranean formation to increase the production of hydrocarbons during a secondary or tertiary oil recovery process. During a secondary or tertiary oil recovery process, many injection wells are controlled by monitoring the surface pressure, and then maintaining said pressure below the parting, i.e., fracturing, pressure of the formation receiving the injected fluids. However, many injection wells do not exhibit a discernible surface pressure, and thus cannot be controlled in this manner. Other injection controllers have maintained a constant mass flow rate of fluid into the subterranean formation regardless of the pressure variations occurring during fluid injection. U.S. Pat. No. 3,455,382 entitled "Injection Flow Control Apparatus for Wells", and issued to D. V. Chenoweth on July 15, 1969, describes an injection well controller of this type.
None of the previous control techniques teach measuring the pressure at the face of the zone receiving the fluid during injection while using such measured pressures to maintain the bottomhole pressure relatively constant during the injection of said fluids.
SUMMARY OF THE INVENTION
This is a method and apparatus for controlling the injection of fluid into an underground formation which continually measures the bottomhole pressure adjacent said underground formation during injection of said fluid and maintains the rate of injection so that the bottomhole pressure does not exceed a selected pressure or stays within a preset range. In a preferred embodiment means are provided to maintain both the rate of injection and the measured downhole pressure within preset ranges. This control technique allows optimization of injection rates, thereby increasing the recovery of hydrocarbons during a secondary or tertiary recovery process. It also prevents fracturing the formation by injecting fluid at a pressure above the formation parting pressure. If the injection fluid fractures the formation, the effectiveness of the recovery process is greatly reduced and more oil is left unrecovered.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view showing a preferred embodiment of the apparatus of the instant invention installed at a well site.
FIG. 2 is a block diagram of the injection control system.
FIG. 3 shows a schematic of the error arbiter indicated in FIG. 2 for selection of a control error used in the control technique.
FIG. 4 shows a schematic of the open/close comparator indicated in FIG. 2 which determines whether the control valve in the fluid flow line requires opening or closing.
FIG. 5 shows a schematic of a system indicated in FIG. 2 which determines the magnitude of the control error.
FIG. 6 shows a schematic of a proportional generator indicated in FIG. 2 which creates a control signal to operate the control valve.
FIG. 7 shows a logic output indicated in FIG. 2 used to regulate the control of fluid injection.
DETAILED DESCRIPTION OF THE INVENTION
The apparatus and method of the instant invention have been adapted to operate on a solar energy-battery powered system, thus eliminating the need to run cables for electrical power to the relatively isolated geographical locations where injection wells are often found. The resulting cost savings of the use of such a solar powered system increases the advantage of the use of the instant invention.
Referring now to FIG. 1, therein depicted is a schematic drawing of a preferred embodiment of the control apparatus of the instant invention. A combined bottomhole pressure detector and transmitter 1 is placed in wellbore 90 through tubing 109 and wellhead casing 3 below the earth's surface 4 so that it is adjacent zone 5 into which fluid is injected. The pressure transmitter's output signal is sent via cable 2 to injection controller 7 which is mounted on post 7A. As will be explained below, controller 7 has an output control signal used to regulate the rate of flow of injection fluid.
The bottomhole pressure is measured downhole by the pressure detector preferably utilizing a strain gauge pressure transducer and is sent through cable 2 to the injection controller 7 to be used for the regulation of the fluid injection rate. The injection controller is also connected to a turbine meter 11 which measures the injection rate of fluids into the well. The output control signal of the injection controller is connected to control valve 10 through line 8 to regulate the rate of flow of the injection fluid. The control valve 10 is the means used to regulate the flow of fluids through the flow line down into the subterranean formation 5.
In the method of the instant invention, fluid from a source (not shown) is injected through a filter 12 in flow line 108, through a turbine meter 11 where the flow rate is monitored, through the control valve 10, and then down tubing 109 into the subterranean formation 5. In the method of the instant invention the bottomhole pressure in the vicinity of zone 5 is detected during injection of said fluid and the detected pressure is transmitted to the injection controller 7. The injection controller is powered by the solar panel 13, mounted on a post 7A above the injection controller. The injection controller uses the measured pressure and injection rate to determine the needed regulation of the flow of fluids into the well.
FIG. 2 shows a block diagram of how one embodiment of the control system inside the injection controller 7 functions. Control systems other than the specific one shown in FIG. 2 can be used but it is considered that the system shown is preferred. A suitable commercially available controller is the 300 CD Solar Powered Set Point Controller manufactured by End Devices, Inc., Box 522, Midland, Tex. 79701.
A signal 22 representing the bottomhole pressure measured by the bottomhole pressure sensor is transmitted to a pressure processor 23 which places the signal in a form compatible with the internal circuits of the controller 7. The output of pressure processor 23 is transmitted to a pressure subtracter 25. The pressure subtracter 25 compares the measured bottomhole pressure to a preset pressure value 24. The pressure subtracter 25 then determines the difference between the actual bottomhole pressure and the preset pressure value and transmits that difference to the error arbiter 30. Error arbiter 30 will be explained in connection with FIG. 3.
At the same time as the bottomhole pressure is transmitted to the injection controller, the injection rate 26 is also measured and transmitted through line 9 (as depicted in FIG. 1) to the injection controller 7. The rate is sent to a rate processor 27 which converts the rate signal into a form suitable for use as an input signal rate subtracter 29. The rate subtracter compares the injection rate to a preset rate from set point 28. The rate subtracter then determines the difference between the actual injection rate and the preset rate and sends that difference to the error arbiter 30. The difference between the pressure rate and the preset pressure rate as determined by the pressure subtracter 25 is also sent to the open/close comparator 32 which will be described in connection with FIG. 4. In a like manner, the difference between the injection rate and the preset rate as determined by the rate subtracter 29 is also sent to the open/close comparator 32.
The error arbiter 30 determines which of the calculated differences, either the pressure difference from subtracter 25 or the injection rate difference from subtracter 29, has the larger positive value. The arbiter 30 then sends this higher calculated difference, the control error, to the magnitude extractor 31 which will be discussed further in relation to FIG. 5. The magnitude extractor 31 determines the magnitude of the calculated difference (i.e., control error) electrically and sends that information to the proportional generator 34 and the dead band detector 35, both of which will be discussed later in connection with FIG. 6.
The dead band detector 35 determines if the magnitude of the control error as calculated by the magnitude extractor 31 is greater than a selected percent, e.g., 1% of the preset values from set points 24 and 28. If the magnitude of the control error is not greater than a selected percent of the preset value, the dead band detector 35 does not send a signal to the proportional generator 34. This maintains the position of the control valve 10 at its previously determined position.
Unless inhibited by the dead band detector 35, the proportional generator 34 receives the control error signal and produces an electrical signal proportional to the change required to regulate the control valve in response to the magnitude of the error signal so that the control valve will be opened or closed in proportion to the desired change in injection rate. The proportional generator 34 sends this generated signal to the output logic 33.
The open/close comparator 32 takes the pressure and injection rate errors as calculated by the pressure subtracter 25 and the rate subtracter 29, respectively, and compares them to the current control valve setting and determines whether the control valve 10 needs to be opened or closed. The open/close comparator 32 then sends this information to the output logic.
The output logic 33 receives the information from the open/close comparator 32 and the proportional generator 34 and sends a control signal to an output driver 36 which transmits the control instructions to the control valve 10 to open or close a directed amount, or to remain in the same position.
The entire injection controller is preferably powered by a solar panel 39 which is connected to battery 110 and battery monitor 38. The solar panel maintains the charge on the battery at an operative level. If the battery monitor shows that the power as supplied by the solar panel and battery is insufficient to allow the functioning of the system, the battery monitor sends a response to the output logic 33 which prevents any change in the then-current operating position of control valve 10.
Some of the component parts of the schematic block diagram of FIG. 2 will now be examined in more detail. It is considered that the other component parts need no further explanation to those skilled in the control systems art area. FIG. 3 shows a schematic diagram of the error arbiter 30. The arbiter receives the pressure error signal 44 from subtracter 25 and the rate error signal 45 from subtracter 29 and sends them to an error comparator 46 which determines which of the errors is the more positive. The pressure error and rate error signals are also transmitted to electronic switch 47. The output signal from the error comparator is also transmitted to electronic switch 47. The error comparator's output signal tells the switch which of the pressure or rate error signals is the more positive. The switch then transmits the selected more positive error to the magnitude extractor 31 as the control error 48.
FIG. 4 shows a schematic diagram of the functioning of the open/close comparator 32. The pressure error 44 and the flow rate error 45 are fed into comparators 56A and 56B, respectively. The comparators compare the pressure error and rate error to a reference level 55 for each, and determine if the pressure and rate error are above or below their reference set point. If either comparator 56A or 56B, or both has a flow line output signifying either too high bottom hole pressure or too high a flow rate, then OR gate 57 has a positive output which is sent to inverter 52. If the inverter has a zero pulse, this directs the output logic 33 to close the control valve 10. If the inverter has a positive pulse, it directs logic curcuit 33 to open the control valve 10. Thus the output signal of the comparator communicates whether the valve 10 should be opened or closed. The signal from proportional generator 34 determines the extent the valve is opened or closed.
FIG. 5 shows a schematic of the functioning of the magnitude extractor 31. The control error 85 as selected by the error arbiter 30 is the input signal for the magnitude extractor. The control error signal 85 is transmitted to an electrical switch 88 and also to a multiplying circuit 86. The multiplying circuit multiplies the control error by -1. The control error also goes to a circuit 87 which detects if the control error 85 is a positive input. The output of circuit 87 is also transmitted to the electronic switch 88. The output of the multiplier circuit 86 is the third input for the electronic switch 88. The output from the "detect positive input" circuit 87 directs internal switch 101 to connect with terminal 102 or 103. If there is a positive input to 87, switch 101 connects with terminal 102. If there is no positive input to 87, then internal switch 101 connects with terminal 103. This assures that the output of switch 88 is always negative. This negative signal is transmitted to circuit 91 which multiplies the value of the output from switch 88 by -1. As there are two negative values, the output 92 from circuit 91 is always positive and has a magnitude of the error 85. The output 92 is then communicated to the proportional generator 34 and dead band detector 35.
FIG. 6 shows a schematic of the proportional generator (34 in FIG. 2) used to generate and transmit a control signal having an electrical pulse of a width or time duration in proportion to the magnitude of the control error 92. This control signal ultimately controls the opening size of valve 10. A suitable proportional generator is set forth in FIG. 6 although others could be used. The proportional generator receives the electrical signals from the magnitude extractor 31 and the dead band detector 35. As stated above, the dead band detector only determines if the control error magnitude 92 as determined by the magnitude extractor 31 is greater than a selected percent (e.g., 1% of a preset value). Dead band detector 35 thus has an output only if the magnitude of the control error as determined by extractor 31 is less than a certain percentage of the preset value. The input from the dead band detector 35 goes through an inverter circuit 59 and from there into one input of AND gate 60.
Comparator circuit 93 sends its output to the other input of the AND gate 60. If there is any input at all from the dead band circuit 35, AND gate 60 is thus activated, and sends a signal 69 to output logic 33. Signal 69 inhibits the output logic circuit thereby maintaining control valve 10 at its then-current position. Signal 69 also inhibits the input from comparator 93 to the edge triggered pulse generator 100 and prevents the generation of a minimum pulse 70.
The solar panel-battery current source 39 generates a constant current which builds a charge on capacitor 104. The comparator 97 compares the voltage on the capacitor to a reference voltage 98. A suitable comparator circuit such as 93 and 97 is commercially available from Motorola, Inc. and is identified as MLM 358. When the capacitor voltage exceeds the reference voltage, comparator 97 produces a high output to edge triggered pulse generator 99. A suitable generator for 99 and 100 is commercially available from RCA, Inc. and is identified as a CD 40 98 BE. The pulse generator generates a sawtooth signal of known configuration, which is sent to dump switch 96. When the generated signal reaches the switch, the switch is closed and the capacitor is discharged. The capacitor voltage then continuously varies from zero up to the reference voltage. The capacitor output voltage is sent to ramp buffer 95 which isolates the upper circuit from the lower voltage generating circuit. The output voltage is next transmitted to the ramp size gain potentiometer 94.
Comparator 93 receives the voltage from ramp size gain potentiometer 94 and compares it to the error magnitude 92 determined by the magnitude extractor (as indicated in FIG. 5). The comparator's output is high when the voltage from ramp size gain potentiometer 94 decreases to zero as the capacitor 104 is discharged. The comparator's output is low when the error magnitude 92 is less than the voltage from the ramp size gain potentiometer. The net effect is that a signal proportional to the error magnitude is sent to edge triggered pulse generator 100.
Edge triggered pulse generator 100 accepts the proportional impulse signal from comparator 93 (unless the output from the comparator is blocked by the dead band detector 35) and generates a pulse 70 of a minimum width required to operate control valve 10. The minimum width pulse 70 is inverted in inverter circuit 105, and it is then transmitted to the output logic 33. The minimum width pulse 70 then is proportional to the control error 85 and informs the output logic how much correction is needed in the position of control valve 10.
The output logic circuit 33 uses the minimum width pulse 70 as determined by the proportional generator 34 as one input as is shown in greater detail in FIG. 7. Another input connection to the output logic circuit is the signal from the dead band detector 35 should it activate its AND circuit 60. An additional input is the open/close comparator signal 58 from the open/close comparator 32. The minimum width pulse signal and the signal 69 from the dead band detector 35 are combined in an OR circuit 72 after the signal from the dead band detector is inverted in an inverting circuit 71. The signal leaving the OR circuit 72 is injected into another inverting circuit 73. From there it goes to AND gate 75 together with the open/close comparator signal. The open/close comparator signal is also sent to inverting circuit 74 and from there to another AND gate 76 which receives its other input from inverter 73.
If the signal from inverter 73 (from dead band detector 35) is negative, it inhibits AND gates 75 and 76. This prevents any signals or output from terminals 81, 82, 83 and 84. Thus, the valve 10 stays in an unchanged position. If the signal from inverter 73 is positive, AND gates 75 and 76 have an output upon receiving a signal 58. Signal 58 is fed to one input of AND gate 75 and after being inverted by inverter 74 is fed to the other input of AND gate 76. Thus, only one of AND gates 75 and 76 has a non-zero output at any one time.
There are two sets of terminals shown, a first set 81 (closed) and 82 (not closed) and a second set 83 (not open) and 84 (open) but only two terminals are used at any one time--one terminal from each set. Assume terminals 81 and 84 are selected in "close" signal 58 (together with the signal from inverter 73) which activates AND gate 75 but not AND gate 76. Thus in this case there is a control signal on terminal 81. If there is an "open" signal 58 (negative), AND gate 75 is inhibited and AND gate 76 has an output signal which appears on terminal 84 to control the opening of valve 10 to the new control position. If terminals 82 and 83 are selected to have an output, there must be a positive signal from battery 54 indicating that the battery is sufficiently charged. Terminals 82 and 83 control relays which, if the battery becomes discharged, will disable the signals on terminals 81 and 84 and "freeze" valve 10 in its then-current position.
The apparatus and method of the preferred embodiment were tested commencing in November 1979 in an injection well for a waterflood in the North Cowden Field in Texas. The injection control unit was set to maintain a bottomhole pressure of 1850 psi during fluid injection. For a four-month period from December 1979 through March 1980 the controller maintained a bottomhole pressure at an average 1843 psi with an average fluid injection rate of 520 bbl/d.
It should be readily apparent to one skilled in the art that this invention is not limited to the embodiments described herein. Rather, the scope of our invention is defined by the appended claims.
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An injection well control method and apparatus controls fluid injection rates during secondary or tertiary petroleum recovery operations by monitoring bottomhole pressure adjacent an underground formation receiving the injected fluids while simultaneously adjusting the fluid injection rate to substantially reduce unwanted variations in said bottomhole pressure. The injection controller is further adapted for operation on a solar-powered circuit to eliminate the need for electrical power lines in remote geographical locations.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND
1. Field of the Invention
This invention relates to tank-type toilets and, more particularly, to an apparatus and method for conserving water during the flush cycle of the toilet.
2. The Prior Art
The conventional tank-type water closet or toilet is configurated with a water reservoir or tank located above and to the rear of the pedestal. An outlet from the tank directs water into the pedestal where it flushes the wastes therein into the sewer system. A manually operable stopper occludes the outlet and serves as the mechanism for initiation of the flush cycle. A float mechanism inside the tank senses the water level to operate a water inlet valve and replenish the water in the tank after each flush cycle. The flush cycle is commenced by
(1) raising the stopper to allow the water in the tank to flush the pedestal,
(2) the lowering water level in the tank causing
(3) the float to fall and thereby
(4) opening the inlet valve to permit refilling of the tank before the stopper has again closed.
As can be readily observed, the foregoing opening of the inlet valve to refill the tank before the stopper has closed directs water from the inlet valve to the drain. However most conventional toilets are configurated such that there is a sufficient reservoir of static water available in the toilet tank to accomodate a complete suitable flushing of the toilet. The extra water contributed by the premature opening of the inlet valve is generally wasted. For example, it has been estimated that a conventional toilet tank contains a water reservoir of about 41/2 gallons. This is generally considered to be adequate for the flushing cycle. It has also been determined that opening of the inlet valve prior to the cessation of the flushing cycle results in about 11/2 gallons of additional water being used for the flushing cycle and, thereby, wasted.
When consideration is given to the millions of tank-type toilets in use both in residential and commercial buildings, the amount of water wasted during the flushing cycle represents a significant quantity of water. Additionally, since the wasted water is not required for suitably flushing the toilet, the additional water contributes to overloading of sewage treatment facilities. Various water conservancy devices have been proposed and include, for example, the placement of bricks or the like as displacement means in the toilet tank to displace an equal volume of water thereby reducing the total volume of water used in the flushing cycle.
In view of the foregoing, it would be a significant advancement in the art of conserving water, particularly during the flushing cycle of a tank-type toilet, by restraining the toilet tank float until a significant quantity of the static water in the toilet tank has been drained therefrom and thereafter allowing the toilet tank float to be lowered so as to open the inlet valve to refill the toilet tank. It would also be an advancement in the art to provide an apparatus which can be readily adapted to be placed in various commercial models of toilet tanks. An even further advancement in the art would be to provide a method for suitably controlling the lowering of the toilet tank float substantially automatically. Such an apparatus and method is disclosed and claimed in the present invention.
BRIEF SUMMARY AND OBJECTS OF THE INVENTION
The novel apparatus and method of this invention involves a pivotally mounted lever arm having a toilet tank float engagement means on one end and a water-fillable weight on the other end. The weight of the water in the water-fillable weight is sufficient to substantially support the weight of the toilet tank float engaged by the engagement means. A calibrated drain hole is provided in the water-fillable weight to accommodate draining of the water therefrom. Drainage of the water from the water-fillable weight provides a predetermined time delay to change the balance of the lever arm thereby allowing the toilet tank float to be lowered toward the end of the draining of the tank. The lowered float opens the inlet valve and the toilet tank is again refilled with water from the inlet valve. The size of the calibrated drain opening is predetermined so as to delay lowering of the toilet tank float until substantially all of the water has been drained from the toilet tank thereby conserving water by inhibiting its being wasted by going directly out the drain.
It is, therefore, a primary object of this invention to provide an apparatus for conserving water during the flush cycle of a tank-type toilet.
Another object of this invention is to provide an improved method for conserving water during the flushing cycle of a tank-type toilet.
Another object of this invention is to provide a lever arm with means for engaging a toilet tank float at one end and a variable weight counterbalance on the other end wherein the variable weight is provided by a water-fillable weight.
Another object of this invention is to provide means for releasably engaging the apparatus of this invention inside the tank of a tank-type toilet.
These and other objects and features of the present invention will become more fully apparent from the following description and appended claims taken in conjunction with the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a schematic perspective view of the internal mechanism of a tank-type toilet shown in the partial environment of a toilet pedestal with portions broken away for purposes of clarity;
FIG. 2 is a side elevation of the internal mechanism of the toilet tank apparatus of FIG. 1 during the initial stages of the flushing cycle with portions broken away for sake of clarity;
FIG. 3 is a side elevation of the toilet tank mechanism of FIGS. 1 and 2 near the completion of the flushing cycle with portions broken away for sake of clarity;
FIG. 4 is a perspective view of one preferred embodiment of the apparatus for releasably mounting the apparatus of this invention in a toilet tank with portions broken away for sake of clarity; and
FIG. 5 is a perspective view of a another preferred embodiment for releasably engaging the apparatus of this invention in a toilet tank with portions broken away for sake of clarity.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The invention is best understood by reference to the drawing wherein like parts are designated with like numerals throughout.
Referring now to FIGS. 1-3, the water saver apparatus of this invention is shown generally at 10 as mounted in a conventional toilet tank 12 so as to be concealed therein beneath toilet tank lid 14. Toilet tank 12 is a conventional toilet tank and is mounted in fluid communication with a toilet pedestal (shown herein broken away as toilet pedestal 11). Toilet tank 12 is interconnected to a water inlet line 16 and is supplied with water from a water shut-off valve 18 in a water supply line 20.
Toilet tank 12, lid 14, water inlet line 16, shut-off valve 18 and water supply line 20 are all conventional apparatus. Other conventional apparatus include an inlet standpipe 22, a water inlet 25, and a water inlet valve 24 which is interconnected to a toilet tank float 26 by means of float rod 28 and a bracket 30. Other conventional components include an overflow standpipe 32, drain stopper 34, lift rod 36, and drain valve seat 38. These conventional components are set forth herein so as to provide an appropriate environment to assist in understanding the novel apparatus and method of this invention. The operation of these conventional components will not be discussed in depth except as they relate to the operation of the apparatus and method of this invention. Although a particular type of toilet tank may be illustrated herein, it is to be specifically understood that the apparatus and method of this invention is not restricted to use in a toilet tank having the specific components shown but may be readily adapted to various commercial models of tank-type toilets.
With particular reference to the novel apparatus and method of this invention, the water saver 10 includes a lever arm 56 having a water-fillable weight 50 on one end and a toilet tank float engagement means 58 on the other end. Toilet tank float engagement means 58 is configurated as an upwardly turned hook in the end of an arm 57 formed on the end of lever 56. Toilet tank float engagement means 58 is specifically configurated to restrain toilet tank float 26 by being engaged beneath float rod 28.
Lever arm 56 is pivotally mounted to overflow standpipe 32 by means of a pivot pin 60 secured to a retaining ring 62. Retaining ring 62 is dimensionally configurated to be releasably mounted to overflow standpipe 32 at a position adjacent an upper level 19 (shown in broken lines, FIG. 2) of water in toilet tank 12.
Water-fillable weight 50 is configurated as an open end container secured to the end of lever arm 56 and includes a calibrated drain hole 52 in the bottom thereof. The volume of water-fillable weight 50 is coordinated with the length of lever arm 56 on each side of pivot 60 and the combined weight of toilet tank float 26 and float rod 28 so as to adequately support toilet tank float 26 above the receding water level (illustrated schematically at 21, FIG. 2) during the flushing cycle. Importantly, as stopper 34 is raised and water is allowed to flow outwardly from tank 12 as indicated by flow arrows 40, sufficient water is retained within water-fillable float 50 so as to impede the lowering of toilet tank 26. The opening of inlet valve 24 is thereby suitably delayed until a substantial quantity of water has been drained from toilet tank 12.
Since it is desirable to have toilet tank float 26 ultimately lowered thereby opening inlet valve 24, a calibrated opening 52 is provided in the bottom of water-fillable weight 50. Accordingly, as the water level 21 (FIG. 2) drops in toilet tank 12 the water level in water-fillable weight 50 also starts to lower as indicated schematically at 51 (FIG. 2).
With particular reference to FIG. 3, the toilet tank mechanism is shown at the completion of the flush cycle with the stopper 34 again seated against valve seat 38 and toilet tank float 26 in its lowered position thereby opening valve 24. The lowering of toilet tank float 26 is accommodated by drainage of water, indicated schematically herein as water 54, through drain hole 52 so that the weight of the water-fillable weight 50 is overcome by the combined weight of toilet tank float 26 and float rod 28. The size of drain hole 52 is predetermined with respect to the volume of water contained in water-fillable weight 50 so as to provide a sufficient time delay between the raising of stopper 34 and its subsequent lowering into sealing relationship with valve seat 38. In this presently preferred embodiment of the invention, drain hole 52 is configurated to slowly drain water from water-fillable weight 50 at such a rate that the toilet tank 12 is substantially drained and stopper 34 is again seated on valve seat 38 before any substantial degree of opening of valve 24 is obtained by lowering of toilet tank float 26. Clearly, however, any suitable delay can be selectively predetermined for water-fillable weight 50 by selectively determining the opening of drain aperture 52 and, therefore, the rate at which water flows therethrough.
Referring now more particularly to FIG. 4, one preferred embodiment for securing a pivot 70 for lever arm 56 in a toilet tank 13 is shown and includes a spring clip 72 formed from a strip of resilient material. Spring clip 72 is fabricated with a configuration generally representing the letter W. The distance across the W configuration of spring clip 72 is greater than the internal dimensions of toilet tank 13 to thereby advantageously utilize the outwardly pressing force of spring clip 72 when the same is inserted into toilet tank 13.
Although spring clip 72 is shown generally in the form of the letter W, it could be readily reversed in its orientation so as to generally represent the letter M. Alternatively, the two ends of spring clip 72 could be joined so as to form a continuous loop below lid 15. Importantly, regardless of the configuration chosen, spring clip 72 is configurated to pivotally support lever arm 56 in the desired location in tank 13 and to avoid interference with the movement of toilet tank float 26 and float rod 28.
Referring now more particularly to FIG. 5, another preferred embodiment for securing a pivot 87 for lever arm 56 in a toilet tank 13 is illustrated generally as a bracket 80. Bracket 80 is fabricated from a cylinder 82 with a spring-biased rod 85 extending from each end. Rod 85 is configurated with a piston 84 in engagement with a spring 83 at one end and termintes in a foot 86 at the other end. Spring 83 is configurated as a compression spring and resilently urges rod 85 and, more particularly, foot 86 against the inside walls of toilet tank 13.
Bracket 80 is mounted in toilet tank 13 by first removing lid 15 and pushing rods 85 inwardly to compress spring 83 while lowering bracket 80 into position into toilet tank 13. Pivot 87 is supported on the end of a downwardly depending shaft 81 extending from bracket 80. In this manner, pivot 87 for lever arm 56 is selectively located at the appropriate position in toilet tank 13. Preferably, bracket 80 and, more particularly, pivot 87 is suitably adjusted in toilet tank 13 so that pivot 87 is adjacent the upper level of water in toilet tank 13 as set forth with respect to pivot 60 and water level 19 of FIG. 2.
THE METHOD
The method of this invention involves placing the water saver apparatus 10 in a toilet tank by pivotally supporting lever arm 56 therein either by means of pivot 60 (FIGS. 1-3), pivot 70 (FIG. 4), or pivot 87 (FIG. 5). In each configuration, lever arm 56 is pivotally suspended in the appropriate toilet tank at a position adjacent the upper level 19 (FIG. 2) of the water therein. The water-fillable weight 50 is thereby immersed in the water to accommodate filling with water by forcing the water through the drain aperture 52.
Upon commencing the flush cycle for the toilet tank 12 (FIGS. 1-3) by raising rod 36 and, correspondingly, stopper 34, the desired water conservation sequence provided by water saver 10 is commenced. In particular, as the water level (water level 21, FIG. 2) drops away from both water-fillable weight 50 and toilet tank float 26 the level of water (water level 51, FIG. 2) in water-fillable weight 50 also lowers but at a slower rate than water level 21. Accordingly, sufficient weight is imparted to the end of lever arm 56 so as to support the weight of toilet tank float 26 and thereby suspend the same above the lowering water level 21 (FIG. 2). After sufficient water has drained from drain aperture 52, the residual weight of water-fillable weight 50 is overcome by the combined weight of toilet tank float 26 and float rod 28 thereby lowering toilet tank float 26 and opening inlet valve 24. With inlet valve 24 opened, the inrushing water 27 from inlet port 25 refills toilet tank 12 (FIG. 3), preferentially, after stopper 34 is again reseated on valve seat 38.
As the lowered water level (water level 23, FIG. 3) raises through the action of the inrushing water 27, toilet tank float 26 correspondingly rises allowing water-fillable weight 50 to be lowered into contact with the rising water level. Thereafter, the rising water level enters water-fillable weight 50 through drain aperture 52 again refilling water-fillable weight 50. Accordingly, the water saver apparatus 10 is again functionally prepared to operate on the next flush cycle of the toilet.
The invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive and the scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.
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An apparatus and method for conserving water during the flush cycle of a tank-type toilet. The apparatus includes a pivotally mounted lever arm having a water-fillable weight on one end and a toilet tank float engagement means on the other end. The water-fillable weight serves as a counter balance to maintain the toilet tank float in an elevated position to thereby hold the water inlet valve closed during the initial stages of the flush cycle. The apparatus also includes means for mounting the pivot mechanism in the toilet tank. The method involves slowly draining water from the water-fillable weight during the flush cycle so as to allow the toilet tank float to be lowered toward the end of the flush cycle and thereby open the inlet valve to refill the toilet tank.
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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 the field of tracks installed in garage openings to accommodate the wheels of garage doors and in particular to enable the garage door to be rolled down in a closed position and to also enable the garage door to be rolled up so that it is generally parallel to the garage floor and the garage is opened to permit entry and exit of vehicles or other items in the garage.
2. Description of the Prior Art
In general the concept of improving a garage door track has been performed. In conventional garage door tracks, the exterior edges of the track are sharp which can create a risk of a cut to an installer and a home owner. As illustrated in FIG. 3A , the prior art garage door track 2000 has sharp ends 2100 and 2200 and a reinforcing member 2300 with sharp ends 2400 and 2500 .
One improvement is to cause the track edges to be hemmed outwardly. Another variation is to cause the track to be rolled inwardly as described in U.S. Pat. No. 5,954,111. The use is also described in U.S. Pat. No. 6,250,360. In general, the prior art garage door tracks have no stiffening ribs and no mechanism to provide extra support to the track to prevent rollout of the garage door wheels from the track as the garage door is moved upwardly toward the horizontal open position.
There is a significant need for an improved garage door track which addresses the deficiencies of the known prior art garage door tracks.
SUMMARY OF THE INVENTION
In general, the present invention relates to improvements in a track and track support structure for a sectional overhead garage door.
In general, the garage door track is an elongated piece of material such as steel, having an outer section with a wall extending at one end to an interior wall section which in turn extends to an inner section having a wall. In general, the outer section is adjacent a wall of a garage door opening, the interior wall section extends generally perpendicularly to the outer section, and the arcuate inner section is farthest from the garage door wall and is rounded and curves toward the outer section. An opening between a distal end of the outer section and the distal end of the inward curve of the inner section enables the wheels of the garage door to enter and be retained in the track area surrounded by the outer section, the interior wall section and the arcuate inner section.
In the prior art, the distal end of the outer section and the distal end of the inward curve of the outer section are sharp. Attempts to reduce the sharp ends have been made by hemming the distal ends outwardly from the track interior against an outer wall of the outer section and forming a hemmed edge and extending against an outer wall of the inward curve of the inner section. Other attempts to reduce the sharp ends were to create interior roll formed beads. However, to achieve this the material needs to be very thin which reduced the strength of the track and the garage door wheels would bind on the interior roll formed beads.
Hemming is bending in the sharp edges of the track either outwardly so that the edges are bent against adjacent outer walls of the track or bent inwardly so that the edges are bent against adjacent inner walls of the track. It has been discovered, according to the present invention, that if the outermost distal edge portions of the track which include the distal end of the outer section and the distal end of the inward curve of the arcuate inner section are respectively hemmed and bent inwardly against an adjacent inner wall section of the outer section and against an adjacent inner wall of the inwardly curved portion of the arcuate inner section, then hemming the edge of the garage door track inwardly provides increased strength and a safer smooth edge. The inward hemming will also not interfere with the roller wheels of the garage door. The entire track section has a common exterior wall and a common interior wall.
It has been discovered, according to the present invention, that hemming the edge of the garage door track inwardly provides increased strength and a safer smoother edge. An inside hemmed edge will provide a means of door roller retention with increased strength of the inward hemmed edge. This solves the problem associated with conventional garage door tracks, including: (a) edge imperfections of a steel edge which can lead to track failure; (b) an edge imperfection could be a bulge, crimp or edge stress concentration; (c) at the blade edge of the steel, edge buckling can lead to failure of the door.
It has further been discovered, according to the present invention, that a hemmed edge will provide increased resistance to track bowing. The hemmed edge solves the problem associated with sharp edges. Sharp edges can cut hands or fingers during installation of the garage door into the track or throughout its service life. The stronger design can now be now be produced in a reduced steel thickness without sacrificing the strength and integrity of the track. This also facilitates a reduced cost unit rate and a single thickness for all residential tracks. This reduces inventory for even more reduced costs of manufacturing.
It has further been discovered, according to the present invention, that the addition of stiffening ribs into the outer section, interior inner wall, and adjacent the arcuate inner section of the track increases strength rigidity and reduces track bowing and track roll out. Track roll out is used to describe the fallout and failure of the door and door rollers. In the present invention, four stiffening ribs have been incorporated into the garage door tracks. A first stiffening rib is formed on the top sidewall of the outer track section. Two spaced apart stiffening ribs are formed on the interior sidewall section, and a fourth spaced apart stiffening rib is formed in the wall of the curl section which is the portion of the interior sidewall that curves into the arcuate inner section of the track. These roll formed channels or stiffening ribs will provide increased strength to the entire track set. These channels combined with the hemmed inward edge provide increased strength on the entire track set which would take 30-40% thicker steel to achieve the same strength, providing a weight savings of at least 30%. This in turn saves cost per set in the manufacturing. This increased strength will allow the manufacturer to run one gauge (thickness) of steel, thereby eliminating the need for multiple gauges. One gauge can now be used for light duty to heavier duty residential applications by only changing the reinforcing angle. The lower cost to the manufacturer is passed on to the user/dealer and reduced inventory cost.
It has been discovered, according to the present invention, that the addition of the top stiffening rib not only increases strength, but also provides a channel and space/area for the door rollers to ride up in. This is while the door is traveling to the raised position. Without the top stiffening rib, roller drag occurs. This is a problem with 10 inch, 12 inch and 15 inch radius track. Carriage house style doors that are 3 sections tall with 28 inch oversize sections and larger 32 inch sections have the same roller drag problem. While the door is rolling up through the radius on the top of the track, the door rollers get forced against the top of the track. This causes roller drag (binding/friction). Roller drag causes extra wear on the hinges, rollers, door sections and garage door operators. The top stiffening rib channel solves this problem. The extra space/area allows the roller to rise/raise into the channel (rib) allowing it to turn freely with no binding and dragging. This provides smooth door action throughout the entire radius transition. It works almost the same way in the down cycle. As the garage operator pushes the door through the radius position, the door is pushed against the front of the track in the vertical position. The stiffening rib channel provides the extra space to move the rollers forward and not bind in the radius. This results in a big improvement in smooth bind free performance, providing extra life for door parts including cost effective performance at no extra cost and extra strength for the life of the door track.
Another improvement is a reinforcing angle which matches the ribs on the section of the track which is the top horizontal section of track parallel to the floor. The reinforcing angle provides extra supporting strength to the horizontal track portion by having strengthening ribs which match the strengthening ribs of the track section. A reinforcing angle for the garage door track has been straight cut and has had a sharp edge since it was invented. This sharp edge has a sharp point. This has caused injury to installers and homeowners for years. Having a radius curved edge will eliminate the sharp point and provide a safer edge. There is no added cost and no loss of strength but it provides a substantial improvement over the prior art straight cut tracks for garage doors.
It should be noted that the reinforcing angle that have no stiffening ribs [industry standard design] Prior art drawing FIG. 3A would have to be 0.075 thick [14 Ga steel] To provide the same strength as the 0.065 [16 Ga steel] reinforcing angle with the present invention. This provides significant savings in the cost of the part. The reduced weight savings in addition to the cost of part savings, would reduce shipping costs. Less weight equals more product per truckload reducing shipping and the final cost of each Track set. Plus radius cut safer edge provides added safety and easy handling of completed track set with no added costs to manufacturing.
It has further been discovered, according to the present invention, that a shorter length on the horizontal section of the track rail section will make the track stronger by reducing unsupported span. Most prior art horizontal garage door track sections are 8 feet 6 inches for a 7 foot door; or 9 feet 6 inches for an 8 foot door. Reducing the horizontal track length by 12 inches it moves the point of support (back hang) closer to the top roller of the door. The distance from the back-hang to the top roller is considered unsupported span. Unsupported span tends to let the track twist and bow. This could lead to track roll out or failure. The door roller on the top could fall out of the rack because of the bow/twist. Some prior art involves extra holes in the track. The holes are used to move the back hang forward which looks odd and unsightly. Shortening the horizontal track provides and facilitates the strongest back hang.
Sometimes the vertical section of the garage door track is damaged by the owner hitting it with his car. The present invention can be used to replace only the vertical part and inter-fit with the remainder of the existing undamaged track, even if does not have the improvements in the track as described above.
The objects of the present invention are to incorporate into a garage door track all of the discoveries and improvements as set forth above.
Further novel features and other objects of the present invention will become apparent from the following detailed description, discussion and the appended claims, taken in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
Referring particularly to the drawings for the purpose of illustration only and not limitation, there is illustrated:
FIG. 1 is an end view of the present invention garage door track illustrating a first stiffening rib of the top sidewall of the outer track section placed closest to a garage door wall when installed, two spaced apart stiffening ribs on the interior sidewall when installed, and a fourth spaced apart stiffening rib in the wall of the curl section which is the portion of the interior sidewall that curves into the arcuate inner section of the track, the arcuate inner section being farthest away from a garage door wall when installed and having a curved section extending to an inward curving section closest to the outer wall section, leaving a gap into which roller wheels from a garage door are inserted;
FIG. 2 is an end view of the present invention garage door track when viewed from a horizontal section of track including a matching reinforcing angle with a section affixed to the interior sidewall of the garage door track and a second portion hanging in the air;
FIG. 3A is a side perspective view of a prior art garage track with a straight wall having no strengthening ribs and a straight reinforcing angle, the track and reinforcing angle having sharp exterior ends to their respective walls;
FIG. 3B is a perspective view of the combination garage door track including a matching reinforcing angle with a section affixed to the interior sidewall of the garage door track and a second portion hanging in the air;
FIG. 4 is a front perspective view of the present invention garage door track with backing members used to affix the distal end of the garage door track to a garage ceiling, also illustrating a stop bolt to prevent the garage door wheels from rolling out of the track, also illustrating a rear view of the matching reinforcing angle and illustrating a flag bracket retaining the garage door track at the location where the garage door track extends from a horizontal section to a vertical section and illustrating a return spring member to assist in raising the garage door;
FIG. 5 is a rear perspective view of the present invention garage door track illustrated in FIG. 4 ; and
FIG. 6 is a perspective view when standing in a garage with the garage door down, the right side of the garage door wheels inserted into a right vertical right section of track, which vertical right section of track extends onto and is affixed to a portion of the ceiling of the garage.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Although specific embodiments of the present invention will now be described with reference to the drawings, it should be understood that such embodiments are by way of example only and merely illustrative of but a small number of the many possible specific embodiments which can represent applications of the principles of the present invention. Various changes and modifications obvious to one skilled in the art to which the present invention pertains are deemed to be within the spirit, scope and contemplation of the present invention as further defined in the appended claims.
Referring to FIG. 1 , there is illustrated an end view of the present invention garage door track 10 , illustrating two of the major improvements of the present invention. The garage door track 10 comprises an outer wall section 20 having a distal end 22 , an exterior wall 24 and an interior wall 26 , with one of the innovations being that at the distal end 22 , the garage door track is hemmed inwardly with the inward first hem 28 having a round exterior end 30 and pressed parallel to and against an adjacent section of the interior wall 26 . A second innovation is that the outer section wall 32 bounded by interior wall 26 and exterior wall 24 has a strengthening rib 34 formed into it and centrally disposed along the width “W 1 ” of the outer wall section 20 , the strengthening rib 34 extending outwardly away from an interior chamber 70 to be described.
The outer wall section 20 extends at its proximal end 36 to an interior side wall section 40 having a wall 42 bounded by an interior wall 44 and an exterior wall 45 with a second strengthening rib 46 formed into wall 42 and extending away from the interior chamber 70 . The interior side wall section 40 has a spaced apart third strengthening rib 48 formed into wall 42 and extending away from the interior chamber 70 . The interior side wall section 40 extends to a curl portion 50 which is still part of wall 42 and bounded by interior wall 44 and exterior wall 45 with a fourth strengthening rib 52 formed into wall 42 and extending away from chamber 70 . Second strengthening rib 46 is spaced apart from third strengthening rib 48 . The length “L 1 ” is from the proximal end of exterior wall section 20 where it joins interior side wall section 40 to adjacent the distal end of fourth strengthening rib 52 . The section distance “L 1 -A” extends from the proximal end 36 to first space 46 A of second strengthening rib 46 and a distance “L 1 -B” extends from a first space 46 A of second strengthening rib 46 to a second space 46 B of second strengthening rib 46 . A length “L 1 -C” extends from a second space 46 B of the second strengthening rib 46 to a first space 48 A of third strengthening rib 48 . The third strengthening rib 48 has a distance “L 1 -D” extending from 48 A to 48 B and the fourth strengthening rib 52 has a distance “L 1 -E”, with distances “L 1 -A”, “L 1 -B”, “L 1 -C”, “L 1 -D” and “L 1 -E” combining to be “L 1 ”. Curl portion 50 extends to arcuate inner section 54 which extends to an inward curved portion 56 terminating in a distal end 58 of arcuate inner section 54 I which is hemmed inwardly with second hem section 60 pressed against interior wall 57 and having a rounded end 62 . A gap “G 1 ” is between first hem section 28 and second hem second 60 leading interior chamber 70 bounded by outer section 20 , interior side wall section 40 and arcuate inner section 54 so that wheels of a garage door can be inserted through the gap “G 1 ” and into chamber 70 .
Referring to FIG. 2 , there is illustrated the present invention garage door track with hemmed distal ends and four strengthening ribs and an additional innovation of a reinforcing angle 100 having a wall 102 with an interior 104 and an exterior 105 . The reinforcing angle 100 has a first section 106 having a first strengthening rib 108 and a spaced apart second strengthening rib 110 which are formed to match second strengthening rib 46 and third strengthening rib 48 of interior side wall section 40 and spaced apart so that the strengthening ribs 46 and 108 are aligned and strengthening ribs 48 and 110 are aligned, with the distal end 112 of the first section of the reinforcing angle 100 terminating adjacent the fourth strengthening rib 52 . As best illustrated in FIG. 3B , the reinforcing angle 100 is slidably affixed at a location of the rear wall 24 of the interior side wall section 40 of track section 10 by an affixation member 114 which extends through an oval opening 116 in first section 106 of reinforcing angle 100 and a corresponding opening in section 40 of track 10 so that the location of the reinforcing angle 100 can be adjusted. As illustrated in FIG. 4 , all respective reinforcing ribs run the length of the track and the length of the reinforcing angle.
As illustrated in FIG. 2 and FIG. 3B , the reinforcing angle 100 has a second section 120 which is generally perpendicular to the first section 106 at its proximal end 103 and extends away freely in the air. The second section 120 of the reinforcing angle 100 also has strengthening ribs 122 and 124 between its proximal end 126 adjacent proximal end 103 and the distal end 128 of the second section 120 of reinforcing angle 100 which further strengthens the track. The edge of the reinforcing angle 100 has a radius to prevent a sharp edge cut to an installer or homeowner.
Referring to FIG. 4 , there is illustrated a front perspective view of a completed track section and supporting members for the section of track 10 A which extends in a horizontal direction to receive the rollers of a garage door when the garage door is rolled up so that it is generally parallel to the garage door floor when the garage is open. FIG. 5 is a rear perspective view of most of the embodiment illustrated in FIG. 4 .
The rear track section 10 A has the same innovations of the hemmed ends 28 and 60 and supporting ribs 34 , 46 , 48 and 52 . Adjacent the distal rear end 8 A of horizontal track section 10 A at a distance beyond the reinforcing angle section 106 of reinforcing angle 100 and affixed to the back of track section 10 A are backing members 200 having a multiplicity of openings 202 , 210 having a multiplicity of openings 212 and 220 having a multiplicity of openings 222 . The rear track section 10 A is affixed to a ceiling of a garage by affixation members such as one way bolts or one way screws respectively extending through one or more of the multiplicity of openings 202 , 212 and 222 of the respective backing members 200 , 210 and 220 . A stop bolt 230 extends through an opening in the back wall 24 of interior side wall section 40 of the track section 10 A adjacent the distal end 8 A and extends into opening 70 to prevent the wheels of the door from moving past the distal end 8 A and off the track 10 A.
The angle support 100 is only on the horizontal portion of the track 10 A and supports only a portion of the track section 10 A. A flag bracket 300 is mounted to the garage wall. The flag bracket 300 has a first section 320 with mounting members 330 affixed to an extended portion of the reinforcing angle 100 with a coiling spring member 340 having a coil 342 to help raise the garage door. The flag bracket 300 has a multiplicity of slotted openings 350 , 360 , 370 and 380 to adjustably mount the distal end 102 of the reinforcing angle 100 to one or more affixation members 390 such as mounting bolts which extend through the proximal section 400 .
The track section 10 A extends from its horizontal position around a curved section before it is joined to a vertical section 10 B of track 10 . A flag 410 located at a distal end 420 of the flag bracket 300 has mounting members 430 which affix the flag 410 to the distal end 10 A-D of track section 10 A. The flag 410 also has mounting members 440 which affix the flag 410 at an upper or distal end 10 B-D of vertical track section 10 B. In this way, the track sections 10 A and 10 B of track 10 are supported.
Another innovation of the present invention is to reduce the distance from the distal end 8 A to distal end 10 A-D of horizontal track section 10 A by 12 inches. This section is known as unsupported span covering the distance from the back hangers 200 , 210 and 220 to distal end 10 A-D. In the prior art, the span of 8 feet 6 inches or more enables the track section 10 A to twist and bow leading to track roll out. The reduction of span length to 7 feet 6 inches for a 7 foot tall door (or reduction to 8 feet 6 inches for a eight foot tall door) provides for a much stronger unsupported span reducing the track twisting and bowing and reducing the incidence of rack roll out.
Referring to FIG. 6 , there is illustrated a view standing inside a garage with the garage door viewed from a rear view in the down condition with the right side of the garage door wheels inside the right vertical section of track and the horizontal section of track extending around a curve and mounted to the ceiling of the garage on the right side of the garage door track structure. The rear track section 10 A which is horizontal is adjacent the ceiling 500 of garage 600 with the backing members 200 , 210 and 220 with their respective affixation members extending through respective openings 202 , 212 , into the ceiling 500 with the backing members illustrated adjacent the distal end 8 A of the horizontal track section 10 A of track 10 . The flag bracket 300 is mounted to the upper interior garage wall 550 with its first section 320 affixed to an extended portion of the enforcing angle 100 with the coil spring member 340 having a coil 342 affixed to the bottom 710 of the garage door 700 to help raise the garage door 700 . The enforcing angle 100 is only against the horizontal section 10 A of the track 10 . The back 24 of the lowermost portion of the vertical track section 10 B of track 10 is affixed to flag bracket 430 which is affixed to the back 720 of the garage door 700 . Mounting brackets 800 , 810 and 820 further affix the vertical track section 10 B to respective locations along the vertical distance of the back of the garage door 720 . Garage door wheels 760 , 770 , 780 and 790 are illustrated inserted into chamber 70 along respective locations along respective vertical locations of the vertical track section. The wheels 760 , 770 , 780 and 790 are affixed to a side of the garage door 700 . It will be appreciated that the left track 10 and its vertical and horizontal track sections are a mirror image of the right track section illustrated in FIG. 6 with wheels affixed onto the left side of the garage door inserted into a corresponding chamber in a left track section.
The wheels of the garage door ride on the vertical track sections until they arrive at the horizontal track sections so that the garage door is horizontal adjacent the ceiling 700 and generally parallel to the floor 900 . The garage door 700 is rolled down the vertical track sections to close the garage.
Of course the present invention is not intended to be restricted to any particular form or arrangement, or any specific embodiment, or any specific use, disclosed herein, since the same may be modified in various particulars or relations without departing from the spirit or scope of the claimed invention hereinabove shown and described of which the apparatus or method shown is intended only for illustration and disclosure of an operative embodiment and not to show all of the various forms or modifications in which this invention might be embodied or operated.
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An improvement in garage door tracks which includes placing an inwardly pressed hem on the distal ends of the sections of track which surround the gap by which wheels from a garage door are placed into a track chamber. The hems on the distal end provide increased strength and a safer smoother edge. The inward hemming also does not interfere with the roller wheels of the garage door. This further solves the problem of track failure and bulge or crimping and causes less stress on the garage door track. A further innovation is to have strengthening ribs at different locations on the garage door track to provide further strength to the garage door track. A further innovation is to provide strengthening ribs at different locations on the garage door track to provide further strength to the garage door track.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims domestic priority on U.S. Provisional Patent Application Ser. No. 61/184,350, filed on Jun. 5, 2010, the content of which is incorporated herein by reference.
FIELD OF THE INVENTION
The present invention generally relates to an apparatus for preparing a stone base for subsequent construction and, more particularly, to a screed machine that will level a stone base for the installation of a pre-cast concrete wall.
BACKGROUND OF THE INVENTION
Construction of a large number of structures, including buildings, sewer lines, prefabricated structures, etc., begins with the placement of a stone base. In some instances, the stone base must be accurately placed and graded for the proper construction of the structure. For example, a gravity sewer line is constructed at a sloped grade under which the stone base is graded at that same slope to provide proper support for the sewer line. Another example of a stone base that requires precise grading is the stone base under a pre-cast concrete wall.
A pre-cast concrete wall is manufactured at a remote site and shipped to the job site to be erected. A pre-cast concrete wall, constructed as disclosed, for example, in U.S. Pat. No. 7,530,203, granted on May 12, 2009, to Robert W. Hare, et al., is formed with a footer beam that is placed on a graded stone base. A plurality of the pre-cast concrete wall panels are placed around the pre-graded stone base to form an enclosed foundation for a building to be subsequently built on the foundation. The proper support of the footer beams requires that the stone base beneath the pre-cast concrete walls is graded level in both longitudinal and transverse directions so that the stone will contact the underside of the footer beam all along the erected foundation.
Conventionally, the grading of the stone base is first rough graded to within about an inch of being level around the location for the erection of the pre-cast concrete walls. Final grading is accomplished by first setting grading monuments, such as a piece of a wooden two by four placed into the stone base, around the perimeter of the foundation to be erected and then leveled at the desired elevation by a laser level. The stone base can then be hand graded by sliding a screed between consecutive monuments so that the stone base between the monuments is at the same elevation as the adjacent monuments. This process is repeated around the perimeter of the foundation until the entire area on which the pre-cast concrete walls are to be erected is leveled at the desired grade elevation. This process is extremely time consuming and labor intensive.
Accordingly, it would be desirable to provide an apparatus that would be operable to grade a stone base accurately and uniformly without requiring the setting of elevation monuments and hand screeding to accomplish the graded stone base.
SUMMARY OF THE INVENTION
It is an object of this invention to overcome the aforementioned disadvantages of the known prior art by providing a manually operated screed machine for leveling a stone base for the installation of pre-cast concrete walls.
It is another object to provide a screed assembly that is vertically movable relative to ground support members to maintain a selected grade elevation for the stone base as the screed machine is moved along the stone base where the pre-cast concrete walls are to be positioned.
It is a feature of this invention that the screed assembly is mounted on a telescopic mast that is operably connected to an actuator to affect vertical movement of the screed assembly.
It is an advantage of this invention that the actuator can be electronically coupled to a laser receiver to affect movement of the screed assembly in conjunction with a laser level defining the final grade for the stone base.
It is another feature of this invention that the screed machine is supported on the ground by a pair of longitudinally spaced rollers.
It is another advantage of this invention that the rollers allow the screed machine to be moved over the stone base.
It is still another advantage of this invention that the screed assembly is positioned in front of the forwardmost roller so that the rollers are supporting the screed machine on the final grade of the stone base.
It is still another feature of this invention that the screed assembly is formed with a forwardly projecting wedge portion that sweeps excess stone base laterally as the screed machine is moved forwardly over the stone base.
It is yet another feature of this invention that the screed assembly is formed with a pair of laterally extending wings that project in opposing directions from the wedge portion to deflect stone base material laterally away from the rollers.
It is yet another advantage of this invention that each of the wings is mounted on a pivot to permit a positioning of the wings in selective angular orientations relative to the wedge portion.
It is still another advantage of this invention that the rollers compact the leveled stone base after the stone base is leveled by the screed assembly.
It is still another object of this invention to provide a method of fine grading a stone base to prepare for the installation of pre-cast concrete walls on the stone base.
It is a further feature of this invention that the stone base is rough graded before the screed machine is placed on the stone base.
It is still a further feature of this invention that the screed machine is pulled along a path on the stone base corresponding to the location along which the pre-cast concrete wall panels are to be installed.
It is a further advantage of this invention that the final grade is set on a laser level with the signal therefrom being received on the screed machine to cause vertical adjustment of the position of the screed assembly.
It is yet another object of this invention to provide a pivot mechanism to allow the screed machine to turn corners on the stone base without disturbing the final grade thereof.
It is still another feature of this invention that the frame of the screed machine supports a jack stand that is selectively positionable into engagement with the stone base to allow the screed machine to be lifted above the stone base and rotated to change directions for the movement thereof.
It is still another advantage of this invention that the jack stand is positioned at approximately the center of gravity of the screed machine so that the entire screed machine can be balanced on the jack stand for rotation about the axis corresponding to the jack stand.
It is yet another advantage of this invention that the extension of the jack stand is powered by an actuator.
It is still another object of this invention to provide a monitor to indicate the lateral inclination of the screed machine.
It is another feature of this invention that the lateral level monitor includes a sight level mounted the mast of the screed machine.
It is yet another feature of this invention that the frame of the screed machine is provided with a handle assembly that allows an operator to manually pull the screed machine along the desired path on the stone base.
It is a further feature of this invention that all of the actuators on the screed machine are electrically powered from a battery supported on the screed machine.
It is yet another object of this invention to provide a screed machine for leveling a stone base that is durable in construction, inexpensive of manufacture, carefree of maintenance, facile in assemblage, and simple and effective in use.
These and other objects, features and advantages are accomplished according to the instant invention by providing a screed machine having a forwardly positioned screed assembly including a wedge portion and pivoted wing members. The frame is supported on two rollers longitudinally spaced behind the screed assembly. The screed assembly is mounted on a mast for vertical movement in conjunction with a laser receiver that provides a signal indicating the final desired grade of the stone base. The machine can be turned at a corner by extension of a jack stand to elevate the entire machine for rotation about the axis defined by the centrally located jack stand so that the screed machine can be redirected into a different direction without disturbing the final grade of the stone base. The screed machine is manually moved along the stone base by an operator pulling on the handle pivotally connected to the frame. A sight level provides a monitor for the lateral orientation of the screed assembly.
BRIEF DESCRIPTION OF THE DRAWINGS
The advantages of this invention will be apparent upon consideration of the following detailed disclosure of the invention, especially when taken in conjunction with the accompanying drawings wherein:
FIG. 1 is an upper, left front perspective view of the screed machine incorporating the instant invention, the wings being pivoted outwardly to widen the screed width of the apparatus;
FIG. 2 is an upper, right rear perspective view of the screed machine shown in FIG. 1 ;
FIG. 3 is a left rear perspective view of the screed machine shown in FIG. 1 ;
FIG. 4 is a front elevational view of the screed machine having the wings pivoted inwardly to a non-operational position;
FIG. 5 is a front elevational view of the screed machine similar to that of FIG. 4 , but having the screed broken away to view the structure at the front of the apparatus, the wings being pivoted outwardly;
FIG. 6 is a left side elevational view of the screed machine having the wings pivoted outwardly;
FIG. 7 is a rear elevational view of the screed machine, the wings being pivoted inwardly to a non-operative position;
FIG. 8 is a rear elevational view of the screed machine similar to that of FIG. 7 , but having the wings pivoted outwardly;
FIG. 9 is a top plan view of the screed machine having the wings pivoted inwardly;
FIG. 10 is a top plan view of the screed machine similar to that of FIG. 9 , but having the wings pivoted outwardly;
FIG. 11 is a right rear perspective view of the screed machine with the handle being broken away to better view the frame components of the apparatus, the wings being pivoted outwardly;
FIG. 12 is a right side elevational view of the screed machine having the wings pivoted outwardly and the central support jack extended to allow the screed machine to make a turn;
FIG. 13 is a front elevational view of the screed machine shown in FIG. 12 ;
FIG. 14 is a cross-sectional perspective view of the left side of the screed machine taken along lines 14 - 14 of FIG. 9 ;
FIG. 15 is a cross-section perspective view near the center of the screed machine taken along lines 15 - 15 of FIG. 10 ; and
FIG. 16 is a perspective view of the screed machine collapsed into a compact transport orientation.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 1-16 , a screed machine incorporating the principles of the instant invention can best be seen. Left, right, front and rear references are use as a matter of convenience and are determined by standing at the rear of the machine 10 and facing the handle assembly 16 mounted at the forward end to pull the machine 10 along a direction of operative travel. The screed machine 10 has a generally rectangular main frame 11 having a central transverse cross member 11 a . The main frame 11 rotatably supports a pair of longitudinally spaced, transversely extending rollers 15 that engage the surface of the stone base to compact and smooth the surface being leveled, as will be discussed in greater detail below. The main frame 11 has a pair of grips 13 located on each transverse side of the frame to provide an apparatus on which people can grasp to push the screed machine 10 when necessary. The main frame 11 also includes a crane hoist 14 centrally located on the main frame 11 so that a crane can be attached to the main frame 11 to lift the machine 10 into and out of a foundation excavation. Preferably, a removable or hinged cover plate 12 is mounted on top of the frame 11 to shield the operative devices described in greater detail below.
The handle assembly 16 is mounted at the front end of the main frame 11 and projects forwardly to be grasped to pull the machine 10 over the surface of the stone base. The handle assembly 16 is preferably pivotally attached to the main frame 11 by pivots 17 . The handle assembly 16 can be formed with a U-shaped handle 16 a that terminates in a mounting leg 16 b that is oriented orthogonally to the handle 16 a . The mounting legs 16 b are connected to the pivots 17 so that the height of the handle 16 a can be varied to the preference of the operator. As best seen in FIGS. 3 and 11 , the handle assembly 16 also includes a pivot control device 18 , including an apertured plate 18 a affixed to the main frame 11 and a pivot lock 19 that is engagable with a selected one of the apertures in the plate 18 a to lock the handle 16 a in a selected height.
A screed assembly 20 is pivotally mounted on the main frame 11 and is positioned in front of the main frame 11 to engage the top surface of the stone base to level the stone base. The screed assembly 20 includes a U-shaped support frame 21 pivotally connected to the main frame 11 at pivots 23 located approximately centrally on the main frame 11 to give the pivotal movement of the screed assembly 20 an arc that is substantially linear forwardly of the main frame 11 . The support frame 21 has mounted thereon a screed member 25 that includes a rearward linear portion 26 extending transversely across the entire front of the machine 10 and projecting outboard of the main frame 11 to either side thereof. The screed member 25 also includes a V-shaped wedge portion 28 mounted to the front of the linear portion 26 to provide a screed member 25 that has longitudinal depth and operates to move excess stone outboard of the surface being leveled by the machine 10 .
The screed assembly 30 also includes a pair of laterally spaced side extension wings 30 positioned at each respective outboard end of the linear portion 26 of the screed member 25 . Each side extension wing 30 is pivotally connected to the respective end of the linear portion 26 by a vertical hinge 32 to permit the side extension wing 30 to move between a retracted, inoperative position seen in FIGS. 4 , 7 and 9 , and an extended operative position seen in FIGS. 1 , 2 , 5 , 6 , 8 , 10 and 11 . The movement of the side extension wings 30 is best seen in comparison of FIGS. 4 and 5 , and in comparison of FIGS. 7 and 8 , and also FIGS. 9 and 10 . A position control apparatus 35 is operable to lock each of the side extension wings in a selected pivoted position.
An apertured plate 36 mounted on top of the vertical hinge 32 is engaged by a spring-loaded pivot lock 38 having a perpendicularly extending actuation lever 39 . With the spring-loaded pivot lock 38 retracted, the side extension wing 30 can be pivoted to the desired position and the actuation lever released to engage the pivot lock 38 with one of the holes in the plate 36 to lock the side extension wing 30 in position. The movement of the side extension wings 30 into an operative position expands the transverse width of the surface of the stone base being leveled by the screed assembly 20 , which will provide room for the machine 10 to make a turn, as will be described in greater detail below.
The screed assembly 20 is pivotally movable to cause a vertical adjustment of the screed member 25 by a screed control mechanism 40 . A mast 41 is mounted on the transverse support frame member 22 to be vertically movable therewith. The mast 41 preferably includes a base member 42 and an extendable top mast member 43 supported by the base member 42 which is attached to the transverse support frame member 22 . A laser receiver 45 is connected to the top mast member 43 by an adjustable mounting apparatus 46 that permits the laser receiver 45 to be positioned vertically along the top mast member 43 . An electrically powered linear actuator 47 is mounted on the main frame 11 and operatively connected to the base member 42 . The linear actuator 47 is operatively coupled to the laser receiver 45 through a controller 48 that incorporates switches for automatic control of the screed member 25 and manual control thereof.
When in the automatic control mode, the controller 48 receives a signal from the laser receiver 45 that the laser receiver 45 is moving up and/or down with respect to a laser level signal (not shown). The controller 48 activates the linear actuator 47 to cause the linear actuator 47 to expand or contract, as appropriate, to move the mast member 41 and, thus, the screed member 25 , thereby keeping the screed member 25 at a level orientation as the machine 10 is moved across the top surface of the stone base. The support panel 44 , on which the control mechanism 48 is mounted, is preferably mounted on the handle 16 for convenient access by the operator. The control mechanism 48 is also provided with a sight level 49 that indicates the level of the machine 10 in a transverse direction. One skilled in the art will recognize that electrical wires for the control mechanism and related electrically powered components are removed from the drawings for purposes of clarity, although some components, such as the operative connection between the laser receiver 45 and the control mechanism 48 may be wireless.
An electrically powered jack 50 is mounted on the frame 11 , preferably the transverse cross member 11 a . The jack 50 has a pivotable linkage member 52 , configured as a four-bar linkage, to permit the bottom plate assembly 51 to remain in a vertical orientation. The bottom plate assembly 51 includes a bottom plate member 54 that is rotatable relative to the remainder of the assembly 51 . The pivotable member 52 is operatively connected to an electrical jack actuator 53 that upon extension and contraction effects vertical movement of the linkage member 52 . The bottom plate 52 at the terminus of the linkage member 52 can swivel relative to the linkage member 52 on which it is mounted. As is represented in FIGS. 12-15 , the extension of the linkage member 52 presses the bottom plate 54 onto the stone base and raises of the screed machine 10 above the surface of the stone base. The swiveling bottom plate 54 , on which the weight of the machine 10 is supported on the stone base, allows the entire machine 10 to be rotated and, thus, affect a turn of the machine 10 to be movable in a different direction. Once the machine 10 is reoriented, the linkage member 52 is retracted and the screed machine 10 is free to operate in the new direction.
Power for the electrically operated components, such as the linear actuator 47 , the control mechanism 48 and the jack actuator 53 , is provided by a 12-volt marine battery 55 supported on a battery support pan 57 mounted on the main frame 11 between the rollers 15 . The battery support pan 57 is positioned higher than the rollers 15 and, thus, will not contact the stone base. The support panel 44 has mounted thereon a battery life gauge 59 operably connected to the battery 55 to provide a visual indication of the amount of electrical power remaining in the battery 55 . The battery 55 is preferably rechargeable.
The screed machine 10 operates in conjunction with a laser level (not shown) that is set up on site and emits a laser signal to indicate the proper grade of the stone base being prepared. In the case of a stone base to be prepared for a pre-cast concrete wall, the laser level emits a laser signal that indicates a level grade at a given elevation. In the case of a sewer line that is placed on a slope gradient, the laser level emits a laser signal that is indicative of that slope gradient. The laser signal is received by the laser receiver 45 that must be positioned on the top mast member 43 by manipulating the mounting apparatus 46 . The screed machine 10 is then placed on the stone base at a position corresponding to the desired elevation of the prepared stone base in an orientation that will coordinate the movement of the screed machine 10 with the alignment of the position of structure to be erected on the stone base, typically by a crane or a powered lift that is connected to the crane hoist member 14 to lower the screed machine 10 into the excavation where the stone base has been placed.
The screed machine 10 has the jack 50 retracted and preferably has the side extension wings 30 retracted into the inoperative position and locked into place with the position control apparatus 35 . The transverse orientation of the screed machine 10 must be level, which can be authenticated by observing the pendulum 49 . If the sight level 49 indicates that the screed machine 10 is not level, the stone base at which the screed machine 10 is to start operation must be manually leveled so that the screed machine 10 starts operation in a transversely level orientation. The screed control mechanism 40 is powered on and switched into the automatic mode of operation. The screed machine 10 is then ready for movement along the path corresponding to the location at which the structure, which in this example would be a pre-cast concrete wall, would subsequently be erected.
Operation of the screed machine 10 is preferably accomplished by two people. One person grasps the handle 16 a , which can be pivotally positioned through manipulation of the position control device 18 to locate the handle 16 a at a convenient height, and pulls the screed machine along the desired path. The second person utilizes a shovel to assure that a supply of the stone base is piled in front of the wedge portion 28 of the screed member 25 entirely across the transverse width of the screed member 25 . If the screed machine 10 is moved and operated without a supply of stone base in front of the screed member 25 , the screed member 25 can leave a section of the path of the stone base below the desired grade. If the supply of the stone base in front of the screed member 25 is too great, the screed machine 10 will be more difficult to pull along the desired path. Accordingly, the stone base needs to be rough graded to within about an inch or so of the desired final grade before the screed machine 10 is utilized.
As the first person pulls on the handle assembly 16 , the screed machine 10 is dragged along the desired path of the stone base that is to be finally graded. The laser signal received by the laser receiver 45 identifies the elevation along which the laser receiver 45 is to travel. As the laser receiver 45 moves up or down outside of a predetermined range, corresponding to the screed member 25 changing elevation, electrical power is directed to the linear actuator 47 by the control mechanism 48 to cause the base 42 of the mast 41 to be raised or lowered accordingly. As a result, the screed member 25 , which is connected to the base 42 of the mast 41 moves vertically to keep the position of the screed member 25 at the desired elevation. The depth of the screed member 25 from the wedge portion 28 to the linear portion 26 keeps the stone base level without ridges and valleys caused by the vertical adjustment of the screed member 25 through operation of the control mechanism 48 .
When the screed machine 25 approaches a corner on the desired path along which the stone base is to be finally graded, it is desirable to widen the transverse width of the path being graded on the stone base to affect the turn at the corner, as will be described in greater detail below. To increase the transverse width of the graded path, the operator needs to depress the actuation lever 39 on the side extension wing 30 corresponding to the inside of the turn to be made so that the side extension wing 30 can be rotated outwardly into an appropriate operative position, whereupon the actuation lever 39 can be released and the side extension wing 30 locked into place. Because the bottom edge of the side extension wings 30 are co-planar with the linear portion 26 and wedge portion 28 of the screed member 25 , the side extension wing 30 simply widens the path being graded by the screed machine 10 .
One skilled in the art will recognize that the side extension wings 30 increase the drag on the screed member 25 and, therefore, increases the force required to move the screed machine 10 . If additional assistance is required to move the screed machine 10 along the path being graded, the other person, or persons, helping the operator can grasp the grips 13 and assist in pushing the screed machine 10 . At the turn, the screed machine 10 is moved along the path to be graded until the distal tip of the side extension wing 30 that has been deployed into the operative position has cleared the path to be graded after the turn.
When the screed machine 10 has been moved to a position where the deployed side extension wing 30 the location of the jack 50 is at or near the center of the new path on the stone base to be graded after the turn. The operator deactivates the control mechanism 48 by either turning the control mechanism 48 off or switching the control mechanism 48 into manual mode, and then activates the actuator 53 to extend the jack 50 and engage the bottom plate 54 on the graded surface of the stone base immediately below the screed machine 10 . Continued extension of the jack 50 will raise the screed machine 10 , as is reflected in FIGS. 12 and 13 . Balance of the machine 10 is maintained because the jack 50 is located at the center of gravity of the machine 10 and also by the operator holding the handle 16 .
Once elevated off of the stone base, the machine 10 can be pivoted about the vertical axis defined by the bottom plate assembly 51 due to the swiveled bottom plate 54 . Accordingly, the screed machine 10 can be aligned on the next path to be graded. The extra transverse width of the screed member 25 provided by the extension of the wing 30 graded off a sufficient portion of this next path that the entire screed machine 10 will be placed on a leveled surface to start operation along this next path to be graded. When the screed machine 10 is properly aligned on the next path, the side extension wing(s) 30 are repositioned to the inoperative position and the jack 50 is retracted to place the rollers 15 and the screed member 25 back onto the stone base. The control mechanism 48 can then be switched back to the automatic mode and the screed machine 10 can be pulled along this next path as described above until reaching the next turn.
When finished, the entire perimeter on the stone base corresponding to the erection of the pre-cast concrete walls into a foundation will be graded to a level elevation as defined by the laser level and the paths on the stone base compacted by the weight of the screed machine 10 exerted on the rollers 15 . The pre-cast concrete walls can be erected on the graded paths with full support from the graded stone base. Similarly, the screed machine 10 can be used to grade and compact the stone base for a sewer line, the primary difference being that the laser level will be set on the slope gradient for the sewer line and the automatic function of the control mechanism 48 will properly adjust the screed machine to grade the stone base along the desired slope gradient.
It will be understood that changes in the details, materials, steps and arrangements of parts which have been described and illustrated to explain the nature of the invention will occur to and may be made by those skilled in the art upon a reading of this disclosure within the principles and scope of the invention. The foregoing description illustrates the preferred embodiments of the invention; however, concepts, as based upon the description, may be employed in other embodiments without departing from the scope of the invention.
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A screed machine is formed with a forwardly positioned screed assembly including a wedge portion and pivoted wing members. The frame is supported on two rollers spaced behind the screed assembly, which is mounted on a mast for vertical movement in conjunction with a laser receiver that provides a signal from a laser level indicating the final desired grade of the stone base. The machine can be turned at a corner by extension of a jack stand to elevate the machine for rotation about the axis defined by the centrally located jack stand so that the screed machine can be redirected into a different direction without disturbing the final grade of the stone base. The screed machine is manually moved along the stone base by an operator pulling on the handle pivotally connected to the frame. A sight line provides a monitor for the lateral orientation of the screed assembly.
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BACKGROUND OF THE INVENTION
1. Technical Field
The method and apparatus of the present invention relate generally to earth sheltered, multi-level structures. More specifically, the present invention relates to a method and apparatus for constructing the exterior frame of a multi-level earth-sheltered structure. As is well known in the art, subterranean structures are subject to significant lateral pressure. The novel design of the structure's frame minimizes the effect of this lateral pressure exerted by the earth against the sides of the structure. The minimization of lateral forces simplifies the design and cost of the structure. This allows a multi-level structure, heretofore too expensive, to be created.
Currently, most earth-sheltered structures utilize substantially vertical exterior framing similar to above ground structures. As is well known in the art, the earth exerts substantial lateral pressure below the surface acting against the sides of a structure. When vertical walls are used, this exterior framing is perpendicular to the lateral pressure. Consequently, the force acting on the external structure is maximized. As a result, the structure must be designed so as to withstand this horizontal pressure. As is also understood in the art, these forces vary linearly with depth. Therefore, a correspondingly more substantial structure is required as the depth, i.e. number of subterranean floors is increased. Clearly, as the substantiality of the structure increases, so to does its cost.
Due primarily to cost considerations, the current practice for construction of earth-sheltered structures, is to utilize a single level below ground. If a multi-level structure is desired, this means that at least one level will be "above ground." Clearly, this minimizes the benefits of an earth-sheltered structure.
Implementation of the support structure of the present invention allows multiple subterranean levels to be constructed, maximizing the benefits associated with earth sheltered construction. Use of the techniques taught by the present invention are applicable to both residential dwellings as well as commercial structures.
2. Description of the Prior Art
As mentioned, the most common earth-sheltered structure design implements exterior framing having a generally vertical orientation. Many examples of this exist including the homes illustrated in Homes in the Earth and Earth Sheltered Residential Design Manual. One of the primary concerns in the design of the structure is the earth load on the external walls. As taught in the prior art, this results in a need for shear walls to help resist the lateral forces exerted by such earth loads.
Clearly, there would be many different ways to accommodate this excessive side load. For example, the side wall could be of a sufficient thickness in order to withstand such pressures. Alternatively, materials for construction could be chosen having sufficient strength to withstand these side loads. Still further, bracing or other auxiliary support structures could be used to lend additional support to otherwise conventional framing. Inherent in such construction alternatives is the additional cost which would be associated therewith. Such costs would be not only in additional materials, but also in the labor to install them.
An alternative is to "neutralize" to some degree these lateral forces. This is the novel technique utilized by the present invention which results in a great cost savings both in terms of materials and in construction labor allowing multiple subterranean levels to be constructed.
As will be explained in more detail below, the technique taught by the present invention divides the lateral force present into both horizontal and vertical components thereby decreasing the amount of horizontal pressure which must be accommodated by the wall.
Consequently, there is a great need for a framing structure which permits the cost effective construction of multi-level earth-sheltered structures.
Therefore, it is a primary objective of the present invention to provide a framing apparatus and method of construction for multi-level, earth-sheltered structure wherein sufficient structural support therefor may be obtained without the need for heavy duty internal reinforcing structure.
A further objective of the present invention is to provide a support frame wherein the external wall thereof is slanted at an angle to the subterranean lateral forces thereby dividing the horizontal component of the load factor into a horizontal and vertical component and thereby decreasing the amount of horizontal pressure which must be accommodated by the wall.
It is a further objective of the present invention to provide an "interior frame" support structure wherein all framing members are contained within the exterior wall.
It is a further objective of the present invention to provide an "exterior frame" structure wherein a portion of the supporting structure is located external to the exterior wall.
It is a further objective of the present invention to provide a framing structure wherein safety and convenience are enhanced by having a rear egress.
A further objective is to provide a framing structure wherein an earth covered roof may be supported.
A still further objective is to provide a framing structure wherein a conventional, above earth roof may be supported.
A still further objective of the present invention is to provide a framing structure, portions of which may be preformed and shipped to the construction site for assembly, thereby eliminating the need for on-site assembly of each component of the structure.
It is a further objective of the present invention to provide a framing structure which may be used for a single level structure as well as for multi-level structures.
It is a further objective of the present invention to provide a framing structure adapted to allow air flow to circulate around the structure between the exterior and interior walls creating a "thermal envelope" promoting heating and cooling efficiencies.
It is a further objective of the present invention to provide a framing structure the trusses of which may be constructed from a variety of materials such as wood, steel, aluminum, and the like.
It is a further objective to provide a framing structure wherein the interior may be designed as desired.
It is a final objective to provide a framing structure as described above which may be used for both commercial and residential structures.
SUMMARY OF THE INVENTION
The present invention discloses a multi-level, earth sheltered building having a foundation for supporting the building and corresponding to the exterior shape of the structure. The teachings and techniques of the present invention are applicable to both commercial and residential structures. An exterior framing structure adapted to support an exterior wall and for supporting the structure is secured to the foundation. A first embodiment disclosed is an interior frame.
A plurality of stacked truss sets is adapted to define the perimeter of the structure, each of the sets being formed by a plurality of individual trusses stacked one atop the other. The number of trusses stacked corresponds to the number of floors in the structures. Each of the trusses include, a first generally vertical elongated inner member having top and bottom portions, a second outer elongated member having top and bottom portions, the outer member bottom portion being joined with the inner member at the bottom portion thereof, a connecting member connecting the inner and outer member top portions in a spaced apart relation such that the second member slopes upwardly and outwardly from the bottom portion thereof thereby defining an angle between the inner and outer members. Therefore, each truss is generally triangularly shaped. The bottom of the second truss is attached to the top of the first truss such that the outer slanted members of the trusses in the pair are aligned to present a substantially continuous outwardly sloping surface. The plurality of stacked truss sets are secured to the foundation in horizontally spaced apart relation defining the perimeter of the structure. The exterior wall is fastened to the truss sets thereby forming the exterior wall thereof. The dirt is then replaced adjacent to and in contact with the exterior wall. The upwardly and outwardly sloping exterior wall reduces some of the horizontal load associated with the underground structure.
The present invention so discloses an exterior frame wherein the truss design comprises a first generally vertical elongated inner member having top and bottom portions. A second outer elongated member having top and bottom portions is joined with the inner member at the bottom portion thereof. A connecting member connecting the inner and outer member top portions in a spaced apart relation such that the second member slopes upwardly and outwardly from the bottom portion thereof whereby each truss is generally triangularly shaped. In this exterior frame embodiment, the truss height corresponds to the height of the structure. The exterior frame embodiment provides additional structural support which may be especially beneficial in structurally challenging situation such as where an earth sheltered roof is employed.
Intermediate floors in the structure are accommodated in either design. In the interior frame embodiment, floor joists may be supported on the top connecting member of the truss. In the exterior frame embodiment, the floor joists may be supported by support members secured to the truss at intermediate positions corresponding to the floor level. The walls and flooring may be constructed so as to provide an air circulation zone defining a thermal envelop thereby further enhancing thermal efficiency of the structure.
Interior walls may be constructed in the conventional manner, the layout being dictated by personal preference or commercial requirements.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1-8 illustrate the primary embodiment for the present invention,
FIG. 1 an outwardly directed perspective view of a portion of a back wall of the frame structure illustrating two floors thereof and showing the connection of the frame trusses and how the floor joists would be seated thereon,
FIG. 2 is a top view of the truss construction of a corner of a single floor of the frame structure.
FIG. 3 is top view showing the construction of a corner in a two-floor embodiment and also illustrating the support of a roof,
FIG. 4 is a side sectional view of a rear wall of the frame structure in a two-floor embodiment showing the support trusses and a floor joist seated thereon.
FIG. 5 a perspective view of trusses used to construct a corner in the frame structure of the present invention.
FIG. 6 is an end view of the frame structure of the present invention illustrating a rear egress which may be included therewith.
FIG. 7 is a top view of the rear egress structure of the framing apparatus of the present invention.
FIG. 8 is a side view of an entire earth-sheltered structure using the frame structure of the present invention.
FIGS. 9-13 illustrate an alternative embodiment for the present invention.
FIG. 9 is a perspective view of the trusses used in a second embodiment of the frame structure of the present invention.
FIG. 10 is a top view showing the construction of a corner in an alternative embodiment.
FIG. 11 is a top view showing the support structure of the second alternate embodiment including the roof support structure.
FIG. 12 is a side view of the structure utilizing the second alternative embodiment including the support of a roof thereby.
FIG. 13 is a side view showing a truss of the second embodiment including the manner in which the two floors and an earth-sheltered roof would be supported.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIGS. 1-8 illustrate a first preferred embodiment of the present invention.
The theory behind the operational effectiveness of the present invention is twofold. First, by using a triangularly shaped truss to support the exterior wall, additional structural support is obtained resulting from this triangular shape. Secondly, by slanting the exterior wall which contacts the earth surrounding the structure, the lateral subterranean force is divided from a largely horizontal force into smaller vertical and horizontal components, thereby reducing the force against which the structure must compensate. It should be noted that the framing structure disclosed by the present invention relates primarily to the perimeter of the frame. Thus, details concerning the interior floor plans are not shown or discussed, that being left to the individual tastes and preferences of the resident. It should be further noted that the angular separation between the inner and outer members of the trusses, has been exaggerated in the figures to illustrate the shape thereof. For example, while the angle illustrated in the figures may appear to be approximately 45 degrees, it is believed that 10-15 degrees is more likely what would be used in practice, determined in part by soil type. However, the present invention encompasses all such angles and is not limited to any particular value or range and could range from nearly zero to 89 degrees.
In this first preferred embodiment, the vertical dimensions of the trusses used to make up the frame are one floor in height. Therefore, multi-level structures are constructed by vertically stacking trusses one upon the other, the number of trusses stacked being equivalent to the number of floors or levels in the structure. For example, in FIG. 1, two floors are illustrated wherein an upper second series of trusses 40 representing the second and any upper floors, are placed atop a lower first series of trusses 30 corresponding to the first floor. As seen in this outwardly looking figure, and using the first level series of trusses for numerical reference, each truss 30 comprises a generally vertical inner member 32 and an outwardly sloping outer member 34. As seen in the figure, members 32 and 34 are joined in the lower portions thereof and are horizontally spaced at the upper portion thereof such that a generally V-shaped structure is defined by the two members. The members may be individual components or integrally formed. The trusses may be constructed of wood, steel, aluminum, or other suitable material.
Horizontal top, connecting cross piece 36 is fastened to the upper portions of members 32 and 34 thereby forming a triangle. Cross member 36, in addition to providing structural rigidity to the truss, is used to support the floor joists 50 discussed below. As mentioned, in the preferred embodiment, truss 30 is mounted such that inner member 32 assumes a generally vertical orientation. When so mounted, outer truss member 34 is then oriented upwardly and outwardly relative to truss member 32. Interior vertical member 32 provides a support against which the interior sheetrock may be fastened. The outer sloping member 34, as explained further below, provides a support against which the exterior wall 38 may be secured.
As illustrated in the figure, a plurality of floor joist members 50 would be utilized to support the second floor. As is true with conventional construction, the plurality of floor joists 50 would be oriented to run from front to back of the structure. The floor joists 50 would be adapted to be secured to and rest on the top cross piece 36 of the trusses 30 positioned along the front or back of the structure. Additionally, a supporting plate 52 would be adapted to run between consecutive truss pairs as illustrated in the figure. This support plate 52 is adapted to be mounted to the top of cross piece 36 adjacent the vertical member 42 of the second floor truss 40. Floor joists 50 would have a generally rectangular notch 54 cut into the outer portion thereof for receiving plate 52 as indicated. Thus, support plate 52 provides an additional connection for securing the floor joists 50 to the trusses 30. Additionally, support plate 52 provides additional lateral support for consecutive truss pairs.
As mentioned above, in this first embodiment, a multi-level structure embodying the teachings of the present invention would have a number of stacked trusses equivalent to the number of floors or levels. The trusses associated with each level would have an identical construction. Thus, a second floor truss 40 would have a generally vertical inner member 42, an outwardly sloping outer member 44 joined at the lower portion thereof, and a top cross piece 46 mounted to the upper portions of members 42 and 44. Therefore, members 42, 44, and 46 of upper truss 40 correspond to members 32, 34, and 36 of lower truss 30.
As seen in FIG. 1 and illustrated in the figures below, the upper, second floor trusses 40 are mounted to the lower, first floor trusses in such a fashion that the outer, upwardly sloping member 44 of upper truss 40 in conjunction with member 34 of lower truss 30 forms a nearly continuous, upwardly and outwardly sloping surface.
As mentioned above, the outwardly and upwardly sloping members 34, and 44 of the lower and upper truss pairs 30 and 40 provide a means for supporting an exterior wall. By securing the exterior wall to members 34 and 44, the wall will have an upwardly and outwardly sloping orientation corresponding to members 34 and 44 to which it is mounted. In a preferred embodiment of the invention, the trusses 30 and 40 would be spaced at approximately eighteen inch intervals. Additionally, the exterior wall could be comprised of conventional 4'×8' sheets of plywood. In such a case, the sheets could be mounted widthwise on center of alternating trusses. Clearly, other sizes of wall segments could be used. Sealing between segments would be accomplished in a conventional manner such as by caulking or the like. For the purposes of discussion herein, exterior wall segments secured to lower trusses 30 are designated 38 and exterior wall segments secured to upper trusses 40 are designated 48 although a single appropriately sized segment could be used. This exterior wall surface 38 and 48 would be secured to the outwardly and upwardly sloping member 34 and 44, respectively, by means of conventional nails or the like.
As mentioned above, this upwardly and outwardly sloping exterior wall surface 38 and 48 provides the means by which the invention's objectives are partially accomplished. As will be clear to those with at least an elementary understanding of physics, a horizontal force vector acts on a surface angle thereto the resulting force acting on the surface may be thought of as the sum of two smaller forces. Consequently, by slanting the exterior wall, the effect of the horizontal force is reduced and hence the structural support necessary to withstand this force is reduced. Combining this decrease in lateral force with the increase in structural support resulting from the triangular truss design results in the practicality of multi-level subterranean structures.
As mentioned above, the horizontal force acting on the wall increases with depth below ground. Since the slanting of the wall decreases the effect of this force, the structure may be built to a greater depth (i.e. more levels to a point where the horizontal force acting on the surface reaches the structural limit). In addition to the decrease in the horizontal force component resulting from the slant in the exterior wall, the triangular construction of the trusses provides greatly enhanced rigidity and structural integrity.
As mentioned above, since the truss 30 is mounted to concrete slab 80 in such a manner that member 32 assumes a generally vertical orientation and since member 34 and 32 are joined at the lower portions thereof but with the upper portions being horizontally spaced, it is clear that an angle is defined by members 32 and 34 with the apex thereof being at the juncture of members 34 and 32. As mentioned, the amount of this angle determines the quantity of advantage which may be achieved due to the slanted wall portion of the present invention support structure. It is envisioned that it might be desirable to utilize different degrees of slant between members 32 and 34 in order to minimize the negative effects of the lateral forces present in different soil types.
While it is within the scope of this invention that the framing trusses would be individually constructed at the building site and therefore specifically designed to accommodate the soil type existing at the construction site, for economic reasons, it may be desirable to have trusses prefabricated and shipped to the construction site. In that case, the trusses could be prefabricated with a pre-set angular separation which would accommodate most soil types. Thus, the prefabricated trusses could simply be shipped to the building site without the need for assembly. Alternatively, a series of prefabricated trusses could be constructed having several different angular mounts to accommodate a certain number of soil types.
Finally, FIG. 1 illustrates the means used to support the flooring for the first floor of the structure. As mentioned above, in one embodiment, the entire structure rests on a concrete slab 80 which is poured as the foundation for the structure. It is this concrete slab 80 on which the first floor trusses 30 are mounted. In another embodiment, a concrete foundation would be poured around the perimeter of the structure. In either case, the trusses 30 would be secured to the concrete by conventional securement means such as anchor bolts, similar to the way in which the frame of a conventional home is secured to the foundation.
The floor 70 of the lowest level would be supported by a floor support means 60 comprising a series of floor support studs 62 seated between a pair of upper and lower 2×4 floor mounting plates 64a and 64b respectively. Lower plate 64b in turn could be secured to concrete slab 80 as shown using conventional concrete nails, anchor bolts, or the like. Alternatively, plate 64b could be supported on a bed of grave, sand, or the like. In the preferred embodiment, these floor support studs 62 would be a plurality of rectangularly shaped wood blocks, for example, small lengths of 2×4's. Floor 70 would then be secured to the plate 64a by means of conventional nails or the like. In the preferred design floor support studs 62 would be of sufficient height to permit air to circulate freely under the floor in order to implement the thermal envelope discussed in more detail below. This technique, utilizing floor mounting plates 64a and 64b, is preferable in that it lends additional lateral stability to the floor support studs 62 as well as providing an easier surface into which the floor 70 may be nailed. It is contemplated that a plurality of plates running width wise under the floor would be used although other configurations would be equally suitable. The floor mounting plates 64a and 64b would be secured to the floor support studs by means of conventional nails or the like.
As mentioned above, the exterior walls having contact with the earth, normally the rear and side walls are constructed according to the slanted design disclosed herein. FIG. 1 illustrates the techniques used to construct the side and rear walls as taught by the present invention using a plurality of trusses 30 in order to create a wall structure having an upwardly and outwardly slanted orientation. However, the corners of the structure provide a special challenge since the angled surfaces of adjacent perpendicular walls must be accommodated.
A special corner piece is provided to accommodate the junction of the side and rear walls. In the preferred embodiment, it is envisioned that this corner construction could be provided by a prefabricated corner insert 90 which could be shipped to the construction site, preassembled and ready to be inserted into place. Alternatively, corner piece 90 could be constructed at the job site. This corner piece is illustrated in FIGS. 2 and 5 below.
FIGS. 2 and 5 are top and perspective views, respectively, of a corner piece 90 which might be used with the present invention. As seen in this figure, the corner piece 90 would comprise three trusses 91a-c. Generally speaking, these trusses 91a-c assume a generally V-shape similar to wall trusses 30 and 40, having a generally vertical inside member 91a-c, an outwardly slanted outer member 94a-c the inner and outer members being joined at the bases thereof. A top cross piece 96a-c is adapted to connect the inner and outer members. The three trusses 91a-c making up the corner piece 90 differ from the other trusses in that the angle between the inner and outer members thereof must be such as to permit the junction of the outer walls 38 from perpendicular wall segments such as side and rear walls. While this is not difficult, it is a consideration which must be taken into account when designing the corner piece 90. The exterior walls 38 would be fastened to the outward slanted member 94a-c in the same manner as with the other trusses, namely by use of nails or other conventional fastening means.
FIGS. 3 and 4 represent top and side views, respectively, of a two-story embodiment utilizing the concepts and teachings of the present invention. As mentioned above, and as can be seen clearly in the figures, especially FIG. 4, the upper trusses 40 are mounted on the top cross piece 36 of the bottom trusses 30 such that the outer, sloping members 34 and 44 form a generally continuous, outwardly sloping surface. Thus, when the outer exterior wall 38 and 48 are mounted to the outer truss members 34 and 44, they form a continuous, outwardly and upwardly sloping flat surface. As mentioned above, the fill dirt would be pushed up against these exterior wall surfaces 38 and 48.
Also shown in FIGS. 3 and 4 are top and side views, respectively, of a two-story embodiment of a corner construction according to the teachings of the present invention. An upper corner piece 190 is positioned atop the lower corner piece 90 in a manner similar to the way in which the upper trusses 40 are positioned atop lower trusses 30. Namely, the upper slanted member 194b is positioned atop member 94b so as to present as continuous a sloping surface as possible. As mentioned, it is along this surface that exterior walls from adjacent sides of the structure would be joined. In order to facilitate this joining of adjacent exterior sides, it will be noted from FIG. 3 that the outer slanted members 94b and 194b are beveled so as to present a flat mounting surface to the side being secured.
In addition to the structure discussed above, another unique feature of the present invention is its design of a rear egress 100 for the earth-sheltered structure. Providing a rear egress to the structure clearly enhances safety and convenience by providing a second means of escape in the case of fire or other emergency. Rear egress 100 is a feature heretofore not feasible on earth-sheltered structures. In the past, such a rear egress was difficult if not prohibitively expensive to build into an earth-sheltered structure. The present invention allows a rear egress to be easily accommodated in the present invention. Such a rear egress 100 is illustrated in FIGS. 6 and 7 below.
FIG. 6 is an end view of the present invention centered about the rear egress 100. As seen in the figure, the framing structure of the rear egress 100 is constructed in a fashion similar to that for the remaining structure. A plurality of trusses 130 and 140, similar to trusses 30 and 40 in the main structure, are stacked vertically as shown in order to create the multi-story rear egress of the structure. As indicated above in connection with the remainder of the structure, the number of stacked trusses would correspond with the number of floors in the multi-level structure. The vertical stacking of trusses 130 and 140 is accomplished in the manner described with the remaining structure, so that the outwardly and upwardly sloping member of the stacked trusses 134 and 144, form a generally continuous sloping surface. Again, as stated above, it is against the continuous, flat surface presented by the slanted member to which the exterior wall surface would be fastened using nails or other conventional fastening means. As is discussed more below, the triangular trusses are used for those walls which are earth covered. For walls not earth covered, conventional "vertical wall" construction may be used.
The plurality of trusses 130 and 140 comprising side walls of 162 and 164 at the rear egress 100 of the structure would be oriented perpendicular to the rear of the remaining structure as shown and discussed below in connection with FIG. 7. It is envisioned that a series of steps 120 (FIG. 8) would be constructed from the first floor of the structure leading up to the doorway 150. In the preferred embodiment, doorway 150 would be positioned on the second, or uppermost floor. It is this doorway 150 through which access to the rear of the structure would be made.
In general, it is contemplated that the upper floor of the rear of the structure would be "dug out" such that rear wall (not shown) of rear egress 100 is exposed, i.e. not covered with earth. It will be recalled from the discussion that walls covered with earth would utilize the slanted wall truss design disclosed herein. Therefore, if the rear wall 160 is exposed, it would comprise a generally vertical design using vertical support studs 170 as illustrated, as opposed to the slanted truss construction for the side walls 162 and 164 of rear egress 100. If the base of doorway 150 is not at surrounding ground level, a series of external steps 125 could be used to ascend or descend to ground level. The remaining structure components in rear egress 100, such as the floor joists and the like, would be constructed in a fashion equivalent to that for the remaining structure. If the rear wall (not shown) of the lower floor of the rear egress 100 is underground, it would be constructed using the slanted wall technique with trusses 130 as illustrated clearly in FIG. 8 below.
FIG. 7 is a top view of the rear egress 100 of the present invention. The view in FIG. 7 is of the top, egress floor and does not include any lower floors. As indicated in this view, the roof joists 185 run from front to back of the structure, including the rear egress portion of the structure, as in a conventional construction.
As mentioned above and seen clearly in the view of FIG. 7, rear egress 100 comprises a rearward extension of the structure. The principle components of rear egress 100 are the two side walls 162 and 164 and rear wall 160 (not shown). Side walls 162 and 164 and the lower floor of rear wall 160 would likely be earth-sheltered, whereas upper floor rear wall 160 is likely to be exposed. Consequently, side walls 162 and 164 and the lower floor rear wall (not shown) would be built according to the slanted wall truss construction techniques discussed herein. Conversely, upper floor rear wall 160 would be built using conventional, i.e. vertical wall, construction.
FIG. 8 is a side view of an example of an entire structure utilizing the framing structure of the present invention. As mentioned above, most earth-sheltered dwellings are built into a hill with the front of the structure exposed. Consequently, the front wall 28 of the structure is constructed conventionally with a generally vertical wall as shown. Similarly, the upper floor rear wall 160 (not shown) of rear egress 100 is generally not earth covered and therefore constructed with conventional vertical walls. Conversely, since it is likely that the lower floor rear wall (not shown) would be earth covered, it would be built using the slanted truss construction discussed above. Furthermore, it will be noted from the figure that corner pieces 190 and 90 are shown for main structure second floor rear wall and main structure and rear egress first floor rear walls indicative of the slanted nature anticipated for these walls. Finally, a stair step 125 may be provided in order to accommodate a difference between the door 150 and the surrounding earth.
The remaining exterior walls, i.e. main structure and rear egress 100 side walls as well as the rear wall of the main structure, would be constructed using the slanted wall construction taught by the present invention.
As discussed above, one point of distinction between this first embodiment and the alternative embodiment discussed below is the design of the roof 20. In this first embodiment, it is anticipated that a conventional, exposed roof would be used. Such a roof 20 is illustrated in FIG. 8. The roof joists 185 would be run from a plate 182 atop the front wall 28 to the rear wall. To these roof joists 185 would be mounted the roof rafters 180 in the conventional manner. Due to the relative light weight of a conventional roof, such as that illustrated in FIG. 8, the wall trusses 30 and 40 are sufficient for support. However, in the case of an earth covered roof, sufficient weight is present that additional structural support may be necessary. This is the motivation for the alternative embodiment below.
As mentioned above in connection with FIGS. 6 and 7, it is anticipated that entry and exit from the structure would be made from the second floor. In that case, a set of stairs 20 would probably be provided in the rear egress 100. One such set of stairs 120 is illustrated in FIG. 8. It will be clear that many other configurations of stairs 120 are possible. Additionally, it may be seen from the figure that the construction of stairs 120 as shown would define space 65 in the first floor of the egress. Such a space 165 may be used as a mechanical room or the like.
FIGS. 9-3 illustrate the second, alternative embodiment. This second, alternative embodiment is referred to as the "exterior frame" embodiment. One major point of distinction between this secondary embodiment and the primary embodiment is the use of a single truss to provide the external support structure for all levels of the multi-level structure. Therefore, there is no stacking of trusses corresponding to the number of floors in the structure, as there is in the primary embodiment. Another major distinction is the type of roof used. As mentioned above, in some situations it may be desirable to utilize an earth covered roof. In this case, it might be necessary to provide some additional structural support therefor. The alternative embodiment discussed below provides additional support.
FIG. 9 is a perspective view showing the construction of a truss 230 according to the support structure of the second embodiment of the present invention. A plurality of trusses 230 are used to provide the support for the structure. As discussed in the primary embodiment, the trusses described here would be utilized on those exterior walls where the wall is covered with earth. Where the wall is exposed, it would likely be constructed using conventional, vertical wall techniques. As in the primary embodiment, the truss comprises an upwardly and outwardly slanted piece 234 and a vertical piece 232. However, in the case of the second embodiment, the two members are joined at their respective tops, thereby creating a downwardly opening V-shape as seen in the figure. An additional point of distinction between the first and second embodiments is that the generally vertical member 232 is positioned outwardly of the slanted member 234. It is contemplated that in one preferred design, members 232 and 234 could be I-beams which would provide great structural support. It is also envisioned that these beams could be covered with plaster or the like to prevent rusting etc. As in the above embodiment, members 232, 234 and 236 may be individual components or integrally formed.
In this second embodiment, a plurality of vertically spaced, horizontal support members 240 are fastened to the interior face of the slanted member 234. An exterior wall 238 is secured to the exterior of the horizontal support members 240 between consecutive trusses 230. As with the primary embodiment, this exterior wall 238 may be constructed of sheets of plywood or the like. Thus, the exterior wall 238 will be inclined at an angle equal to the angle of inclination of slanted member 234. This slanted exterior wall 238 serves the same purpose of exterior wall 38 and 48 in the primary embodiment, namely, to reduce a portion of the load exerted by the earth against the structure. Therefore, exterior wall 238 rests atop the fill dirt which is pushed up against the exterior wall once the framing has been completed.
As can be seen in the figure, the lower portions of members 232 and 234 are further supported in a spaced apart relation by their securement to base 236. Base 236 thus completes the generally triangular shape of truss 230. In a preferred embodiment, the base 236 of trusses 230 would be mounted on a concrete slab 280 which would form a foundation for the structure. Alternatively, in some cases it might be preferable to mount the trusses on gravel or even on dirt, depending on the environmental situation in which the structure exists. However, in most situations, the use of a concrete slab 280 would provide the most suitable foundation support for the structure. As with members 232 and 234, base 236 may also be fabricated using an I-beam.
In a fashion similar to that in the primary embodiment, the floor 270 of the lowest level is adapted to be positioned atop, and secured to, a plurality of support studs 262. In a preferred embodiment, the floor support studs 262 could assume any number of acceptable forms but in simplest form could be a series of small 2×4 sections. In a fashion identical to the primary embodiment, support studs 262 would be mounted between two horizontally running plates 264a and 264b to provide additional support and stability. The lower plate 264b would be positioned on the concrete foundation or gravel bed. The plate 264b could be secured to concrete foundation slab 280 by means of concrete nails or other similar fastening means familiar to those skilled in the art. The floor 270 in turn would be secured to upper plate 264a by means of conventional nails or the like. Use of discrete floor support studs 262 permits not only a strong support for floor 270 but also permits the air flow necessary to effect a thermal envelope as discussed above. In the situation where a thermal envelope is to be employed, the height of floor support studs 262 would be sufficient to raise the lower surface of floor 270 to the level of the truss base 236 or above.
As also seen in this figure, each truss 230 comprises a top plate 239 having a generally square shape mounted at the juncture of the two truss members 232 and 234. This top plate 239 may be used for mounting a roof support I-beam 242 as indicated in the figure.
As mentioned above, the main use for this alternative embodiment illustrated in FIGS. 9-13, is the situation where an earth-sheltered roof is to be utilized. In that case, the roof 244 typically would be formed of precast concrete slabs. These preformed concrete slabs, especially when earth covered, have a weight much greater than that associated with a conventional wood roof. Therefore, a support structure must be capable of supporting this additional weight. In the present embodiment, additional support is provided by trusses 230 and the steel I-beams 242 mounted to the top plate 239. In a preferred embodiment, these horizontally spaced I-beams 242 would run from front to back of the structure as in conventional structure construction. The preformed concrete slabs 244 comprising the roof would then be secured to the top of I-beams 242 as indicated in the figure.
Finally, as mentioned above, the vertical extent of trusses 230 corresponds to the total height of the structure. Thus, intermediate flooring would be positioned along the vertical extent of the trusses 230. Therefore, a means must be provided for mounting and support of these intermediate floors. One preferred means for accomplishing this in the alternative embodiment is to mount a horizontally oriented I-beam 246 on the interior of the slanted member 234. This method is discussed in detail below in connection with FIG. 13. Another preferred method of supporting intermediate floors is illustrated in FIG. 9.
In the embodiment illustrated in FIG. 9, the intermediate floors, such as 272, would be supported by a series of floor joists 286. These floor joists 286 provide a means onto which intermediate floor levels may be mounted for support. In the embodiment illustrated in FIG. 9, a two-story structure is provided. Thus, there is one intermediate floor level supported by floor joists 286. As with roof support beams 242, floor support joists 286 would likely be oriented to run front to back of the structure. Floor joists 286 would preferably be supported by a plate such as 284. Floor joists 286 may be secured to plate 284 by means of conventional support brackets 288 or the like. This joist support plate 284 would run between truss pairs being secured to the front of mounting bracket 248 which is in turn secured to the front of slanted member 234 of truss 230 using conventional bolts or the like. It is contemplated that plate 284 and floor joists 286 would be 2×10s but could clearly be other suitable supports. Details of the construction of the intermediate floors is given below in connection with FIG. 13.
FIG. 10 is a top view of the structure embodying the alternative embodiment of the present invention. As seen in this figure, a corner is constructed in a fashion similar to that in the primary embodiment wherein the outwardly slanted member 294 of a corner piece 290 is used at the intersection of the horizontal support members 240 of adjacent walls. Additionally, as seen in this view, the horizontal roof support I-beams 242 are positioned mounted to the top plate 239 (not shown) at the top of each truss member 230. The preformed concrete slabs 244 comprising the roof of the alternative embodiment would then be mounted secured to and supported by the roof support I-beams 242.
FIG. 11 is another top view showing a more extended portion of a wall built according to the alternative embodiment of the present invention. Seen clearly in this view are the roof support I-beams 242 which would run from the front to rear of the structure and are mounted to the top of each truss 230. Since the intermediate floor support I-beams 246 would likely also run front to back they would be hidden from the view of FIG. 11.
FIG. 12 is a rear view of the second embodiment of the present invention showing with particular clarity the mounting and support of the roof 244 atop the roof support I-beams 242 mounted to the top of each truss member 230. Also seen especially clearly in the view of FIG. 12 is the slant associated with member 234 of truss 230. As stated above, this slant is used to deflect some of the side loading associated with the dirt surrounding the earth-sheltered structure. As mentioned above, the dirt would be pushed up against the exterior wall 238 mounted between each consecutive truss 230 and against the horizontal mounting members 240. The roof support I-beams 242 are oriented front to back of the structure. Thus they are shown "end on" in the view of FIG. 12. Additionally, the intermediate floor support beams 246 shown in hidden lines, are also adapted to run front to back of the structure.
FIG. 13 is an enlarged side sectional view of the structure of another alternative embodiment of the present invention. The view taken for this figure is of a truss used on the rear walls of the structure. As mentioned above, in this alternative embodiment, the height of the truss 230 corresponds to the height of the structure. Thus, intermediate floors must be supported along slanted member 234. As seen in the embodiment of FIG. 13, the means for supporting the intermediate floor is a series of I-beams 246. The floor support I-beams illustrated in FIG. 13 provide an alternative to the floor joists 286 discussed above in connection with FIG. 9. These floor support I-beams 246 are supported on truss 230. A notch or ledge is provided on the front face of member 234 adapted to support the end of I-beam 246 as seen in the figure. It is envisioned the floor support I-beams 246 would run front to back of the structure as would the roof support beams 242. The floor 272 of the second level would be supported by these floor support I-beams 246 onto which the floor 272 could be attached. In this case, the floor I-support beams 246 would take the place of conventional floor joists such as those illustrated above in connection with FIG. 9. The floor support I-beams of FIG. 13 could be used in more structurally demanding situations such as in clear span warehouses or the like. As seen in the figure, the wall studs 252 in the first and second floors would be mounted to the floor and upper I-beam in the conventional manner using plates 254. Corner piece 256 provides a means for joining adjacent wall segments.
As seen in the figure and discussed above, horizontal cross members 240 span between consecutive truss pairs. These horizontal members 240 are used both for lateral support as well as to support exterior wall 238 (not shown). As discussed above, the exterior wall 238 is mounted at an angle which corresponds to the angle of inclination of member 234. This angular orientation of the wall in combination with the increase structural integrity resulting from the triangular truss configuration achieves the increased structural support allowing a multi-level sheltered structure to be built.
Finally, FIG. 13 illustrates the positioning of roof support beams 242 mounted to the top of truss 230 using plate 239. As mentioned above, in the preferred embodiment, the roof support I-beam 242 would be oriented from the front to the rear of the structure. The concrete roof 244 would be positioned on top of these roof support I-beams 242 as shown. The roof 244 would likely be comprised of preformed slab portions but many alternative designs are possible. The weight of roof 244 would probably provide force sufficient to keep it in place precluding the need for securement means. However, if additional securement is desired bolts or the like may be used.
It is obvious that numerous other modifications and variations of the present invention are possible in view of the above teachings. For example, as mentioned above the present invention is directed primarily at the exterior structure framing. Consequently no interior details except the basic wall structure were discussed. Rather, the interior design may be chosen as desired to accommodate the specific tastes of the owner. Construction of interior walls may be accomplished in the conventional manner. Of course the truss members could be constructed of individual components or formed integrally from a single piece. Additionally, several methods may be used to support the floor as were discussed.
Therefore it is to be understood that the above description is in no way intended to limit the scope of protection of the claims and is representative only of the several possible embodiments of the present invention.
There has thus been shown and described an invention which accomplishes at least all of the stated objects.
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The present invention discloses a multi-level, earth sheltered structure having a foundation for supporting the structure and corresponding to the exterior shape of the structure. The teachings and techniques of the present invention are applicable to both commercial and residential structures. Two truss design embodiments are disclosed both producing a slanted outer wall which reduces some of the forces acting on the structure. Use of both earth covered and exposed roofs are accommodated. A thermal envelope may be utilized further maximizing thermal efficiency. Interior walls may be constructed in the conventional manner, the layout being dictated by personal preference or commercial requirements.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to pleated window coverings in general, and more specifically relates to a novel take up reel means that ensures that laterally opposed ends of a window covering remain in a horizontal plane when the covering is being raised of lowered.
2. Description of the Prior Art
Modern home construction techniques use substantial amounts of glass since home buyers like to have substantially unrestricted views of their home settings.
Greenhouses or solarium structures and are becoming increasing popular in particular; they often include glass panes positioned in horizontal, vertical, and sloped planes.
Skylights are also in great demand since they provide free lighting.
The major drawback of these glass using structures is that they suffer from the drawbacks of "the Greenhouse Effect."
The wavelength of light changes as it passes through glass; heat reflected from a surface inside a solarium, for example, cannot escape as readily as it entered because the wavelength of infrared radiation (heat) is shorter than that of visible light. Thus, the inside of a solarium is a heat trap because once the wavelength of the light has been shortened, it cannot so easily pass through the glass again.
The most popular solution to the problem has been the use of window shades in general.
The most practical type of window shade is believed to be the pleated variety; these shades reflect incoming light to substantially offset the Greenhouse Effect but they do not spoil the view because they can be drawn up whenever desired.
Moreover they can be provided in translucent or transparent form as well to enhance the view even when they are in their lowered position.
Pleated window coverings are easier to clean than the outdated venetian blinds and their modern day counterparts which have narrower slats. More importatnly, perhaps, pleated window coverings, since their accordion-like structure is a continuous, integrally formed structure, they do a better job of reflecting light vis a vis discrete slat blinds.
Unfortunately, pleated window coverings of the prior art suffer from one of the more aggravating drawbacks that afflict the discrete slat blinds; they have a tendency for their base to skew from the horizontal when raised or lowered.
This skewing is caused by uneven take up of the cord used to draw the blinds or coverings. Specifically, a take up reel in the form of a roller member is positioned at the top of the pleated window covering. One or more cords extending the length of the window covering having their top ends secured to the roller member so that as it rotates in response to drawing or lowering of the covering, the cord or cords wrap around the roller member.
The uneven raising or lowering is attributed to the different overlapping patterns that affect the laterally spaced coils, i.e., a coil on the left hand side of the roller member may experience substantial overlap with the result that a single rotation of the roller member can take up a large amount of cord due to the larger effective diameter of the roller member caused by the winding of the cord upon itself whereas the cord being wound at the other end of the roller member might experience less overlapping. Since the coiling is allowed to occur without any control means, the amount of overlapping is entirely random and a tilt of the base of the window covering as a result of different amounts of overlapping almost always occurs.
There is a need for a window covering assembly that can be raised or lowered in the substantial absence of skewing.
Another drawback of heretofore known pleated window coverings is that their track assemblies are deficient in several respects. For example, solarium structures and the like often have vertical glass sections that meet sloped glass sections; to cover such structures, a gentle curve must be formed in the track which mounts the window covering. Unfortunately, the tracks that have been developed are heavy and require special bending tools to adapt them to particular settings.
Moreover, since wheel members are generally used to rollingly engage the tracks, the art has developed means for interconnecting laterally spaced sets of track-engaging wheel members. Again, the means developed by the art have been inadequate; specifically, cloth mateials are generally employed to interconnect the laterally spaced wheels, with unfortunate results.
There is therefore a need for an improved, easily bendable track and a need for an improved means for interconnecting laterally spaced track-engaging wheel members.
SUMMARY OF THE INVENTION
The inventive assembly overcomes the shortcomings of the prior art by providing a novel track, a novel wheel member housing, a novel wheel member housing interconnecting means, and perhaps most importantly of all, a novel roller member that prevents cord overlapping during the take up process so that skewing is eliminated.
The novel track has the general appearance of the letter "F" when seen in plan view; the vertical portion of the "F" is the base portion of the track in that the wheel members of the novel assembly rollingly engage that portion. More specifically, the portion ofthe "F" positioned intermediate the truncate, horizontally extending arms thereof is the portion of the track means base upon which the wheels actually roll. Thus, said arms provide a guide means for the wheels.
Due to the thin structure of the track, it can be bent on site so that installation of the window covering is easily accomplished.
In the preferred embodiment of the invention, a pair of vertically spaced wheel members rollingly engagement the guide portion of the track means, i.e., the base portion of the track means intermediate the parallel arms of the "F"-shaped member, on the "back" side of the track (the side of the track facing the mullion), and one wheel member rollingly engages the "front" side of the track. The "front" wheel is masked from view by a portion of the wheel member housing that covers it.
The wheel member housing thus mounts three (3) wheel members. They are positioned at the corners of an imaginary equilateral triangle.
Laterally opposed wheel member housings are interconnected by an elongate, horizontally disposed, rigid interconnecting means. The interconnecting means is a hollow, triangular in transverse section extruded piece of aluminum; each wheel member housing has a complementally formed triangular insertion member projecting laterally therefrom that is adapted to press fittingly engage the interconnecting member when inserted into the hollow interior thereof. Each side wall of the interconnecting member has the dimension of an individual slat in the window covering.
The triangular shape of the rigid interconnecting member ensures that it will conform to the shape of the window covering as it is drawn, i.e., the pleated, integrally formed slats of the covering will overlie the flat side walls of the triangular interconnecting member and the presence of the interconnecting member will thereby be effectively concealed. A plurality of the interconnecting means are provided at vertically spaced intervals along the extent of the window covering as design applications require.
The novel roller member of the inventive assembly has a standard driving means positioned at one of its ends. The driving means itself is housed in a non-rotating housing, and said non-rotating housing is fixedly secured to a slideably mounted base means.
The base means has a disc-shaped appearance and is slideably mounted in a cylindrical housing; both the base means and the housing are formed of a suitable low friction material to allow the base to slide relative to the fixed position housing with little resistance.
The opposite end of the roller member is plugged with a centrally bored plug member. A fixed position, elongate screw member having a preselected number of threads per inch formed therein is mounted by a suitable bracket assembly so that the longitudinal axis of symmetry of the screw member is coincident with the axis of rotation of the roller member.
The bore in the plug is threaded so that when the roller rotates responsive to activation of its driving means, the screw threaded engagement of the screw member and said bore effects axial travel of the slideably mounted roller member.
Since the roller member undergoes axial displacement as it rotates, each winding of cord about its periphery is presented with an empty, unoccupied space and no cord is wound upon itself. Thus, the effective diameter of the roller is not increased by overlapping cord, and both cords on the roller member, affixed thereto at opposite ends thereof, will coil up at the same rate and the window covering will not skew.
The invention accordingly comprises the features of construction, combination of elements and arrangement of parts that will be exemplified in the construction hereinafter set forth, and the scope of the invention will be indicated in the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
For a fuller understanding of the nature and objects of the invention, reference should be made to the following detailed description, taken in connection with the accompanying drawings, in which:
FIG. 1 is a perspective view of the novel structure, taken from the rear side thereof so that the rear wheels of the novel wheel assembly can be seen and so that the novel rigid interconnecting members can be seen as well;
FIG. 2 is a plan view of the novel track;
FIG. 3 is a plan view depicting the track mounted directly on a mullion;
FIG. 4 is a plan view depicting the track mounted in spaced relation to a mullion, showing how a pair of track members can be overlapped to narrow the spacing between laterally adjacent wheel members;
FIG. 5 is a side elevational view of the novel wheel housing;
FIG. 6 is an elevational view taken along line 6--6 of FIG. 5;
FIG. 7 is an elevational view showing how the wheel members positioned within the wheel member housing rollingly engage the track member. The insertion member that is integrally formed with the wheel member housing has been eliminated from this FIG. to simplify it;
FIG. 8 is an end view of the novel interconnecting member;
FIG. 9 is an end view showing the triangular portion of the wheel member housing snugly positioned within the hollow interior of the interconnecting member;
FIG. 10 is a side elevational view of a bore lining that prevents cord fraying;
FIG. 10A is an end view of the bore lining member shown in FIG. 10;
FIG. 11 is a side elevational view of the novel roller member and its associated mounting means; and
FIG. 12 is a side elevational view of the roller member similar to that of FIG. 11, but showing a motor-driven roller member instead of the chain driven roller member of FIG. 11.
Similar reference numerals refer to similar parts throughout the several views of the drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, it will there be seen that a window covering that incorporates all of the teachings of this invention is designated by the reference numeral 2 as a whole.
It should be understood from the outset that several features of the inventive structure 2 represent advances in the art, and that any one of them or any combination of them could be incorporated into window coverings of the prior art.
For example, as will become clear as this description proceeds, the novel roller ember and its precision winding means could be incorporated into an otherwise "old" window covering, i.e., it could be incorporated into a window covering lacking the other novel means disclosed hereinafter.
As a further example, the interconnecting members of this invention, described hereinafter in detail, could be incorporated into "old" window coverings to dramatically improve them, even if the other features of the inventive assembly were not adopted; moreover, the same is true of the novel track member disclosed hereinafter, the novel wheel housing, and other inventive elements of this invention.
FIG. 1 shows that the window covering selected as the preferred environment for the new parts disclosed hereinafter is of the pleated type; the pleats have an accordion-like structure and are denoted 4.
The particular window covering illustrated in FIG. 1 has a vertical section 6 and a sloped, generally horizontal section 8; one of the important teachings of this invention relates to a novel track construction that allows a gentle bend to be formed in the structure as depicted in FIG. 1 in the absence of heavy duty bending tools.
Referring now to FIG. 2, it will there be seen that the novel track member 10 has the appearance of the letter "F" when seen in end view; the relatively thin construction of track 10 enables it to be bent on site instead of at the installer's place of business. Accordingly, the construction of track 10 eliminates the need to pre-measure the curvatures of the glass areas to be covered and allows the installer to bend the tracks on site.
Track 10 includes base 12 and parallel arms 14, 16 normal thereto.
The portion of base 12 intermediate arms 14, 16 is the portion upon which the wheel members of the novel assembly roll when the invention assembly is in use and will hereinafter be referred to as the guide portion 18.
The portion of base 12 lying outwardly of arms 14, 16 is denoted 20; a screw-receiving bore 22 is formed in outlying portion 20 and the utility of such bore 22 is shown in FIG. 3 to which FIG. attention is now directed.
A window formed by a plurality of glass sections will have a plurality of horizontally disposed trunions and vertically disposed mullions separating the individual glass panes. A mullion 24 is shown in FIGS. 3 and 4 in vertical section; in each of FIGS. 3 and 4, mullion 24 separates two windows, each of which is provided with the novel window covering assembly of the present invention.
The track mounting shown in FIGS. 3 and 4 is shown to illustrate the versatility of track member 10; FIG. 3 shows it mounted directly on a mullion, and FIG. 4 shows a spaced mounting.
Referring specifically to FIG. 3, it will there be seen that a screw member 26 extends through bore 22 shown in FIG. 2 and serves to fixedly and abuttingly secure track 10 to mullion 24. When so mounted, guide portions 18 of the respective tracks 10 are laterally spaced from their respective mullions and are accordingly capable of receivng the wheel members of the inventive assembly.
The mounting of FIG. 3 will leave visible the mid-portion 28 of mullion 24. Where it is desired to cover the mullion, the track mounting arrangement of FIG. 4 may be employed.
In FIG. 4, outlying portions 20 of track 10 are positioned so that one of said portions overlies the other as depicted; this aligns bores 22. Spacer 30 is then positioed between mullion 24 and the innermost track 10 and an elongate screw 26a is positioned through the aligned bores 22 and screwed into the mullion as depicted. This mounting covers mullion 24 from view; the space between guide portions 18 of the tracks 10 and the surface of mullion 24 accommodates the wheel members of the novel assembly.
Referring now to FIG. 5, it will there be seen that the wheel housing is denoted 32 as a whole.
Housing 32 houses three rotatably mounted wheel members 34, 36, 38, all of which are shown in phantom lines because they are positioned on the "hidden" side of such housing 32 in the view of FIG. 5. (Actually, only the hubs of the wheels are depicted in FIGS. 5 and 6 to simplify the drawings).
Wheel members 34, 36 are positioned in a vertical plane when operatively deployed, and rollingly engage portion 18 of track 10. Wheel member 38 is positioned on the visible side of track 10, however, and is preferably hidden from view by opaque cover 40, shown in FIGS. 1, 5, 6 and 7.
Cover 40 is integrally formed with housing 32; housing 32 also includes a pair of outwardly turned covers 42, 44 for wheel members 34, 36, respectively. The term "outwardly" is used because the direction "inwardly" will hereinafter be used to indicate the direction toward the center of a window covering, i.e., the term "outwardly" refers to the direction away from the center of the covering, or to the direction of the next adjacent covering on the opposite side of a mullion.
In keeping with the aforementioned terminology, then, FIG. 6 should be understood as depicting wheel member housing 32 positioned so that wheel coverings 40, 42 and 44 are extending outwardly, and the member 46 is extending inwardly.
As best shown in FIG. 5, member 46 is triangular in configuration; it is so shaped because it fits in the triangular shaped hollow interior of the rigid interconnecting member that interconnects laterally spaced wheel member housings as best shown in FIG. 1 and as will become more clear as this description proceeds.
A pair of small, triangular in configuration ridges, collectively designated 48, are integrally formed on each flat wall of member 46 as best shown in FIG. 5; each ridge 48 gradually diminishes in height as it extends from base wall 50 of member 46 as shown FIG. 6. (Member 46 projects inwardly from base wall 50 whereas cover members 40, 42, 44 project outwardly therefrom; thus, the height of ridges 48 diminishes as they extend inwardly).
The purpose of member 46 and ridges 48 is made clear in FIG. 8; member 46 will hereinafter be referred to as insertion member 46 because it is inserted into the hollow interior of the elongate, rigid interconnecting member 52 the end of which appears in FIGS. 8 and 9. Member 52 is preferably formed of aluminum and extruded; its inner dimension is slightly larger than the outer dimension of insertion member 46 so that the latter may be inserted thereinto. Ridges 48 provide a wedging action as insertion member 46 is inserted into the triangular hollow cavity of interconnecting member 52. Due to the narrow line of contact formed by each triangular ridge 48, the friction resistance to insertion of the insertion member 46 into the cavity of member 52 is minimized while the wedging action nevertheless insures against inadvertant separation of the wedged-together members.
Thus, a wheel member housing 32 on a first side of a window covering associated with a first track is rigidly interconnected with its horizontally aligned, laterally spaced counterpart on the opposite side of the same window covering by interconnecting member 52. Specifically, each wheel member housing 32 is positioned so that its insertion member 46 is inwardly directed and the members 46 are inserted into the opposite ends of interconnecting member 52. Due to the triangular shape of interconnecting member 52, it conforms to the shape of the individual slats or pleats 4 (FIG. 1) as they fold upon one another, accordion style, attendant drawing of the window covering. Interconnecting members 52 are of course positioned at intervals on the hidden or rear side of the covering as shown in FIG. 1.
To prevent cord fraying as it passes through the bores (not shown) formed in the insertion member 46 and interconnecting member 52, bore lining member 54 is provided (see FIGS. 10 and 10A).
Bore lining member 54 includes main body portion 55 that is bored as at 56 to slidingly receive a cord therethrough (not shown). An annular flange 57 is angled as shown to conform to the shape of the interconnecting member 52 as is the unflanged opposite end 58 of the liner 54.
Referring now to FIGS. 11 and 12, it will there be seen that the slideably mounted roller member of the present invention is designated by the reference numeral 60 as a whole.
Numerous means for slideably mounting the same are of course available and the means shown in FIGS. 11 and 12 are merely illustrative.
Bracket 61 is secured by suitable means to roller housing 62 as shown, and is apertured to receive elongate screw member 64. Threaded lock nuts 63 (FIG. 11) or a permanent mounting means 65 (FIG. 12) may be employed as a part of the slideable mounting means.
In the embodiment of FIG. 11, screw 64 engages threads formed in plug 66 so that rotation of roller member 60 effects axial travel of said roller 60 because the position of screw 64 is fixed.
In the embodiment of FIG. 12, the distal free end 67 of screw 64 is not threaded but since roller 60 is slideably mounted and since screw member 64 is fixed position, the same rotation-responsive axial travel of roller 60 occurs; a compression fit effectively unites screw member 64 and plug 66 in this embodiment.
Referring now to the left side of FIGS. 11 and 12, it will there be seen that the means for effecting rotation of roller 60 in FIG. 11 is a manual bead chain 68 and the rotation means in FIG. 12 is an electric motor means 69.
In both embodiments, the means for effecting rotation of roller member 60 is housed in a non-rotatable housing designated 70. Housing 70 is fixedly secured to a base member 72 which is slideably mounted with respect to roller member housing 62. Base member 72 is preferably formed of nylon or other suitable low friction material so that the sliding movement of base 72 relative to housing 62 is relatively friction free.
A string or cord 74 has its lowermost end secured to the lowermost portion 3 of the window covering 2 (FIG. 1). The uppermost end of string 74 is fixedly secured to roller 60 as at 76 (FIG. 11).
As chain 68 is pulled or motor means 69 is activated, roller 60 rotates about its axis of rotation and slides along said axis under the driving influence of the screw member 64. In the embodiment shown in FIG. 11, roller member 60 is rotating in a direction that causes it to travel to the right as viewed in said FIG. Accordingly, string 74 winds about roller member 60 in the non-overlapping manner designated 78 because an open or unoccupied section of roller 60 will be presented to each length of string 74 as it undergoes coiling.
Another string, not shown, coils about the other end of roller 60. Only one string is shown in FIG. 11 to simplify the drawing and both strings are omitted from FIG. 12 for the same reason.
The means for slideably mounting roller 60 is thus seen to be simple yet effective. The elimination of string overlapping, the provision of the versatile "F"-shaped track member, the novel wheel housing and the rigid interconnecting member that aesthetically conforms to the pleats of the window covering, individually and collectively represent important advances in the art of window coverings.
It will thus be seen that the objects set forth above, and those made apparent from the foregoing description, are efficiently attained and since certain changes may be made in the above construction without departing from the scope of the invention, it is intended that all matters contained in the foregoing description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.
It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described, and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween.
Now that the invention has been described,
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A slideably and rotatably mounted roller member performs a precision take up reel function in the environment of a track mounted, drawable, pleated window covering. The roller member slides along an axis coincident with its axis of rotation as it rotates so that cord being wound therearound attendant its rotation is taken up in the absence of overlapping. One end of the roller member is provided with a centrally bored and threaded plug that screw threadedly engages a fixed position screw member; as the roller member rotates, the engagement of the screw member and the bore drives the plug and hence the roller member in an axial direction. The slideable mount of the roller member is provided in the form of a base member which is slideably received within the roller member housing. A novel "F"-shaped track member is engaged by wheel members positioned in a novel wheel housing, and laterally opposed wheel housings are interconnnected by a rigid interconnecting member that conforms to the shape of the pleats formed in the window covering. The assembly ensures that the window covering remains level at all of its functional positions.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to improved designs for rotary drill bits having removable nozzles for air or other drilling fluid and more particularly to a means for retaining said fluid nozzle in place.
2. Brief Description of the Prior Art
The placement of one or more passageways in a rotary drilling bit to conduct air or other drilling fluids from the central bore of the bit to the rotating cutters is well known. The drilling fluid thus directed serves to cool the cutters and to carry cuttings away from the cutters. However, the presence of these passageways makes it possible for cuttings and other foreign materials to enter the interior of the bit when the circulation of the drilling fluid ceases and thus to impair the further operation of the bit. This problem has been dealt with by placing check valves or filters in the interior bore passageways of rotary drill bits. For example, Nickles U.S. Pat. No. 3,198,269 discloses a single passageway leading from the interior bore of the bit to the space directly above the rotary cutters. A spring loaded check valve is placed in the interior bore and in the single passageway and serves as a nozzle to direct drilling fluid between the cutters and also serves to prevent reverse flow through the passageway into the interior bore. The check valve is removable through the top of the bit when it is disconnected from the drill string.
The check valve assembly in the drill bit disclosed in the Nickles patent is removable from the bit only through the top thereof, thus necessitating the detachment of the drill bit from the drill string in order to remove the check valve assembly. Furthermore, the Nickles bit provides for only one passageway to direct drilling fluid between the bits and thus does not permit the application of a stream of drilling fluid at multiple points on the cutter. In applicant's prior U.S. Pat. No. 3,685,601, there is disclosed an improvement in drill bits in which there are provided a plurality of passageways for discharging air or other drilling fluid between the cutters and each passageway having a nozzle or check valve assembly removably positioned therein. In this construction, the nozzle or check valve is removably secured in place by means of a set screw. There is some disadvantage to the use of a set screw in this arrangement since the set screw may come loose during operation and allow the air nozzle or check valve assembly to fall out.
Moore U.S. Pat. No. 3,744,581 discloses a different type of fluid nozzle for roller cutter drill bits which is removably positioned and secured by a check valve and sealed by a peripheral 0-ring. The use of a set screw in this type of nozzle is subject to the same disadvantage mentioned above.
Scarborough U.S. Pat. No. 3,084,751 discloses an air nozzle for rotary cutter drill bits which is held in place by a thick wire having a head somewhat like a nail for ease of removal. The retaining wire or rod is inserted into matching grooves in the outside of the nozzle member and the inside of the passageway in which the nozzle member is fitted. This arrangement has the slight disadvantage that it is necessary to have an extra groove machined or cut in the passageway in which the nozzle is positioned. This cutting or machining operation adds to the expense of manufacture of the drill bit.
Mori U.S. Pat. No. 3,220,754 discloses a removable air or other drilling fluid nozzle in a drag type bit. The nozzle is constructed similarly to that of Scarborough and is held in place by a retaining rod inserted into a groove cut on only one side of the nozzle and aligned with a matching groove in the passageway in which the nozzle is fitted. This arrangement is complicated to manufacture and is difficult both in assembly and in disassembly.
SUMMARY OF THE INVENTION
This invention relates to new and useful improvements in rotary drill bits. The invention provides for a drill bit having a body with a plurality of arms extending therefrom, each arm having a bearing shaft for supporting a rotary cutter mounted thereon. The body defines a central recess; a plurality of cooling passageways extend through the body from the central recess to the bearing shafts and a plurality of jet passageways extend through the body from the central recess to discharge air or other drilling fluid between adjacent cutters. Flow control means, such as fluid nozzles or check valves, are placed in each of these jet passageways so that flow of drilling fluid from the central recess and between the cutters is allowed, but flow from outside the body of the bit, through the jet passageways, and into the central recess is prevented. The flow control means serves as a nozzle to direct flow between the cutters as desired. The nozzles are removably positioned in the jet passageways and held in place by the split ends of a bifurcated pin member. The retaining pin member has a head similar to that of a nail for ease of removal for releasing the nozzle for replacement or repair.
One of the objects of this invention is to provide an improved rotary drill bit with multiple passageways extending through the body of the bit to facilitate the direction of multiple streams of drilling fluid onto the cutters as desired and having removable fluid directing nozzles positioned therein retained in place by easily removable retaining pins.
Another object of this invention is to provide a rotary drill bit having a plurality of passageways for directing multiple streams of drilling fluid onto the cutters thereof and each provided with a fluid directing nozzle removably positioned therein and retained in place by a retaining pin having a head positioned external to the bit for ease of removal.
Another object of this invention is to provide an improved rotary drill bit having one or more removable, fluid directing nozzles positioned for directing streams of fluid onto the cutters and having bifurcated pin members securing said nozzles in position.
Other objects of this invention will become apparent from time to time throughout the specification and claims as hereinafter related.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view partly in elevation and partly in section on the center line showing a rotary drill bit embodying the improved removable nozzle and retaining means of the subject invention,
FIG. 2 is a section view taken on the line 2--2 of FIG. 1 showing the relationship of the retaining pin to the fluid directing nozzle, and
FIG. 3 is an isometric detail view of the retaining pin for the air nozzle, also shown in FIGS. 1 and 2.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 discloses the principle features of a rotary drill bit embodying the subject invention. FIG. 1 is a longitudinal sectional view of the bit and so only one of the rotary cutters is shown of the three cutters normally constituting the bit structure. The body 10 of the drill bit defines a centrally located recess 11 and has three arms 12 (only one of which is shown) depending therefrom. Each of the arms 12 has a shaft 13 with a rotary cutter 14 supported thereon in the usual manner with the aid of ball bearings 15 and roller bearings 16. The cutter is shown with a plurality of tungsten carbide cutting inserts 17, although a tooth type cutter could be used equally well. The drill bit body 10 is threaded as shown at 18 for connection to a drill string (not shown).
Cooling passageways 19 extend through the body 10 from the central recess 11 to the recesses between the bearing shafts 13 and cutters 14, whereby relatively cool air or other drilling fluid may be introduced to cool the bearing shafts and cutters as they become heated in the drilling operation. Jet passageways 20 extend through the body 10 from the central recess 11 and are arranged to discharge air between the exterior surfaces of the cutters 14 whereby cuttings and other foreign matter are carried away from the cutters.
A nozzle 21 for air or other drilling fluid is secured in the lower portion of each jet passageway 20 by removable retaining pin 22. The air nozzle 21 is preferably one having a spring loaded check valve 23 of a type shown and claimed in applicant's U.S. Pat. No. 3,685,601. The retaining pin 22, which is an essential novel feature of this invention is preferably used in conjunction with a check valve-air nozle of the type shown. However, this retaining pin arrangement can be used to hold other drilling fluid nozzles in position such as the nozzles illustrated in U.S. Pat. Nos. 3,084,751 and 3,744,581. The check valve 23 in nozzle 21 prevents the introduction of cuttings and other damaging foreign matter into the central recess 11, the cooling passages 19, the area between the shafts and the cutters, and other interior parts of the bit when the air flow therethrough is discontinued.
The details of the retaining pin 22 and the use of the retaining pin in securing nozzle 21 in place are shown in FIGS. 2 and 3. Retaining pin 22 has a solid body portion 24 with a bifurcated end portion having legs 25 and 26 which are tapered as indicated at 27. The opposite end of the retaining pin 22 has enlarged head portions 28 and 29 separated by a peripheral groove 30.
The air nozzle 21 has a peripheral groove 31 which is positioned opposite a passageway 32 through the side of body 10 extending into passageway 20. When nozzle 21 is inserted into passageway 20, the peripheral groove 31 is aligned with passageway 32. The retaining pin 22 is then placed into passageway 32 and driven into place by a hammer or the like. When pin 22 is driven against the edge of nozzle 21 the beveled end portions 27 of the bifurcated end of pin 22 separated and are driven into groove 31 between the bottom edge of the groove and the surface of the passageway 20, as seen in FIG. 2. When the pin 22 is driven into place, as shown in FIG. 2, the head portion 29 abuts the outer surface of the bit and limits the further penetration of the retaining pin.
The retaining pin 22 is left in the position shown during normal operation of the drill bit. When it is desired to repair or replace the nozzle member 21, pin 22 may be removed by application of any suitable tool, such as pliers or a claw hammer, to the groove 30 at the head of the pin to pull the same out of retaining position and release the nozzle for removal.
It will be appreciated that the nozzles shown can be easily secured in the jet passageways of many standard rotary drill bits without modification of such bits. The retaining pin 22 cooperates with the groove 31 and the nozzle 21 to retain the nozzle in position and does not require the machining or cutting of a further groove in the passageway 20 as is required in the case of certain prior art drill nozzles.
The nozzles may be serviced or replaced as necessary with great ease and efficiency and without danger of the retaining pin coming loose and allowing the nozzle to fall out. When the nozzle used is a check valve type nozzle, as shown, it is apparent that these nozzles afford a minimum opportunity for failure and that the nozzles are positioned to direct the air betwen the exterior surfaces of the cutters as desired and exclude the entry of foreign matter into the interior recesses and passageways of the drill bit.
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A rotary drill bit having a plurality of journal-mounted rotating cutters and jet passageways through which drilling fluid is discharged between the cutters is provided with removable nozzles for air or other drilling fluid. The nozzles are provided with a peripheral groove and secured in place in said passageways by the divided ends of a bifurcated retaining pin.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
FIELD OF THE INVENTION
[0001] The present invention relates to an antitheft device that is particularly well suited for use with wheels, e.g., bicycles, motorcycles and automobiles having at least one wheel that can be secured by an unbreakable device passing therethrough.
BACKGROUND OF THE INVENTION
[0002] The loss of a bicycle to theft is an economic loss as well as a substantial inconvenience to the now-stranded cyclist. The loss of a favorite, customized or bicycle of exotic manufacture can also represent a substantial emotional loss from the time and energy associated with selecting just the right combination of features for the rider.
[0003] A number of anti-theft devices have been proposed that are intended to secure a bicycle or motorcycle and thereby prevent or impede theft. See, e.g., U.S. Pat. Nos. 3,747,376; 3,908,414; 5,092,142; 5,475,993; 5,487,285; 5,732,577; 5,913,906; 6,820,448; 7,437,898; 7,481,048; 7,712,339; 8,621,898; 8,881,559; US 2014/036233; and U.S. D579,756.
[0004] Despite such devices, those individuals with intent continue to find methods and techniques to defeat such anti-theft devices. Many of those techniques include the use of a handheld bolt cutter with hardened cutting jaws, a portable angle grinder or even a conventional hacksaw to cut through the antitheft device. Such cutters fail the target material in tension, but they induce the tension via the lateral component of the wedge-shaped blades. This means that a bolt cutter is a battle between the compressive strength of the cutting blades versus the compressive strength of the locking device. If both have near-equal hardness, it is difficult to predict which one will win. The battle becomes one of the quantum of pressure that can be applied on the device by the cutting jaws.
[0005] Typical, commercially available bolt cutters exhibit hardened blades of about 62 HRC and can cut 6 mm 48 HRC wire but only HRC 19 rods of 11 mm. This means why traditional chains of interlinked, connected wire stock, even if hardened and/or made of unique alloys, must be made so large and heavy: the bolt cutter acts on the individual wire stock diameter, not the overall chain width.
[0006] Surveillance videos show that members of the public rarely question or interfere with a thief in the act of breaking or cutting through a bicycle locking device, even when obviously using a bolt cutter or cut-off saw. Thus, cyclists cannot rely on help from passersby who might witness acts of theft in progress. The locking device must do more than just buy time—it must actually work.
[0007] It would be desirable to have an anti-theft device that was made from a material that could not be cut, melted, ground or drilled with handheld tools.
[0008] Some antitheft devices, such as the popular U-shaped devices, are defeated because they are large enough to secure only one wheel and the bike frame to a support. This leaves the other wheel vulnerable to removal and theft unless two such devices are carried and used together. This would double the cost and inconvenience of securing a bicycle against theft.
[0009] It would be desirable to have an anti-theft device that was sufficiently long in reach to secure both wheels and the frame to a stationary support.
[0010] Many locking systems are designed with a plurality of flat leg segments joined at a riveted joint that allows one leg segment to rotate and stack closely with the adjacent segments so as to fold into a compact unit that can be stored in a seat bag or on a frame clip. Such design considerations are visually appealing to consumers because they are easy to carry. Unfortunately, all of the currently known designs of this type are made from some version of steel, hardened steel or hard aluminum.
[0011] While titanium may have been suggested for bicycle locks (see, e.g., US Patent Publication Nos. 2014/0109631 and 2014/0260439), no specific grade or type of titanium is specified.
[0012] Titanium is available in various grades, based on the material properties. Commercially pure titanium is available in increasing hardness from Grade 1 to grade 4. These grades of titanium can be formed, engraved with conventional machines, and cut so that they can even be used as rings and similar jewelry. Stronger grades of titanium are alloys that have been mixed with one or more Group III-Group VIII materials (e.g., vanadium, molybdenum, nickel, ruthenium, palladium, chromium, zirconium, molybdenum, and aluminum) to increase their hardness. Sometimes referred to as “aircraft grade” titanium alloys, such materials are so hard that they are almost impossible to engrave, form or cut.
SUMMARY OF THE INVENTION
[0013] It is an objective of the invention to provide an antitheft device that cannot be cut by handheld bolt cutters.
[0014] It is further an objective to provide a portable antitheft device that can be carried on or by a bicycle without materially compromising the weight and handling of the bicycle in transit when so laden.
[0015] In accordance with these and other objectives of the invention that will become apparent from the description herein, an antitheft device according to the invention comprises an antitheft device comprising a plurality of interlinked titanium alloy arm members, each of which exhibits a hardness of HRC 30 or more and a cross sectional distance of 8 mm or more.
[0016] The security device according to the invention is sufficiently light to be suitable for use with and carried on a bicycle while also exhibiting a high degree of resistance to breach by bolt cutters, saws and angle grinders. Such robust resistance makes the device also suitable for use with motorcycles and automobiles.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 shows an isometric view of an antitheft device according to the invention with two extension members, a locked arm and a lockable arm.
[0018] FIG. 2 is a side view of the device shown in FIG. 1 .
[0019] FIG. 3 illustrates additional details of an extension arm member.
[0020] FIG. 4 depicts a lockable arm member.
[0021] FIG. 5 is an isometric view of a saddle-shaped washer.
[0022] FIG. 6 is an end view of a connection between extension arm members in which opposing saddle-shaped spacers form a pivot plane and a deformed rivet permanently connects the arm members.
[0023] FIG. 7 is a side view of the connection shown in FIG. 6 .
[0024] FIGS. 8-10 depict side, bottom and isometric views, respectively, of a saddle washer used in the invention.
[0025] FIG. 11 presents a saddle washer having two bevels or chamfers to round off the upstanding edges of the arcuate side.
[0026] FIG. 12 is a view of a joint connection using two, opposing, rounded off saddle washers to form a planar connection between an extension arm and the locking arm.
[0027] FIG. 13 is a cross sectional view showing the connection of FIG. 12 .
[0028] FIG. 14 is a sectional view of the lock connecting the locked arm and the lockable arm.
[0029] FIG. 15 is an external view of the connection shown in FIG. 14 .
[0030] FIG. 16 depicts a security washer that may be used between opposing saddle washers to shield the space between saddle washers from insertion of a blade or prying tool.
[0031] FIG. 17 is a cross sectional view of the security washer of FIG. 16 .
[0032] FIG. 18 shows the security washer in place between opposing saddle washers at a pivotable connection of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0033] The present device uses a plurality of connected extension arm members (the number of which determine the overall length available of the device), a locking arm that has a locking device permanently connected thereto, and a lockable arm with a bore through the leading edge thereof. In use, the leading edge of the lockable arm is inserted into a transverse opening in the lock housing and a leading rod member on the lock device is secured into the lock housing so that it passes through the bore in the leading edge of the lockable arm.
[0034] For the present invention, a hard titanium alloy is preferred. One way to measure the hardness of titanium or alloys thereof is with a Rockwell test. Such a test determines the hardness by measuring the depth of penetration of an indenter under a large load compared to the penetration made by a preload. There are different scales, denoted by a single letter, that use different loads or indenters. The result is a dimensionless number noted as HRA, HRB, HRC, etc., where the last letter is the respective Rockwell scale. See Table 1.
[0000]
TABLE 1
Rockwell Hardness Scales
Scale
Abbreviation
Load (kg F )
Indenter
A
HRA
60
120° diamond spheroconical †
B
HRB
100
1/16-inch-diameter (1.588 mm) steel
sphere
C
HRC
150
120° diamond spheroconical
D
HRD
100
120° diamond spheroconical
E
HRE
100
⅛-inch-diameter (3.175 mm) steel
sphere
F
HRF
60
1/16-inch-diameter (1.588 mm) steel
sphere
G
HRG
150
1/16-inch-diameter (1.588 mm) steel
sphere
[0035] Materials tested with the HRC protocol are generally harder than those tested with the HRB protocol. There is, however, some overlap between the upper end of the HRB (100 kg) scale and the lower end of the HRC (150 kg) scale, e.g., an HRB (100 kg) of 97 corresponds generally to an HRC (150 kg) of about 20, and an HRB (100 kg) of 120 corresponds with an HRC (150 kg) of about 55 for non-austenitic steels. (See http://www.woodcousa.com/bhn.pdf.) HRC values of less than 20 are said to have questionable accuracy.
[0036] Titanium alloys having a hardness of HRC 30 or more are preferred for use in the present invention, e.g., titanium exhibiting HRC (150 kg) hardness within the range of 30-68 or HRB within the range of 105-120 or more. Even more preferably, the titanium hardness is within the range of HRC (150 kg) 33-50. Such high hardness is generally beyond the ability of hand tools to cut, saw or grind away. Table 1 lists suitable materials and includes unalloyed titanium by way of comparison.
[0000]
TABLE 2
Material Name
HRC
Titanium Grade 7
11.0
Titanium Grade 7, Annealed
11.0
Titanium Grade 12
11.0
Titanium Grade 18 Ti-3Al-2.5V-0.05Pd
15.0
Titanium Grade 3
16.0
Titanium Grade 4
23.0
Titanium Grade 4, Annealed
23.0
Titanium Ti-3Al-2.5V (Grade 9), alpha
24.0
annealed
ATI Allvac ® 3-2.5 Titanium Alloy, Heat
24.0
Treatment: 704° C. (1300° F.) Anneal
ATI Allegheny Ludlum Grade 9 Titanium
25.0
(UNS R56320)
ATI Allegheny Ludlum Grade 18 Titanium
25.0
(UNS R56322)
Titanium Grade 3, Annealed
26.0
ATI Allvac ® 6-2-4-2-Si UNS R54620 modified
28.0
Titanium Alloy
Titanium Ti-6Al-2Nb-1Ta-0.8Mo (Ti-621/0.8),
30.0
as-rolled
Titanium Ti-6Al-2Nb-1Ta-0.8Mo (Ti-621/0.8),
30.0
Alpha-Annealed
Titanium Ti-6Al-2Nb-1Ta-0.8Mo (Ti-621/0.8),
30.0
STA-1
Titanium Ti-6Al-2Nb-1Ta-0.8Mo (Ti-621/0.8),
30.0
STA
Titanium Ti-6Al-2Nb-1Ta-1Mo
30.0
Titanium Ti-6Al-2Nb-1Ta-1Mo, Annealed
30.0
Titanium Ti-13V-11Cr-3Al (Ti-13-11-3)
30.0
Solution Treated
ATI Allvac ® 6-4ELI Titanium Alloy, Heat
30.0
Treatment: 704° C. (1300° F.) Anneal
ATI Allegheny Ludlum Grade 23 (6-4 ELI)
30.0
Titanium (UNS R56401)
Titanium Ti-15V-3Cr-3Al-3Sn ST 850° C.
31.0
(1560° F.), Aged 545° C.
Titanium Ti-6Al-2Sn-4Zr-2Mo (Ti-6-2-4-2),
32.0
Duplex Annealed
Titanium IMI 829 (Ti-5.5Al-3.5Sn-3Zr-1Nb-
32.0
0.25Mo-0.3Si)
Titanium Ti-10V-2Fe-3Al (Ti 10-2-3), Anneal
32.0
1 hr. 760° C.
Titanium Beta C (Ti-3Al-8V-6Cr-4Mo-4Zr)
32.0
Solution Treated 815° C.
ATI Allvac ® 6-4 Titanium Alloy, Heat
32.0
Treatment: 704° C. (1300° F.) Anneal
ATI Allvac ® 6-7 UNS R56700 Titanium Alloy
32.0
ATI Allvac ® Grade 15-3-3-3 UNS R58153
32.0
Titanium Alloy
ATI Allvac ® 38-644 UNS R58640 Titanium
32.0
Alloy
Titanium Ti-5Al-2.5Sn, ELI, Annealed
33.0
Titanium Ti-6Al-2Sn-4Zr-2Mo-0.1Si; Duplex
34.0
Annealed
Titanium Ti-6Al-2Sn-4Zr-2Mo (Ti-6-2-4-2),
34.0
Sheet
Titanium Ti-13V-11Cr-3Al; (Ti-13-11-3)
34.0
Annealed 800° C., 30 min.
Titanium Ti-8Mn, Annealed
34.0
Titanium Ti-7Al-4Mo Annealed
34.0
ATI Allvac ® 6-2-4-2 Titanium Alloy, Heat
34.0
Treatment: 982° C. (1800° F.) + Age
Titanium Ti-8Al-1Mo-1V (Ti-8-1-1) Duplex
35.0
Anneal
Titanium IMI 834
35.0
Titanium Ti-6Al-4V ELI (Grade 23), Annealed
35.0
ATI Allvac ® 8-1-1 Titanium Alloy, Heat
35.0
Treatment: 982° C. (1800° F.) + Age
ATI Allvac ® 6-6-2 Titanium Alloy, Heat
35.0
Treatment: 718° C. (1325° F.) Anneal
ATI Allegheny Ludlum Grade 5 Titanium 6Al-
35.0
4V (UNS R56400)
Titanium Ti-5Al-2.5Sn (Grade 6)
36.0
Titanium Ti-8Al-1Mo-1V (Ti-8-1-1)
36.0
Titanium Ti-8Al-1Mo-1V (Ti-8-1-1) Annealed
36.0
8 hr at 790° C. (1450° F.)
Titanium Ti-6Al-4V (Grade 5), Annealed
36.0
Titanium Ti-6Al-4V (Grade 5), Annealed Bar
36.0
Titanium Ti-6Al-2Sn-4Zr-6Mo (Ti-6-2-4-6)
37.0
Annealed
Titanium Beta C (Ti-3Al-8V-6Cr-4Mo-4Zr ST
38.0
815° C., Aged 510° C.
Titanium Ti-6Al-2Sn-4Zr-6Mo (Ti-6-2-4-6)
38.0
STOA
Titanium Ti-6Al-6V-2Sn (Ti-6-6-2) Annealed
38.0
Titanium Ti-7Al-4Mo, STA
38.0
ATI Allvac ® 6-2-4-6 Titanium Alloy, Heat
38.0
Treatment: 885° C. (1625° F.) + Age
ATI Allvac ® Ti-17 Titanium Alloy, Heat
38.0
Treatment: 899° C. (1650° F.) + Age
Titanium Ti-13V-2.7Al-7Sn-2Zr, ST 815° C.,
39.0
Aged 540° C. (1000° F.)
Titanium Ti-6Al-2Sn-4Zr-6Mo (Ti-6-2-4-6)
39.0
STA-1
Titanium Ti-6Al-2Sn-4Zr-6Mo (Ti-6-2-4-6)
39.0
STA-2
Titanium Ti-6Al-2Sn-4Zr-6Mo (Ti-6-2-4-6)
39.0
BSTA
Titanium Ti-6Al-4V (Grade 5), STA Bar
39.0
Titanium Ti-10V-2Fe-3Al (Ti 10-2-3) ST
40.0
760° C.; Age 525° C. (980° F.)
Titanium Ti-11.5Mo-6Zr-4.5Sn, ST 720° C.,
40.0
Aged 495° C.
Titanium Ti-8Mo-8V-2Fe-3Al ST 800° C.,
40.0
Aged 540° C. (1000° F.)
Titanium Ti-5-5-8-3 (Ti-5Mo-5V-8Cr-3Al),
40.0
1 to 3 mm Sheet
Titanium Ti-5Al-2Sn-2Zr-4Mo-4Cr (Ti-17)
40.0
Alpha-Beta Processed
Titanium Ti-5Al-2Sn-2Zr-4Mo-4Cr (Ti-17)
40.0
Beta Processed
Titanium Ti-6Al-4V (Grade 5), STA
41.0
Titanium Ti-13V-11Cr-3Al (Ti-13-11-3) Aged
42.0
400° C.
Titanium Ti-6Al-6V-2Sn (Ti-6-6-2) STA
42.0
870° C./565° C.
Titanium Ti-13V-11Cr-3Al; (Ti-13-11-3)
43.0
Annealed 850° C. (1560° F.) + Aged 510° C.
8 hr
Titanium Ti-13V-2.7Al-7Sn-2Zr, ST 760° C.,
44.0
Aged 440° C.
Titanium Ti-6Al-6V-2Sn (Ti-6-6-2) STA
44.0
910° C./540° C. (1000° F.)
Titanium Ti-13V-11Cr-3Al (Ti-13-11-3)
46.0
SolnTreat; Age 450° C.
Titanium Ti-13V-11Cr-3Al (Ti-13-11-3) Aged
50.0
490° C.
[0037] The most preferred titanium for use as the extension members, rivets and spacer elements in the present invention has a hardness of HRC 35 or higher. Such a material can be found in a Grade 5 titanium alloy (Ti-6Al-4V).
[0038] The specific shape of the rod member can exhibit a round or rectangular cross section, but a preferred shape exhibits a cross sectional diameter or length of 8 mm or more, preferably a diameter within the range of 10-20 mm. Such a shape and diameter are sufficiently hard and exhibit such a high tensile strength that they are not readily cut by bolt cutters or saws (hand-operated or battery-operated). Such dimensions and hardness are also a visual deterrent for those intent on using a portable angle grinder that may serve as a psychological deterrent and redirect the would-be thief toward other lock systems that do not have such a robust system.
[0039] The ultimate tensile strength of the titanium alloy can also be used as an indicator for suitability in the present invention. This tensile strength may help avoid potential variances due to surface absorption of oxygen from annealing. An exemplary listing of the ultimate tensile strengths of various titanium alloys is found in Table 3.
[0000]
TABLE 3
Alloy
Designation
Tensile Strength (MPa)
Commercially Pure
ASTM Grade 1
241
Commercially Pure
ASTM Grade 2
345
Commercially Pure
ASTM Grade 3
448
Commercially Pure
ASTM Grade 4
552
Ti-3%Al-2.5%V
ASTM Grade 9
621
Ti-0.8%Ni-0.3%Mo
ASTM Grade 12
483
Ti-3%Al-8%V-6%Cr-4%Zr-
Beta C
1172
4%Mo
Ti-15%Mo-3%Nb-3%Al-
Timetal 21 S a
792
0.2%Si
Ti-6%Al-4%V
ASTM Grade 5
897
Ti-2.5%Cu
IMI 230
540
Ti-4%Al-4%Mo-2%Sn-0.5%Si
IMI 550
1104
Ti-6%Al-6%V-2%Sn
1035
Ti-10%V-2%Fe-3%Al
1241
Ti-15%V-3%Cr-3%Sn-3%Al
1000
Ti-8%Al-1%Mo-1%V
897
Ti-6%Al-5%Zr-0.5%Mo-
IMI 685
850
0.2%Si
Ti-6%Al-2%Sn-4%Zr-2%Mo
931
Ti-6%Al-2%Sn-4%Zr-6%Mo
1172
Ti-5.5%Al-3.5%Sn-3%Zr-
IMI 829
960
1%Nb-0.3%Mo-0.3%Si
Ti-5.8%Al-4%Sn-3.5%Zr-
IMI 834
1030
0.7%Nb-0.5%Mo-0.3%Si
a Solution treated
[0040] An ultimate tensile strength of 700 MPa or more (at 20° C.) is preferred for the titanium members and parts use in the present invention. Even more preferable is a tensile strength of about 930 MPA or more.
[0041] The specific shape of the rod member can exhibit any number of potential geometric shapes in cross section, e.g., round, triangular, rectangular, hexagonal, octagonal, etc. provided that the cross sectional distance is sufficiently large to be impractical to cut with handheld bolt cutters, e.g., a cross sectional distance of at least 8 mm, preferably a cross sectional distance within the range of 9-20 mm, and even more preferably a cross sectional distance of 10-14 mm. A preferred shape uses commercially available rod stock that exhibits a cross sectional diameter within the range of 8-12 mm.
[0042] Turning now to the figures, FIGS. 1 and 2 shows an antitheft device 1 according to the invention. Two extension rod members 3 , 4 (also called “first rod members” herein) are interconnected with each other and with locked rod member 5 (referenced as “third rod member” herein) and lockable rod member 2 (referred to as “second rod member” herein) at first ends 6 . Any number of extension rods 3 , 4 may be used to provide additional length to antitheft device 1 .
[0043] An opposing pair of saddle washers 7 have an arcuate side that contacts the round external surfaces of each rod and an opposing flat or planar side that provides a planar interaction surface 8 in which each rod can pivot relative to the rod with which it is connected by rivet 9 , e.g., between rod 2 and rod 3 . Saddle washers 7 also serve to protect rivets 9 from attack using the connected rods as cutting guides by a saw blade or bolt cutter jaws.
[0044] Locked rod member 5 is permanently secured to lock 10 . Lockable rod member 2 can become secured by lock 10 when lockable rod 2 is inserted into lock hole 11 and lock mechanism 12 is engaged. See also FIG. 13 .
[0045] FIGS. 3 and 4 show additional details of extension rod 3 . As shown extension rod 3 is cylindrical with a substantially circular cross sectional shape having a length 17 and rod diameter 18 . Substantially parallel, transverse bores 13 , 14 with countersink bores 15 , 16 that exhibit greater diameter than bores 13 , 14 . Bore centers 19 , 20 of bores 13 , 14 respectively are desirably located at least one third and preferably at least one half of a rod diameter from the terminal ends 21 , 22 of rod 3 .
[0046] FIGS. 5-13 illustrate additional details of the saddle washers 7 and the pivotable connections between connected rods, e.g., extension rods 3 , 4 . As shown, saddle washer 7 has a planar side 23 and an arcuate side 24 . Arcuate side 24 preferably exhibits a radius of curvature 25 that is substantially the same as rods 3 , 4 to provide a good fit. Washers 7 also exhibit a transverse bore 26 having a close tolerance fit for securing rivet 9 without undue play between rivet 9 and spacer 7 when assembled.
[0047] As shown in FIGS. 6 and 7 , the ends of rivet 9 are exposed above the outer diameter of rods, 3 , 4 . While exposed ends are operative to secured rods 3 , 4 together they also provide a potential vulnerability for attack by a portable angle grinder that might remove the deformation flanges 27 on either end of rivet 9 . To that end, rivet 9 may also be set at or below the outer surface 31 of the connected rods, e.g., rods 4 and 5 , in countersink boring 32 .
[0048] The outer diameter 28 of spacer 7 may be the same or substantially the same as the rod diameter 18 . The rising edges 29 of washer 7 can present a sharp edge for users. First and/or second chamfers 30 , 31 can be used to reduce incidents of cutting or snagging at edges 29 while also retaining the security and planar motion features of saddle washers 7 between connected rods.
[0049] FIGS. 14 and 15 illustrate additional details of lock 10 . As shown, distal end 33 of lock body 35 extends through rod 5 and into countersink bore 32 where it is deformed in-situ to make enlarged end 34 that permanently holds lock body 35 to locking rod 5 .
[0050] Within lock body 35 , locking member 36 is able to be removed vertically and axially from within lock body 35 by operation of a key (not shown) in keyhole 37 from a secured position 38 to an unsecured position (not shown). Locking member 36 also exhibits a distal pin 39 that engages the transverse bore 14 of lockable rod 2 when in secured position 38 and disengages from rod 2 when moved axially within lock body 35 or removed completely from lock body 35 . Secured bushings 40 , 41 within lock body 35 are used to center and secured locking member 36 within lock body 35 . Preferably, the external surface 42 of locking member 39 and the corresponding internal surfaces 43 , 44 of bushings 40 , 41 exhibit mating threads that allow locking member 36 to be threaded into and secured within lock body 35 .
[0051] FIGS. 16-18 illustrate the optional use of a security washer 45 between opposing saddle washers 7 . Preferably, at least one security washer is used in the antitheft device according to the invention and even more preferably a security washer is used at each joint connection in the device. Security washer 45 preferably exhibits a shaped radial edge 46 , such as counter-sloping sections 47 , 48 that meet in an acute or obtuse angle 49 at substantially the vertical mid-point 50 of the height of security washer 45 . Such a profile shape makes it more difficult for a blade or saw edge to attack the joint at the intersection of the opposing saddle washers 7 . The inner area 51 of security washer 7 preferably has opposing countersink portions 52 to receive saddle washers 7 and centered on a central bore 53 for passing rivet 9 therethrough.
[0052] The foregoing illustrations and descriptions are not intended to serve as limitations on the scope of the appended claims.
[0053] Each of the patents and published applications that have been cited herein are hereby incorporated by reference.
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The invention relates to an anti-theft device that is both highly resistant to attack by hand-carried bolt cutters and saw blades while also exhibiting a weight suitable for use with bicycles. The device is made with a plurality of interlinked titanium alloy arm members, each of which exhibits a hardness of HRC 30 or more and a cross-sectional distance of 8 mm or more.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
FIELD OF THE INVENTION
The present invention relates to electromagnetic interference (EMI) shielding and more particularly to improved screen shielded windows for radio frequency (RF) and EMI shielded enclosures.
DESCRIPTION OF THE PRIOR ART
Shielded enclosures such as rooms are used to attenuate interference for a wide variety of applications such as nuclear magnetic resonance (NMR), laser alchemestry, hyperthermia, sensitive electronic testing and others. Known shielded enclosures include a single or double layer of electrically conductive shielding material such as copper or steel sheet, foil or grid entirely enclosing a shielded space. For example, the walls, floor and ceiling of a room may be surrounded by electrically continuous layers of a conductive shield, and the shield may be grounded at a single point to bypass to ground the electromagnetic energy to which the shield is subjected. It is important to maintain the integrity of the shielding where apertures such as doors and windows are required.
Windows are desired in some shielded enclosures. For example, in enclosures used with NMR equipment, the extremely sensitive equipment is located within the enclosure where it is shielded from ambient electromagnetic interference. The controls for the equipment include EMI emitting devices such as computers and peripheral devices and must be located outside of the enclosure. A window in the wall of the enclosure permits the operator to view the shielded equipment and a patient undergoing NMR procedures.
Conflicting objectives are present in the design of windows for shielded enclosures. In order to maintain the effectiveness of the shielding in the region of the window, the window should have high shielding capabilities. Yet, the window should be highly optically transmissive so that the view through the window is as clear and interference free as possible.
One type of shielded window that has been used in the past incorporates a single layer of conductive grid, typically a woven wire cloth. The grid covers the window opening and is attached and electrically connected to the shielding layer of a shielded enclosure. With a single grid layer, optical interference results from blocking of a certain portion of the window sight opening by the wire and from distracting effects if the wire is too large or if the wire grid is too fine. The wire size and mesh count of the wire cloth can be selected to maximize electrical conductivity and minimize optical interference.
Single layer metal grids are used where shielding requirements are not demanding. However for many purposes a single grid layer cannot provide enough shielding. To increase shield effectiveness of a window, double layers of similar metal grids such as wire cloth have been used. Double, spaced apart grid layers provide the necessary shielding performance, but are subject to serious problems of optical interference. There is an added cause of optical interference when two grids are superimposed. Due to a phenomenon called the moire effect, disturbing interference patterns are seen when an observer looks through a window with two conductive grids. Attempts have been made to reduce this problem by rotating or skewing the two grids to provide an angular offset. An angle of about twelve degrees is typical. However, variations in the offset angle and in the wire size or mesh count do not appreciably reduce the moire interference.
A different approach to solving this problem is described in U.S. Pat. No. 4,696,547. No grids are employed. Instead, an electrically conductive liquid fills the space between a pair of transparent window panels. While this approach is capable of providing both high shielding effectiveness and low optical interference, the complexity and expense of that window system can be a disadvantage in some cases.
SUMMARY OF THE INVENTION
A principal object of the present invention is to provide a window for shielded enclosures that achieves high shielding performance with a simple and low cost shielding grid system while avoiding the optical interference caused by the moire, effect.
In brief, the objects and advantages of the present invention are achieved by providing an EMI shielded enclosure having walls enclosing an electromagnetic radiation shielded space. The walls include a substantially continuous metal shield, a window opening in a wall and a window mounted in the opening for blocking electromagnetic radiation while transmitting visible light. The window includes a first shielding screen electrically connected to the continuous metal shield and lying in a first plane spanning the window and a second shielding screen electrically connected to the continuous metal shield and lying in a second plane spanning the window. The first and second planes are spaced apart from one another. Both of the screens are formed of electrically conductive shielding material arrayed in mesh patterns. In accordance with the present invention, the mesh pattern of the first screen differs dimensionally from the mesh pattern of the second screen.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention together with the above and other objects and advantages may best be understood from the following detailed description of the embodiment of the invention illustrated in the drawings, wherein:
FIG. 1 is a fragmentary, elevational view of part of a shielded enclosure provided with a window incorporating the features of the present invention;
FIG. 2 is an enlarged, fragmentary, sectional view taken along the line 2--2 of FIG. 1;
FIG. 3 is a greatly enlarged, fragmentary, elevational view of a portion of the window of FIG. 1; and
FIG. 4 is a greatly enlarged, fragmentary, sectional view of the shielding screens of the window of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, FIG. 1 shows a part of a wall 10 of a shielded enclosure 12 such as a room. Mounted in the wall 10 is a shielded window designated as a whole as 14 constructed in accordance with the principles of the present invention. The window 14 is provided with an improved shielding screen system generally designated as 16 for achieving high EMI shielding performance without an undesirable degree of optical interference.
The room 12 including the wall 10 may be of any preferred type of construction. As seen in FIG. 2, the wall 10 includes a frame element 18 serving along with other similar frame members to form a window opening 20 in the wall 10. A shielding layer 22 of metal on an outer surface of the wall 12 is continuous around the entire room 12 and its edges extend near the window opening 20. In the illustrated embodiment, frame member 18 is wood and the shielding layer 22 is copper sheet. If desired, both the inner and outer wall surfaces may be provided with shielding layers 22. A decorative finished appearance is provided on both the inner and outer wall surfaces by layers or sheets 24 of a surface material such as a plastic laminate.
Window 14 includes a structural frame 26 of similar cross sectional shape throughout (FIG. 2) extending completely around the window opening 20. Preferably the frame 26 is an extruded shape of a metal such as aluminum with mitered corners abutting at the corners of the window opening 20. The frame metal will usually be coated with a conductive metal such as tin. At the outer side of the frame a continuous mounting flange 28 extends over the outer wall and overlies the edge region of the shielding layer 22. Fasteners 30 extend through the flange 28 and shielding layer 22 into the frame element 18 to mount the frame securely in place in the window opening 20 and to assure a continuous, low resistance electrical connection between the frame 26 and the shielding layer 22. An inner wall 32 in a plane extending between the outer and inner surfaces of the frame 26 defines a window sight opening 34.
The window shielding screen system 16 includes first and second shielding screens 36 and 38 covering and shielding the entire window sight opening 34. As described below in more detail, each shielding screen is a grid of electrically conductive material selected and oriented in accordance with the present invention. Frame 26 includes inner and outer, spaced apart, oppositely directed screen mounting channels 40 and 42 located near the inner and outer surfaces of the frame 26. The edges of the shielding screens 36 and 38 are received in channels 40 and 42 continuously throughout the periphery of the window 14. Flexible beads or splines 44 tightly wedge or clamp the screens 36 and 38 in the channels 40 and 42 and assure intimate, high conductivity electrical contact between both of the shielding screens and the frame. The shielding screens 36 and 38 are sprayed with a very thin layer of black die to reduce glare and improve vision through the window assembly.
Two panes 46 and 48 of glass or other transparent window glazing material are attached to the frame 26 by double sided adhesive foam attachment strips 50. The shielding screens 36 and 38 are between the panes 46 and 48 and are protected from accidental contact and damage. In addition, the panes 46 and 48 block the travel of sound and the movement of air through the window 14. If this type of protection or isolation is not required, one or both of the panes 46 and 48 may be omitted. The shielding screen system 16 may be used without window panes to provide the desired EMI shielding.
Decorative trim pieces 52 cover the edges of the window 14 at the inner and outer wall surfaces to hide the transition between the wall 12 and the window, including flange 28 and fasteners 30, and to provide a neat and finished appearance. Central leg portions 54 of the trim pieces 52 are frictionally received in retention grooves 56 of the frame 26 to hold the pieces 52 in place.
Electrical continuity between the wall 12 and window shielding system 16 is provided by the frame 26. Flange 28 is in continuous intimate contact with the shielding layer 22, while the shielding screens 36 and 38 are in continuous intimate contact with the screen mounting channels 42. The result is an electrically continuous shield over and around the window area. The use of two shielding screens maintains the effectiveness of the shield across the window sight opening 34. By employing the principles of the present invention in the design of the system 16, a higher degree of visibility through the window 14 is possible.
The shielding screen system 16 of the present invention can best be seen in FIGS. 3 and 4. Each shielding screen 36 and 38 is a grid of electrically conductive material having a mesh pattern. In accordance with the present invention, the mesh patterns of the two screens 36 and 38 are dimensionally different which results in the greatly reduced optical interference over that encountered with dual screen systems having duplicate mesh patterns. In order to achieve the desired dimensional difference, the shielding screen 36 is a comparatively finer grid while the shielding screen 38 is a relatively coarser grid.
Shielding screen grids with mesh patterns may be formed of many different types of structures. Woven wire cloth is preferred due to its availability and relative cost. However other structures such as lattices, expanded grates, perforated sheets, grids vacuum deposited on glass sheets and others might also be used.
In a grid such as employed in the shielding screens 36 and 38, the intersecting elements of conductive material subdivide the area of the grid into an array of open areas, each of which is termed a mesh. The relative fineness or coarseness of the grid is described in terms of mesh count. Mesh count is the number of openings along a given linear direction. For example, a conventional window insect screen material has a mesh count of eighteen per inch in both orthagonal directions.
In accordance with the present invention, the mesh counts of the screens 36 and 38 differ from one another. When the difference exceeds about twenty percent, the interference and distraction caused by the moire effect is substantially reduced or eliminated. In order to maintain the shielding effectiveness of the coarser grid screen and to avoid blocking too much of the total viewing area with the finer grid screen, the mesh count difference ratio should not be more than about two to one. A finer grid screen having a mesh count about eighty percent larger than the mesh count of the coarser grid screen generally optimizes the advantages of the invention.
Because an important goal of the present invention is to reduce optical interference and distraction, the coarser grid of the screen 38 should be fine enough to avoid distracting an observer. For best results, the mesh pattern of the shielding screen 38 should preferably have a mesh count larger than the sixteen per inch mesh count of conventional window screen material. While a coarser mesh could accomplish many of the results of the invention, the use of a somewhat finer mesh prevents an observer from seeing the grid of wires when looking through the screen 38 with normal eye focus. The best results are obtained if the grid count is higher than about twenty per inch with cloth woven from wire having a diameter in the approximate range of 0.0040-0.0080 inch.
The advantages arising from a mesh pattern difference between screens 36 and 38 suggests that the mesh count of screen 36 should be relatively high. However, to avoid optical interference, it is preferred that the grid of screen 36 not be too fine. If the grid is too fine, a blurred or fuzzy or "ghost" image can result. The best results are obtained if the grid count of the fine grid screen 36 is less than about fifty per inch with cloth woven from wire having a diameter in the approximate range of 0.0040-0.0060 inch.
The undesired effects of moire pattern interference are further reduced by an angular offset between the grids of the screens 36 and 38. As seen in FIG. 3, the wires of screen 36 are arrayed at an angle to the wires of screen 38. In typical dual screen systems used in the past, angular offsets of twelve degrees have been used with two similar screens. With dimensionally different shielding screens in accordance with the present invention, a larger angle in the range of fifteen to twenty-five degrees produces better results.
The optical quality of the shielding system is decreased if the shielding screens 36 and 38 are not spaced apart. It is preferable if the two screens are located at different distances from the eyes of an observer. Preferably, the screens are separated by more than about one-half inch. Depending upon the thickness of wall 12, the screens may be separated by as much as about two inches.
In the preferred embodiment of the invention, screen 36 is a plain square weave cloth of similar warp wires 58 and shute or weft wires 60 both having a diameter of 0.0050 inch in a pattern having a mesh count of forty-three per inch in both axes. Screen 38 is a plain square weave cloth of similar warp wires 62 and shute or weft wires 64 both having a diameter of 0.0075 inch in a pattern having a mesh count of twenty-four per inch in both axes. An observer can see through the screens 36 and 38 because the screens are respectively about sixty-two and sixty-seven percent open or unobstructed by wire in the direction perpendicular to the planes of the screens. The preferred wire material for screens 36 and 38 is an austenitic stainless steel having low electrical resistivity. Both screens are regular orthagonal grids. Wires 58 and 62, as well as wires 60 and 64, are positioned at an offset angle of twenty degrees. The screens 36 and 38 are parallel and spaced one and one-half inches apart. Both screens are spray coated with black die or otherwise blackened to reduce the glare from the stainless wire. The advantages of the present invention can be realized without employing this specific arrangement.
While the invention has been described with reference to details of the illustrated embodiment, these details are not intended to limit the scope of the invention as defined in the appended claims.
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A window for electromagnetic interference shielded enclosures has a shielding screen system with two grids having dimensionally different mesh patterns to overcome optical interference and distraction resulting from the moire effect. The screens are supported in spaced, angularly offset positions on a continuous frame providing electrical continuity between the shielding system and the shielding layer of a surrounding wall.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
FIELD OF THE DISCLOSURE
[0001] The disclosure is related to consumer goods and, more particularly, to methods, systems, products, features, services, and other elements directed to media playback or some aspect thereof.
BACKGROUND
[0002] In the context of cavity wall structures for construction, the walls are typically formed of two wythes. These may both be of masonry, the wythes being spaced apart to form a vertical space or cavity therebetween. Alternatively, it may have an outer masonry wall such as of bricks, with an inner building wall of wood, wallboard, concrete, concrete masonry units (“CMU”), tile, or similar commonly used interior wythe materials.
[0003] It has long been common in the field of cavity wall construction to use masonry anchors or other similar fastening mechanisms in order to anchor the two wythes to one another, thereby forming a conjoined, singular wall structure. Such anchors are typically fabricated from metal, such as steel, and comprise two elements attached, either in manufacture or upon installation, one element being a masonry reinforcement and the other at least one bracket.
[0004] Typically, the masonry reinforcement comprises a pair of generally parallel, elongate arms connected by a series of transverse bars. Most commonly, the masonry reinforcement is configured in either a ladder-type configuration with the transverse bars extending perpendicular to the elongate arms, or a truss-type configuration, wherein the transverse bars form a series of triangles with the elongate arms. In installation, the masonry reinforcement is positioned on a mortar joint within the inner wythe and acts as the support structure of the anchoring system. Multiple anchoring systems may be installed on several mortar joints within a particular cavity wall.
[0005] Extending externally laterally from the masonry reinforcement are a plurality of spaced-apart brackets. The brackets are typically welded to the inboard (closer the cavity) elongate arm of the masonry reinforcement. That weld may be at each node formed at the junction of an elongate arm and the transverse bar.
[0006] Multiple configurations of the brackets are known in the art. For example, a common configuration comprises two “eyes” at the terminal ends of a single U-shaped bracket, as shown in FIG. 1 . The eyes receive a fastening member, such as a wall tie, that is affixed to the outer wythe. Typically, such U-shaped brackets are welded to the top of the masonry reinforcement, providing three welding points between the masonry reinforcement and bracket, but placing the masonry reinforcement and bracket on two different horizontal planes. While this configuration generally ensures a strong connection between the masonry reinforcement and bracket, while maintaining a generally horizontal configuration of the bracket relative the mortar joint, the added thickness within the mortar joint may decrease the strength of the wall structure as less mortar may occupy the thickness of the joint.
[0007] A similar prior art U-shaped bracket is depicted in U.S. Pat. No. 6,735,915, wherein the base of the “U” is concave, thereby defining two weld points between the masonry reinforcement and bracket. This eliminates the added thickness of the anchoring system when the bracket is welded on top of the masonry reinforcement, as in other prior art systems.
[0008] The eyes of the bracket must also provide sufficient strength to withstand tensile stress tending to pull the two wythes apart. Currently, it is known in the art to provide a partially closed eye at the two terminal ends of the U-shaped bracket. In manufacture, such brackets are formed by first bending a single wire to form the U-shaped portion of the bracket, and then performing the secondary operation to bend the two ends of the wire into the semi-circular eye, either prior to or during installation.
[0009] The stem of the bracket, i.e. the legs of the “U”, must also resist compressive stress.
[0010] The Applicant has perceived a need for an improved masonry anchor, and how to accomplish that.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] Features, aspects, and advantages of the presently disclosed technology may be better understood with regard to the following description, appended claims, and accompanying drawings where:
[0012] FIG. 1 is a perspective view of a prior art masonry anchor;
[0013] FIG. 2 is a top plan view of an example masonry anchor;
[0014] FIG. 3 is a top plan view of another embodiment of a bracket of the masonry anchor of FIG. 2 ; and
[0015] FIG. 4 is a perspective cut-away view of a cavity wall showing the masonry anchor of FIG. 2 upon installation.
[0016] The drawings are for the purpose of illustrating example embodiments and may not be drawn to scale. The inventions are not limited to the arrangements and instrumentalities shown in the drawings.
DETAILED DESCRIPTION
[0017] Referring to FIGS. 2-4 , example embodiments of a masonry anchor are illustrated. The invention relates to a masonry anchor 10 for securing and maintaining the position of an inner wythe 102 of a cavity wall 100 to the outer wythe 104 , as shown in FIG. 4 . While the invention will be described with respect to specific examples, those skilled in the art will appreciate that there are numerous variations and permutations of the described systems and techniques that fall within the spirit and scope of the invention.
[0018] The masonry anchor 10 includes the masonry reinforcement 12 connected to a plurality of brackets 14 , typically by welding. More specifically, the bracket 14 may be butt-welded to the masonry reinforcement at the terminal ends 20 a , 20 b of each leg 22 of the bracket 14 . Welding may be accomplished by electric arc welding, for example. In this example, both the masonry reinforcement 12 and bracket 14 are fabricated from metal, such as steel. This may also be galvanized steel or epoxy-coated rebar, or similarly rigid materials may be used to form the masonry reinforcement 12 and bracket 14 . Other materials are also possible.
[0019] The masonry reinforcement 12 includes an inboard (closer to the cavity) arm 15 and outboard arm 16 conjoined by a series of spaced-apart transverse members 18 , typically equally spaced. In the embodiment depicted in FIG. 2 , transverse members 18 run latitudinally (orthogonally) to the arms 15 , 16 , forming a ladder configuration. Transverse members 18 are spaced apart so as to correspond to the width of the masonry unit, such as a brick or concrete block being used in the inner wythe 102 , as shown in FIG. 4 . However, it will be understood by those skilled in the art that other configurations, such as a truss configuration, may be employed without departing from the spirit and scope of the invention. The junction between each transverse member 18 and arms 15 , 16 forms a node 19 .
[0020] The brackets 14 include a pair of generally equi-length legs 22 and at least one eye 24 . As shown in FIG. 2 , one configuration of the bracket 14 comprises a pair of generally parallel legs 22 and a pair of eyes 24 joined by a connecting region 26 located proximal the eyes 24 , generally forming a “U” shape. The eyes 24 are adapted to receive a fastening member, such as the fastening member 106 as shown in FIG. 4 .
[0021] In the example of FIG. 2 , the bracket 14 comprises two legs 22 providing two terminal ends 20 a and 20 b for butt-welding to the masonry reinforcement 12 . The two-leg configuration places the weld points of the bracket in a single plane for uniform connection to the masonry reinforcement 12 . In an alternative embodiment, bracket 14 may include two legs 22 and a single eye 24 , the bracket generally formed in a “V” shape. It will also be understood that bracket 14 may alternatively include a pair of legs 22 and three or more eyes 24 . For example, the third eye may be medially disposed on the connecting region 26 between the dual-eye configuration shown in FIG. 2 .
[0022] Referring now to the example shown in FIG. 3 , a bracket includes a pair of parallel legs 122 and a pair of corresponding eyes 124 joined by a connecting region 126 . As depicted in FIG. 3 , each leg 122 generally aligns with the center of its corresponding eye 124 . This configuration may increase the strength of the masonry anchor 10 by making the legs 122 and the welding points generally subject to pure tension or pure compression, which may reduce the possible torque associated with the configuration of FIG. 2 . As such, the bracket of FIG. 3 may withstand a greater force than if the legs 122 were offset from the eyes 124 , or if the legs 122 were not generally perpendicular the inboard arm 15 of the masonry reinforcement 12 . The FIG. 2 embodiment is nonetheless considered quite viable, as it requires less bending of the bracket 14 and therefore may be easier and/or cheaper to manufacture.
[0023] As shown in FIG. 1 , the ends of the bracket in prior art masonry anchors terminated in the eyes. As a result, manufacture of prior art brackets requires a multi-step process whereby the “U” shape is formed, and then secondarily, the eyes are “closed.” Additionally, such eyes may be weaker and less resistant to tensile stress, (i.e. forces tending to separate the inner wythe from the outer wythe) given the lack of complete closure of the terminally located eyes and their tendency to pull open upon the action of such tensile forces.
[0024] In manufacture, the bracket 14 shown in FIG. 2 may be formed from a metal rod stock or wire. In some cases, the bracket 14 may be formed from a single rod stock. To form the eyes 24 , the rod stock is spiraled or turned at two points along the rod stock. Because the terminal ends 20 a and 20 b are not necessarily fixed upon manufacturing, (as they are when the eyes are formed at the ends of the prior art U-shaped brackets), the present manufacturing process provides the added flexibility to modify the length of the legs 22 depending upon the desired width of the cavity. For example, brackets 14 may be manufactured having one general size for the legs 22 , as measured from the terminal ends 20 a , 20 b to the center of the eyes 24 . The brackets 14 may then be cut to size by shortening the legs 22 at the terminal ends 20 a , 20 b.
[0025] The eyes 24 of the example bracket 14 shown in FIG. 2 may also provide additional strength as compared to the terminally located eyes present in the prior art. In particular, the eyes 24 are fully closed upon spiraling of the rod stock to form the bracket 14 . Thus, any tensile force acting upon the bracket 14 via the fastener-to-eye connection and tending to separate the inner wythe 102 and outer wythe 104 may tighten the eyes 24 around their respective fastening member 106 , rather than pull the eyes 24 apart.
[0026] While the invention has been described with respect to certain embodiments, variations and modifications will be recognized by those of skill in the art which will nonetheless come within the spirit and scope of the invention, as further set forth in the claims which follow.
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A device is described for anchoring and inner wythe in a cavity wall to an outer wythe in order to secure and maintain the position of the inner wythe relative to the outer wythe, the device including a masonry reinforcement retained within the mortar joint of the inner wythe and a plurality of spaced apart brackets attached to the masonry reinforcement, the brackets being formed from a piece of rod stock with terminal end, where at least one eye formed as a turn of the rod stock is disposed between the terminal ends.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
TECHNICAL FIELD
[0001] This document generally describes friction and wear reduction techniques for equipment positionable in a wellbore, more particularly friction and wear reduction techniques using graphene as a lubricant.
BACKGROUND
[0002] In connection with the recovery of hydrocarbons from the earth, wellbores are generally drilled using a variety of different methods and equipment. According to one common method, a roller cone bit or fixed cutter bit is rotated against the subsurface formation to form the wellbore. The drill bit is rotated in the wellbore through the rotation of a drill string attached to the drill bit and/or by the rotary force imparted to the drill bit by a subsurface drilling motor powered by the flow of drilling fluid down the drill string and through downhole motor.
[0003] Frequently, as a well is being drilled, a string of coupled casing is run into the open-hole portion of the well bore and cemented in place by circulating cement slurry in the annulus between the exterior of the casing string and the wall of the wellbore. This is done by methods known in the art and for drilling purposes known in the art. Then the wellbore is drilled deeper. When drilling deeper, the rotating drill string is run through the interior of the casing string with the bit on the bottom of the drill string. The drill string comprises drill pipe joints joined together at tool joints (i.e. thread connections) and is rotated by the drilling rig at the surface. As the drill string is rotated the drill pipe, and more particularly the larger outside diameter portion of the tool joints may rub against the interior wall of the casing.
[0004] Rotating drill strings, like all moving mechanisms, exhibit friction that can result in mechanical wear of either or both the casing and the drill string. Friction and mechanical wear can cause drilling inefficiencies, due to increased power needed to overcome frictional resistance or due to maintenance or repair of assemblies due to wear.
DESCRIPTION OF DRAWINGS
[0005] FIG. 1 is a diagram of an example drilling rig for drilling a wellbore.
[0006] FIG. 2 is a flow diagram of an example process for a friction and wear reduction technique for downhole tools disposed in a wellbore.
[0007] FIG. 3 is a flow diagram of an example subsequent operation for friction and wear reduction techniques for downhole tools disposed in a wellbore.
[0008] FIG. 4 is a flow diagram of an example process for the application of lubricant for downhole tools.
DETAILED DESCRIPTION
[0009] FIG. 1 is a diagram of an example drilling rig 10 for drilling a wellbore 12 . The drilling rig 10 includes a drill string 14 supported by a derrick 16 positioned generally on an earth surface 18 . The wellbore 12 is at least partly lined by a casing 34 . The drill string 14 extends from the derrick 16 into the wellbore 12 through a bore in the casing 34 . The lower end portion of the drill string 14 includes at least one drill collar 20 , and in some implementations includes a subsurface drilling fluid-powered motor 22 , and a drill bit 24 . The drill bit 24 can be a fixed cutter bit, a roller cone bit, or any other type of bit suitable for drilling a wellbore. A drilling fluid supply system 26 circulates drilling fluid (often called “drilling mud”) down through a bore of the drill string 14 for discharge through or near the drill bit 24 to assist in the drilling operations. The drilling fluid then flows back toward the surface 18 through an annulus 28 formed between the wellbore 12 and the drill string 14 . The wellbore 12 can be drilled by rotating the drill string 14 , and therefore the drill bit 24 , using a rotary table or top drive, and/or by rotating the drill bit with rotary power supplied to the subsurface motor 22 by the circulating drilling fluid.
[0010] To reduce the amount of friction between the drill sting 14 and the casing 34 , a lubricant layer 60 is applied to the outer surface 19 of the drill string 14 , and a lubricant layer 62 is applied to an inner surface 21 of the bore of the casing 34 . In some embodiments, the lubricant layers 60 , 62 can be layers of graphene.
[0011] In some embodiments, graphene can be applied to the inner surface 21 of the casing 34 and the outer surface 19 of the drill string 14 to form the lubricant layers 60 , 62 . For example, graphene in a powdered form may be sprinkled, blasted, power coated, or otherwise applied to the casing 34 and the drill string 14 . In another example, the casing 34 and the drill string 14 may be contacted (e.g., rubbed) with solid graphite to leave behind graphene layer as the lubricant layers 60 , 62 . In some embodiments, graphene can be suspended in a liquid (e.g., ethanol) to form a graphene suspension, and the suspension can be sprayed onto the inner surface of the casing 34 and the outer surface 19 of the drill string 14 to form the lubricant layers 60 , 62 . For example, the graphene suspension may be sprayed using commercially available air-powered or airless sprayers.
[0012] In some implementations, commercially available solution processed graphene (SPG) containing graphene monolayer flakes dispersed in ethanol having a weight concentration of graphene as 1 mg/L can be used on the inner walls of the casing 34 , liners and risers, and/or on the outer surface 19 of the drill string 14 at the start of a drilling operation. SPG can be sprayed or sprinkled on the intended steel surfaces using any appropriate commercially available spraying or sprinkling systems.
[0013] In some implementations, graphene can provide improved tribological properties, and the application of graphene on contacting downhole surfaces can reduce friction and wear. In some implementations, the contact between the casing 34 and the drill string 14 downhole can wear out lubricant layers 60 , 62 , and replenishment of the lubricant coatings, e.g., graphene, may be provided. The lubricant layers 60 , 62 can be reapplied by sprinkling solution-processed graphene on drill pipes, drill collars, the bottom hole assembly, or other downhole tools when they are tripped out of the wellbore 12 so that a fresh coating can be established. In some implementations, solution processed graphene can be added on a continuous basis to the circulating drilling fluid to help replenish the worn out graphene coatings downhole.
[0014] In some implementations, the application of a protective graphene layer can reduce the coefficient of friction during rotary operations, as well as reduce the sliding friction during tripping or during sliding drilling. In some implementations, the application of protective graphene layers can also reduce the wear on the inner surface 21 of the casing 34 , wear on the drill string 14 , as well as the mechanical wear of bottom hole assembly tools during drilling operations. In some implementations, application of graphene can improve the wellbore integrity and the life of downhole tools/tubulars, e.g., measurement-while-drilling tools, logging while drilling tools, stabilizer blades, connection subs, bits, teeth, rotary steerable systems, drill pipes, heavy weight drill pipes, drill collars.
[0015] A monitor 70 measures an indicator of mechanical wear between the drill string 14 and the casing 34 . In some implementations, the monitor 70 can measure a concentration of one or more predetermined materials suspended in the drilling fluid and corresponding to at least one of the drill string 14 and the casing 34 . For example, the drill string 14 and the casing 34 may be constructed of known materials (e.g., steel, iron, aluminum, ceramic), and the monitor 70 may be configured to detect and measure amounts of the known materials worn off from the downhole components and suspended in drilling fluid that flows to the surface from downhole. The concentrations of such known materials may be measured over time to estimate an amount of wear that has occurred along the drill string 14 and the casing 34 .
[0016] In some implementations, the monitor 70 can measure an amount of torque developed between the drill string 14 and the casing 34 . For example, the amount of torque developed between the drill string 14 and the casing 34 may be used to estimate the amount of wear that has occurred along the drill string 14 and the casing 34 and/or estimate the downhole friction acting between them.
[0017] In some implementations, the monitor 70 can indicate one or more mechanical dimensions of the drill string 14 and/or the casing 34 . For example, the drill string 14 may start its service life with an initial outer diameter that gradually shrinks as friction and mechanical wear erode away the outer surfaces of the drill string 14 . In another example, the casing 34 may start its service life with an initial inner diameter that gradually grows as friction and mechanical wear erode away the inner surface of the casing 34 . The monitor 70 may be configured to measure these and/or other mechanical dimensions of the drill string 14 and/or the casing 34 to determine an amount of wear that has occurred along the drill string 14 and/or the casing 34 .
[0018] In some example drilling operations, the casing 34 , liners, or risers can run in the wellbore 12 according to a drilling program. The drill string 14 can be tripped in to the wellbore 12 to drill the well. The downhole wear in casings can be monitored by the monitor 70 by running in logs (e.g., ultrasonic imager log, caliper log) to measure the inside diameter of the casing 14 . Based on the log readings, percent of casing wear volume can be estimated using wear models. In some examples, if the percent of casing wear volume is more than a tolerance amount, e.g., 20%, then steps to mitigate this wear can be taken. Such steps may involve adding commercially available SPG to the circulating drilling fluid so that it can replenish the lubricating layers 60 , 62 . However, in examples in which the drilling program permits, the drill string 14 can be tripped out to reapply SPG on the outer surface 19 to further mitigate wear.
[0019] In some implementations, casing wear can be monitored or estimated by inspecting the drilling fluid for steel shavings, visually or using any other appropriate inspection technique. For example, collected steel shavings can be used to estimate the casing wear volume, and if beyond tolerance, then mitigation steps can be taken. In such examples, if the application of SPG does not show any improvement in downhole casing wear, then the concentration of graphene in the SPG solution can be increased.
[0020] FIG. 2 is a flow diagram of an example process 200 for a friction and wear reduction technique for downhole tools disposed in a wellbore, such as those discussed in the descriptions of FIG. 1 . Though depicted sequentially as a matter of convenience, at least some of the actions shown can be performed in a different order and/or performed in parallel. Additionally, some embodiments may perform only some of the actions shown. In some embodiments, the operations of FIG. 2 , as well as other operations described herein, can be implemented as instructions stored in a computer-readable storage medium and executed by a processor,
[0021] The process 200 starts by providing an outer tubular member having a bore with an inner surface (block 205 ). For example, the casing 34 of FIG. 1 has the inner surface 21 along the bore. A first lubricant layer is applied to at least a portion of the inner surface of the outer tubular member (block 210 ). For example, a layer of graphene can be applied (e.g., sprayed, sprinkled, rubbed) onto the inner surface 21 as the layer 62 . The outer tubular member is then positioned in at least a portion of the wellbore (block 215 ). For example, the casing 34 can be placed in the wellbore 12 .
[0022] The process 200 continues by providing a drilling assembly including an inner member having an outer surface, said inner member having a central longitudinal axis aligned with a central longitudinal axis of the outer member (block 220 ). For example, the drill string 14 may be provided, and the drill string 14 has the outer surface 19 . A second lubricant layer is applied to at least a portion of the outer surface of the inner member (block 225 ), and the inner member is inserted into the bore of the outer tubular member (block 230 ). For example, a layer of graphene can be applied (e.g., sprayed, sprinkled, rubbed) onto the outer surface 19 as the lubricant layer 60 , and then the drill string 19 can be inserted into the bore of the casing 34 .
[0023] A drilling fluid is provided through the bore of the drilling assembly (block 235 ). For example, drilling fluid can be circulated through the bore of the drill string and returned back to the surface through the annulus between the drill string and the casing in a conventional drilling operation in block 235 .
[0024] An indicator of at least one of mechanical wear and friction between the outer member and the inner member is measured (block 245 ). For example, the monitor 70 can be used to measure an indicator of mechanical wear between the drill string 14 and the casing 34 . If the measured indicator is determined (block 250 ) to have not exceeded a predetermined threshold level, then a subsequent action is not triggered in response to the determining (block 255 ). If the measured indicator is determined (block 250 ) to have exceeded the predetermined threshold level, then a subsequent operation is triggered in response to determining that the measured indicator exceeds the predetermined threshold level (block 260 ).
[0025] In some embodiments, the measured indicator can be a concentration of one or more predetermined materials suspended in the drilling fluid and corresponding to at least one of the outer member and the inner member. For example, as the drill string 14 and the casing 34 wear, some of the material used to construct the drill string 14 and the casing 34 may be worn off and enter the drilling fluid. In some examples, the worn material may be suspended in the drilling fluid. In some examples, the worn material may mix with the drilling fluid. In some examples, the worn material may interact chemically with one or more compounds or elements of the drilling fluid. As the drilling fluid recirculates back to the surface, the worn material or evidence of it is carried to the surface as well. In some embodiments, the monitor 70 can be configured to detect the worn material or evidence of it, for example, using a magnetometer, a spectrometer, reagent testing, or any other appropriate technique for detecting materials carried by the drilling fluid. In some implementations, when a predetermined amount of material is detected in the drilling fluid, a subsequent operation may be triggered. For example, graphene may be added to drilling fluid or graphene may be re-applied to the drill string 14 by tripping it out.
[0026] In some embodiments, the measured indicator can be a measured amount of torque developed between the inner member and the outer member. For example, the monitor 70 can measure the amount of torque that is developed between the drill string 14 and the casing 34 . The measured torque can be used to determine an amount of friction between the drill string 14 and the casing 34 and/or can be used as an indicator of the amount of wear for the drill string 14 and the casing 34 . In some implementations, when a predetermined amount of torque is measured, a subsequent operation may be triggered. For example, graphene may be added to drilling fluid or graphene may be re-applied to the drill string 14 by tripping it out.
[0027] In some embodiments, the measured indicator can be one or more mechanical dimensions of at least one of the outer member and the inner member. For example, the monitor 70 or a human operator can use a caliper, gauge, or other appropriate device to measure the physical dimensions of the inner surface 21 of the casing 34 and/or the outer surface 19 of the drill string 14 . In operation, as the drill string 14 and the casing 34 wear, the dimensions of the inner surface 21 may generally increase (e.g., the bore within the casing 34 may gradually get larger) and/or the dimensions of the outer surface 19 may decrease (e.g., the drill string 14 may erode). In some implementations, when a predetermined amount of wear is detected, a subsequent operation may be triggered. For example, graphene may be added to drilling fluid or graphene may be re-applied to the drill string 14 by tripping it out.
[0028] In some implementations, drilling parameters such as torque, hook load, and weight-on-bit can be monitored to estimate the downhole friction acting on the drill string. If, for example, the drill string experiences 20% higher torque than normal during the drilling activity, steps to mitigate the downhole friction should be taken. The steps to reduce friction, as described above, can include adding SPG to the circulating drilling fluid or if applicable in the drilling program, tripping out the drill string to reapply SPG on the outer surfaces. In another example, if the drilling rig is working near its rated torque capacity, then the drill string can be tripped out to reapply SPG on its outer walls.
[0029] Another example method to monitor downhole friction can include estimating the friction factor using appropriate models. For example, a friction factor of higher than 0.5 in the cased hole section may suggest that the drill string should be tripped out to reapply SPG. Even higher values of friction factors, e.g., 0.8 or 0.9, can be addressed by using relatively higher concentrations of graphene in the SPG solution. If selected concentrations of graphene used in SPG do not help mitigate downhole friction, the concentration of graphene in SPG can be further increased.
[0030] In various implementations, the wear on the drill string 14 , including the drill pipe body, tool joints and the any other component in the bottom hole assembly, can be monitored by inspecting visually, or by using any other appropriate inspection technique, to analyze the wear on the drill string 14 when it is tripped out during drilling operations. In some implementations, measuring the wall thickness of the drill pipe or any component in the bottom hole assembly can be one of the techniques used to determine the wear in the drill string 14 . For example, a 5% or greater reduction in wall thickness may indicate a need for reapplication of SPG on the outer surface 19 . Additionally, areas on the drill string that display shine and wear due to downhole friction may be selected for reapplication of SPG solution to replenish the worn away layers of graphene to mitigate friction.
[0031] FIG. 3 is a flow diagram of an example subsequent operation 300 for friction and wear reduction techniques for downhole tools disposed in a wellbore. In some implementations, the subsequent operation 300 may be the subsequent operation triggered in block 260 of FIG. 2 .
[0032] The operation 300 starts by extracting the inner member from the bore (block 305 ). For example, the drill string 14 of FIG. 1 can be extracted from the casing 34 . A lubricant layer is then applied to the outer surface (block 310 ) and the inner member is re-inserted into the bore. For example a layer of graphene can be re-applied (e.g., sprayed, sprinkled, rubbed) onto the outer surface 19 , and then the drill string 14 can be re-inserted into the casing 34 .
[0033] In another implementation, the subsequent operation triggered in block 360 of FIG. 2 can include increasing a concentration of graphene suspended in the drilling fluid. For example, when the monitor 70 determines that indications of friction or wear have exceeded a predetermined threshold, the monitor 70 can transmit a signal as an indicator to additional equipment or human operators that one or more lubricants, such as graphene, should be added to the drilling fluid being pumped downhole to carry the lubricant to the inner surface 21 and/or the outer surfaces 19 .
[0034] FIG. 4 is a flow diagram of an example process 400 for the application of lubricant for downhole tools, such as those described in FIG. 1 . Graphene monolayer flakes dispersed in ethanol can be applied on steel surfaces by spraying or sprinkling SPG on the intended steel surfaces using any appropriate commercially available spraying or sprinkling systems. Application of this graphene-containing ethanol solution on the steel surfaces, and further evaporation of the liquid ethanol part, leaves behind few layers of graphene on the steel surfaces. In some implementations, reapplication of spraying SPG can be done based on field measurements and/or estimation of downhole friction and wear parameters as explained in the description of the process 400 below.
[0035] The process 400 starts in block 401 during the drilling of any appropriate oil or gas well at a well site. Lubricant layers of graphene can be applied to the tubulars used during the drilling operation, e.g., casings, liners, risers and the drill string including the bottom hole apparatus (BHA). At block 402 , casings, liners, and risers are used in any appropriate drilling operation and can experience contact with the drill string on their inner walls. At block 404 , SPG is sprayed on the inner as well as outer walls of the casings, liners and risers that are run in for drilling the well. Inner walls may have contact with the outer body of the drill string during the drilling operation, and as such graphene may be used to reduce wear and friction. Outer walls may have contact with the inner walls of the previously run in casings, liners, and risers in the well when a new set is being run in to be installed. In such example situations, graphene can help reduce friction and wear between the outer body of the casing run in and the inner body of the previously installed casing.
[0036] The casings, liners, and risers are run into the hole after application of SPG solution on the inner and outer was at block 405 . At block 408 , the downhole casing, liner, and riser wear are measured or estimated using calipers or other techniques as practiced in the industry.
[0037] At block 411 the measured and estimated values of downhole friction and wear are compared with predetermined tolerance limits set for the operation. If the predetermined tolerance limits have not been exceeded, then the drilling operation continues at block 414 , e.g., until the target depth is reached. If the predetermined tolerance limits have been reached at block 411 , then SPG can be added to the circulating drilling fluid to replenish the graphene layers that have worn out due to downhole contact. After addition of the SPG, drilling can continue at block 414 until the target depth. Further monitoring of friction and wear can be done to determine the effectiveness of adding SPG. In some implementations, if the predetermined tolerance limits have been reached at block 411 , then the drill string can be tripped out at block 413 in order to replenish the graphene layers that have been worn out due to downhole contact. After tripping out, SPG can be sprayed again on the outer walls of the drill string to replenish the graphene layers in block 406 . The drill string can be subsequently tripped in to continue with the drilling operation in block 407 . In some implementations, the operations of blocks 412 and 413 can be followed separately or together to reduce the downhole friction and wear.
[0038] If tripping out is required as a part of the drilling operation at block 415 , for example to change the bit or BHA or due to any other operational reason, the wear on the drill string is measured or estimated at block 416 . If tripping out of the drill string is not required at block 415 , then additional monitoring of the drilling parameters and wear is done while continuing to drill ahead to the target depth.
[0039] Referring now to block 403 , the drill string including the BHA is used in any appropriate drilling operation to reach the target depth. The outer wall of the drill string can experience contact with the inner wall of the casings, liners, and risers during the drilling operation. To reduce friction and wear due to such contact, at block 406 SPG is sprayed on the outer wall of the drill string including the BHA before tripping it in the wellbore at block 407 .
[0040] As drilling operations progress toward the target depth, the drilling parameters are monitored at block 409 to determine if the efficiency of the drilling operation may be improved and/or downhole friction and wear may be reduced, by taking further steps to lubricate surfaces of the drill string. At block 410 , the downhole friction experienced in the riser and the cased hole section (e.g., due to contact with the outer wall of the drill string) is estimated using techniques known in the industry.
[0041] At block 411 the measured and estimated values of downhole friction and wear are compared with predetermined tolerance limits set for the operation. If the predetermined tolerance limits have not been exceeded, then the drilling operation continues at block 414 . If the predetermined tolerance limits have been reached at block 411 , then the drill string is tripped out at block 413 in order to replenish the graphene layers that have been worn out due to downhole contact. After tripping out, SPG is sprayed again on the outer walls of the drill string to replenish the graphene layers in block 406 . The drill string is subsequently tripped in to continue with the drilling operation in block 407 . In some implementations, if the predetermined tolerance limits have been reached at block 411 , then SPG can be added to the circulating drilling fluid to replenish the graphene layers that have worn out due to downhole contact. After addition of the SPG, drilling can continue at block 414 until the target depth. In some implementations, the operations of blocks 412 and 413 can be followed separately or together to reduce the downhole friction and wear.
[0042] If at block 415 , it is determined that the drill string does not need to be tripped out, then the drilling parameters are monitored again at block 409 . If at block 415 , it is determined that the drill string does need to be tripped out, then the wear on the drill string is measured or estimated at block 416 . If at block 417 the measured wear on the drill string is determined to be higher than predetermined tolerance limits, then SPG is sprayed on the outer walls of the drill string at block 406 to replenish the worn out graphene layers. If the measured wear is within the predetermined tolerance limits, then the drill string is tripped back in at block 407 to continue the drill operation, e.g., to reach the target depth.
[0043] Although a few implementations have been described in detail above, other modifications are possible. For example, the logic flows depicted in the figures do not require the particular order shown, or sequential order, to achieve desirable results. In addition, other steps may be provided, or steps may be eliminated, from the described flows, and other components may be added to, or removed from, the described systems. Accordingly, other implementations are within the scope of the following claims.
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The subject matter of this specification can be embodied in, among other things, a method that includes providing an outer tubular member having a bore with an inner surface, applying a lubricant layer to at least a portion of the inner surface of the outer tubular member, positioning the outer tubular member in at least a portion of the wellbore, providing a drilling assembly including an inner member having an outer surface, applying a lubricant layer to at least a portion of the outer surface of the inner member, inserting the inner member into the bore of the outer tubular member, providing a drilling fluid through the bore of the drilling assembly, rotating the inner member relative to the outer member, measuring an indicator of mechanical wear between the outer member and the inner member, determining that the measured indicator exceeds a predetermined threshold level, and triggering a subsequent operation.
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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 pertains to a hanger and screen assembly for use with rain gutters. In particular, the present invention pertains to a hanger and screen assembly that is assembled with a conventional rain gutter to protect the gutter from clogging with leaves and/or other debris. The hanger is specifically configured to facilitate the installation of the screen over the top opening of the gutter and the screen is specifically configured to overlap like screens at its opposite ends to provide a continuous screen cover over the gutter opening with no gaps between adjacent screens.
(2) Description of the Related Art
It is a well known practice to place lengths of screen over the top openings of gutters to protect the gutters from becoming clogged with leaves and/or other debris. Various different types of gutters, gutter hangers, and screens have been developed in the prior art for the purpose of preventing leaves and other debris washed off of roof surfaces from collecting inside gutters bordering the roof surfaces, and for the purpose of facilitating the assembly of the gutters, gutter hangers, and screens to the eaves of the roof.
An example of a prior art gutter and gutter hanger is disclosed in U.S. Pat. No. 3,416,760. The gutter hanger disclosed in this patent is typical of prior art hangers. A disadvantage associated with prior art hangers is that, when the gutter and hanger are assembled to the roof eave from the roof, it is difficult for the workman to lean over the edge of the roof to locate the gutter and gutter hanger in their proper positions against the eave and secure the gutter and gutter hangers to the eave. Very often the workman will only reach over the edge of the roof to locate the gutter and gutter hanger against the eave and then attempt to fasten the gutter hanger to the eave with a fastener such as a nail or wood screw without actually being able to see the end of the gutter hanger being attached to the eave. Often this will result in the gutter and gutter hanger being attached to the eave in improper positions relative to each other, and at times this will result in the workman completely missing the gutter hanger with the fastener as the fastener is driven into the eave.
What is needed to overcome this disadvantage of prior art gutters and gutter hangers is an improved gutter hanger with a means of positively locating a fastener such as a nail or wood screw in a hole of the gutter hanger to attach the hanger to the eave without requiring that the workman view the gutter hanger hole to locate the fastener in the hole.
Examples of typical prior art gutter screens are disclosed in U.S. Pat. Nos. 2,209,741 and 4,907,381. Many prior art gutter screens have a forward edge specifically configured to be attached to a forward edge of a particular gutter. These screens are disadvantaged in that they likely are not capable of being used with other gutters not having the specific forward edge configuration for the screen. Moreover, many prior art gutter screens of this type are disadvantaged in that it is difficult to attach the forward edge configuration of the gutter screen to the forward edge of the gutter along the entire length of the screen section.
Many prior art gutter screens are also disadvantaged in that they do not comprise any means of retaining the rearward edge of the screen over the top opening of the gutter. These types of prior art gutter screens have rearward edges that are free to move up away from the top opening of the gutter and often become separated from the gutter after a period of use. Still further, many prior art gutter screens are disadvantaged in that they are designed to be assembled over the top opening of a gutter in an end-to-end relationship. After a period of time, the sections of screen tend to separate from each other forming gaps between adjacent lengths of screen that enable leaves and other debris washed from the roof surface to pass through the gaps and possibly clog the gutter.
What is needed to overcome the above set forth disadvantages of prior art gutter leaf screens is a leaf screen that is specifically designed to be used with a particular gutter hanger, where the forward edge of the leaf screen is configured to be engaged against and retained by a front section of the gutter hanger specifically configured to receive the forward edge of the leaf screen, and the rearward section of the hanger is provided with tabs that project upward and forward from the hanger and engage the rearward edge of the screen to retain the screen rearward edge on the hanger.
SUMMARY OF THE INVENTION
The present invention overcomes the disadvantages associated with prior art gutter hanger and screen assemblies by providing an improved hanger and screen assembly with gutter hangers having specific configurations designed to facilitate the installation of the screens on the hangers and retain the screens on the hangers as well as facilitating the assembly of the hangers on a roof eave, and screen lengths having specific configurations to facilitate the attachment of the screens on the hangers and to overlap adjacent screen lengths to prevent gaps from forming between adjacent screens.
The gutter hanger of the present invention includes a middle section dimensioned to span across the top opening of a conventional gutter between the back wall and front wall of the gutter. A front section of the hanger is connected to the forward end of the hanger middle section and has a specific configuration designed to engage inside the top edge of the front wall of a conventional gutter. The front section has a general C-shaped configuration with the opening of the C-shaped configuration facing rearwardly toward the hanger middle section. The opening is provided to receive a forward edge of the screen and to retain the screen forward edge.
One or more tabs are provided on the middle section of the hanger toward the rearward end of the hanger. The tabs extend upwardly and forwardly from the middle section and are provided to engage the rearward edge of the screen. The rearward edge of the screen is wedged between the tabs and the hanger middle section and is secured in this position over the gutter top opening by the tabs.
The sections of screen are easily inserted on the hanger and over the top gutter opening by first inserting the forward edge of the screen inside the C-shaped front section of the hanger, and then inserting the rearward edge of the screen between the tabs and the middle section of the hanger. The screen is slightly bent across its lateral width as it is assembled on the hangers and the resiliency of the screen causes the screen front edge and rear edge to engage between the front section and the tabs of the hanger thereby securely attaching the screen on the hanger.
A rearward section of the hanger is configured to engage over the top of a conventional gutter backwall. The rearward section extends upwardly from the rear end of the hanger middle section, over the gutter backwall, and then downward behind the gutter backwall. A hole is provided completely through the rearward section of the hanger to accommodate a fastener such as a nail or wood screw. The nail or wood screw is passed through the hole in attaching the hanger to the eave of a roof. A substantially horizontal transverse groove is formed in the rear section of the hanger. The groove intersects the hole at the center of the hanger rear section and facilitates the locating of a fastener in the hole by guiding a tip of the fastener along the groove until it is inserted through the hanger hole.
The front middle and rear sections of the hanger are formed unitarily and are preferably formed of metal.
BRIEF DESCRIPTION OF THE DRAWINGS
Further objects and features of the present invention are revealed in the following detailed description of the preferred embodiment of the invention and in the drawing figures wherein:
FIG. 1 is a side elevation view, in section, of the gutter hanger and leaf screen assembly of the present invention assembled with a conventional gutter to the eave of a roof;
FIG. 2 is a perspective view of the gutter hanger of the present invention;
FIG. 3 is an end view, in section, of the gutter hanger taken along the line 3--3 of FIG. 2;
FIG. 4 is an end view, in section, of the hanger of the present invention taken along the line 4--4 of FIG. 2; and
FIG. 5 is a partial view showing the right hand of the leaf screen of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows the gutter hanger and leaf screen assembly 10 of the present invention assembled to a conventional gutter 12 and supporting the gutter on the eave 14 of a roof. The hanger and screen assembly of the invention is basically comprised of a plurality of screen lengths 16 (only one of which is shown in FIG. 1) and a plurality of hangers 18 (only one of which is shown in FIG. 1). For simplicity, only one screen length 16 and one hanger 18 will be described. Preferably, both the screen length and hanger are constructed from metal However, other types of materials may be employed in constructing the screen and hanger of the present invention.
The hanger 18 of the assembly is shown in FIG. 2. The hanger is basically comprised of a middle section 22 having opposite forward and rearward ends, a forward section 24 connected at the forward end of the middle section, and a rearward section 26 connected at the rearward end of the middle section.
The middle section 22 is an elongated member having a predetermined length sufficient to span laterally across the top opening of a gutter 12 between the forward wall 28 and rearward wall 32 of the gutter. A center ridge 34 is formed in the middle section 22 to provide reinforcement to the middle section. A pair of tabs 36 are formed in the middle section on opposite sides of the ridge 34 and adjacent the rearward end of the middle section. The tabs 36 are substantially identical and are formed by a pair of U-shaped cuts made through the middle section with the portions of the middle section defined by the cuts being bent upward from the middle section. As is best seen in FIG. 1, the tabs 36 extend upwardly and forwardly of the middle section 22. As is best seen in FIGS. 3 and 4, the opposite longitudinal sides 38, 42 of the middle section 22 are bent downwardly to form reinforcing flanges extending along the lateral length of the middle section.
The forward or front section 46 of the hanger 18 is formed unitarily with the front end of the hanger middle section 22. As seen in FIGS. 1 and 2, the front section 46 has a general C-shaped configuration with the opening 48 of the C-shaped configuration facing rearwardly toward the hanger middle section 22. The dimensions of the hanger front section 46 are determined to enable the front section to be easily inserted into an edge channel 52 formed along the top edge of the front wall of many conventional gutters. The dimensions of the front section 46 are also determined to facilitate the engagement of the front edge of the screen 16 of the present invention inside the C-shaped opening 48 of the front section as will be explained. As is best seen in FIGS. 2 and 3, the bends formed in the hanger front section 46 to produce the C-shaped configuration are provided with gussets 56 at their opposite ends. The gussets 56 formed at the opposite ends of the bends reinforce the bends and the front section 46 of the hanger.
The rearward or rear section 62 of the hanger 18 is formed unitarily with the rearward end of the hanger middle section 22 and extends upwardly from the middle section rearward end. The rear section 62 of the hanger is specifically configured to engage over the top edge of a backwall 32 of a conventional gutter. The rear section 62 is formed with an upwardly extending front portion 64, a bend portion 66 at the top most end of the front portion 64, and a rear portion 68 extending downwardly from the bend 66 behind the front portion 64. The front and rear portions 64, 68 and the connecting bend 66 of the hanger rear section 62 give the rear section a general inverted U-shaped configuration that enables the rear section 62 to be easily fastened over the top edge of a gutter backwall 32.
A pair of coaxial holes 72 extend through both the front and rear portions 64, 68 of the hanger rear section 62. As seen in FIGS. 2 and 4, the holes 72 are centered in the rear section 62. A groove 74 is formed in the front portion 64 of the rear section 62. The groove 74 extends transversely across the rear section front portion 64 and intersects the forward most of the holes 72 at a midpoint of the groove. The groove is provided to facilitate the insertion of a fastener such as a nail or wood screw in the hole 72 as will be explained.
The screen 16 of the present invention has a general rectangular configuration defined by a front edge 82 formed by a forward most fold in the screen and a rear edge 84 formed by a rearward most fold in the screen. A front screen flange 86 is formed between the front edge fold 82 and the front end 88 of the screen. The front flange 86 formed by the front edge fold 82 extends beneath the screen along the entire longitudinal length of the screen 16 between a left side edge (not shown) and an opposite right side edge 92 of the screen.
A rearward flange 94 is formed between the rearward most fold at the rear edge 84 of the screen and the rear end 100 of the screen. As seen in FIG. 5, the screen rear flange 94 is formed from a first section 96 of the screen that is folded under the screen at the rear edge 84 fold line, and a second section 98 of the screen that is folded underneath the first section 96 along a second fold line 102. The first section 96 of the flange extends beneath the screen 16 in a forward direction and the second section 98 of the flange extends beneath both the screen and the flange first section in a rearward direction. The general Z-shaped cross section of the screen rear flange 94 gives the rear flange a resiliency that biases the rear edge 84 of the screen in an upward direction.
Left and right flaps or tabs 104 (only the right tab is visible in FIG. 5) are provided at the opposite left and right side edges 92 of the screen. As is best seen in FIG. 5, the flaps 104 are formed only on that portion of the screen left and right side edges between the front edge 82 and the rear edge 84 of the screen. Preferably, the flaps 104 extend completely across the lateral width of the screen between the front edge 82 and rear edge 84. The flap shown in FIG. 5 does not extend to the front and rear edges 82, 84 of the screen to provide a better view of the forward and rearward most folds and the front and rear flanges formed in the screen by the folds. It should be understood that in the preferred embodiment of the screen 16, the left and right flaps 104 extend from the front edge 82 of the screen to the back edge 84 of the screen. The left and right flaps 104 are provided at the left and right side edges 92 of the screen to overlap between adjacent screen lengths as will be explained.
In assembling the gutter hanger and screen assembly 10 of the present invention to a conventional gutter, and in mounting the assembly and the gutter to the eave 14 of a roof, the hanger 18 is first assembled to the gutter 12. As seen in FIG. 1, in assembling the hanger 18 to the gutter the front section 46 of the hanger is first inserted inside the edge channel 52 of the gutter. The front section 46 is easily inserted into the edge channel 52 of the gutter by first positioning the hanger 18 in a general vertical orientation relative to the gutter front channel 52 as viewed in FIG. 1. In this orientation of the hanger 18, the forward most end 106 of the hanger is engaged beneath the underside of the gutter channel 52. The hanger is then rotated in a clockwise direction as viewed in FIG. 1, causing the forward most end 106 of the hanger front section 46 to engage inside the lip 108 formed at the top end of the gutter channel 52. As the hanger is rotated clockwise, the C-shaped configuration of the front section 46 wedges, inside the channel 52 at the top edge of the gutter front wall 28.
Simultaneously with the attachment of the hanger front section 46 inside the gutter channel 52, as the hanger 18 is rotated clockwise the rear section 62 of the hanger is engaged over the top edge of the gutter backwall 32 with the bend 66 of the rear section engaging over the top edge of the gutter back wall and the front and rear portions 64, 68 engaging over front and rear surfaces of the back wall. With the hanger 18 assembled to the gutter 12 in the relative positions of the hanger and gutter shown in FIG. 1, the hanger and gutter are ready to be secured to the eave 14 of the roof.
In assembling the hanger and gutter to the eave, the back wall 32 of the gutter and the rear portion 68 of the hanger rear section are placed in their desired position against the eave 14. Most gutters, including that of the present invention, are hung from the roof. The workman on the roof cannot see the hanger because the roof shingles hang over the gutter hanger and obstruct the workman's view. The workman assembling the hanger and gutter to the eave inserts a fastener, such as the nail 112 shown in FIG. 1, into the holes 72 through the hanger rear section and drives the nail into the eave 14 thereby securing the hanger and the gutter to the eave. The groove 74 provided in the hanger rear section assists the workman when the hanger and gutter are assembled to the eave by a workman on the roof 114. The workman need only reach over the edge of the roof and feel for the groove 74 provided in the hanger rear section 62 without actually seeing the groove 72. The workman then places the tip of the fastener 112 in the groove 74 and slides the fastener tip along the groove until it falls into the holes 72 provided through the hanger rear section 62. In this manner, the groove 74 provided in the rear section of the hanger assists the workman in locating the fastener in the hanger hole 72 without requiring that the workman actually see the hole, thus greatly facilitating attachment of the hanger and gutter to the eave from the roof.
Once the hanger 18 and gutter 12 have been attached to the eave 14, the lengths of screen 16 are assembled on the hanger. In assembling the screen 16 on the hanger 18, the front flange 86 is first inserted inside the opening 48 of the C-shaped hanger front section 46. The resiliency of the screen at the front edge 82 formed by the forward most fold enables the front flange 86 to be resiliently bent toward the underside of the screen along the front edge 82 to wedge the screen front edge 82 securely in the opening 48 of the hanger front section 46 and inside the channel 52 of the gutter.
With the front edge 82 of the screen secured in the hanger front section 46 and the gutter channel 52, the screen is then bent slightly across its lateral width to position the rearward end 100 of the screen in a position just forward of the pair of tabs 46 of the hanger 18. The rearward end 100 of the screen is then inserted between the hanger middle section 22 and the tabs 36 to securely wedge the rearward end 100 between the middle section and tabs. The engagement of the screen rearward end 100 between the hanger middle section 22 and the tabs 36 securely holds the rear of the screen on the hanger.
The resiliency of the screen across its lateral width maintains the engagement of the screen front edge 82 inside the hanger front section 46 and the gutter channel 82 and also maintains the engagement of the screen rear end 100 between the hanger middle section 22 and the tabs 36. The general Z-shaped configuration of the rear of the screen 16 biases the rear screen edge 84 upward toward the end of the roof 14 to position the screen 16 as a continuation of the roof surface. The Z-shaped configuration of the rear end of the screen also enables the screen to extend rearwardly covering the entire gutter top opening while still providing the positive engagement between the rear end 100 of the screen and the hanger middle section 22 and tabs 36.
In the preferred embodiment of the invention, each screen length 16 extends longitudinally along the gutter for about four feet. Larger or smaller longitudinal lengths of screen 16 may be employed if so desired. When assembling screen lengths side by side on the hangers 18 of the present invention, the left side edge of one screen will abut up against the right side edge of an adjacent screen with the flaps or tabs 104 overlapping. This ensures that no gaps are provided between adjacent lengths of screen for leaves or other debris to fall between.
While the present invention has been described by reference to a specific embodiment, it should be understood that modifications and variations of the invention may be constructed without departing from the scope of the invention defined in the following claims.
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An improved gutter hanger and leaf screen assembly is comprised of hangers formed with holes and grooves at their rearward ends for attachment of the hangers to the eave of a roof. The holes in the hangers are provided for the insertion of fasteners such as nails or wood screws therethrough, and the grooves are provided to position the fasteners in the holes by first inserting a tip of the fastener in the groove and sliding the fastener tip along the groove until it falls into the hole. The hangers are also provided with forwardly projecting tabs which facilitate the attachment of the leaf screen of the assembly onto the hangers and secure the rearward ends of the leaf screen on the hangers. The leaf screen of the assembly is formed with folds at its forward and rearward edges that are provided to securely hold the leaf screen on the hangers. Opposite left and right side edges of the leaf screen are also provided with flaps that overlap adjacent leaf screens when several screens are assembled side by side over the top openings of gutters. The overlapping flaps prevent gaps from forming between adjacent leaf screens and prevent leaves or other debris from falling through gaps between adjacent leaf screens.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
This application claims the benefit of provisional application 60/175088, filed Jan. 7,2000.
FIELD OF THE INVENTION
The present invention relates to methods and apparatus for detecting and preventing undesirable scale deposition, and more particularly relates, in one embodiment, to methods and apparatus for detecting and preventing undesirable scale deposition that employ electrodes which intentionally cause scale deposition as a diagnostic indicator.
BACKGROUND OF THE INVENTION
The accumulation of inorganic mineral scales in oil field formation and production equipment is a major problem for the oil industry. Deposition of inorganic mineral scale in oil-bearing formations and on production tubing and equipment causes significant and costly loss of production. Other industries have similar problems with scale deposition. The primary offenders are carbonates and sulfates of calcium, barium and strontium. These compounds may precipitate as a result of changes in pressure, temperature and ionic strength of produced fluids or when connate reservoir waters mix with injected waters during secondary recovery operations. In order to avoid costly losses in production or post-scale treatments, it is necessary to prevent deposition of scale downhole as well as in post production processing. Scale is a particular problem when equipment is in contact with certain brines.
Current scale probes indicate the onset of scale deposition. However, in order to take preventive action, an advance sensor is required which detects the onset of scaling conditions before actual scale deposition occurs on the surfaces to be protected. The advantage of such a sensor would be that time for preventive measures is gained and the need for remedial work is avoided. It would be advantageous if a scale prediction probe could be devised which would be able to determine conditions just prior to when undesirable scaling would occur.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a method and apparatus for preventing scale from forming on surfaces, particularly oil field production equipment.
It is another object of the present invention to provide a scale prediction probe which would be able to determine conditions just prior to those under which undesirable scaling would occur.
In carrying out these and other objects of the invention, there is provided, in one form, a method for predicting scale deposition in a general environment which involves providing a localized environment where scale is preferentially formed first (relative to the general environment), where the localized environment is adjacent the general environment, and monitoring the deposition of scale in the localized environment. Preemptive action may thus be taken to prevent scale deposition in the general environment in response to the results obtained from monitoring the deposition of scale. Finally, the intentionally formed scale is removed from the localized environment so the method can be practiced again.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of an electrode configuration for a calcium carbonate scale sensor in accordance with the apparatus and method of this invention, where FIG. 1A schematically shows a scale free electrode at time t=0, and where FIG. 1B schematically shows a scaled cathode at a later time t=t;
FIG. 2 is a graph of voltage potential v. current density in a current/voltage relationship at the scale sensing electrode of this invention under various conditions; and
FIG. 3 is a schematic diagram of an electrode configuration for a barium sulfate or strontium sulfate scale sensor in accordance with the apparatus and method of this invention.
DETAILED DESCRIPTION OF THE INVENTION
The scale prediction probe of the present invention provides a surface that will preferentially scale over before any other surface in the general area. Stated another way, scale-forming conditions are intentionally caused to be formed in a localized environment adjacent a general environment so that scale forms on that localized environment or surface before any other surface in the general environment has scale deposited thereon. Further, the degree of “over scaling potential” may be controlled and remotely adjusted to suit individual conditions.
It may thus be understood that the inventive scale prediction probe may be used to predict, and thus prevent, the deposition of undesirable scale in the general environment. It should be recognized that this concept of prediction is different from that used by some researchers where “predict” is used to mean being able to accurately measure the amount of scale formed on a surface.
Two probe embodiments form the basis of the invention. The first embodiment uses an inert electrode with a controlled surface pH, and the second embodiment is a dual surface probe where one area generates a controlled release of sulfate ions, for example, and the second surface acts as the scale collector. The first embodiment is for the prediction of calcium carbonate scale deposition and the like, in one non-limiting case, while the second embodiment is for barium and strontium sulfate scale deposition prevention, in other non-limiting cases.
During cathodic protection in sea water and other saline solutions (brines) the cathodic surface becomes coated with scale in preference to nearby non-cathodic surfaces. This scale deposition is induced due to the electrical generation of alkaline conditions at the electrode surface. This high surface pH can be caused as described below. The effect of the localized increased pH is to drive the scaling reaction such as that depicted below:
Ca 2+ +2HCO 3 − ⇄CaCO 3 ↓+CO 2 +H 2 O
The increase in alkalinity of the electrode surface is generated by an applied electric current. This current may be controlled either galvanostatically, potentiostatically, or may have some time-dependent voltage/current control. The electrode may be of the same or different material as the system, but should not generate scaling species. Carbon steel may be appropriate in some conditions due to the cathodic polarization induced by the recording and stimulating equipment. Preferably, the electrode is an inert electrode material such as platinum-plated or platinum-coated titanium. However, the invention is not limited to any particular metal for the electrodes.
FIG. 1 provides a schematic diagram of the principal parts of the invention; however, it would be appreciated that the actual configuration used in practice would depend on the individual system in which the sensor would be installed. The electrode configuration or apparatus for the calcium carbonate scale inhibitor of FIG. 1 is generally referred to as 10 , where the reference electrode 12 may be positioned adjacent the cathode 14 which is opposite and adjacent (in another, facing direction) the auxiliary electrode 16 having fluid flow in the direction indicated. Note the cathode 14 and anode 16 are downstream from the reference electrode 12 . The reference electrode 12 is used to measure the electrical potential of the cathodic or working electrode 14 . Measurements taken by reference electrode 12 are used by the instrumentation to control the potential/current applied by the auxiliary electrode 16 on the cathodic (working) electrode 14 . Reference electrode 12 also provides a fixed point of reference for comparison of electrochemical potentials in other systems (where a recognized standard reference electrode is utilized).
FIG. 1A shows the apparatus 10 at some initial time, t=0, where cathode 14 is scale-free. FIG. 1B shows the apparatus 10 at some later time, t=t, where the cathode 14 has scale 18 deposited thereon. It will be appreciated that the early detection of carbonate scales other than calcium carbonate could be achieved by the method and apparatus of this embodiment. It will also be appreciated that cathode 14 and anode 16 make up the localized environment in one embodiment of the invention. The localized environment is adjacent the general environment 17 . Generating the applied electric current across cathode 14 and anode 16 conditions the cathode 14 to be slightly more scaling than the bulk fluid.
The measurement of intentional scale build-up on the electrode depends upon the detection of the diffusion limited current due to the reduction of a suitable species in the electrolyte. For example, in sea water, oxygen is reduced to hydroxyl ion, and diffusion of the gas to the electrode surface is increasingly limited by the build-up of scale. This results in a diffusion-limiting current at the electrode surface. FIG. 2 shows the effect of scale build-up on the current voltage relationship at the electrode surface. The values of the diffusion limiting currents (I lim 1 , I lim 2 , and I lim 3 ) are given at three different times or scale levels, with scale increasing on the cathode in the direction right to left in FIG. 2 . That is, I lim decreases with time as scale is formed on the electrode. FIG. 2 is an example of how the curve would move with time.
The diffusion limited current may be detected by electrochemical methods other than the full potential sweep shown in FIG. 2, such as electrochemical impedence measurements and current potential logging, as non-limiting examples among others. In essence, impedence measures the response of the working electrode to a varying applied potential frequency in terms of electrical impedence. Current potential logging measures the current passing between two electrodes and the potential of the electrodes. This data is then statistically analyzed.
The surface pH is dependent upon the cathodic current density and the rate of diffusion of alkaline species away from the electrode and the rate of diffusion of acidic species toward the electrode. If the temperature, surface geometry, current density and flow characteristics of the brine or other fluid are known, then by using Fick's laws of diffusion and basic chemical/electrochemical equations, the surface pH may be calculated. Control of the surface pH is less accurate using calculated values from diffusion laws (e.g. Fick's law) due to variability of hydrodynamics, etc., and would only be used as a “sighting shot” or to determine approximate settings for obtaining empirical data. Alternatively, control values may be obtained from experimental data and used for other conditions by interpolation or extrapolation.
If the auxiliary and working (cathode or sensing) electrode are identical, then they may be interchanged, or the auxiliary may be used as a blank scale reference/normal scaling potential reference. An additional benefit of this technique is that electrode cleaning of a scaled surface is possible by applying a high current density to the electrode that has the effect of generating gas bubbles that disrupt and remove the scale from the electrode surface. Thus, the electrode surface can be used for accurate monitoring again.
As the presence of scale is detected through reduction in current density as shown, the scale prediction probe can give a signal for the release of a certain, predetermined amount or rate of scale inhibiting chemical or agent into the fluid of the system. This step may be initiated when the current density falls below a certain preset threshold. Such a preset threshold would be individual for each system and could not be specified in general or in advance. By injecting scale inhibiting agents or chemicals only when needed, conservation of the agent and costs associated therewith can be achieved. Scale inhibiting chemicals and agents are well known in the art. Additionally, the use of injection mechanisms such as nozzles, pipes, needles, and the like are also well known in the art. Similarly, the removal of scale by applying a high current density to the electrode as described above could also be triggered or caused once the current density falls below a certain preset threshold.
In the embodiment for barium and strontium sulfate scale deposition, one change to the above embodiment is there is present an additional surface suitable to generate a controlled release of sulfate ions.
The formation of sulfate-containing scales is not strongly affected by pH, and thus the above embodiment cannot create an increased scaling tendency for these scale types. However, by the introduction of a local excess of sulfate ion (barium or strontium, for example, where appropriate), over the bulk concentration of these ions, then the local scaling tendency will be increased. This latter technique is the basis of the sulfate scaling tendency embodiment of the invention.
Shown in FIG. 3 is a schematic diagram of an electrode configuration for a barium sulfate or strontium sulfate scale sensor. The electrode configuration is generally denoted as 20 . The detecting or scaling electrode 22 (corresponding to the cathode 14 in the carbonate scale detection embodiment) is immediately down stream of a sulfate generating electrode 24 , the sole purpose of which is to generate a controlled excess of scaling ion (sulfate, barium, strontium, etc.). This excess ion then drifts over the sensing electrode 22 (i.e. the working electrode, as in the previously described embodiment) and causes deposition when the bulk fluids are close to saturation with respect to the scale being deposited on the sensing/detecting electrode 22 .
The comparator electrode 26 shown in FIG. 2 is similar to the sensing electrode 22 down stream of the generating electrodes and serve the purpose of determining if the actual system is in a scaling condition without the presence of the excess ions supplied by electrode 24 . Counter electrodes 30 serve the function of auxiliary electrodes 16 in the FIG. 1 embodiment.
The generation of sulfate, barium or strontium scaling ions for producing an excess scaling tendency is necessary for the second embodiment, for without it, the electrode sensor 22 will only detect scale at the same time the entire system experiences the onset of scaling.
In the foregoing specification, the invention has been described with reference to specific embodiments thereof. However, it will be evident that various modifications and changes can be made thereto without departing from the broader spirit or scope of the invention as set forth in the appended claims. Accordingly, the specification is to be regarded in an illustrative rather than a restrictive sense. For example, scales other than those specifically mentioned, and electrode configurations other than those specifically shown and described, falling within the claimed parameters, but not specifically identified or tried in a particular application to inhibit scale formation, are within the scope of this invention.
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A method for predicting scale deposition in a general environment has been discovered which involves providing a localized environment where scale would preferentially form, where the localized environment is adjacent the general environment. Monitoring the deposition of scale in the localized environment is performed for the purpose of taking preemptive action to prevent scale deposition in the general environment once scale begins to form, or a certain threshold is reached. Scale is removed from the localized environment so that monitoring can be performed by the probe again. Preemptive action will often be the introduction of a scale inhibiting agent into the general environment. An apparatus for practicing the method of predicting and preventing scale deposition in a general environment is also described.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to the construction art and more particularly to an improved construction module and the method of making the improved construction module.
[0003] 2. Description of the Prior Art
[0004] Construction modules have long been utilized in a variety of applications such as for walls, doors, cabinets, drawer fronts, counter tops and the like. In some applications, such as aircraft, recreational vehicles and similar structures, it is desired that the modules be as light weight as possible and still strong and rigid enough to be suitable for the intended purpose. Further, such modules are often required to be visually attractive so as to provide an appealing combination with the other decor in the structure. Additionally, it is, of course, desired that the construction module be economical to purchase by the end user and therefore be economical to fabricate so that the lower cost is passed on to the customer.
[0005] In many such applications there have heretofore been utilized construction modules fabricated from metal coated honeycomb, corrugated aluminum, aluminum skin over ribs or dividers, thin plywood and other such constructions. While many of these modules were light weight, they often were not rigid enough or strong enough for the purpose for which they were intended. Such lack of rigidity or strength often caused distortion of the panel when used for the intended purpose. Also, many of these prior art modules were not visually attractive from all aspects from which they were viewed. For example, even though a decorative cover could be placed on the exterior and/or interior surfaces of such structures such as doors, drawer fronts, cabinet walls and the like which are often viewed from both sides, the edge portions thereof were not as attractive as often desired. Also, many of the prior art construction modules were relatively expensive to the end user, thereby limiting the use thereof.
[0006] Thus, there has long been desired a construction module that is light weight, rigid, strong and visually attractive on all surfaces thereof and economical in cost.
SUMMARY OF THE INVENTION
[0007] Accordingly, it is an object of the present invention to provide an improved construction module.
[0008] It is another object of the present invention to provide an improved construction module that is light in weight, strong and rigid.
[0009] It is another object of the present invention to provide an improved construction module that is economic to fabricate and economic for purchase by the end user.
[0010] It is yet another object of the present invention to provide an improved construction module that can be provided with a visually attractive appearance on all surfaces thereof.
[0011] It is yet another object of the present invention to provide an economical method of fabricating a light weight, rigid, strong and visually attractive construction module.
[0012] The above, and other objects of the present invention are achieved, in a first preferred embodiment, by providing three panels which, for convenience in description, are designated as a top panel, an intermediate panel and a bottom panel. Each of the three panels is comprised of a plurality of thin sheet wooden laminate layers bonded together. A portion of the intermediate panel has been removed to define a cavity extending therethrough and the cavity is bounded by peripheral wall members thereof. The number of laminate layers in each panel may be the same or the number of laminate layers in each panel may be different depending on the application. For convenience of description, the embodiments of the present invention described herein are provided with the three panels each having three laminate layers. In fabricating the construction module of the present invention more or less than three laminate layers may be utilized in each of the panels as may be desired for particular applications. Each of the laminate layers may be, for example, on the order of one eighth inch thick, though a greater thickness or a smaller thickness may be used as desired for particular applications.
[0013] Each of the top panel and bottom panel has an outer surface and an inner surface and the intermediate panel has an upper surface and a lower surface. After the desired portion of the intermediate panel has been removed to define the cavity therein, the inner surface of the top panel is affixed to the upper surface of the intermediate panel and the inner surface of the bottom panel is affixed to the lower surface of the intermediate panel to provide the construction module. If desired, the outer surface of the top panel and/or the outer surface of the bottom panel may be provided with thin veneer layer replicating a wood grain or any other desired visually attractive configuration. The side surfaces of the top panel, intermediate panel and bottom panel may be left in the natural state as this appearance is often considered visually attractive or such surfaces may also be provided with a veneer layer or any other desired visually attractive configuration. The construction module of this first preferred embodiment of the present invention is a hollow core construction module thereby combining the desired light weight with a strong and rigid construction that is also visually attractive and economical to fabricate. The peripheral edges of the construction module provide a strong support for the attachment of hinges, handles or the like as necessary in many installations. The shape of the cavity in the intermediate panel may be varied as desired for particular applications. For example, in the applications wherein the construction module of the first embodiment of the present invention may be utilized as a door, an enlarged portion of the intermediate panel may be left intact in regions adjacent a peripheral edge to provide a proper mounting region for a conventional door handle to be mounted therein.
[0014] In another preferred embodiment of the present invention, which is similar to the first preferred embodiment, the cavity in the intermediate panel may be in two portions and the two portions separated by a transverse member left intact and extending between peripheral edges. The transverse member may be positioned at any desired location in the intermediate panel to accommodate any desired attachment that may be required in particular applications.
[0015] In a second preferred embodiment of the present invention, a top panel, an intermediate panel, and a bottom panel are provided and may be the same as the top panel, intermediate panel and bottom panel, described above. However, in this second preferred embodiment, a preselected portion of each of the top panel and the bottom panel is also removed to define cavities extending therethrough as well as removal of a preselected portion of the intermediate panel to define the cavity extending therethrough. The cavities in the top panel, intermediate panel, and bottom panel are placed in an aligned array to provide a cavity extending through the entire construction module. A transparent member such as a pane of glass may be placed in the aligned cavity array to allow visual perception through the construction module. Alternatively, depending upon the application of the construction module, an entire window assembly may be mounted in the aligned cavity array.
[0016] In a third preferred embodiment of the present invention, a top panel, an intermediate panel and a bottom panel are provided and may be the same as the top panel, intermediate panel and bottom panel described above. In this third embodiment one or more portions of the top panel and/or the bottom panel are removed to provide cavities therethrough. The upper surface and/or the lower surface of the intermediate panel is provided with a decorative covering in preselected portions thereof. The decorative covering may be a fabric, a coat of paint or any other desired visually attractive configuration. The top panel and the bottom panel are attached to the intermediate panel in an aligned position so that the decorative covering on the upper surface and/or the lower surface of the intermediate panel are aligned with the cavities in the top panel and/or the bottom panel to allow viewing of the decorative covering.
[0017] The fabrication of the construction module of the present invention may be accomplished in a preferred method according to the principles of the present invention. The first plurality of thin sheet laminate layers in the top panel are provided with a heat activated glue therebetween. The second plurality of thin sheet laminate layers of the bottom panel are provided with a heat activated glue therebetween and the third plurality of thin sheet laminate layers of the intermediate panel are provided with a heat activated glue therebetween. The top panel and the bottom panel are positioned in the desired location on the intermediate panel and the assembly of the three panels are placed into a heated press. The press may be of any desired contour for forming the construction module into any preselected configuration. The press and the final construction module may be flat, curved, or contoured in any desired arrangement. The press is energized and activates the adhesive between the layers of each of the top panel, the intermediate panel and the bottom panel as well as forming the panels into the desired contour configuration.
[0018] The three layers are then removed from the press and the appropriate cavities are cut into the desired layers. After removal of the selected portions from the selected layers to define the desired cavities therein, a heat activated adhesive is applied to the inner surface of the top panel and the inner surface of the bottom panel and/or the upper and/or lower surface of the intermediate panel. The three panels are again assembled and aligned as desired and placed back into the press and the press again energized to activate the adhesive and bond the three layers together to form the construction module. The construction module may be trimmed at the peripheral edges thereof to provide the desired final configuration.
BRIEF DESCRIPTION OF THE DRAWING
[0019] The above and other objects of the present invention as incorporated into the preferred embodiments may be more fully understood from the following detailed description taken together with the accompanying drawing wherein similar reference characters refer to similar elements throughout and in which:
[0020] FIG. 1 is an exploded view of a preferred embodiment of a construction module according to the principles of the present invention;
[0021] FIGS. 2A and 2B illustrate intermediate panels useful in the first preferred embodiment of the present invention;
[0022] FIGS. 3A and 3B illustrate contours into which the construction module of the present invention may be formed;
[0023] FIG. 4 illustrates another preferred embodiment of the present invention; and,
[0024] FIG. 5 illustrates another preferred embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0025] Referring now to the drawing, there is illustrated in FIG. 1 a first preferred embodiment of the present invention generally designated 10 . The embodiment 10 has a top panel 12 , an intermediate panel 14 and a bottom panel 16 . The top panel 12 is comprised of a first plurality of thin sheet laminate layers 12 a , 12 b and 12 c bonded together by a suitable adhesive therebetween. Each of the thin sheet laminate layers may be a wood sheet and each may have a thickness on the order of one eighth of an inch. All of the first plurality of thin sheet laminate layers 12 a , 12 b and 12 c are substantially coextensive. It is to be understood that the thickness of each of the first plurality of thin sheet laminate layers 12 a , 12 b and 12 c may be selected as desired for particular applications and, additionally, may not all be the same thickness. Further, the number of the first plurality of thin sheet laminate layers may be greater than three or less than three as desired for particular applications. The illustration of three layers in the first plurality of thin sheet laminate layers is for illustrative purposes as is the thickness of one eighth of an inch thereof
[0026] A decorative veneer layer 18 may be bonded to an outer surface 20 of the top panel 12 , the top panel 12 also has peripheral edges 22 which, in embodiment 10 , define a rectangular configuration. The top panel 12 also has an inner surface 21 .
[0027] The bottom panel 16 is comprised of a second plurality of thin sheet laminate layers 16 a , 16 b and 16 c bonded together by a suitable adhesive therebetween. Each of the thin sheet laminate layers 16 a , 16 b and 16 c may be similar to the then sheet laminate layers 12 a , 12 b and 12 c of the top panel 12 and may be a wood sheet and each layer, may have a thickness on the order of one eighth of an inch. All of the second plurality of thin sheet laminate layers 16 a , 16 b and 16 c are substantially coextensive and, in embodiment 10 , are coextensive with the top panel 12 . It is to be understood that the thickness of each of the second plurality of thin sheet laminate layers 16 a , 16 b and 16 c may be selected as desired for particular applications and, additionally, may not all be the same thickness. Further, the number of the second plurality of thin sheet laminate layers may be greater than three or less than three as desired for particular applications. The illustration of three layers in the second plurality of thin sheet laminate layers is for illustrative purposes as is the thickness of one eighth of an inch thereof.
[0028] A decorative veneer layer 24 may be bonded to an outer surface 26 of the bottom panel 16 . The bottom panel 16 also has peripheral edges 28 which, in embodiment 10 , define a rectangular configuration to match the rectangular configuration of the top panel 12 .
[0029] The intermediate panel 14 is comprised of a third plurality of thin sheet laminate layers 14 a , 14 b and 142 c bonded together by a suitable adhesive therebetween. Each of the third plurality of thin sheet laminate layers 14 a , 14 b and 14 c may be similar to the layers 12 a , 12 b and 12 c of top panel 12 and layers 14 a , 14 b and 14 c of intermediate panel 14 and may be a wood sheet and each of the layers 14 a , 14 b and 14 c may have a thickness on the order of one eighth of an inch. All of the third plurality of thin sheet laminate layers 14 a , 14 b and 14 c are substantially coextensive with the top panel 12 and bottom panel 16 . It is to be understood that the thickness of each of the third plurality of thin sheet laminate layers 14 a , 14 b and 14 c may be selected as desired for particular applications and, additionally, may not all be the same thickness. Further, the number of the third plurality of thin sheet laminate layers may be greater than three or less than three as desired for particular applications. The illustration of three layers in the third plurality of thin sheet laminate layers is for illustrative purposes as is the thickness of one eighth of an inch thereof.
[0030] The intermediate panel 14 also has peripheral edges 32 which, in embodiment 10 , define a rectangular configuration to match the rectangular configuration of the top panel 12 and bottom panel 16 . The intermediate panel 14 has an upper surface 34 and a lower surface 36 .
[0031] In embodiment 10 a preselected portion of the intermediate panel 14 has been removed to provide an intermediate panel cavity 38 extending therethrough and defining peripheral wall members 40 , 42 , 44 and 46 bounding the intermediate panel cavity 38 .
[0032] The top panel 12 , intermediate panel 14 and bottom panel 16 are joined together to provide the construction module 48 . To join the top panel 12 to the intermediate panel 14 , a layer of adhesive is applied between the inner surface 21 of the top panel 12 and the outer surface 40 of the intermediate panel 16 . The bottom panel 16 is joined to the intermediate panel 14 by applying a layer of adhesive between the lower surface 36 of the intermediate panel 16 and the inner surface 27 of the bottom panel 16 . The preferred process and method for bonding together all of the structure to form the construction module 48 according to the principles of the present invention is described below. After joining together the up 12 , intermediate panel 14 and bottom panel 16 the peripheral edges may be trimmed to provide the desired peripheral configuration.
[0033] Referring now to FIG. 2 there is illustrated therein several alternate intermediate panels useful in the construction module 48 for various applications of the present invention. FIG. 2A shows a plan view of an intermediate panel 50 which may be fabricated in a manner generally similar to the manner of fabricating intermediate panel 14 described above. In the intermediate panel 50 there are two selected portions 52 A and 52 B of the intermediate panel 50 that are removed to define two cavity portions 54 A and 54 B defining the intermediate panel cavity 54 therethrough. The intermediate panel cavity portions 54 A and 54 B are separated by a transverse member 56 between the peripheral walls 58 and 60 . Depending upon the particular applications for which the intermediate panel 50 may be utilized, the transverse member may provide additional support for a handle or knob (not shown) that may be desired to be attached thereto. The intermediate panel 50 may be bonded to a top panel such as top panel 12 described above and to bottom panel 16 in the manner as above described and as described below in connection with the description of the preferred process and method for fabricating a construction module such as construction module 48 .
[0034] FIG. 2B shows a plan view of an intermediate panel 70 which may be fabricated in a manner generally similar to the manner of fabricating intermediate panel 14 described above. In the intermediate panel 70 there are three selected portions 72 A, 72 B and 72 C of the intermediate panel 70 that are removed to define three cavity portions 74 A, 74 B and 74 C defining the intermediate panel cavity 74 therethrough. The intermediate panel cavity portions 74 A and 54 B are separated by a first transverse member 76 between the peripheral walls 78 and 80 . The intermediate panel cavity portions 74 B and 74 C are separated by a second transverse member 82 between the peripheral walls 78 and 80 . Additionally, a supporting portion 84 may be left in the intermediate panel 70 to provide support for example, a door knob or door handle structure (not shown) that may be installed therein for the applications of a construction module utilizing the intermediate panel 70 in a door application. The intermediate panel 70 may be bonded to a top panel such as top panel 12 described above and to bottom panel 16 in the manner as above described and as described below in connection with the description of the preferred process and method for fabricating a construction module such as construction module 48 .
[0035] The construction module 48 as described above ans as shown in the drawing is planar in contour. However, a construction module according to the principles of the present invention may be fabricated in any desired contour. FIG. 3A illustrates an edge elevational view of a construction module 90 having a top panel 92 , an intermediate panel 94 and a bottom panel 96 fabricated in a manner as described above in connection with the embodiment 10 and formed into a curved contour. FIG. 3B illustrates an edge elevational view of a construction module 100 having a top panel 102 , an intermediate panel 104 and a bottom panel 106 fabricated in a manner as described above in connection with the embodiment 10 and formed into a sinusoidal type contour. The contours illustrated in FIGS. 3A and 3B are only two of the many possible, contours that may be desired for particular applications of the present invention.
[0036] FIG. 4 illustrates an exploded view of another embodiment generally designated 110 of a construction module 112 according to the principles of the present invention. The embodiment 110 is generally similar to the embodiment 10 described above and is generally fabricated in the same manner and has a top panel 114 , an intermediate panel 116 and a bottom panel 118 . In the embodiment 110 a decorative layer 120 on a preselected portion of the upper surface 122 . A similar decorative layer may be placed on the bottom surface 124 . A preselected portion indicated by the dotted lines 119 may be removed to define intermediate panel cavity 123 therethrough to provide a lighter weight tot the construction module 112 .
[0037] A preselected portion 126 of the top panel 114 is removed to define a top panel cavity 128 extending therethrough bounded by the top panel peripheral walls 130 , 132 , 134 and 136 .
[0038] A preselected portion 138 of the bottom panel 118 is removed to define a bottom panel cavity 128 extending therethrough bounded by the bottom panel peripheral walls 142 , 144 , 146 and 148 . The bottom panel cavity 140 is provided in those configurations of the present invention wherein a decorative layer on the bottom surface of the intermediate panel 116 .
[0039] The top panel 114 is bonded to the intermediate panel 116 in a manner so that the top panel cavity 138 is aligned with the decorative layer 120 on the intermediate panel 116 . Similarly, if a decorative layer is provided on the lower surface 124 of the intermediate panel 116 , the bottom panel 118 is bonded to the intermediate panel 116 so that the bottom panel cavity 140 is aligned with the decorative layer on the lower surface 124 of the intermediate panel 116 .
[0040] FIG. 5 illustrates an exploded view of another embodiment generally designated 150 of a construction module 152 according to the principles of the present invention. The embodiment 150 is generally similar to the embodiments 10 and 110 described above and is generally fabricated in the same manner and has a top panel 154 , an intermediate panel 156 and a bottom panel 158 . In the embodiment 150 a preselected portion 160 of the intermediate panel 156 is removed to define an intermediate panel cavity 162 therethrough bounded by the peripheral walls 164 , 166 , 168 and 170 . Additionally, if desired, another preselected portion indicated by the dotted lines 161 may be removed to define a second intermediate panel cavity 1163 therethrough to provide a lighter weight tot the construction module 152 .
[0041] The top panel 156 is generally similar to the top panel 114 of embodiment 110 and has a top panel cavity 172 extending therethrough. The bottom panel 158 is generally similar to the bottom panel 118 of embodiment 110 described above and has a bottom panel cavity 174 extending therethrough.
[0042] The top panel 154 is bonded to the intermediate panel 156 in a manner so that the top panel cavity 172 is aligned with the intermediate panel 162 on the intermediate panel 156 . Similarly, the bottom panel 158 is bonded to the intermediate panel 156 so that the bottom panel cavity 174 is aligned with the intermediate panel cavity 162 of intermediate panel 116 . A transparent member (not shown) may be placed in the aligned cavities 162 , 172 and 174 to provided a window type configuration. Alternatively, depending upon the particular application for the construction module 152 , an entire widow assembly may be mounted in the aligned cavities 162 , 172 and 174 .
[0043] The preferred method of fabricating the construction module of the present invention utilizes a heated, contoured press. According to this preferred method, a first plurality of thin sheet layers is assembled to form the top panel and a heat reactive adhesive is applied between the first plurality of thin sheet layers. If a veneer layer is desired it is applied to the outer surface of the top most layer and the heat reactive adhesive is applied therebetween. Similarly, a second plurality of thin sheet layers is assembled to form a bottom panel and a heat reactive adhesive is placed between the second plurality of thin sheet layers. If a veneer layer is desired, it is placed adjacent the lowest most layer and a heat reactive adhesive is placed therebetween. A third plurality of thin sheet layers is assembled to form an intermediate panel and a heat reactive adhesive is placed between the third plurality of thin sheet layers. The decorative layer, if required for the desired construction module is placed adjacent the uppermost layer of the intermediate panel and/or the lowest most layer of the intermediate panel and the heat reactive adhesive is placed therebetween The intermediate panel is placed between the top panel and the bottom panel in an aligned position as may be required by the structure of the particular construction module as described above. The aligned top panel, intermediate panel and bottom panel is placed in a heated press to bond together the first plurality of thin sheet layers, and to bind together the second plurality of thin sheet layers and to bond together the third plurality of thin sheet layers and form the top panel, intermediate panel and bottom panel into the desired contour. The top panel, intermediate panel and bottom panel are removed from said heated press and are separated from each other. The selected portions of each of the tp, intermediate panel and bottom panel are removed as desired depending on the particular construction module panel configuration and a heat reactive adhesive is placed between the inner surface of the top panel and the upper surface of the intermediate panel and a heat reactive adhesive is placed between the inner surface of the bottom panel and the lower surface of the intermediate panel. The assembled top panel, intermediate panel and bottom panel is placed back into the heated press to bond together the top panel, intermediate panel and the bottom panel to form the desired construction module. The construction module is removed from the heated press and the peripheral edges thereof may be trimmed as desired to the final configuration.
[0044] This concludes the description of the preferred embodiments of the present invention. From the above it can be seen that there has been described an improved light weight, strong and rigid construction module that may be finished to provide any desired visually attractive appearance.
[0045] While particular embodiments and applications of the present invention have been above described and illustrated, the present invention is not limited to the precise construction and arrangements disclosed. Those persons knowledgeable in the art may conceive of certain modifications, changes and variations in the detailed embodiments disclosed above as illustrative, to suit particular circumstances or products to be formed. The invention is therefore not intended to be limited to the preferred embodiments depicted, but only by the scope of the appended claims and the reasonably equivalent apparatus and methods to those defined therein.
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A construction module having a multi-layered top panel, a multi-layered intermediate panel and a multi-layered bottom panel which are bonded together and desired cavities are provided through one or more of the top panel, intermediate panel and bottom panel.
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BACKGROUND OF THE INVENTION
This invention relates to apparatus for application and contouring mastic and more particularly concerns an improved adjustable blade assembly.
In the construction of drywall partitions in various types of buildings, the joint between adjacent panels of wallboard is covered by a strip of tape and a layer of mastic is applied over the tape to provide smooth surface continuity across the edges. The layer of mastic is of a slightly crowned configuration, being somewhat thicker at the center of the tape, and tapering toward feather edges where it blends with the surface of the adjacent drywall panel. The mastic commonly is applied to a taped drywall joint by running a mastic applicator vertically downwardly along the vertical joint and over the tape. Often, a first layer of mastic is applied in a lesser width, such as a width provided by a seven inch applicator and then a second layer is provided using a wider applicator tool.
The mastic applicator tool is supported by a handle which not only carries the weight of the tool and its mastic content but which also presses the mastic from the tool so that the dispensed mastic may be smoothed and contoured by a blade carried at the tool trailing edge. Thus, pressure exerted upon the handle tends to force mastic from the tool and also presses the tool and thus its contouring blade toward the wall to control thickness of applied mastic.
Mastic applying tools of this type are shown in a number of United States patents including the following: U.S. Pat. Nos. 2,571,096, 2,666,323, 2,711,098, 2,824,442, 2,889,699, 2,984,857, and 3,343,202. In these patents the contouring blade is fixedly mounted and adjusted by various means which enable the blade to assume one of a number of cured configurations as may be desired by the operator. Such contouring blades are difficult to adjust. It is often necessary, in order to obtain the proper shape of the resulting contoured mastic, for the operator to both apply an excessively great pressure on the handle and at the same time to move the tool at an undesirably rapid rate. Further, these tools have only a limited number of adjustments and generally attain adjustment by means of exerting pressure upon a flat spring which in turn resiliently presses against members affixed to portions of the blade. These arrangements employ a spring to perform an adjustment of only a single direction, that is, the adjustment can only cause the concavely curved blade to approach a straight condition or an outwardly bowed position. To increas the blade curvature, manual pressure is exerted on the blade as by passing the edge of the blade back and forth across the edge of a door jamb, for example. Thus, the blades are difficult to adjust, can be readily adjusted by the adjusting mechanism only in a single direction and, due at least in part to variable and changing spring characteristics, precision blade adjustment is not available. Prior art blade assemblies, furthermore, have a limited number of adjustment positions and the adjustment mechanism cannot be employed to dislodge or loosen solidifed mastic that may inadvertently remain on the tool after use.
Accordingly, it is an object of the present invention to provide a mastic applying and contouring tool that eliminates or minimizes above-mentioned problems.
SUMMARY OF THE INVENTION
In carrying out principles of the present invention in accordance with a preferred embodiment thereof, a mastic applicator and contouring tool comprises a container having an opening for dispensing mastic therefrom, means for causing mastic to flow from the container through the opening, and a flexible blade assembly for distributing and contouring mastic dispensed from the container. Improved adjustment of blade curvature is attained by adjusting means interconnected between the container and the blade and provided with an adjustable effective length. According to a feature of the invention, the adjusting means is formed of linkage members to provide a substantially rigid interconnection between container and blade with the linkage members relatively shiftable to change the effective length thereof. In a presently preferred arrangement, the linkage members comprise an interconnected cam and cam follower connected to and between the container and blade. Frictional restraint on the cam is provided to hold the assembly in adjusted position. A range of continuous adjustment is provided and this range, in its entirety, is adjusted by an arrangement for adjustably connecting the primary adjustment assembly to the container.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a tool embodying features of the present invention, the tool being shown as it is moved downwardly along a vertically extending taped wall joint;
FIG. 2 illustrates a taped wall joint and a layer of mastic applied thereto by the tool of the present invention;
FIG. 3 is a perspective view of the rear outer end of the container of the tool of FIG. 1;
FIG. 4 is a fragmentary side view of the one corner of the rear of the tool of FIG. 1;
FIG. 5 is a section of the tool of of FIGS. 1 and 3;
FIG. 6 is an exploded perspective view of portions of the adjustment mechanism of the tool of FIGS. 1 and 3; and
FIG. 7 is an enlarged view of the cam adjustment mechanism.
DETAILED DESCRIPTION
As illustrated in FIGS. 1 and 2, a tool generally comprising a container 10 supported by a handle 12 is employed to deposit and contour a layer of mastic 14 along and over a strip of tape 16 that covers a vertical joint between two installed vertical wall panels, 18, 20. FIG. 2 is a horizontal section showing the relation of joint, tape and mastic. It will be seen that the applied strip of mastic has a central portion 22 that is raised, or crowned, and that this central portion tapers to either side, to feather edges 24, 26, where it smoothly and almost invisibly blends with the surface of the respective panels. A smooth and evenly contoured surface of the mastic covering is desired. Thereafter, when covered with a suitable coating such as paint, wallpaper or the like, the joint is not noticeable. Depending upon the nature of the walls and the joint therebetween, and other factors observed by the operator applying the mastic, the mastic is to be applied in different thicknesses and with different curvatures. As the operator becomes more skilled, a greater variety of mastic curvatures may be employed and, therefore, a greater range and a finer adjustment are needed.
A tool embodying principles of the present invention provides a range of infinitely variable or continuous adjustments by securing the blade ends to the container and positively driving a central portion of the blade in two directions, driving the blade downwardly in order to decrease its concave curvature, (or to obtain an outwardly bowed configuration) and also positively driving the blade upwardly so as to increase its concave curvature. The adjustment mechanism provides an essentially rigid adjustable length interconnection between the blade and container and also provides a mechanism to hold the blade in its adjusted condition.
Tool container 10 is formed of a pair of rigid sidewalls 28, 30 having edges that converge at forward ends 32, 34. Extending between the sidewalls and seated in inwardly facing appropriately configured grooves formed on the interior surfaces of the side walls are a curved rear wall 36, an angulated outer (or bottom) wall 38 and an angulated wall 40 fixedly secured to the forward edge of the outer wall 38. The sidewalls and thus the rear wall, outer wall and forward wall are secured to one another by a plurality of laterally extending tension rods 42a, 42b, 42c, etc., which extend the full length of the apparatus through suitable apertures in the side walls and have nuts affixed to the threaded ends thereof beyond the side walls, thus tensioning each of the rods and firmly holding the container walls in assembled condition.
A pair of forward wheels 44, 46 is rotatably mounted on ends of a transversely extending forward support bar 48 which is pivotally connected to the container forward wall 40 by means of a pivot pin 50 extending along an axis perpendicular to the wheel axis. In use on a vertical wall joint the wheel axes are horizontal and the pivot pin axis is substantially vertical.
A pressure plate 52 extends completely across the entire area of the container from side to side and from front to back, having a forward pivot edge captured within and thus loosely and pivotally bearing upon the inner surface of the forward edge 54 of the angulated front wall 40. The pressure plate has a sealing gasket 56 secured to its rear and side edges to bear against the rear and side walls to seal the mastic containing chamber 60 thereof. The center of curvature of the rear wall, as viewed in FIG. 5 coincides with the pivot edge of the pressure plate so that the rear edge of the plate remains in contact with the rear wall throughout its pivotal motion.
Pressure plate 52 is urged about its forward fulcrum in a counterclockwise direction as viewed in FIG. 5 by means of a pair of springs 62, 64 connected between rearwardly projecting edges of forward wall 40 and studs 66, 68 fixed to the outer surface of the pressure plate near the sides thereof.
Handle 12 is fixed to a sleeve 70 which in turn is pivoted to a handle support bracket 72 that is detachably fixed to the pressure plate 52 by means of bolts and wing nuts 74, 76. A latch operator 77 on the end of the handle is connected by means of a cable 78 to a latch 79 that selectively locks the handle sleeve 70 to bracket 72 to prevent relative pivotal motion thereof.
Bottom wall 38 extends toward, but is forwardly spaced from, the outer or bottom edge of the curved rear wall 36 to define therebetween a container opening 80 from which mastic is dispensed from the chamber 60.
The entire apparatus is supported by means of the handle which is connected to the pressure plate. The pressure plate is only movably connected with and confined within the container walls, its outer pivotal motion being limited by removable stop pins 82, 84. However, the plate is a close sliding fit within the container. With the chamber 60 containing a suitable supply of mastic, the entire apparatus, including the mastic contained therein, is readily supported by the handle, via the pressure plate and its engagement to and within the container side walls. The entire pressure plate is readily removed upon withdrawal of the stop pins.
The apparatus may be pressed against the taped wall joint by exerting pressure upon the handle 12. The latter, in turn, applies pressure to the rearward end of the pressure plate at which end the bracket 72 is secured to the plate. Pressure applied to the plate is transferred to the confined body of mastic which can flow from the container only through the restricted opening 80. The mastic therefore, in turn, applies pressure to the bottom of the container to press the latter against the wall panels 18, 20 as the tool is moved downwardly.
A flexible and adjustable curvature mastic distribution and contouring blade assembly, together with a mechanism for controlling curvature thereof, are carried by the container rear wall 36 adjacent the container opening 80. The blade assembly comprises a molded plastic blade carrier 88 having a generally rectangular cross section and having an outwardly facing longitudinal groove formed therein to provide tight and snug reception of a wear resistant, contouring and mastic applying blade 92, which is preferably made of a flexible stainless steel. Each end of the carrier 88 is slidably received and captured within outwardly facing grooves 98 at the rear ends of the edges of the respective side walls 28, 30. Blade 92 is adjusted relative to the carrier by means of a pair of screws 100 threaded into the carrier at each end thereof and bearing upon an inner end of the blade (FIG. 4). Thus, as the blade wears it may be moved further outwardly of the carrier to insure projection of the blade beyond the carrier edges. The outer surface of the carrier is chamfered to enhance the outward flow and distribution of the mastic.
To retain the blade assembly within the side wall grooves 98 each side wall carries a metal shoe 108 having an inwardly directed bottom flange with a rearward projecting end portion 112. The wear shoe is bolted to the end walls and held in place by a plate 114, so that the rearward flange 112 is directly beneath the outer edge of the carrier 88 to retain the carrier within the side wall slots 98 and to further secure and position the carrier with respect to the side walls.
The central portion of carrier 88 is formed with a pair of mutually spaced upstanding drive lugs 130, 132 of generally triangular configuration having mutually aligned apertures in their narrower upper ends which receive a bushing 134 in which is mounted a pivot shaft 136 which may take the form of a nut and bolt.
Both of drive lugs 130 and 132 extend upwardly through an elongated rectangular aperture 140 in a rigid mounting and stiffening channel 142 (see FIGS. 5 and 6). Channel 142 is formed of an extruded aluminum or other suitable rigid material and is fixedly connected to the rear wall 36 by means of a plurality of screws 144 which are accessible through slots 146 formed in the front wall of channel 142. The channel has a downwardly facing recess 148 in which is received the blade carrier 88 with its lugs 130, 132 projecting upwardly through aperture 140. The upper surface of carrier 88 is spaced below the web 150 of the channel (see FIGS. 4 and 5) in order to provide for blade curvature adjustment, as will be described below. Side legs 152, 154 of the channel member are a snug but slidable fit along the front and back sides of the carrier 88. This provides for stiffening and lateral support of the carrier and blade which, therefore, can bend only in the plane of the blade.
A pair of bolts 160, 162 are threaded into the web of the channel member 142, on opposite sides of and adjacent the centrally located aperture 140. The bolts are fixed in position by means of nuts 164, 166 threaded on the bolts and bearing against the upper surface of the channel member. Lock nuts 168, 170 are also threaded on the bolts which pass through outwardly extending ears 174, 176 formed on a mounting bracket 178. Bracket 178 includes a flat back plate 180 and laterally outwardly extending side legs 182, 184 at the lower ends of which are formed the bracket mounting ears 174, 176. Springs 186, 188 are compressed between the mounting ears 174, 176 and the enlarged heads 190, 192 of the bolts. Thus, the entire mounting bracket itself may be readily adjusted vertically (as viewed in FIGS. 3 and 6), moved toward or away from the stiffening channel 142, merely by loosening the holding nuts 164, 166 and turning the bolts 160, 162 to raiser or lower the entire bracket. Springs 186, 188 are relatively stiff and will not deflect significantly in response to forces applied during normal operation of the tool. The springs act solely as shock absorbers to allow deflection and absorption of energy in the presence of suddenly applied excessive forces as might occur if a loaded tool should accidentally fall to the floor.
Pivoted on the shaft 136 that extends through the blade carrier ears 130, 132 is a yoke plate 194 having a circular aperture 196. The yoke plate carries adjustment position indicia indicated by numerals 1-6 thereon. A cam 198 in the form of a circular disc 200 having a decreased diameter but thicker hub 202 is formed with a circular opening 204 that is centered at a point positioned slightly above the center of the circular periphery of hub 202 and also slightly above the center of circular opening 196 of the yoke plate. Hub 202 is received as a snug but sliding fit within the aperture 196 of the yoke plate. The yoke plate aperture 196 forms a cam following surface that engages the cam to drive the yoke plate toward or away from the blade carrier. A deformable cylindrical bushing 206 having an axial aperture 207 is positioned within the opening 204 of the cam. A drive pin 208 is fixed to the surface of cam disc 200 and extends axially rearwardly into an aperture 210 in a lever 212. Lever 212 is formed with an enlarged circular body portiion 214 having a radially outwardly extending arm 216 that termintes in a flat finger tab 218 which may be readily grasped by an operator for adjustment of the tool. A pivot shaft in the form of a headed bolt 220 extends through a central aperture 222 of the lever body section, through the hole 207 of the bushing and through a hole 226 of the central portion 180 of the mounting bracket 178. A nut 228 is threaded on the end of the pivot bolt 220. Shaft 220 is coaxial with cam opening 204 and, therefore is slightly above the center of hub 202 and slightly above the center of yoke opening 196.
The unstressed axial length of bushing 206 is greater than the distance between the facing inner surfaces of the mounting bracket 178 and lever 212 when the parts are assembled. Accordingly, upon assembly, the bushing is axially compressed, and since it is circumferentially restrained, the compression forces the bushing inwardly against the pivot shaft 220 and outwardly against the inner surface of circular hole 204 of the cam member.
Lever 212 is formed with an index marker 230 that is lined up with the numeral 1 of the yoke plate when the lever 212 is in its limiting counterclockwise position as illustrated in solid lines in FIG. 7. In this position the blade has its minimum curvature or, if deemed necessary or desirable, it may be even bowed downwardly, (outwardly convex). As the lever 218 is moved from its extreme limiting position (shown in solid lines in FIG. 7) wherein it rests upon the top of the leg 182 of mounting bracket 178, cam 198 rotates about the axis of pivot shaft 220, being driven by the interengagement of drive pin 208 and aperture 210 of the lever. Because the periphery of the cam is eccentric to the cam pivot axis the yoke plate is shifted and this motion of the yoke plate has a component of vertical motion which pulls the blade carrier ears 130, 132 upwardly (as viewed in FIG. 7), thus pulling the central portion of the blade carrier upwardly and increasing the concave curvature of the blade of which the ends are captured in the side walls of the container. As the lever is rotated counterclockwise (as viewed in FIG. 7) the center of the blade carrier is driven downwardly to decrease blade curvature. This the arrangement provides a positive bidirectional drive of the blade carrier, enabling the blade to be positively driven to and retained in any one of an unlimited number of positions. The lever is provided with a freedom of one hundred-eighty degrees of motion between limiting positions (shown in solid and dotted lines in FIG. 7) wherein it abuts the upper surface of legs 182, 184 of the mounting bracket. In a presently preferred configuration, the center of the hole in the yoke is offset below the center of the pivot shaft by 0.050 inches, thus providing a total range of adjustment of 0.100 inches.
In order to adjust this range of adjustments in its entirety, that is, to shift the limiting positions of the range, the mounting bracket itself is adjustable. As previously described, this is achieved by moving the mounting screws 160, 162 so as to raise or lower the mounting bracket. This secondary adjustment of the entire range of adjustments afforded by the cam and yoke plate arrangement significantly facilitates manufacuring and assembly and, in particular, greatly relaxes manufacturing tolerances that would be otherwise required for attainment of precision adjustment and precision location of the range of adjustment. Thus, each individual tool may be adjusted individually by the operator to choose his own particular preferences with regard to the range of adjustments that he would prefer to employ. Further, the adjustment of the mounting bracket itself in effect significantly extends the range of adjustments available with this tool. Accordingly, one may employ the described cam and yoke arrangement for making exceedingly fine adjustments in infinitely small steps by means of the lever which moves through a relatively long distance. In effect, this achieves an amplification of the small actual adjustment for presentation to the operator as a larger lever motion and concomitantly larger indicating scale of adjustment. Stated otherwise, a relatively large motion of the lever produces a relatively small amount of adjustment, and thus, a fine precision adjustment is more readily achieved. However, with such fine adjustment only a limited range of adjustment would be available because of the larger lever motion that is provided. This problem is alleviated by making the mounting bracket itself adjustable so as to provide adjustment of the entire range.
As previously mentioned, the bushing 206 is axially compressed upon assembly and thus is forced both outwardly against the surface of hole 204 of the cam plate and inwardly against the surface of the pivot shaft 220. Accordingly, the bushing frictionally presses against the surface of shaft 220 and may rotate around the the pivot shaft when the lever is pivoted to drive the cam which frictionally grasps the outer periphery of the bushing. However, the frictional forces exerted by the bushing are sufficient to prevent inadvertent displacement of the lever and, thus, of the blade and its carrier from adjusted position.
The cam and yoke plate act as a form of linkage of effectively adjustable length, rigidly interconnecting the carrier with the container, the yoke plate providing a first linkage member and the eccentric cam providing the second linkage member of an exceedingly short, or small, effective length (an effective length equal to the 0.050 inch eccentricity).
It will be seen that the described adjustment mechanism provides a positive adjustment that fixedly and rigidly positions the center of the blade and carrier with respect to the container. Thus, because the outer ends of the blade carrier are fixed, the blade and carrier then will assume a smooth continuous curvature determined by the adjusted and fixedly maintained position of its center. Not only can the adjustment mechanism drive the central portion of the blade downwardly to decrease its concave curvature, but it can also drive it upwardly to increase its concave curvature. This bidirectional positive drive has an unexpected advantage in dislodging or loosening mastic that inadvertently may have been left to harden on or about the blade. In prior tools, where such mastic hardens on the blade, the tool must be disassembled to remove the hardened mastic. In the tool described herein, on the other hand, the positive bidirectional drive of the carrier and flexing of the blade achieved by rotating the operating lever back and forth, is sufficient to loosen and dislodge hardened mastic in many cases.
The adjustable mounting bracket, being adjustably mounted by means of the springs 186, 188, provides both shock resistance to the mechanism and shifting of the adjustment range. It may be noted, as previously mentioned, that these springs do not deflect significantly during the normal adjustment or operation of the tool so that the adjustment does, in truth, provide an effectively rigid interconnection and an adjustable interconnection between the blade carrier and the container.
The foregoing detailed description is to be clearly understood as given by way of illustration and example only, the spirit and scope of this invention being limited solely by the appended claims.
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A mastic applicator or "flat box" for use in application of mastic to tape drywall joints includes a container for storing and dispensing mastic. The container has a pressure plate which both supports the apparatus from a handle and applies pressure to force the mastic from an opening that extends across the direction of motion of the tool. To distribute and contour the mastic a flexible blade assembly extends along the rearmost edge of the opening and is positively driven through a range of infinitely adjustable positions by a means of a lever and camming linkage arrangement. The entire adjustment mechanism is itself adjustably mounted so as to selectively adjust the entire adjustment range.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
TECHNICAL FIELD
The present invention relates to an improved method and apparatus for recovering a liquid which is floating on another liquid, for example, oil floating on water, or oil of low specific density floating on oil of higher specific density.
BACKGROUND OF THE INVENTION
It is known to remove oil from water on which it is floating using devices called oleophilic skimmers. These oleophilic skimmers are rotating discs usually provided in sets, mounted on axes parallel to the liquid surface such that each disc is partially immersed in the liquid. As each disc rotates, the surfaces of the immersed portion thereof become coated with oil which is then carried away from the bulk liquid as the disc continues to rotate. The oil is removed from each disc at a point further along the rotation path by a scraper or blade associated with the disc and is then channelled to the oil outlet or tank.
SUMMARY OF THE INVENTION
Examples of oleophilic skimmer apparatus are described in British patents numbers 1419114, 1523590 and 1554458 as well as in published British patent applications 2041231, 20508556 and 2156234.
It has now been found that improved oil recovery rates may be obtained using an oleophilic skimmer apparatus in which at least one disc is provided rotating in a plane which is inclined at an acute angle to the liquid surface.
In particular, it has been found that the uptake of oil by the disc, or discs, increases as the angle between the plane of the disc and the liquid surface decreases. However, at low angles, although the rate of uptake of oil is still high, emulsification of the floating oil begins to occur. That is, at disc inclination angles of about 15° and lower, the shear forces acting on the floating oil globules tend to disrupt the globules and cause an emulsion to form. This impairs the performance of the apparatus.
Accordingly, in order to obtain a good rate of oil recovery, whilst avoiding the problems of emulsification of the floating oil, it would be preferable to angle the oleophilic skimmer disc, or discs, at about 20° to the liquid surface. Furthermore, some tests have shown a peak in recovery rates using discs angled at 20° to the liquid surface.
In practice, there are difficulties in physically collecting the oil taken up by a disc angled at so shallow an angle as 20° to the liquid surface. It has been found to be simpler to collect the oil using a slightly greater angle of disc inclination (25°-30°) and a reasonably high rate of oil uptake has still been achieved. For smaller discs, having a diameter of 280 mm for example, an inclination angle of 25° has been found to provide an optimal compromise between rate of oil uptake and ease of collection. For larger discs, having diameters of 1-2 metres, a somewhat greater angle of 28° provides a better compromise position. For discs of even greater diameter a slightly larger inclination angle than 28° may be necessary, but it is believed that the rate of change of the optimal angle with increasing disc diameter levels off and it is not expected to exceed more than about 30° even for extremely large discs.
Another advantage of using oleophilic discs inclined at an acute angle to the liquid surface (e.g. inclined at about 70° or less to the liquid surface) is that it is possible to collect the oil without impurities if the peripheral speed of the disc is appropriately selected (the required speed varies with the type of oil being collected). In particular, by selecting the correct rotational speed for an inclined disc it becomes possible to collect oil omitting even the impurities which cause a coloured appearance (i.e. the collected oil is colourless).
Furthermore, when using oleophilic skimmer discs inclined at an acute angle to the liquid surface (e.g. inclined at about 70° or less to the liquid surface) an additional advantage is obtained in that the collected liquid is in a purer form. For example, when oil is collected from the surface of a body of water using an oleophilic skimmer disc arranged perpendicular to the liquid surface then the collected liquid tends to include about 15% water (by weight), whereas when the oil is collected using a disc angled at 25°-30° to the liquid surface then the recovered liquid includes only 11/2% of water (by weight), and at 20° inclination only 3/4% of water is included.
Also, additional advantages are obtained when using oleophilic disks angled at 45° or less to the liquid surface, particularly when the skimmer apparatus is being used in open water where a swell may occur. One such advantage is that it is possible to pick up a group of oils of different types and to separate them out one from the other (i.e. the different types of oil form different layers in the collection tank).
The present invention provides a method and an apparatus for recovering a liquid floating on another liquid, using at least one rotating disc partially immersed in liquid and having an axis of rotation transverse to the liquid surface.
In preferred embodiments of the invention the or each at least one disc is arranged to rotate in a plane inclined at 70° or less to the liquid surface. In some particularly preferred embodiments, an inclination of about 45° or less to the liquid is used, and in other particularly preferred embodiments, an inclination of 25°-30° is used.
Further features and advantages of the present invention will become clear from the following description of embodiments thereof, given by way of example, illustrated and by the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a front elevational view of one embodiment of a skimmer apparatus according to the present invention;
FIG. 2 is an enlarged partial sectional view showing the construction of the drive for the disc in the embodiment of FIG. 1;
FIGS. 3a and 3b show elevational views of plates A and B (omitting the floats) of FIG. 1, in which: FIG. 3a shows plate A, and FIG. 3b shows plate B;
FIGS. 4a and 4b show the collection tube of FIG. 1 in diagrammatic form, in which:
FIG. 4a is illustrative of the structure and position of the collection tube relative to plates A and B, and
FIG. 4b is a section on line C-C' of FIG. 4a, and
FIG. 5 illustrates the forces acting on an angled disc in open water where waves occur.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
One embodiment of skimmer apparatus according to the present invention is illustrated in FIG. 1. This embodiment will be described in terms of collection of oil from the surface of a body of water.
As is conventional for oleophilic skimmer devices, the apparatus comprises a framework 1 supported on floats 2.
An air motor 4 is provided, mounted at one end of the framework 1, so as to drive the rotation of a "perspex" disc 10 via a drive shaft 5 mounted between two parallel plates A and B. Scrapers 12 are provided, each mounted at one end on plate A, or plate B, respectively and with the other end thereof carrying a rubbing piece 13 which slides on the disc 10 surface as the disc rotates. A collection tube 15 mounted on the framework 1 and passing through plates A and B collects the liquid gathered by the scraper 12.
The mechanism for driving the rotation of the disc 10 will be described with reference to FIG. 2.
As mentioned above, the air motor 4 is connected at one end to the framework 1. At the other end the motor 4 is attached to plate B by a motor mounting flange 11. The end of the motor shaft extends through plate B and is keyed to one end of the stainless steel drive shaft 5 which extends between plates A and B. The other end of the drive shaft 5 is seated in an end bearing 17 provided on plate A.
The drive shaft 5 serves as an axle on which the disc 10 is mounted. The disc 10 is fixed to the drive shaft 5 via stainless steel retaining flanges 18 which are bolted together through the disc.
The advantage of using an air motor to drive the drive shaft 5 is that this avoids the isolation problems which arise when using electrical motors in such close proximity to water. The air motor is driven by a current of air (supply and feed lines not shown) and the motor speed may be varied by varying the flow rate of the air current. Use of a variable speed motor enables the peripheral speed of the skimmer disc to be adjusted (dependent upon the type of oil being collected) so as to enable the oil to be collected substantially without impurities. A suitable air motor for use in this embodiment is the LBZ11 AROO5 model produced by Atlas Copco.
The dimensions and mounting of the framework 1 on the floats 2, and of the motor 4 and drive shaft 5 to the framework 1, are such that the disc 10 is inclined at an acute angle to the surface on which the floats 2 rest and, when the floats 2 are resting on a liquid surface, a portion of the disc 10 is immersed in the liquid. Rotary movement of the drive shaft 5 causes the disc 10 to rotate in a plane inclined at an acute angle to the surface on which the floats 2 are resting. As best seen in FIG. 1, the rotation of the drive shaft 5 is about an axis of rotation such that the drive shaft 5 and its axis of rotation is also at an acute angle to a horizontal plane. Likewise, the disc 10 is inclined at an acute angle to a laterally extending axis of the floats 2.
The rigidity of the apparatus is assured by a group of threaded rods 21,23 and spacers 22 forming a middle, linking part of the framework 1. One end of each of the threaded rods 21,23 engage the drilled and tapped ends of the spacers 22.
In the embodiment of FIG. 1 the mounting arrangement for the disc 10 is quite rigid so that the disc 10 is inclined to the liquid surface at a constant angle. However, in other embodiments the mounting may be adjustable, either manually or automatically, so as to enable the degree of immersion of the disc and/or the inclination angle to be altered, for example periodically or continuously in response to monitoring means checking the extent of immersion of the disc 10.
The arrangement of the oil collection portion of the apparatus (i.e. the scrapers 12 and oil collection tube 15) may be seen from a comparison of FIGS. 1, 3 and 4.
Each scraper 12 is an irregular V-shape in cross-section with one of the ends being attached to plate A, or plate B, respectively and the other of the ends attached to a rubbing piece 13 preferably made of "teflon" or polytetrafluoroethene (PTFE).
The mounting of the scrapers 12 on plates A and B is such that one limb 12a of each scraper is downwardly inclined and the apex of the V-shape forms a trough into which will run oil scraped off the disc 10 by the rubbing pieces 13. This "trough" portion of each scraper 12 passes through a respective opening 20 in the side of the collection tube 15 so that oil will flow from the scrapers 12 into the collection tube 15 under gravity.
In the example illustrated by FIG. 1 the scraper limbs 12a are arranged to remove oil from the peripheral 60-70% of the disc diameter, i.e. each scraper limb operates over a length equal to 70% of the radius of the disc. In order for the apparatus as a whole to operate at maximum efficiency the disc 10 should be immersed in liquid such that the outer 70% of the disc becomes wetted.
In operation, the apparatus of FIG. 1 floats at the surface of the liquid which is to be treated. The position of the drive shaft 5 is arranged to give a desired degree of immersion and angle of inclination of the disc 10 relative to the liquid surface. When the motor 4 is switched on, the disc 10 is caused to rotate via the drive shaft 5. As the disc 10 rotates, the immersed portion thereof becomes wetted with oil floating at the surface of the liquid and carries that oil out of the bulk liquid. The rubbing pieces 13 on the scrapers 12 wipe the oil from the surfaces of the disc 10. The oil flows along the downwardly-sloping limbs 12a of the scrapers 12 into the collecting tube 15. The collecting tube 15 may be provided with an outlet through which the collected oil may be continuously removed, by gravity or pumping, for example into an accompanying tanker.
The effect on oil recovery rates of the angle of inclination of the disc 10 is substantial, as the following Tables 1 and 2 show. In each case a single disc of diameter 28 cm was used on water bearing a layer approximately 10 mm deep of automatic transmission hydraulic oil.
TABLE 1______________________________________Rotational Speed 26 rpmAngle of inclination ofdisc to liquid surface Oil Recovery rate(degrees) (Liters/Hour)______________________________________90 7345 10428 12420 160______________________________________
TABLE 2______________________________________Rotational Speed 44 rpmAngle of inclination ofdisc to liquid surface Oil Recovery rate(degrees) (Liters/Hour)______________________________________90 14645 20828 24820 320______________________________________
Embodiments of the invention may include more than one disc although in general this would require a separate drive shaft, or axle, to be used for each disc and so would produce a more bulky structure.
The discs 10 used in oil recovery embodiments may be made from the usual materials which are relatively inert to water (fresh or salt) and oil, such as metals and plastic (e.g. stainless steel, polyvinylchloride). However it has been found that a marked improvement in oil recovery rate occurs when polymethyl methacrylate resin (Lucite,"Perspex") discs are used.
Compare the test results shown in Tables 3,4 and 5 below. In each case a disc of 280 mm diameter was used in a tank on a body of water having on its surface a 29 mm layer of motor engine oil. The water was continuously recirculated through the tank. All speeds are measured in revolutions per minute and angles are measured relative to the horizontal. Recovery rates of oil are measured in litres/hour.
TABLE 3______________________________________Stainless Steel DiscAngle of Disc Recovery Recovery RecoveryInclination at 26 rpm at 28 rpm at 35.5 rpm______________________________________90° 73 -- --45° 104 137 17328° 124 156 19220° 160 -- --______________________________________
TABLE 4______________________________________Stainless Steel Disc with improved scraper(P.T.F.E.) and enlarged take off channelAngle of Disc Recovery Recovery RecoveryInclination at 26 rpm at 40 rpm at 57 rpm______________________________________45° 115 192 29415° 215 294 379______________________________________
TABLE 5______________________________________"Perspex" DiscAngle of Disc Recovery RecoveryInclination at 22 rpm at 30 rpm______________________________________90° 158 20345° 185 30025° 195 379______________________________________ (N.B. Inferior results for 22 rpm at angles of inclination closer to the horizontal due to emulsification)
It will be seen from the above tables that a "Perspex" disc of comparable size to a stainless steel disc and operating at similar speeds provides significantly greater take-off rates of oil. For speeds of rotation up to at least 40 rpm rate of oil removal is approximately proportional to the speed of rotation. It is believed that "Perspex" gives these improved results because of the material's electrolytic, or electrostatic, properties. Thus it is expected that other materials having similar, or comparable, electrolytic or electrostatic properties will also be advantageous disc materials.
When using discs of polymethyl methacrylate resin it is necessary to use discs of appreciable thickness so as to provide sufficient rigidity and strength (excessive flexure of the disc makes collection of liquid from the disc surface difficult, however some flexibility is useful in order to enable the disc to withstand shock stresses, e.g. from waves). In theory it would be possible to use very thick discs (even going so far as to use a rotating tilted cylinder to replace a disc) but in practice the circumferential surface of the disc can cause undesirable edge effects in the liquid surface, such as eddies, if the discs become too thick.
For smaller discs, for example 280 mm in diameter, a thickness of 5 or 10 mm is adequate. For larger discs, for example 1 metre in diameter, a thickness of 20 mm or more may be necessary. In order to minimise the undesirable edge effects that may occur when using a thick disc, whilst maintaining the desired strength and rigidity, the disc may be tapered or stepped so as to have a thicker portion at the centre of the disc and a thinner portion at the disc edge.
Another advantage provided by polymethyl methacrylate resin discs is that any scoring of the disc surface (for example caused by abrasion by solid particles in the water) is smoothed away relatively quickly by the action of the collected oil or the like on the disc surface.
The size of the discs and of the overall apparatus may be tailored to the particular use to be made of the apparatus.
For example, there are two main types of environment in which skimmer apparatus according to the invention is likely to be used. Firstly, it may be used in a separation tank such as that described in our copending European patent application no. 90307609.9, to help purify effluent passing through such a tank. In such a case smaller discs may be appropriate (e.g. 290 mm, 314 mm in diameter). Secondly, skimmer apparatus may be used in open water, such as the sea, in order to clear up oil slicks and the like. Here an appropriate disc size should be chosen bearing in mind the likely swell which will be experienced (e.g. a 1 m diameter disc should be suitable where a 1/2 m swell is expected). For open sea work the apparatus should cater for a swell of 2 metres, in which case a 4 metre diameter disc would be appropriate (if formed of polymethyl methacrylate, such a disc would probably require a thick central region, perhaps 40 mm thick, and could be stepped or tapered to a thin edge region).
The requirements on a skimmer intended for use in open water are rather different from those on a skimmer intended for use in a separation tank. For example, a skimmer used in a tank need not have floats to keep it in position but could instead be mechanically fixed to the tank walls. More significantly, a skimmer used in open water is likely to experience considerable forces because of wave action and an angled skimmer disc suffers the additional problem of waves lapping over the top edge of the disc. These problems are discussed further below in relation to FIG. 5.
As will be seen from FIG. 5, when an angled disc is used, for example, in the sea, waves may occur of sufficient height to sweep over the upper disc edge x, x'. This would impair the operation of the skimming apparatus. One way of overcoming this is to increase the angle between the plane of the disc and the liquid surface (assumed to be approximately horizontal) but that leads to a reduction in the take-up of oil or the like by the disc. Furthermore, as the disc becomes more nearly vertical the (wave action) forces on the disc in a direction tending to snap the disc increase. Preferably the disc(s) of skimmer apparatus used in open water should be angled at 45° or less to the liquid surface (assumed to be approximately horizontal). At greater angles of inclination the wave forces acting on the disc are greater in the direction tending to snap the disc than in the disc plane and, furthermore, the recovery rate of oil or the like decreases. The exact angle that can be used will depend to some extent on the size of the disc (as well as depending on the swell expected to be experience). With suitable shielding of the apparatus, to prevent waves from running over the upper edge of the disc, very low angles of inclination should be possible and thus greater recovery rates of oil or the like should be obtainable.
Embodiments of the invention may use floats such that it is possible to alter their buoyancy to compensate for the weight of oil or the like collected and maintain the required depth of immersion.
Although the above specific description has been given in terms of recovery of oil from the surface of a body of water, the invention is applicable far more generally to the separation of liquids having different specific densities and viscosities.
There are a number of modifications that may be made to skimmer apparatus according to the invention. For example, a hood may be provided over the disc so as to catch oil or the like which is flung upward off the disc surface as a result of the disc rotation. The hood shape is adapted to funnel the "caught" liquid into a separate tank or into the main collection tank of the apparatus.
It is also possible to add one or more flanges on the circumferential edge of the disc, or on the disc surface, so as to form a rim projecting out of the plane of the disc, with the aim of trapping oil or the like which may be moving outward along the disc's major surface(s). However, although such flanges can improve the recovery rate of skimming apparatus, it is difficult to collect the trapped liquid from the flanges and the collected liquid as a whole seems to be less pure (e.g. when collecting oil from the surface of water using an angled disc having such a circumferential flange it has been found that the collected liquid contains 11-13% water by weight).
It is preferable when using discs composed of polymethylmethacrylate resin to use rubbing pieces composed of a softer material so as not to scratch the disc. Softer material than PTFE is preferred.
Finally, in outdoor conditions, or in wet/windy conditions where the skimmer has no protection, it is advisable to provide a cover over the apparatus.
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A skimmer device for recovering a first liquid which is floating on a second liquid, e.g. oil on water, uses one or more discs rotating in a plane transverse to the liquid surface (preferably inclined at 70° or less to the liquid surface). Particular benefits accrue, especially when operating in open water, when an inclination angle of 45° or less is used. With a disc inclination angle of 25°-30° to the liquid surface a near optimal compromise is reached between oil take-up rate and ease of collection. Further advantages are obtained with skimmer discs of polymethyl methacrylate resin.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
FIELD
Embodiments herein relate to hydraulic fracturing including proppant placement.
BACKGROUND
A standard approach to optimization under uncertainty is based on original Markovitz portfolio theory and more recently was tailored to oilfield applications with modified definition of efficient frontier (U.S. Pat. No. 6,775,578 B. Couet, R. Burridge, D. Wilkinson, Optimization of Oil Well Production with Deference to Reservoir and Financial Uncertainty, 2004) and Value of Information (Raghuraman, B., Couët, B., Savundararaj, P., Bailey, W. J. and Wilkinson, D.: “Valuation of Technology and Information for Reservoir Risk Management,” paper SPE 86568, SPE Reservoir Engineering, 6, No. 5, October 2003, pp. 307-316). However, these methods employ mean-variance approach and do not provide a much needed insight into the inherent uncertainty of the optimized model and, more importantly, any quantitative guidance on reducing this uncertainty, which is very desirable from the operational point of view.
Application of Global Sensitivity Analysis to address various problems arising in oilfield industry has been described for reservoir performance evaluation, for measurement screening under uncertainty, for pressure transient test design and interpretation, for design and analysis of miscible fluid sampling clean-up, and for targeted survey design. However, these disclosures were focusing only on quantifying uncertainty in specific physical quantities and using that analysis to gain a new insight about the measurement program design and interpretation. The references did not look at optimization of the underlying physical processes.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a workflow summarizing adaptive GSA-optimization approach.
FIG. 2 is a workflow summarizing the inputs and outputs for the example proppant placement and fracture conductivity calculation.
FIG. 3 is a schematic diagram providing a definition of cycle phase shift and perforation spacing for two injectors from a vertical well into a vertical fracture.
FIG. 4 is a schematic diagram illustrating the length of the cycle and length of the proppant-laden portion.
FIG. 5 is a schematic diagram for one example considered. The final placed distribution of proppant is also influenced by mixing between the proppant-laden and clean fracturing fluid portions. The mixing process is characterized by a single mixing length.
FIG. 6 is a workflow illustrating the inputs, outputs, and workflow for the example proppant placement and fracture conductivity calculation.
FIG. 7 is a chart plotting three points of the efficient frontier from the optimization using initial ranges for uncertain variables. Lower values of the objective function (μ−λσ) for increasing values of λ illustrate the inherent penalty for risk.
FIG. 8 is a chart plotting three points of the efficient frontier from the optimization using GSA-updated ranges for uncertain variables. Initial efficient frontier points are also included for comparison. Lower values of the objective function (μ−λσ) for increasing values of λ illustrate the inherent penalty for risk.
SUMMARY
Embodiments herein relate to apparatus and methods for delivering and placing proppant to a subterranean formation fracture including identifying control variables and uncertain parameters of the proppant delivery and placement, optimizing a performance metric of the proppant delivery and placement under uncertainty, calculating sensitivity indices and ranking parameters according to a relative contribution in total variance for an optimized control variable, and updating a probability distribution for parameters, repeating optimizing comprising the updated probability distribution, and evaluating a risk profile of the optimized performance metric using a processor. Some embodiments may deliver proppant to the fracture using updated optimized values of control variables.
DETAILED DESCRIPTION
This disclosed approach combines Global Sensitivity Analysis (Saltelli et al., 2004) with optimization under uncertainty in an adaptive workflow that results in guided uncertainty reduction of the optimized model predictions. Embodiments herein relate to a general area of optimization under uncertainty. The application of the disclosed method relates to well stimulation and hydraulic fracturing in particular. Heterogenous Proppant Placement (HPP) strategies seek to increase propped fracture conductivity by selectively placing the proppant such that the fracture is held open at discrete locations and the reservoir fluids can be transported through open channels between the proppant. Schlumberger Technology Corporation provides well services that include introducing proppant into the fractures in discrete slugs (Gillard, M. et al., 2010; Medvedev, A. et al., 2013). For the purposes of technology development and optimal implementation, tools must be developed for predicting the conductivity of the heterogeneously propped fractures during the increase in closure stress resulting from flow-back and subsequent production. In the presence of uncertainty in formation properties, optimal HPP strategies will result in inherently uncertain predictions of fracture conductivity. Herein, we describe a method to reduce uncertainty in predicted fracture conductivity and identify an optimal HPP operational strategy for an acceptable level of risk.
Embodiments herein show how a predictive physics-based HPP model is used to estimate fracture conductivity under a given closure stress. The input parameters of the model are divided into control variables (operational controls may include dirty pulse fraction, injector spacing, proppant Young's modulus etc.) and uncertain variables (uncertain formation properties may include Poison ratio, Young's modulus, proppant diffusion rates etc.). The model is first optimized to obtain values of control variables maximizing mean fracture conductivity (for a given closure stress) under initial uncertainty of formation properties. An efficient frontier may be obtained at this step to characterize dependence between the optimized mean value of fracture conductivity and its uncertainty expressed by the standard deviation. Global sensitivity analysis (GSA) is then applied to quantify and rank contributions from uncertain input parameters to the standard deviation of the optimized values of fracture conductivity. Uncertain parameters are ranked according to their calculated sensitivity indices and additional measurements can be performed to reduce uncertainty in the high-ranking parameters. Constrained optimization of the model with reduced ranges of uncertain parameters is performed and a new efficient frontier is obtained. In most cases, the points of the updated efficient frontier will shift to the left indicating a reduction in the risk associated with achieving the desired fracture conductivity. The disclosed method provides an adaptive GSA-optimization approach that results in uncertainty reduction for optimized HPP performance.
The workflow is applied for HPP optimization, which requires a capability for the prediction of the placement of proppant and the resultant conductivity within a potentially rough fracture under any prescribed closure stress. This capability receives inputs relating to the pumping schedule, proppant properties and formation properties and provides a prediction of the achieved fracture conductivity. For example, in our demonstration, we utilize the methods in U.S. Provisional Patent Application Ser. No. 61/870,901, filed Aug. 28, 2013 which is incorporated by reference herein in its entirety where the combination of fracture and proppant is represented by a collection of asperities arranged upon a regular grid attached to two deformable half-spaces. The deformation characteristics of the deformable half-spaces are pre-calculated, allowing for very efficient prediction of the deformation of the formation on either side of the fracture. The method automatically detects additional contact as the fracture closes during increasing closure stress (such as during flow-back and production). In addition, the asperity mechanical response is modified to account for the combined mechanical response of the rough fracture surface and any proppant that may be present in the fracture at that location. In this way, the deformation of any combination of fracture roughness and heterogeneous arrangement of proppant in the fracture can be evaluated. The deformed state is then converted into a pore network model which calculates the conductivity of the fracture during flow-back and subsequent production. Embodiments herein allow one to progressively reduce uncertainty in the performance of an optimized HPP operational strategy by iterative reduction of uncertainty in identified properties of the reservoir.
Optimization Under Uncertainty and Global Sensitivity Analysis
Let us consider a general case when the underlying physical process is modeled by a function y=f(α, β), where α={α 1 . . . α N } and β={β 1 . . . β M } are two sets of parameters. Here, α represents the set of control parameters (to be used in optimization), and β denotes the set of uncertain parameters. Mathematically, β's are considered to be random variables represented by a joint probability density function (pdf). Therefore, for each vector of control variables α, the output of the model is itself a random variable with its own pdf (due to uncertainty in β). A mean-variance approach is commonly used for optimization, i.e. a function of the form
F =μ(α,β)−λσ(α,β)
where μ, and σ are the mean and standard deviation of the output y of the numerical simulation, and λ is a non-negative parameter defining a tolerance to risk (uncertainty). The optimization problem can then be formulated as
max
α
F
(
α
,
β
)
For each optimization iteration, a sample of the random vector β is chosen, and the values of y(α, β) are first computed using this sample for a given a and then averaged over β.
Various optimization algorithms can then be used to find the optimal value of α. The process of optimizing under uncertainty will lead to a set of parameters α opt that provide the optimum of the objective function F. Therefore, an optimized model is now available:
y=f (α opt ,β)
Note that the optimized model still has inherent uncertainty due to the uncertainty in parameters β.
A set of solutions to the optimization problem can be plotted in (μ, σ) coordinates, where optimal points corresponding to pre-defined values of λ will form an efficient frontier ( FIG. 7 ). This represents a risk profile of the underlying modeled process. The positive slope of the frontier illustrates the penalty for additional uncertainty (risk).
From the operational perspective, the goal is to reduce this risk while maintaining the same level of expected performance (represented by μ). In order to reduce the uncertainty, one needs to understand where it is coming from. Therefore, a quantitative link between uncertainties in input parameters (β) and uncertainty in the output is desirable. This link can be quantified using Global Sensitivity Analysis based on variance decomposition.
Global sensitivity analysis (Saltelli et al., 2004) based on variance decomposition is used to calculate and apportion the contributions to the variance of the measurement signal V(Y) from the uncertain input parameters {X i } of the subsurface model.
For independent {X i }, the Sobol' variance decomposition (Sobol', 1993) can be used to represent V(Y) as
V ( Y )=Σ i=1 N V i +Σ 1≦i<j≦N V ij + . . . +V 12 . . . N , (1)
where V i =V[E(Y|X i )] are the variance in conditional expectations (E) representing first-order contributions to the total variance V(Y) when X i is fixed i.e., V(X i )=0. Since we do not know the true value of X i a priori, we have to estimate the expected value of Y when X i is fixed anywhere within its possible range, while the rest of the input parameters {X ˜i } are varied according to their original probability distributions. Thus,
S 1 i =V i /V ( Y )
is an estimate of relative reduction in total variance of Y if the variance in X i is reduced to zero.
Similarly, V ij =V[E(Y|X i , X j )]−V i −V j is the second-order contribution to the total variance V(Y) due to interaction between X i and X j . Notice, that the estimate of variance V[E(Y|X i , X j )] when both X i and X j are fixed simultaneously should be corrected for individual contributions V i and V j .
For additive models Y(X), the sum of all first-order effects S1 i is equal to 1. This is not applicable for the general case of non-additive models, where second, third and higher-order effects (i.e., interactions between two, three or more input parameters) play an important role. The contribution due to higher-order effects can be estimated via total sensitivity index ST:
ST i ={V ( Y )− V[E ( Y|X ˜i )]}/ V ( Y ),
where V(Y)−V[E(Y|X ˜i )] is the total variance contribution from all terms in Eq. 1 that include X i . Obviously, ST i ≧S1 i , and the difference between the two represents the contribution from the higher-order interaction effects that include X i .
There are several methods available to estimate S1 i and ST i (see (Saltelli et al., 2008) for a comprehensive review).
In one embodiment, we apply Polynomial Chaos Expansion (PCE) [Wiener, 1938] to approximate the underlying optimized function y=f(α opt ,β). The advantage of applying PCE is that all GSA sensitivity indices can be calculated explicitly once the projection on the orthogonal polynomial basis is computed (Sudret, 2008).
In another embodiment, GSA sensitivity indices can be calculated using an algorithm developed by Saltelli (2002) that further extends a computational approach proposed by Sobol' (1990) and Homma and Saltelli (1996). The computational cost of calculating both S1 i and ST i is N(k+2), where k is a number of input parameters {X i } and N is a large enough number of model calls (typically between 1000 and 10000) to obtain an accurate estimate of conditional means and variances. However, with underlying physical model taking up to several hours to run, this computational cost can be prohibitively high. Therefore, we can use proxy-models that approximate computationally expensive original simulators. Quasi-random sampling strategies such as LPτ sequences (Sobol, 1990) can be employed to improve the statistical estimates of the computed GSA indices.
Once sensitivity indices are computed, uncertain β-parameters can be ranked according to values of S 1 . Parameters with the highest values of S 1 should be selected for targeted measurement program. Reduction in uncertainty of these parameters will result in largest reduction in uncertainty of predicted model outcome. Parameters with lowest values of ST (typically, below 0.05) can be fixed at their base case value, thus reducing dimensionality of the underlying problem and improving the computational cost of the analysis.
The summary of the proposed general workflow is given in FIG. 1 .
The main steps include:
1. Identify control variables (α) and uncertain parameters (β). If applicable, define ranges for control variables. Define probability distribution functions (pdfs) for uncertain parameters. 2. Perform optimization under uncertainty (max F (α, β), where F=μ−λσ) and construct relevant points on the efficient frontier for various values of λ. 3. For a given point on the efficient frontier (defined by prescribed value of λ and corresponding values of control parameters α λ ), calculate GSA sensitivity indices and rank uncertain parameters β according to values of S 1 . 4. Perform additional measurements to reduce uncertainty of parameters β with high values of S 1 and redefine pdfs for those parameters. 5. Optional: fix values of parameters β with low (e.g., below 0.05) values of ST to reduce dimensionality of the optimization problem. 6. Perform steps 2-5 until acceptable level of risk is achieved or until the decision is made that the desired level of performance cannot be achieved with the acceptable level of risk.
Illustrative Example: HPP Optimization Under Uncertainty
We now describe the application to a problem of HPP optimization demonstrating the method.
The underlying physical model along with the methods and numerical tools developed to simulate it are disclosed in “Method for Predicting Heterogeneous Proppant Placement and Conductivity” (U.S. Provisional Patent Application Ser. No. 61/870,901, filed Aug. 28, 2013 which is incorporated by reference above). Below we provide a short description of the main steps involved in calculating fracture conductivity resulting from HPP.
FIG. 2 shows a flow diagram highlighting the inputs and outputs utilized in our specific example of fracture conductivity when considering the heterogeneous placement of proppant from a vertical well intersecting a vertical hydraulic fracture as depicted in FIG. 3 . In this instance, the heterogeneity of proppant in the fracture is achieved through a combination of pulsing of the proppant into the fracture (see FIG. 4 ) and mixing phenomena (see FIG. 5 ) that are characterized by a mixing length.
FIG. 6 shows in more detail how the inputs are broken down into those related to the placement of the proppant and those related to the subsequent deformation and conductivity calculations. The complete list of model inputs utilized by the example application is provided in Table 1 along with descriptions of the inputs, their units and initial ranges used in this example.
We start by following the steps of the workflow disclosed in FIG. 1 .
Step 1. Identify control variables (α) and uncertain parameters (β) and define their ranges and probability distributions.
Control variables (α) include:
1. Injector spacing
2. Pumping rate
3. Full cycle length
4. Proppant pulse length
5. Injector phase shift
6. Proppant Young's modulus
7. Proppant permeability (parameter was fixed in this study since the dominating flow mechanism in successful HPP job should be though the channels formed between the proppant pillars rather than through the proppant itself)
Ranges for control variables are given in Table 1. FIG. 4 illustrates some of these variables related to heterogeneous placement of proppant and consequently some systems can accommodate a pumping schedule that includes variations in proppant concentration with time.
Uncertain variables (β) include:
1. Fracture aperture during placement
2. Proppant mixing length
3. Formation Young's modulus
4. Formation Poisson ratio
Ranges for uncertain variables are given in Table 1. All variables were assumed to be uniformly distributed, except for “Proppant mixing length” that was assumed to be uniformly distributed on a log scale.
TABLE 1 List of inputs for fracture conductivity calculation applied to injection into a vertically oriented fracture from a vertical well. Input Description Units Range Injector Vertical distance between Length (m) 0.5-3 spacing injectors Pumping Volume per 0.1-0.5 rate unit time (bpm) Full cycle Length in time of repeated Time (s) 15-25 length cycle of heterogeneous injection Proppant Fraction of total injection Non- 0.25-0.75 pulse length period dedicated to dimensional proppant injection Injector The systematic delay be- Non- 0-1 phase shift tween the cycles of the dimensional injectors (as fraction of total cycle length) Fracture Fracture assumed to have Length (mm) 3-7 aperture constant aperture during during displacement for this placement demonstration. Proppant The permeability of the Length*Length fixed at permeability permeability can be stress (m 2 ) 10 −10 under stress dependent. In this demonstration it was assumed constant. Proppant Characteristic length scale Length (m) 0.001-0.25 mixing over which proppant and length clean fracturing fluid mix during placement Proppant Assumed elastic constant Stress (MPa) 50-500 Young's characterizing compression modulus of proppant. Formation Stress (GPa) 5-50 Young's modulus Formation Non- 0.15-0.35 Poisson dimensional ratio Closure Stress (MPa) 0.1-30 stress levels
Step 2. Perform optimization under uncertainty (max F (α, β), where F=μ−λσ) and construct relevant points on the efficient frontier for various values of λ.
The underlying quantity to be optimized is fracture conductivity at a predefined closure stress (20 MPa in this example). In general, the objective function can be based on other performance metrics of proppant delivery and placement in the fracture including total hydrocarbon produced through the fracture, hydrocarbon production rate, and a financial indicator characterizing profitability of the fracturing job. Results of the optimization step comprise a risk profile shown in FIG. 7 . Corresponding values of mean, standard deviation for three λ points along with P10-P50-P90 estimates for facture conductivity corresponding to these three operational scenarios are given in Table 2.
TABLE 2 Results of optimization with initial uncertainty. λ = 0 λ = 1 λ = 2 Mean fracture conductivity (D · m) 248.15 232.05 193.6 Mean fracture conductivity (log 10) −9.605 −9.634 −9.713 Standard deviation (log10 cycles) 1.21 1.15 1.10 P90 (D · m) 2.21 2.79 2.83 P50 (D · m) 562 507 408 P10 (D · m) 4582 3619 2622
Step 3. For a given point on the efficient frontier (defined by prescribed value of λ and corresponding values of control parameters α λ ), calculate GSA sensitivity indices and rank uncertain parameters β according to values of S1.
We apply Polynomial Chaos Expansion approach to calculate GSA sensitivity indices for optimized models corresponding to values λ=0, 1, 2. The values for first-order sensitivity index (S1) and total sensitivity index (ST) for each uncertain parameter β are given in Table 3. For all three optimal points on the efficient frontier, “Proppant mixing length” is responsible for almost 70% of variance in predicted fracture conductivity. The second largest contributor is “Fracture aperture during placement” (15-20% of variance).
TABLE 3 GSA sensitivity indices for optimized models (uncertain parameters ranked according to S1). λ = 0 λ = 1 λ = 2 S1 ST S1 ST S1 ST Proppant mixing length 0.72 0.75 0.69 0.73 0.65 0.70 Fracture aperture during 0.17 0.18 0.17 0.18 0.19 0.20 placement Formation Young's modulus 0.08 0.11 0.09 0.13 0.11 0.15 Formation Poisson ratio 0.00 0.00 0.00 0.00 0.00 0.00
Step 4. Perform additional measurements to reduce uncertainty of parameters β with high values of S 1 and redefine pdfs for those parameters.
Based on results of Step 3, “Proppant mixing length” was identified as a single largest contributor to variance of fracture conductivity at 20 MPa. For illustration, we assume that additional measurements were performed to reduce the uncertainty range of this parameter from 0.001 m-0.25 m (slightly more than two log 10 cycles) to 0.005-0.05 (one log 10 cycle) with uniform distribution on log scale.
Step 5. Optional: fix values of parameters β with low (<0.05) values of ST to reduce dimensionality of the optimization problem.
Analyzing total-sensitivity values, we notice that “Formation Poisson ratio” has values very close to zero. Therefore, fixing this parameter in the middle of its original uncertainty range (0.15-0.35) will not significantly affect the outcome of the subsequent analysis (Sobol, 2001) while improving its computational cost since the dimensionality of the problem will be reduced.
Step 6. Perform optimization step 2 with updated ranges of uncertain parameters.
Results of the optimization step are shown in FIG. 8 . Three points of the initial efficient frontier are also included for comparison. The updated efficient frontier has moved to the left (desired reduction in uncertainty) and slightly up. We note that the vertical direction of the shift in efficient frontier depends on underlying values in the physical quantity of interest (fracture conductivity) in the updated range of the uncertain parameter (Proppant mixing length). Corresponding values of mean, standard deviation for three λ points along with updated P10-P50-P90 estimates for facture conductivity corresponding to these three operational scenarios are given in Table 4. We observe the significant reduction in standard deviation (on log scale) compared to the initial case. The reduction in P10-P90 range on a linear scale is also noticeable.
TABLE 4
Results of optimization with updated
uncertainty ranges (based on GSA).
λ = 0
λ = 1
λ = 2
Mean fracture conductivity (D · m)
743.39
698.31
589.72
Mean fracture conductivity (log 10)
−9.129
−9.156
−9.229
Standard deviation (log10 cycles)
0.68
0.59
0.53
P90 (D · m)
81
109
103
P50 (D · m)
981
943
782
P10 (D · m)
4494
3010
2219
The shift of efficient frontier to the left is expected in most cases. With the rare exception when the local variance underlying of values in the physical quantity of interest in the updated range of the uncertain parameter is higher than that in the initial range. Although even for this exception case, we argue that the disclosed approach provides iterative way to accurately estimate risk-reward profile for a given HPP job and allows one to avoid costly mistakes that would result in an underperforming fracture.
We disclosed a method for adaptive optimization of heterogeneous proppant placement under uncertainty. A predictive physics-based HPP model is used to estimate fracture conductivity under the desired closure stress. The input parameters of the model are divided into control variables and uncertain variables. The model is first optimized to obtain values of control variables maximizing mean fracture conductivity (at given closure stress) under initial uncertainty of formation properties. An efficient frontier may be obtained at this step to characterize the dependence between the optimized mean value of fracture conductivity and its uncertainty expressed by the standard deviation. Global sensitivity analysis is then applied to quantify and rank contributions from the uncertain input parameters to the standard deviation of the optimized values of fracture conductivity. The uncertain parameters are ranked according to their calculated sensitivity indices and additional measurements can be performed to reduce uncertainty in the high-ranking parameters. Constrained optimization of the model with reduced ranges of uncertain parameters is performed and a new efficiency frontier is obtained. In most cases, the points of the updated efficient frontier will shift to the left indicating reduction in risk associated with achieving the desired fracture conductivity. The disclosed method provides an adaptive GSA-optimization approach that results in iterative improvement of estimated risk-reward profile of an optimized HPP job under uncertainty.
Some embodiments may use a computer system including a computer processor (e.g., a microprocessor, microcontroller, digital signal processor or general purpose computer) for executing any of the methods and processes described herein. The computer system may further include a memory such as a semiconductor memory device (e.g., a RAM, ROM, PROM, EEPROM, or Flash-Programmable RAM), a magnetic memory device (e.g., a diskette or fixed disk), an optical memory device (e.g., a CD-ROM), a PC card (e.g., PCMCIA card), or other memory device. The memory can be used to store computer instructions (e.g., computer program code) that are interpreted and executed by the processor.
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Apparatus and methods for delivering and placing proppant to a subterranean formation fracture including identifying control variables and uncertain parameters of the proppant delivery and placement, optimizing a performance metric of the proppant delivery and placement under uncertainty, calculating sensitivity indices and ranking parameters according to a relative contribution in total variance for an optimized control variable, and updating a probability distribution for parameters, repeating optimizing comprising the probability distribution, and evaluating a risk profile of the optimized performance metric using a processor. Some embodiments may deliver proppant to the fracture using updated optimized values of control variables.
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SPECIFICATION
CROSS REFERENCE TO RELATED APPLICATIONS
This is a continuation-in-part of copending U.S. patent application Ser. No. 08/550,866, filed Oct. 31, 1995, which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to downhole oil well drilling and production tools and more particularly relates to an improved downhole fluid blasting tool that can be conveyed into a well bore on continuous coil tubing or on threaded pipe, wherein the user has the option of detaching from a carried tool assembly if that assembly becomes stuck and/or plugged in the well bore (e.g. by sand or debris). The improved fluid blasting mechanism is, more particularly, operable by pumping a deformable (for example polymeric) ball valving member through the coil tubing bore or through the work string bore until it seats on a piston. The piston is held in an uppermost position by a return spring. Pressure is applied from the surface via the work string or coil tubing until a pressure differential is reached across the piston which in turn shifts the piston so that is can travel to a lower position, exposing jetting ports that can clean and blast the adjacent casing.
2. General Background
When remedial work is performed on oil and gas wells, and on occasion during the drilling of said wells, certain downhole tool assemblies are conveyed into the well bore on continuous coiled tubing or on a string of connected joints of threaded pipe.
It often becomes desirable to have the option to detach from these tool assemblies. The tool assembly can become stuck and/or plugged in the hole by sand or debris for example.
There are several known downhole tool assemblies which are operated by pumping a steel ball down the workstring. The ball valving member arrives at a releasing device and seats in a piston. Pressure is then applied from the surface through the workstring until a pressure differential is reached across the piston which in turn shears a set of pins or set screws. This movement releases dogs on a collet lock allowing the device to part, leaving the stuck assembly in the hole to be fished out.
Some of the presently available releasing devices allow restricted circulation of fluid through the tool after release. None of the available or prior art devices are relatchable nor can they be released more than one time.
Some patents have issued that disclose devices for releasably connecting one part of the tools string to another. An example is the Smith U.S. Pat. No. 5,419,399 entitled "HYDRAULIC DISCONNECT". In the '399 patent, there is described an improved method and apparatus for releasably connecting one part of a tool string to another, comprising a tubular housing having an uphole and a downhole end, a piston slidably disposed within the tubular housing for longitudinal movement therein between a first position and a second downstream position, the piston having a sealable bore formed therethrough for passage of a pressurized fluid, first connectors for releasably maintaining the piston in the first position thereof prior to sealing of the bore in the piston, a tubular bottom sub having an uphole end for concentric connection to the downhole end of the tubular housing, and a downhole end adapted for connection to a tool string and second connectors for releasably connecting the tubular housing to the bottom sub to normally prevent axial separation therebetween, wherein the piston, upon sealing of the bore to block the passage of the pressurized fluid therethrough and in response to the pressure of the fluid then acting on the piston, is movable from its first to its second position to allow release of the second connectors, whereupon the tubular housing and the bottom sub become separable.
U.S. Pat. No. 5,404,945 discloses a device for controlling fluid flow in oil well casings or drill pipes. The device defines a flow path for fluid through a casing section or drill pipe with the flow path including a throttling valve which restricts or prevents the flow of fluid therethrough. This can be used to prevent U-tubing in casings or can be used to locate leaks in drill pipes or can be used to monitor the position of successive fluids of differing viscosities in a casing string.
An anti-rotation device for cementing plugs with deformable peripheral fins or lips is disclosed in U.S. Pat. No. 5,165,474.
A method and apparatus for hydraulic releasing for a gravel screen is disclosed in U.S. Pat. No. 4,671,361. The '361 patents relates to a tool for use in gravel packing wells, and more particularly to a tool for retention and release of a gravel pack screen assembly when gravel packing wells. The method and apparatus is especially suitable for hydraulic releasing from a screen on a circulation type gravel pack job. The releasing tool comprises a tubular case by which the tool is secured to a gravel pack thereabove and a gravel screen secured thereto below. The case disposed within the collet sleeve assembly show room on top of the case and includes a plurality of collets extending downwardly into the case, the collets being radially outwardly biased into engagement with the case by the lowered end of a releasing mandrel disposed within the collet sleeve. A ball seat on the top of an axial bore extending through the releasing mandrel permits the seating of a ball and downward movement of the releasing mandrel inside the collet sleeve. Removal of the outward bias against the collets and permitting withdrawal of the collet sleeve and releasing mandrel from the case and attached screen therebelow.
The Bissonnette U.S. Pat. No. 4,515,218 discloses casing hardware such as float collars and shoes used in oil well cementing operations. Some of the collars and shoes and constructed of a steel casing with a concrete core inside the casing. The casing structure of the collars and shoes places the core under a predominantly shearing force, so that it will fail at relatively low downhole differential pressures. The invention provides a design for the casing structure which places the concrete core under a predominantly compressive force and greatly increases the amount of pressure the core can withstand without failing.
The Wetzel U.S. Pat. No. 3,997,006 discloses a well tool having a hydraulicly releasable coupler component, a gravel packing apparatus and method for use therewith and a subterranean well having production tubing inserted therein, wherein the coupler comprises hydraulic means for releasing the tubing from the gravel pack apparatus, without rotating said tubing when the coupler is activated and the tubing removed, the lower portion of the coupler remaining in the well with the gravel pack and providing a receptacle for a packing element partially inserted therethrough.
An oversize subsurface tubing pump installation and method of retrieving the pump is disclosed in U.S. Pat. No. 3,809,162. Both the pump barrel and plunger are too large to pass through the tubing. When the pump is to be retrieved, the sucker rods are raised and lift the seating assembly to expose a drain hole in the seating nipple. Fluid drains from the tubing through the exposed drain hole. Continued raising of the sucker rods breaks the connection between the sucker rods and the pump plunger. The sucker rods and then the tubing and pump are pulled from the well. Draining the tube prevents spillage at the top of the well.
A method and apparatus for cementing casing sections and well bores is disclosed in U.S. Pat. No. 3,570,603. Casing sections are cemented in a well bore between producing zones and an upward sequence starting from the bottom. Each casing section is lowered on a running string and running tool to its sitting position, the casing section then being rotated to expand cutter supporting members carried by the casing outwardly to cut a formation shoulder for supporting the cutter members and casing. The running tool is released from the casing and lowered therewith to the casing float shoe, cement being pumped through the running string, tool and shoe to cement the casing in place, running string and tool being removed from the hole.
SUMMARY OF THE INVENTION
The present invention provides a downhole oil well tool apparatus that can include an inside fishing neck on the main body of the device. One of the tools designed to latch with the fishing neck is for example a pulling tool, such pulling tool devices as have been commercially available for years. The present invention provides a bias that allows piston movement in a releasing device in place of shear pins or shear screws. Another apparatus provides a jetting tool that is used to clean the wall of adjacent casing.
A composite ball allows more than one pressure setting to actuate the locking and unlocking piston.
The apparatus of the present invention provides the capability to unlatch and relatch numerous times, using the composite ball by moving the ball through a seat, deforming the ball with pressure.
The present invention allows full circulation of fluid after actuation by forcing the deformable ball valving member through the seat.
The apparatus of the present invention includes a cage portion that catches each of the deformable ball valving member in a cage to prevent those deformable ball valving members from freely moving into the well bore and further restricting flow.
The apparatus of the present invention includes multiple serrated dogs to transfer torque between the two main body parts of the apparatus to permit those two major components to remate with ease.
In one embodiment of the apparatus of the present invention, a jetting device is provided for fluid blast cleaning of a section of well production tubing in an oil and gas well. The alternate embodiment uses an elongated work string that can transmit fluid under pressure down into the well.
The alternate embodiment includes a tool body having upper and lower end portions, a generally cylindrically shaped wall, an exterior surface and a central longitudinal flow bore.
A connector at the upper end of the tool body enables the tool body to be connected to the work string.
A piston mounted in the tool body bore is movable between upper and lower positions. An upper end portion of the piston provides a valve seat. The piston also has a piston bore that communicates with the tool body bore and with the valve seat.
A spring normally urges the piston into the upper position.
One or more jetting orifices extend radially through the tool body wall, the orifices each being in fluid communication with the tool body bore and with the tool body exterior surface. The orifices are positioned to direct pressurized fluid in the direction of the production tubing to be cleaned and fluid blasted.
A ball valving member can be placed into the tool body bore at the seat of the piston by transmitting the ball valving member to the tool body and seat via the work string. The ball valving member has a diameter that is larger than the piston bore diameter at the seat so that the ball can form a seal with the seat when the ball valving member is pumped under pressure to the piston.
The ball valving member and piston are each movable together between upper and lower positions after the ball valving member seats upon the top of the piston.
The jets are normally closed when the piston is in the upper position. When the ball is dropped from the surface for example and flows via the work string to the piston it seats on the top of the piston at the seat. The user then pressures up above the ball to create a pressure differential that shifts the piston and ball from the upper to the lower position. This shifts the ball valving member and seat to a position below the jetting orifices so that pressurized fluid can travel from the tool body bore through the jetting orifices and be used to direct pressurized fluid to clean and fluid blast the production tubing.
BRIEF DESCRIPTION OF THE DRAWINGS
For a further understanding of the nature and objects of the present invention, reference should be had to the following detailed description, taken in conjunction with the accompanying drawings, in which like parts are given like reference numerals, and wherein:
FIG. 1 is a sectional elevational, partially cut-away view of the preferred embodiment of the apparatus of the present invention.
FIG. 2 is a sectional view illustrating the preferred embodiment of the apparatus of the present invention, showing the tool in locked position;
FIG. 3 is a sectional view of the preferred embodiment of the apparatus of the present invention illustrating the tool in a pressured up position;
FIG. 4 is a sectional view of the preferred embodiment of the apparatus of the present invention showing the mandrel removed, the ball valving member having been pumped through to the ball cage to allow circulation;
FIG. 5 is a sectional view of the preferred embodiment of the apparatus of the present invention illustrating the placement of a second ball valving member used to unlock the tool for mandrel reinstallation;
FIG. 6 is a sectional view of the preferred embodiment of the apparatus of the present invention illustrating the mandrel having been reinstalled;
FIG. 7 is a sectional view of the preferred embodiment of the apparatus of the present invention showing the second ball having been pumped through to the ball case to relatch and resume operations;
FIGS. 8A-8B are side views of the deformable ball valving member showing its configuration before (FIG. 8A) and after (FIG. 8B) it is pumped through to the ball cage;
FIG. 9 is an elevational sectional view of an alternate embodiment of the apparatus of the present invention;
FIG. 10 is an elevational sectional view of a second alternate embodiment of the apparatus of the present invention; and
FIGS. 11-13 are sectional, elevational views of the alternate embodiment of the apparatus of the present invention showing a fluid blasting tool.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIGS. 1-3 show generally the preferred embodiment of the apparatus of the present invention designated by the numeral 10. Pulling and releasing tool 10 has an upper end portion 11 and a lower end portion 12 when the tool is assembled and oriented in operating position for running in a well. A flow bore 14 allows circulation through the tool 10 between end portions 11, 12.
The apparatus 10 includes a main body portion 13 having an inner open ended bore 18. At the lower end portion of the main body 13 that is provided a threaded sub member 15. The sub member 15 forms a connection to main body 13 at threaded connection 16. The sub 15 provides lower external threads 17 for attaching main body 13 to other tools, tool sections, pipe or the like.
The main body 13 (FIG. 4) has an upper end portion 19, and a lower end 20. Open ended bore 18 receives an inner mandrel 28. The main body 13 includes a generally tubular cylindrically shaped main body wall 21 with an inside surface 22. A pair of spaced apart beveled annular shoulders 24, 25 define therebetween an annular recess 23. The side wall of the main body 13 has a thin side wall 26 at the annular recess 23. On the sides of the annular recess 23, there are provided thick side wall portions 27 as shown in FIG. 4.
The main body 13 receives an inner mandrel 28, a fluid pressure operated piston 29 and locking dogs 30 that are used to engage the inner mandrel 28 and main body 13. In FIG. 4, mandrel 28 has an upper end 32 and a lower end 31. Inner mandrel 28 has a bore 33 that extends completely through inner mandrel 28. Piston 29 occupies a portion of bore 33 as shown in FIG. 4. The inner mandrel 28 provides an internally threaded connection portion 34 for attachment to a coiled tubing string, work string or the like during use. Threaded connection portion 34 enables a user to raise and lower the tool 10 in an oil/gas well using a coil tubing unit for example.
The piston 29 is hollow, providing a piston bore 35. The piston 29 has an upper end 36 defining a ball valve seat 57. O-ring 37 forms a seal with inner mandrel 28. Annular ring 40 limits travel of piston 29 in an upward direction. In FIG. 1, annular ring 40 is in an uppermost position. Beveled annular surfaces 38, 39 are provided on each side of annular ring 40.
Stop 46 is provided on inner mandrel 28 in the form of a beveled annular shoulder. Annular shoulders 39 and 42 define therebetween a reduced diameter annular recess 44. Piston 29 is of a reduced diameter at 43. A thickened section 45 is provided between annular recess 44 and ball cage 50. Stop 46 limits the travel of piston 29 within the bore of main body 13. Annular shoulder 47 and beveled annular surfaces 48, 49 define ball cage 50.
Ball cage 50 is in an expanded area for receiving ball valving members 52, 53 that are pumped through when inner mandrel 28 is to be released from main body 13. When a ball valving member 52, 53 is pumped from seat 57 to cage 50, it deforms because it must pass through a reduced diameter section of piston bore 35. A cross bar 51 holds the ball valving members 52, 53 within the ball cage 50 after each ball valving member 52, 53 has been pumped therethrough. Otherwise, fluid can flow through cage 50 to the lower end of bore 33. The ball cage 50 is preferably sized to hold as many as six ball valving members (such as 52, 53) after they have been pumped through. Spring 54 biases the piston 29 in an uppermost position as shown in FIG. 1. The spring 54 has an upper end 55 and a lower end 56. Upper end 55 engages the lower end of piston 29. Lower end 56 of spring 54 engages spring stop 58 as shown in FIG. 4.
During use, the apparatus 10 is lowered into the well bore on a work string such as a coil tubing string. The apparatus 10 assumes the position of FIG. 1 when being lowered to the well bore. In this initial position, spring 54 biases the piston 29 in the upper position shown in FIG. 1.
The spring 54 bottoms on stop 58 and engages the lower end of piston 29. Stop 58 threadably attaches at connection 59 to inner mandrel 28. The piston 29 upper end provides annular ball valving seat 57 that is receptive of a ball valving member 52 or 53.
If the tool 10 becomes stuck, it is desirable to release the inner mandrel 28 portion of the apparatus 10 from the main body 13. In such a case, the user pumps a ball valving member 52 into the well bore via a coil tubing unit which has an internal flow bore. When the ball valving member 52 reaches the ball seat 57 and registers upon seat 57, the ball valving member 52 forms a closure with seat 57.
This closure prevents the flow of fluids from the coil tubing unit bore into the tool body bore 14. The user then pressures up the coil tubing unit which increases pressure on ball valving member 52, 53. The use of a coil tubing unit to "pressure up" above a ball valving member is known in the art.
With the present invention, a deformable ball valving member is selected, such as a ball valving member of a plastic material. There are two basic operating pressures, a first pressure shifts tool (piston), a second pressure forces the ball 52 or 53 thru seat 57. This allows pressure to be increased to a predetermined value (first pressure) overcoming the force of bias spring 54, moving piston 29 down and releasing dogs 30. The ball valving member 52 deforms and passes through the ball seat 57 downwardly via the bore 53 and into the ball cage 50. This takes place at the second predetermined pressure value number two. The ball valving member 52 is of a deformable material such as a plastic polymeric material, Teflon® or nylon being preferred.
Once the ball valving member 52 or 53 is pumped from the seat 57 into the ball cage 50 via piston bore 35, the user can circulate fluids into the well. Circulation is possible because the ball valving member 52 no longer forms a closure at the ball seat 57. The ball cage 50 is large enough to hold more than one ball valving members 52, 53. Cross bar 51 prevents further downward movement of ball 52 or 53 once the ball 52, 53 reaches cage 50. Fluid circulation is allowed because the cage 50 is larger in cross section than a plurality of the ball valving members 52, 53.
One of the features of the apparatus 10 of the present invention is the ability to reinstall the mandrel 28 after it has been released. After mandrel 28 is removed from main body 13, and ball 52 has been forced through piston 29 spring 54 forces piston 29 up to the position of FIG. 4. In order to reattach, piston 29 must be moved down to the position shown in FIG. 5 so that the dogs 30 and recess 44 are adjacent. In this position, the mandrel 28 and dogs 30 have an overall diameter that will fit inside bore 18 of main body 13. A reattachment is accomplished by dropping a second ball valving member 53 via the coil tubing string to the seat 57.
Once the second ball valving member 53 is in a sealing position on seat 57 (see FIGS. 5-6). The device 10 is pressured to the first pressure value allowing dogs 30 to move inward as in FIG. 5. Mandrel 28 can now be lowered into main body 13 as overall diameter is reduced. The mandrel 28 and its piston 29 can be reconnected to bore 18 of main body 13 as shown in FIG. 6.
A smaller overall diameter of dogs 30 is achieved by pressuring up the bore 33 above ball valving member 53 to the first preselected pressure value. This forces piston 29 downwardly to the position shown in FIG. 5 and 6. The mandrel 28 can now fit bore 18 of main body 13. To interlock mandrel 28 and body 13, ball valving member 53 is pumped through to cage 50 at the second preselected pressure value. Spring 54 then returns piston 29 and dogs 30 to locked or connected position. This attachment and disattachment can be repeated over and over if desired until cage 50 is filled with ball valving members. In FIG. 8A, a spherical ball valving member 52 is shown before being pumped through to bull cage 50. In FIG. 8B, a deformed ball valving member 52 is shown having a cylindrical outer surface portion 52A and a pair of opposed hemispherical outer surface portions 52B, 52C.
FIG. 9 shows an alternate embodiment of the apparatus of the present invention by the numeral 60. The tool 60 is constructed as the tool 10 of the preferred embodiment, but for the elimination spring 54.
Tool 60 has a shear pin 61 in the embodiment of FIG. 9. The tool 60 is a construction that is not designed to be reset. When a ball valving member 52 or 53 is dropped from the wellhead and travels via coil tubing unit bore to seat 57, the piston 29 can be shifted downwardly by pressuring up within the coil tubing bore. This pressuring up shears pin 61 allowing piston 29 to travel downwardly until recess 44 aligns with dogs 30 as with the preferred embodiment tool 10. However, no spring 54 is provided, so that resetting is not possible. Full circulation is however provided.
FIG. 10 shows a second alternate embodiment of the apparatus of the present invention designated by generally by the numeral 60. Pulling and releasing tool 60 provides an embodiment that solves an inherent problem of ball operated tools that are shear pin operated. One of the inherent problems ball operated tools that use shear pins is that they are prone to shear and release when debris is accidentally picked up by circulating pumps and conveyed downhole into the well bore. Before this debris can be blown through to a safety zone using extra pressure, sufficient differential pressure is often created to shear the pin or pins causing premature release. The debris will generally blow through the tool after this premature release occurs with the shearing of the pins.
With the embodiment of FIG. 10, a shifting of inner piston 29 is delayed briefly. This delaying of the shifting action of piston 29 allows any debris that lodges in seat 29 sufficient time to clear the seat before shifting can occur. The alternate embodiment of FIG. 10 provides an improvement to prior art type ball operated tools of the type that have a shear pin holding arrangement. A delayed shifting of the inner piston of a ball operated tool is not possible with a shear pin held device, but is feasible with a spring loaded device such as is shown in FIG. 10 and described hereinafter.
In FIG. 10, tool 60 includes the same main body 13 as with the embodiment of FIGS. 1-8. The embodiment of FIG. 10 has a mandrel 28 that is sized and shaped similarly to the mandrel 28 of FIGS. 1-8. Likewise, the embodiment of FIG. 10 provides a piston 29 that is slidably movable within the bore of mandrel 28 as with the embodiment of FIGS. 1-8.
In FIG. 10, piston 29 also includes the same annular recess 44 and the same locking dogs 30 as the embodiment of FIGS. 1-8. The tool 60 is operated by dropping a ball from the surface and allowing that ball to flow via a coil tubing unit to seat 57 as occurs in the embodiment of FIGS. 1-8. However, the embodiment of FIG. 10 includes a timer or clock arrangement that delays operation of the releasing mechanism.
This clock capability is in the form of a chamber 61 that holds coil spring 62 and cylindrical tube 63. The tube 63 has an upper end 64 that fits an annular shoulder 65 at the bottom of piston 29 and is sealed by welding. The lower end 66 of tube 63 fits the bore 33 of spring stop 58. Seals are provided at 67, 68. The lower end 66 of cylindrical tubes 63 provides a small orifice 69. The area between mandrel 28 and cylindrical tube 63 forms a chamber 61 that carries spring 28. Chamber 70 is sealed at the top with seal 67 and at the bottom with seal 68. Therefore, in order to move the piston 29 downwardly so that the locking dogs 30 can register in the annular recess 44, the tube 63 must also move down with the piston 29.
Downward movement of the piston 29 and tube 63 is slowed because fluid contained within chamber 61 must flow through orifice 69 into the center bore 70 of tube 63 as shown by arrow 71. This arrangement produces a delay device or "clock" slowing the cycle time of the release sufficiently to allow most of any debris to clear the device without activation. The spring 28 will return the apparatus to is initial position shown in FIG. 10 if in fact debris has been the cause of a restriction at seat 57. The debris should clear the seat before release takes place so that the spring then returns piston 29 to the position shown in FIG. 10.
FIG. 11 shows an alternate embodiment of the apparatus of the present invention designated generally by the numeral 72. Fluid blasting tool 72 has a tool body 73 with an upper end 74 and lower end 75. The upper end 74 has internal threads 76 for forming a connection with a work string. The lower end 75 has external threads 77 so that a connection can be formed with a drill for example. Tool body 73 has an elongated open ended bore 78 that communicates with upper end 74 and lower end 75 of tool body 73. The tool body 73 provides a cylindrical wall 79 with a plurality of jetting orifices 80, 81 extending through the tool body wall 79, each orifice 80, 81 communicating with wall outer surface 82 and wall inner surface 83.
Piston 84 is movable between an upper position (as shown in FIG. 11) and a lower position (as shown in FIG. 12) that is defined by the travel of piston 84 and sleeve 95 downwardly in the direction of arrow 99 until the sleeve 95 reaches stop 98.
Piston 84 provides an annular seat 85 that can receive and form a seal with spherical ball valving member 86. The seat 84 can be a beveled annular seat to assist in deformation of the ball 86. The ball valving member 86 is of an external diameter that is larger than the diameter annular seat 85. However, the ball valving member 86 is of a deformable material such as nylon for example so that the ball valving member 86 can deform to fit through piston bore 87 above cage 89.
Piston bore 87 is smaller than the diameter of ball vavling member 86 so that the ball vavling member 86 can only travel through the piston bore 87 by deforming and being forced by pressurized fluid and a pressure differential created above annular seat 85. This pressure differential is created by raising pump pressure in the work string and tool body bore 78 above seat 85. As a ball valving member 86 is deformed and pumped through in the direction of arrows 88, it is deposited in cage 89.
The cage 89 defines an enlarged diameter portion of bore 78 that can hold a plurality of deformed ball valving members 86. A cross bar 90 is provided at the lower end portion of cage 89 for preventing downward travel of ball vavling members 86 beyond stop 90 after they have been pumped through the reduced diameter section of bore 87.
At the lower end of piston 84 there is provided a collar 91 having a central circular opening 92. Coil spring 93 has an upper end engages the flat annular surface 94 of collar 91. A cylindrically shaped tube 95 fits inside coil spring 93 as shown in FIG. 11. The tube 95 has an upper end that engages annular shoulder 96 of collar 91. The lower end of sleeve 97 fits inside of a correspondingly shaped bore of sleeve 97. An annular shoulder in the form of stop 98 defines the lowermost movement of sleeve 95 and therefore of collar 91 and piston 84.
In FIGS. 11-12, arrow 99 indicates the direction of travel of piston 84, collar 91, and sleeve 95 when a ball valving member 86 has been deposited upon annular seat 85 and pressure increased.
An initial predetermined pressure level can be adjusted by spring rate of spring 93 and/or cross sectional area of piston 84 at seal 84A. For example, 1200 psi can be used to move the ball valving member 86 and piston 84 to the lower position in the direction of arrow 99. This lower position is reached when tube 95 hits stop 98. In this position, the upper end of piston 84 travels below jetting orifices 80, 81. Fluidized pressure within bore 78 and above ball 86 and piston 84 can then be transmitted through orifices 80, 81 for blasting of the adjacent production tubing. After this blasting operation is completed, the pressure above ball valving member 86 and piston 84 is elevated to an higher level (e.g. 3500 psi) sufficient to push ball valving member 85 through the narrow diameter section 87 of the piston bore as the ball 86 deforms (see FIG. 13). The higher pressure can be adjustable by varying seat diameter, the angle of the seat determines how quickly ball will deform (e.g. a long angle will deform a ball quicker than a flat edge) and/or ball material. This results in a travel of the deformed ball 86 in the direction of arrows 88 into cage 89. This also opens bore 78 to complete circulation between the end portions 74, 75 of tool body 72.
One of the features of the present invention as shown in FIGS. 11-13 is the use of sleeve 100 to regulate the number of jetting orifices 80, 81 that are used during the jetting operation. The sleeve 100 is an annular sleeve that can have any desired number of transverse channels 101-102. In this fashion, the tool body 73 can provide a large number of jetting orifices 80, 81 such as 4, 6, 8, etc. in number. The user then selects a sleeve 100 having as many or as few lateral channels 101, 102 as desired. Thus, for example, if the tool body provides eight circumferentially spaced, radially extending jetting orifices 80, 81, (e.g. sixty degrees apart) a sleeve 100 can be selected that only provides two lateral channels 101, 102 (e.g. 180° apart). Even though the tool body provides eight jetting orifices, only two would be used in the jetting operation if the sleeve 100 provides two lateral channels 101, 102. The sleeve 100 could be a removable component of the apparatus 72 that would be custom selected before operation to give the desired location and number of channels 101, 102 (and thus jetting orifices 80, 81) that are used in a particular job.
The following table lists the parts numbers and parts descriptions as used herein and in the drawings attached hereto.
PARTS LIST______________________________________Part Number Description______________________________________10 pulling and releasing tool11 upper end portion12 lower end portion13 main body14 inner open ended bore15 threaded sub16 threaded connection17 lower external threads18 internal bore19 upper end20 lower end21 main body wall22 inside surface23 annular recess24 annular shoulder25 annular shoulder26 thin side wall27 thick side wall28 inner mandrel29 piston30 locking dogs31 lower end32 upper end33 bore34 internally threaded portion35 piston bore36 upper end37 o - ring38 beveled annular surface39 beveled annular surface40 annular ring41 annular shoulder42 beveled annular surface43 reduced diameter portion44 annular recess45 thickened section46 stop47 annular shoulder48 beveled annular surface49 beveled annular surface50 ball cage51 cross bar52 ball valving member .sup. 52A cylindrical surface .sup. 52B hemispherical surface .sup. 53C hemispherical surface53 ball valving member54 spring55 upper end56 lower end57 ball seat58 spring stop59 threaded connection60 pulling and releasing tool61 chamber62 spring63 tube64 upper end65 annular shoulder66 lower end67 seal68 seal69 tube orifice70 tube bore71 arrow72 fluid blasting tool73 tool body74 upper end75 lower end76 internal threads77 external threads78 bore79 cylindrical wall80 jetting orifice81 jetting orifice82 wall outer surface83 wall inner surface84 piston .sup. 84A seal85 annular seat86 ball87 piston bore88 arrow89 cage90 stop bar91 collar92 opening93 coil spring94 flat annular surface95 tube96 annular shoulder97 sleeve98 stop99 arrow100 sleeve101 channels102 channels______________________________________
Because many varying and different embodiments may be made within the scope of the inventive concept herein taught, and because many modifications may be made in the embodiments herein detailed in accordance with the descriptive requirement of the law, it is to be understood that the details herein are to be interpreted as illustrative and not in a limiting sense.
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A downhole oil well pulling and running tool provides a releasable tool body that can be used to release a workstring such as a coiled tubing string from a tool assembly and to reattach if desired. To reestablish circulations (the ability to pump fluid down the workstring and up the annulus of the well) after detachment by increasing the pressure across a seated ball to a predetermined pressure that forces the ball through the seat into a ball cage. The cage is sized and shaped to carry a plurality of the ball valving members so that the unlatching and relatching procedure may be repeated as many times as desired until the ball cage is filled. Also providing a delay or timing system that will allow debris to pass thru the tool without a release.
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FIELD OF THE INVENTION
The present invention relates generally to apparatus for maintaining substantially uniform spacing between construction elements during construction of static structures formed by said construction elements, and, more particularly, to spacer members for use in the construction of walls comprising a plurality of wall elements, such as glass bricks or blocks, bound together by curable matrix material.
BACKGROUND OF THE INVENTION
In the past, the placing of wall elements, particularly of glass bricks or blocks, has often entailed positioning of spaced-apart short, narrow wooden strips between adjacent ones of a first layer of wall blocks and, thereafter, positioning spaced-apart short, narrow wooden strips on top of the first layer of blocks to provide uniform spacing between the first layer and a similarly arranged second layer of blocks. In some situations, protruding wooden wedges are also used at different locations in the different layers of blocks to maintain the vertical alignment of the finished wall. Between these wooden strips is placed reinforcing bar, if desired or necessary, for strengthening the wall structure, as well as the mortar matrix for bonding the blocks to one another. After the wall is erected to the preferred dimensions and the mortar has partially hardened, the wooden wedges, if used, are removed completely or the protruding portions are removed, thereby usually causing destruction of the strips. This is because the wooden strips must remain in the block wall construction until the mortar has hardened since, otherwise, the wall would settle unevenly thereby essentially destroying the aesthetics of the wall construction. If the mortar becomes very hard, removal of the wedges becomes quite difficult because of the adherence of the mortar to the wedges. A further disadvantage attendant to the use of removable spacer wedges is that their removal leaves behind spaces at the joints between the blocks which must subsequently be filled by additional mortar.
Further, once the mortar hardens, it is virtually impossible to remove the spaced-apart wooden strips used to position the blocks, and the wooden strips become a part of the finished wall. These permanent horizontal strips or spacers, however, fail to provide any means for assuring accurate spacing between adjacent blocks in a single row.
In U.S. Pat. No. 4,114,337 and its corresponding Canadian counterpart, Canadian Patent No. 1,062,930, there is disclosed a wasted spacer member for wall elements, particularly glass bricks or blocks, wherein the spacer member remains embedded in the mortar of the wall construction upon completion of the wall structure. The spacer member consists of two cross-shaped or T-shaped elements lying in parallel planes and joined by a web. The outermost surfaces of the cross or T-shaped elements are intended to lie in planes spaced inwardly from oppositely directed block faces whereby the cross or T-shaped elements will be covered by mortar upon filling of the spaces or joints between the blocks with mortar. The width of the arms forming the cross or T-shaped elements defines the width of the joints between the blocks and any structure surrounding the blocks.
In a preferred embodiment, the spacer member described in U.S. Pat. No. 4,114,337 also includes either break-off vanes or discs which are attached to and spaced outwardly from the cross or T-shaped elements, such vanes or discs serving to enclose and contact portions of the exposed block faces in order to assist in vertical alignment and guidance of the blocks during placement thereof.
Each of the variously disclosed embodiments of the spacer members described in U.S. Pat. No. 4,114,337 possess features which are detrimental in one form or another to rapid, efficient and aesthetically pleasing erection of a wall construction formed of a plurality of wall elements, particularly glass blocks, bound to one another by matrix material. For example, if the spacer member of U.S. Pat. No. 4,114,337 is not provided with the aforenoted break-off vanes or discs, then it may well be difficult to assure the spacer member will remain in the desired joint position in which it is placed during wall construction. That is to say, unless extreme care is exercised in block placement, the spacer member is likely to become undesirably displaced along the joint during placement of the blocks such that the blocks themselves will also shift thereby requiring the block and spacer placement operations to be repeated. In addition, the shifting of the blocks will almost inevitably result in contact between the blocks which can easily cause damage to certain wall elements such as glass blocks, and the like.
If, on the other hand, the spacer member disclosed in U.S. Pat. No. 4,114,337 is provided with the aforementioned break-off vanes or discs, displacement of the spacer member during block placement may be substantially eliminated. However, the break-off vanes or discs is likely to preclude complete joint filling in a single application. Moreover, the break-off vanes or discs need to be physically removed subsequent to partial hardening of the initially placed mortar If the break-off vanes or discs are not broken off cleanly, i.e., portions thereof either remain projecting from the exposed block faces or cannot be effectively covered by the required subsequent joint filling operation, then a worker must perform additional steps to eliminate the unwanted remaining vane or disc material Such a spacer member construction of U.S. Pat. No. 4,114,337 thus requires a number of additional steps to be performed subsequent to initial joint filling with mortar, namely, breaking off the break-off vanes or discs, removing any remaining unwanted vane or disc material, and subsequent filling of any inaccessible joint area originally covered by the break-off vanes or discs.
Another known device for use in spacing block-like construction elements that are bound together by mortar material, or the like, involves the use of a pair of vanes or discs, each having a plurality of inwardly directed prongs. The vanes are slidably supported on a metallic wire with their respective prongs facing one another. In use, the vanes are placed against the outer block walls and the prongs project into the joint spaces and define spacing means for maintaining the blocks at desired horizontal and/or vertical spacing from one another as the construction elements and the mortar are placed. When the mortar is partially hardened, the vanes or discs are removed and the wire is gripped by pliers and withdrawn. The spaces left by the prongs (and wire) are then filled with additional mortar material. While such a device is adjustable to virtually any block width, it suffers from the disadvantage that the vanes slide freely along the wires.
U.S. Pat. No. 2,227,842 describes generally cross-shaped and T-shaped block anchoring members including a plurality of intersecting arms. The arms are either wavy or are provided with bosses that engage with specially formed glass blocks having either wavy surfaces or recesses formed in the circumferential walls thereof. Although the anchoring members serve the ancillary function of spacing adjacent blocks from one another, their practical application is limited to usage only with customized blocks having the aforementioned circumferential wall configurations. If used in connection with glass blocks of conventional construction, the anchor members, which are not provided with means for preventing unwanted lateral displacement on conventional blocks, will likely become displaced along with the block joints resulting in unwanted shifting of the blocks.
A cross-shaped and a T-shaped spacer member are also known, as in U.S. Pat. No. 4,774,793, which include channels that loosely receive a central circumferential glass block seam that is formed by the joining of two block shells in conventional glass block manufacture. The disadvantage of this spacer member construction is much the same as that associated with other conventional spacer members, i.e., because the channels are substantially wider than the block seam (sometimes as much as several times the width of the seam), the channels do not normally positively engage the seam and thus they are of little use in preventing lateral displacement of the spacer members. Therefore, shifting of the spacer members and the blocks spaced thereby is likely unless extreme care is taken in the placement of the blocks and spacer members.
A need exists, therefore, for spacer members for maintaining substantially uniform joint spacing between construction elements during construction of a static structure comprising a plurality of construction elements bound to one another by matrix material, whereby the spacer member remains embedded in and covered by the matrix material and permits the matrix material to be placed in and substantially fill all construction joints in a single application.
A further need exists for spacer members for maintaining substantially uniform joint spacing between construction elements during construction of a static structure comprising a plurality of construction elements bound to one another by a matrix material, whereby the spacer members include means positioned interiorly of the planes of the exposed faces of the construction elements for positively establishing and maintaining desired positions of the spacer members, and thereby the construction elements, during construction of the static structure.
SUMMARY OF THE INVENTION
In accordance with the present invention, there is provided a spacer member for maintaining substantially uniform joint spacing between construction elements during construction of a static structure comprising a plurality of construction elements bound to one another by curable matrix material. The spacer member remains embedded in and covered by the matrix material and permits the matrix material to be placed in and substantially fill all construction joints between the construction elements in a single application. The spacer member includes means positioned interiorly of the planes of the exposed faces of the construction elements for positively establishing and maintaining a desired position of the spacer member during construction of the structure.
In a preferred application, the static structure is a wall structure formed by a plurality of blocks, particularly glass blocks, bound to one another by mortar, or the like, and the spacer member includes means for engaging formations provided along side walls of the glass blocks to positively establish and maintain a desired position of the spacer member, and thus the blocks engaged thereby, during construction of the wall structure.
The spacer member of the present invention includes two cross-shaped, T-shaped or L-shaped elements lying in parallel planes and joined by connecting means extending transversely thereto The connecting means is of such length that outermost surfaces of the cross, T- or L-shaped elements lie in planes spaced inwardly from oppositely directed exposed faces of the glass blocks. In a most preferred embodiment, the means for engaging formations provided along side walls of the glass blocks include tab members provided on at least two of the arms forming the cross, T- or L-shaped elements and bifurcated receiving members carried by the connecting means. The tab members are adapted to engage raised side edges of the side walls of the blocks and the receiving members are adapted to receive and engage a raised seam or ridge formed substantially centrally along the periphery of the block side walls and extending continuously thereabout in a plane parallel to the exposed opposite faces of the block.
One or more of the arms of the cross- or T-shaped elements are also preferably frangible such that the shape of the elements can be easily changed, if desired, by the installer. Other details, objects and advantages of the present invention will become apparent as the following description of the presently preferred embodiments and presently preferred methods of practicing the invention proceeds.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will become more readily apparent from the following description of preferred embodiments thereof shown, by way of example only, in the accompanying drawings, wherein:
FIG. 1 is a fragmentary perspective view, in partial section, of a preferred embodiment of the spacer member of the present invention shown as it would be placed upon a construction element;
FIG. 2 is a plan view of the spacer member depicted in FIG. 1;
FIG. 3 is a view of the spacer member of the present invention as seen along line III--III of FIG. 2;
FIG. 4 is a view of the spacer member of the present invention as seen along line IV--IV of FIG. 2;
FIG. 5 is a view of the spacer member of the present invention as seen along line V--V of FIG. 2;
FIG. 6 is an enlarged plan view of a portion of the spacer member of the present invention;
FIG. 7 is a view of the spacer member of the present invention as seen along line VII--VII of FIG. 6;
FIG. 8 is an enlarged end elevational view of another portion of the spacer member of the present invention;
FIG. 9 is a perspective view of a further preferred embodiment of the spacer member of the present invention;
FIG. 10 is a perspective view of a further preferred embodiment of the spacer member of the present invention; and
FIG. 11 is a view similar to FIG. 2 depicting how the spacer member of the present invention can be easily and advantageously modified to assume configurations other than its original form.
DETAILED DESCRIPTION OF THE INVENTION
Turning to FIG. 1, there is shown a construction element, herein designated by reference numeral 2, which for description of a most preferred embodiment of the present invention, may be considered to be a standard glass block, or the like. Glass construction blocks such as block 2, as is known, generally include two oppositely directed normally square or rectangular faces 4 and 6 and four side walls 8. The side walls 8 typically are provided with raised formations or edges 10 which extend continuously about the periphery of the block 2. Located substantially centrally along the block side walls 8 is another formation 12 which is a raised seam or ridge that usually extends continuously about the periphery of the side walls of the block in a plane parallel to the opposite faces 4 and 6 of the block. Glass construction blocks such as block 2 are commonly assembled by the fusion, vis a vis, of two substantially identical half-block portions, hence the formation of seam 12 is a normally occurring result of the manufacture of the block. The features of glass block 2 thus far described are provided for purposes of illustration only and they have been included to enable the reader to appreciate a preferred application of a preferred embodiment of the spacer member of the present invention to be described herebelow.
Positioned upon a corner of block 2 is a preferred embodiment of a spacer member 14 constructed in accordance with the present invention. Spacer member 14 may be formed of any suitable material including plastic, metal, wood, or the like, although a plastic material such as polystyrene is preferred because of its relatively high strength and low manufacturing and material costs. As seen in FIGS. 1 through 5, spacer member 14 includes two cross-shaped spacing elements 16 lying in spaced apart parallel planes, which, incidentally, are substantially parallel the planes formed by faces 4 and 6 of block 2. Elements 16 are joined by a connecting means 18 of such length that, when the spacer member 14 is properly positioned, the outer surfaces of elements 16 are spaced inwardly of the planes formed by block faces 4 and 6.
Cross-shaped elements 16 are used to provide horizontal space between adjacent blocks 2 in a particular layer of blocks as well as vertical space between adjacent layers of blocks. Each cross-shaped element 16 includes a first set of oppositely directed arms 20 which preferably rest upon horizontal portions of raised side edges 10 and a second set of oppositely directed arms 22 intersecting and extending perpendicularly to arms 20. In order to insure secure anchoring of the spacer member in the mortar, as shown in the illustrated embodiment, arms 20 assume a channel-like configuration while arms 22 take the form of a corrugated or notched configuration. However, these arm anchoring configurations may be reversed, both configurations may be identical, or the arms may assume entirely different anchoring configurations or be provided with some other anchoring structure such as through-holes, for example, to enhance interlocking of the mortar with the spacer member. In block placement, the blocks are brought into abutment with the arms 20 and/or 22 such that the width of arms 20 and/or 22 defines the outwardly visible width of the joints between the blocks.
As seen in FIGS. 1-5 and 8, the distal ends of arms 22 include inwardly facing tab members 24 having oppositely directed flange portions 26 (FIGS. 1 and 8) which preferably extend to contact block side walls and which substantially matingly receive the interior shoulder regions 27 of the raised side wall edges 10. The tab members 24, along with other structure to be described hereinafter, establish the position of the spacer member 14 and prevent displacement thereof during placement of the construction blocks 2. It will be understood that, if desired, similar inwardly facing tab members may be provided on the distal ends of arms 20, although these tab members would have flange portions that would extend perpendicularly to the direction of the flange portions 26 of the illustrated tab members 24.
Carried by connecting means 18 at essentially the midpoint thereof are seam-receiving means 28 which are sized to receive and engage seam 12 of block 2. As seen in FIGS. 1-4, and particularly FIGS. 6 and 7, seam-receiving means 28 preferably consist of two oppositely projecting sets of bifurcated receiving elements each of which include a pair of tapered ribs 30 which have an opening width W (FIG. 6), an angle of taper .a (also FIG. 6) and a depth sufficient to provide a closely engaging fit with the corresponding dimensions of raised seam formation 12. For most conventional glass blocks, a suitable opening width W for ribs 30 would be from about one-tenth to one-fourth of an inch, a suitable angle of taper a would be from about 5° to about 20° and a suitable depth would be about one-eighth to about one-fourth inch. With reference to FIG. 3, it will be seen that the length L of the ribs 30 is preferably substantially greater than the height H of connecting means 18 such that the ribs 30 can positively engage a significant length of seam 12 of block 2 (FIG. 1) and the central seam of an adjacent block (not illustrated) in the same layer as block 2. To achieve this end, it is preferred that rib length L be at least about one-half inch although it can extend to one inch or greater. By virtue of such structure, the desired position of spacer member 14, as well as the blocks engaged thereby, can be positively established and maintained throughout subsequent block placement and joint filling operations. This feature, as noted hereinabove, is still further enhanced if the side walls of glass block 2 are provided with the raised edges 10 and the arms 20 and/or 22 of the spacer member include tab members 24 having flange portions 26 for receiving the raised edges 10. Moreover, although the receiving means 28 preferably assume the configuration of bifurcated receiving elements, as illustrated, it is contemplated that the receiving means may take other suitable shapes or forms to achieve the advantages described herein. For example, the receiving elements of the receiving means may simply comprise two oppositely directed lugs, or similar formations, each having a groove dimensioned to closely receive and positively engage raised seam formation 12.
Illustrated in FIG. 9 is another preferred embodiment of the spacer member 14 of the present invention. In this instance spacer member 14 has T-shaped rather than cross-shaped spacing elements. In accordance with this particular embodiment, wherein like references indicate similar elements to those thus far discussed, the only substantial difference between the space member shown in FIG. 9 and the spacer member depicted in FIGS. 1-5 is that one of the arms 20 is eliminated from each of the spacing elements 16 and the upwardly extending flanges 26 of tab members 24 have also been eliminated. This embodiment of the present invention is used, as the reader will appreciate, as a base, top or side edging spacer element of a wall structure formed of construction elements such as block 2.
FIG. 10 reveals another preferred embodiment of spacer member 14. According to this embodiment, rather than a cross or T-shape, the spacer member 14 has L-shaped spacing elements 16. Thus, for each spacing element, only one of the arms 20 and one of the arms 22 are present. This particular embodiment, as is apparent, is used as a corner spacer element for spacing blocks 2 from a sill, jamb, wall or similar framing structure.
Turning to FIG. 11, there is shown a further advantage of the spacer member 14. According to the present invention, the arms 22 are frangible and can be easily broken off where they intersect arms 20. Moreover, although not illustrated, the arms 20 which are not joined by connecting means 18 can also be mechanically removed where they intersect arms 22. Thus, a spacer member 14 originally formed as a cross-shaped spacer member can be readily modified to become either a T- or L-shaped spacer member. Likewise, a T-shaped spacer member may be just as easily transformed into an L-shaped member.
Because of the unique construction of the spacer members of the present invention, aside from having structure for preventing translation of the spacer members, the length of the connecting means 18 in all embodiments is such that the outermost surfaces of the spacing elements lie in planes spaced interiorly of the planes formed by the oppositely facing exposed block faces 4 and 6 (FIGS. 1 and 8). In other words, all the structure forming the spacer element 14 lies entirely between the spaced apart planes defined by block end faces 4 and 6. Consequently, unlike when prior art spacer elements are used in wall construction, a worker using mortar to fill the joints between block construction elements spaced by spacer elements 14 of the present invention can substantially fill the joints in a single application as well as substantially cover and embed the spacer elements 14 without requiring any further treatment of the spacer elements or any subsequent filling of gaps left in the joint.
Although the invention has been described in detail for the purpose of illustration, it is to be understood that such detail is solely for that purpose and that variations can be made therein by those skilled in the art without departing from the spirit and scope of the invention except as it may be limited by the claims.
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A spacer member for maintaining substantially uniform joint spacing between construction elements during construction of a static structure comprising a plurality of construction elements bound to one another by curable matrix material. The spacer member remains embedded in and covered by the matrix material and permits the matrix material to be placed in and completely fill all construction joints between the construction elements in a single application. The spacer member includes structure located interiorly of the planes of the exposed faces of the construction elements for positively establishing and maintaining a desired position of the spacer member during construction of the structure.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority, under 35 U.S.C. §119(e), to U.S. Patent Application No. 61/251,124, filed on Oct. 13, 2009, which is assigned to the present assignee and herein incorporated by reference in its entirety.
BACKGROUND
[0002] 1. Field of the Disclosure
[0003] Embodiments disclosed herein relate generally to wedge thread connections. More particularly, embodiments disclosed herein relate to wedge threads having a solid lubricant coating permanently bonded thereon and related methods of permanently bonding the solid lubricant coating on the wedge threads.
[0004] 2. Background Art
[0005] One type of threaded connection commonly used in oil country tubular goods is known as a wedge thread. Referring initially to FIGS. 1A and 1B , a prior art tubular connection 100 having a wedge thread is shown. As used herein, “wedge threads” are threads, regardless of a particular thread form, that increase in width (i.e., axial distance between load flanks 225 and 226 and stab flanks 232 and 231 ) in opposite directions on a pin member 101 and a box member 102 . The rate at which the threads change in width along the connection is defined by a variable known as the “wedge ratio.” As used herein, “wedge ratio,” although technically not a ratio, refers to the difference between the stab flank lead and the load flank lead, which causes the width of the threads to vary along the connection. Furthermore, as used herein, a thread “lead” refers to the differential distance between components of a thread on consecutive threads. As such, the “stab lead” is the distance between stab flanks of consecutive thread pitches along the axial length of the connection.
[0006] A detailed discussion of wedge ratios is provided in U.S. Pat. No. 6,206,436, issued to Mallis, assigned to the assignee of the present disclosure, and incorporated by reference in its entirety herein. Furthermore, wedge threads are extensively disclosed in U.S. Pat. No. RE 30,647 issued to Blose, U.S. Pat. No. RE 34,467 issued to Reeves, U.S. Pat. No. 4,703,954 issued to Ortloff, and U.S. Pat. No. 5,454,605 issued to Mott, all assigned to the assignee of the present disclosure and incorporated herein by reference in their entirety.
[0007] Referring still to FIGS. 1A and 1B , in wedge threads, a thread seal may be accomplished through contact pressure caused by interference that occurs at make-up over at least a portion of connection 100 between pin load flank 226 and box load flank 225 and between pin stab flank 232 and box stab flank 231 . Close proximity or interference between roots 292 and 221 and crests 222 and 291 complete the thread seal when occurring proximate to such flank interference. Generally, higher pressures may be contained either by increasing interference between the roots and crests (“root/crest interference”) on pin member 101 and box member 102 or by increasing the aforementioned flank interference.
[0008] Prior to make-up, a flowing joint compound commonly referred to as “pipe dope” is typically applied to surfaces of a threaded connection to improve the thread seals and provide lubrication during make-up of the connection. For example, the pipe dope may assist a wedge-threaded connection in achieving a thread seal between load and stab flanks thereof, e.g., as disclosed in U.S. Pat. No. RE 34,467 issued to Reeves. Further, pipe dope may protect the threads of the pin and box members from friction galling during make-up and break-out.
[0009] A flowing joint compound such as pipe dope may be used in wedge thread connections because of the close-fitting manner in which wedge threads make-up. As previously mentioned, wedge threads rely on a full surface contact theory, which means that each contact surface, i.e., corresponding roots/crests and stab and load flank surfaces are either in close proximity or full interference. Thus, due to the tight-fitting characteristics of wedge threads from multiple thread surface interferences, a pipe dope is used so that as the connection is made up and corresponding thread surfaces come together, the pipe dope may be squeezed out so as not to impede the proper engagement of the thread surfaces.
[0010] The use of pipe dope in wedge thread connections is not without certain deficiencies. When a wedge thread connection is made-up, excess pipe dope may become trapped (rather than being squeezed out) between the pin threads and the box threads, which may either cause false elevated torque readings (leading to insufficient make-up or “stand-off”) or, in certain circumstances, damage the connection. Attempts to mitigate pipe stand-off have come in the form of providing features in the thread form to reduce a build-up in pressure of pipe dope used in the make-up of the threaded connections, e.g., U.S. Publication No. 2008/0054633, assigned to the assignee of the present application and incorporated herein by reference in its entirety. In addition, problems associated with excess pipe dope on wedge-threaded connections may be avoided by restricting the amount of pipe dope applied and by controlling the speed at which the wedge-threaded connection is made-up. Limiting the make-up speed of a wedge-threaded connection allows the pipe dope to travel and squeeze out before it becomes trapped within the connection at high pressures. However, limiting the make-up speed of the connection slows down the overall process of assembling the drillstring.
[0011] Pipe stand-off due to inadequate evacuation of pipe dope is detrimental to the structural integrity of wedge thread connections. As the pressure build-up may bleed off during use, the connection is at risk of accidentally backing-off during use. Therefore, stand-off in wedge thread connections is of particular concern as it may lead to loss of seal integrity or even mechanical separation of two connected members. Furthermore, pipe stand-off may be particularly problematic in strings used at elevated downhole service temperatures (i.e., the temperature a tubular would be expected to experience in service). Particularly, in high temperature service (e.g., temperatures greater than 250° F., a steam-flood string, or a geothermal string), even a small amount of stand-off may be deleterious. For example, if a made up wedge thread connection having even an infinitesimal amount of stand-off is deployed to a high temperature well, the pipe dope may flow out of the wedge thread connection, thus reducing the integrity of the thread seal. Further, use of a flowing pipe dope in wedge threads may lead to thread seal leaks, particularly at elevated pressures, as the viscosity of the pipe dope increases.
[0012] Larger OD wedge threads, which utilize pipe dope, may typically require a second application of torque to insure a complete make-up of the threaded connection. Because of the length and configuration of the wedge thread, the larger diameter connections may be susceptible to hydraulic lock and require extra torque to push the thread dope (i.e., force the thread dope to flow) along the length of the connection. Such a procedure is commonly known as “double bumping” a connection because torque is applied a number of times to “squeeze” the pipe dope along the threads. Notably, double bumping increases connection make-up time.
[0013] Accordingly, there exists a need for a thread lubricant capable of being used in tight-fitting wedge thread connections that substantially reduces pipe stand-off concerns and is effective at elevated downhole temperatures.
SUMMARY OF THE DISCLOSURE
[0014] In one aspect, embodiments disclosed herein relate to a tubular connection including a pin member having external wedge threads configured to engage a box member having corresponding internal wedge threads and a solid lubricant coating permanently bonded on at least one of the internal and external wedge threads.
[0015] In other aspects, embodiments disclosed herein relate to a method of manufacturing a connection having wedge threads, the method including machining internal wedge threads on a box member and external wedge threads on a pin member, wherein the internal and external wedge threads are configured to correspond and permanently bonding a solid lubricant coating on at least one of the internal and external wedge threads.
[0016] Other aspects and advantages of the invention will be apparent from the following description and the appended claims.
BRIEF DESCRIPTION OF DRAWINGS
[0017] FIGS. 1A and 1B show cross-sectional views of a prior art tubular connection having wedge threads.
[0018] FIG. 2 shows a cross-sectional view of a solid lubricant coating on a wedge thread in accordance with embodiments of the present disclosure.
[0019] FIG. 3 shows an enlarged detail view of a solid lubricant coating near the thread surface in accordance with embodiments of the present disclosure.
[0020] FIG. 4 shows an enlarged detail view of an alternative solid lubricant coating near the thread surface in accordance with embodiments of the present disclosure.
DETAILED DESCRIPTION
[0021] In one aspect, embodiments disclosed herein relate to a wedge thread connection with a solid lubricant coating permanently bonded thereon and related methods of permanently bonding the solid lubricant coating to the wedge threads. The threaded connection may include a corresponding pin member and box member having wedge threads formed thereon. The solid lubricant coating may be permanently bonded on the pin member, the box member, or both the pin and box members prior to make-up of the connection. One or more layers of the solid lubricant coating may be used depending on the type of end configurations of the connection (i.e., full length pin, full length box, or coupling).
[0022] Referring now to FIG. 2 , a cross-sectional view of a wedge thread 300 having a solid lubricant coating 310 permanently bonded thereon is shown in accordance with embodiments of the present disclosure. The wedge thread 300 is formed on a tubular member 301 , which may be either a pin member or box member. As shown, solid lubricant coating 310 may be permanently bonded to an entire surface of the wedge thread 300 , including thread roots 302 , thread crests 304 , stab flanks 306 , and load flanks 308 .
[0023] As used herein, permanently bonded refers to adhesion of the solid lubricant coating to the wedge thread surfaces after the coating is properly cured, such that the solid lubricant coating 310 does not “flow” during makeup of the connection, but rather, remains as a rigid structure. As such, during make-up of the wedge thread connection the solid lubricant coating 310 behaves as a solid structure and does not flow as a typical pipe dope lubricant would due to forces created by contacting thread roots 302 and thread crests 304 , and stab flanks 306 and load flanks 308 . While the solid lubricant does not flow, the solid lubricant coating may be a pliable compound and somewhat resilient, so that upon make-up of the wedge thread connection the solid lubricant coating 310 may deform slightly to fill voids in the thread flanks (caused by imperfections in the flanks) over multiple make-ups and break-outs of the connection. Unlike a flowing thread compound, which may rely on surface tension to fill the voids in the thread flanks for sealability, the solid lubricant coating 310 of one or more embodiments disclosed herein permanently adheres to and/or bonds to the wedge thread surfaces.
[0024] A magnification of a composition of solid lubricant coating 310 is shown in FIG. 3 in accordance with embodiments of the present disclosure. As shown, an uncoated surface of wedge thread 300 ( FIG. 2 ) may have an average surface roughness Ra of between about 2 and 6 μm. In certain embodiments, the uncoated thread surface may have an average surface roughness of between 1 and 10 μm. Surface treatment or preparation of the base metal of the wedge thread surfaces may be required to prepare the thread surface and serves as an anchor so the solid lubricant coating properly adheres to and is permanently bonded to the wedge threads. Surface treatment of the wedge thread surfaces may include abrasive blasting and/or phosphate coating.
[0025] After surface preparation of the wedge thread surfaces (if needed), a first solid coating (a uniform or substantially constant thickness layer) may be applied and permanently bonded on the wedge thread surface. The first solid coating may be comprised of an epoxy resin containing particles of zinc (Zn). In certain embodiments, the first solid coating may be a corrosion inhibiting coating, or have corrosion inhibiting properties. The content of the particles of zinc in the epoxy resin may be equal to or greater than about 80% by mass. In certain embodiments, the zinc particles may have at least 99% purity. In other embodiments, the zinc particles may have at least 97.5% purity. The first coating 312 may have a thickness value of between about 15 and 35 μm. In certain embodiments, the first coating 312 may have a thickness value of between 20 and 30 μm.
[0026] A second solid coating 314 (e.g., a solid dry lubricant coating) may be subsequently applied and permanently bonded on the first coating 312 and/or the wedge thread surfaces. In one embodiment, the second coating 314 may be comprised of a mixture of molybdenum disulfide (MoS 2 ) and other solid lubricants in an inorganic binder. Other solid lubricants may include, but are not limited to, graphite, tungsten disulfide, boron nitride, and polytetrafluoroethylene (“PTFE”). In one or more embodiments disclosed herein, the type of binder in which the solid lubricants are dispersed may include organic, inorganic, metallic, and ceramic. One of ordinary skill in the art will understand selection of the type of binder in which the solid lubricant may be dispersed based on mechanical properties of materials of the threaded connection.
[0027] The second coating 314 may have a thickness of between about 5 and 25 μm. In certain embodiments, the first coating 312 may have a thickness value of between 10 and 20 μm. First coating 312 may be applied to the wedge threads by spraying, brushing, dipping or any other method known in the art in which the coating thickness can be controlled. Similarly, the second coating 314 may be applied to the wedge threads by spraying, brushing, dipping or any other method known in the art in which the coating thickness can be controlled once the first coating 312 is fully cured and/or dried.
[0028] Referring now to FIG. 4 , an enlarged view of solid lubricant coating 310 ( FIG. 2 ) is shown in accordance with alternate embodiments of the present disclosure. In certain embodiments of the present disclosure, the first coating 312 and the second coating 314 of the embodiment shown in FIG. 3 may be combined into one solid coating 316 . In one embodiment, the combined solid coating 316 may be a uniform layer of a dry corrosion inhibiting coating, which has a dispersion of particles of solid lubricant mixed therein, as shown in FIG. 4 . Solid lubricants may include, but are not limited to, molybdenum disulfide (MoS 2 ) graphite, tungsten disulfide, boron nitride, and polytetrafluoroethylene (“PTFE”). Those skilled in the art will be familiar with combining the dry corrosion inhibiting coating with particles of solid lubricant prior to applying and bonding the coating to the wedge threads.
[0029] The thickness of the combined dry corrosion inhibiting coating 316 may be between about 15 and 35 μm. In certain embodiments, dry corrosion inhibiting coating 312 may have a thickness value of between 20 and 30 μm. The layer of dry corrosion inhibiting coating 316 containing the dispersion of particles of solid lubricant may be applied by spraying, brushing, dipping or any other method known in the art in which the coating thickness can be controlled. Additional discussion of solid lubricant coatings may be found in International Application PCT/EP2003/011238 and U.S. Publication No. 2008/129044, both of which are assigned to Tenaris Connections and incorporated herein by reference in their entirety.
[0030] The solid lubricant coating may be effective at elevated temperatures as well as ambient temperatures. Solid lubricant coatings may be able to withstand much higher temperatures (e.g., 200° C.-350° C.) and not break down. Thus sealing capabilities are maintained at elevated temperatures, unlike grease-based thread compounds, which may lose viscosity at elevated temperatures and substantially reduces the thread compound's resistance to flow. Solid lubricants of embodiments disclosed herein are formulated to perform over a range of elevated temperatures as well as at an ambient temperature.
[0031] The solid lubricant coating of embodiments disclosed herein may provide a number of advantages. In particular, the connection may experience improved sealing characteristics over the currently used grease-based (i.e., flowing) thread lubricants as follows. First, the solid lubricant coating will not continue to flow through the threads over time or with loading of the connection, which for greases reduces the sealing capability and resistance to breakout torque. Second, the solid lubricant coating will not disintegrate or lose viscosity at elevated temperature, which for greases reduces or even eliminates the sealing capability. Finally, the solid lubricant coating, when applied on one or both members may have the ability to laminate (e.g., fill in) imperfections or small amounts of damage caused during multiple make-ups and break-outs of the connection.
[0032] Additionally, embodiments of the present disclosure may provide a solid lubricant for wedge threads that eliminates the possibility of pipe stand-off due to dope entrapment and subsequent bleed-off because of the solid lubricant's resistance to flow. Furthermore, Applicant has advantageously found that the solid lubricant coating disclosed in embodiments herein may be used with wedge threads without affecting the tight tolerances between engaging thread surfaces, which are typically associated with the structure and makeup of wedge threads. Finally, the solid lubricant coating of one or more embodiments disclosed herein may be precisely applied through controlled application of the solid lubricant coating onto the wedge thread surfaces, as opposed to brushing on by hand flowing pipe dope compounds, so as to apply a more even coating on the thread surfaces.
[0033] Further, the connections disclosed herein may be able to withstand increased torque during make-up. Occasionally, connections may be made up to higher torques than are recommended. As such, the wedge thread connection having the solid lubricant was subjected to an excessive amount of torque. For example, a 13.625 inch wedge thread connection was made-up with a 25% increase in torque while a 4.50 inch wedge thread connection was made-up with a 50% increase in torque. Further, the connections were subjected to multiple make-ups and break-outs (e.g., 12 consecutive make and break operations). Results showed that neither connection experienced any galling or deformation in the threaded sections. Thus, the solid lubricant coated threaded connection may be able to withstand higher make-up torques without damage to the connection.
[0034] Further still, the solid lubricant coating on the threads may advantageously reduce the total running time of the drillstring. First, embodiments disclosed herein allow for slightly more misalignment between pin and box members during make-up than previously. For example, a pin and box member of a 4.5 inch wedge thread connection having a solid lubricant thereon was misaligned at make-up up to about 15 degrees. After ten complete make-ups and break-outs of the connection, only minimal to no thread damage was observed on initial threads of the pin and box members.
[0035] Next, because a solid lubricant coating is used in place of the flowing pipe dope, the commonly used double bumping procedure during make-up is no longer required to squeeze flowing pipe dope out of the threads. As previously described, larger outer diameter wedge threads that utilize standard thread dope typically require a second application of torque to insure a complete make-up. Because of the length and configuration of the wedge thread, the larger diameter connections may be susceptible to hydraulic lock and require extra torque to push the thread dope along the length of the connection. With the removal of dope from the connection and its replacement by the solid lubricant coating in accordance with embodiments disclosed herein, hydraulic lock may no longer be an issue.
[0036] In addition, because the solid lubricant is permanently bonded on the threads, a dope compound does not have to be applied prior to make-up, thus reducing the total amount of running time and increasing the productivity of the rig. With a solid lubricant permanently bonded on the wedge threads, application of dope is no longer required, thereby eliminating an assembly step during the make-up procedure. In sum, the overall productivity of the rig may be increased. For example, during rig trials, total make-up time was studied using a 4.5 inch wedge thread connection having a solid lubricant thereon in accordance with embodiments disclosed herein. The average revolutions per minute (“RPM”) during make-up was approximately 19 RPM's while the average RPM during break-out was approximately 21 RPM's. The average cycle time (i.e., the total time to make-up and then break-out the connection) was approximately two minutes, while a standard doped connection would have an average cycle time of 4 to 5 minutes.
[0037] While the present disclosure 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 may be devised which do not depart from the scope of the disclosure as described herein. Accordingly, the scope of the disclosure should be limited only by the attached claims.
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A tubular connection includes a pin member having external wedge threads configured to engage a box member having corresponding internal wedge threads, and a solid lubricant coating applied on at least one of the internal and external wedge threads wherein the solid lubricant coating comprises a first uniform layer of a dry corrosion inhibiting coating made of an epoxy resin containing particles of zinc and a second uniform layer of a dry lubricant coating covering the first uniform layer.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
This application is a Continuation-In-Part of patent application Ser. No. 08/504,858 filed Jul. 20, 1995 entitled Paving Machine with Extended Telescoping Members.
This invention relates to concrete pavers of the slipform variety. More particularly, a concrete paver is disclosed in which telescoping frame members extending across the paver are provided with extension members. These extension members enable the paver to expand to paving widths beyond that presently achieved by conventional telescoping members. Further, the present disclosure does away with the necessity of the installation of a fixed frame extension members. As a result, this invention also substantially reduces machine preparation time for paving at differing machine widths.
BACKGROUND OF THE INVENTION
Concrete slipform pavers are known. Specifically, such pavers include a "tractor" and a "paving kit".
Regarding the tractor, most concrete slipform pavers include a tractor which is comprised of a rectilinear frame which straddles the concrete roadway or runway while it is paved. This frame is propelled and supported on either end by side bolsters and crawler track(s). The frame supports a diesel engine driven hydraulic power unit which supplies power to the tractor and paving kit.
The paving kit is typically suspended below the tractor frame by mechanical means. The paving kit takes its hydraulic power from the power unit on the tractor. The tractor and paving kit comprising the slipform pass over the concrete placed in its path in a relatively even and level mass that can be conveniently paved. During this slipform process the tractor attached paving kit spreads the concrete dumped in the path of the paver, levels and vibrates it into a semi-liquid state, then confines and finishes the concrete into a slab with an upwardly exposed and finished surface. Sideforms mounted to the side of the slipform kit confine the sides of the slab during the paving process.
The tractor typically has either two or four crawler tracks supporting and propelling the frame and attached paving kit. Other kits can be attached to these tractors such as kits for conveying and spreading concrete and trimming and spreading base materials. For the purposes of this description, we will focus on the paving kit used for slipform paving.
With respect to both two and four track pavers, the tractor frame is known to telescope itself normal to the direction of the paving movement. This telescoping normal to the direction of the paving movement enables the tractor frame to span different widths of pavements within the limits of the telescopic extensions. Once these telescopic extensions limits are reached, a fixed frame extension can be added to one or both sides of the telescopic frame for further extension. Despite the telescopic ability of the frame, the process is still a relatively complex and time consuming operation. Adding a fixed frame extension(s) significantly increases the complexity and difficulty of the frame width change.
Regarding the addition of the fixed frame extension, this addition requires that the side bolster and crawler(s) on at least one side of the machine be removed, the fixed frame extension inserted, and the side bolster and crawlers re-attached. Hydraulic and electrical lines must also be disconnected then reconnected. This is not a trivial operation. The frame section and side bolster/-crawlers are heavy members. They must be separately manipulated into place --usually by cranes and their attendant crews. Cranes have scheduling problems, are big, heavy, dangerous, and slow.
SUMMARY OF THE INVENTION
A conventional telescoping frame on a paving tractor is provided with fixed frame extension members for insertion to and attachment with a telescoping frame member. The conventional telescoping frame includes paired forward and paired rear side-by-side female tube members. Each forward and rear tube member conventionally acts for the telescoping support of male extension members which attach directly to the side bolster, which in turn attaches to the hydraulic jacking columns and crawlers. Within the limits of expansion, the male extension members co-acting with clamps acting through the female tube members provide for both movement of the point of crawler support and expansion of the paving width of the tractor frame. Into this combination, extenders are added for attachment to the supported end of the male extension members interior of the female telescoping members. During frame width expansion, the male telescoping members are expanded to register their ends interior of the female telescoping members to attachment access ports in the female telescoping member. The extenders are inserted, supported, and registered at complimentary attachment apertures with attachment to the male telescoping members taking place. Once attachment has occurred, further extension of the male telescoping members occurs. A simple system of pinned cross-bracing reinforces the extended frame with relatively light bracing members. When the telescoping members at both sides of the frame are provided with the extenders to extend the telescoping span of the paver, a tractor of greater expansion and range of expansion capability is provided which obviates the need for fixed frame extensions, and permit frame expansion without heavy lifting equipment.
A system of mating the extenders to male telescoping members is disclosed. The male telescoping member includes single male flange having paired upper and lower pin apertures. Similarly, extenders include paired female flange members with mating upper pin aperture and lower pin apertures. Centrally, and between the paired female flange members, there is a locator pin within the extender. Similarly, and in the single male flange between the pair upper and low pin apertures, there is a locator aperture with gathering surfaces.
In operation, the male telescoping member is extended by crawler movement until registration of the paired upper and lower pin apertures occurs at elongate upper and lower apertures in the box beams. Thereafter, extender insertion occurs with the single male flange penetrating to the locator pin first at the gathering surfaces and then at the locator aperture. With full insertion of the extender, the end of the extender is raised or lowered to center either and upper or lower pin. Once the upper or lower pin is centered, pin insertion occurs. Assuming registration of at least one pin and the locator pin at the locator aperture, insertion of the remaining pin readily follows. Rapid extender connection results.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A is a perspective view of a concrete paver of this invention in conventional operation;
FIG. 1B is a perspective view of a concrete paver illustrating the crawler tracks turned 90° from the paving disposition illustrated in FIG. 1A and with the telescoping members in an orientation where the extending members may be inserted into the paver female telescoping tractor frame to increase the paving width;
FIG. 1C is a detail of the insertion of the extending members--it being understood that light lifting equipment (not shown) causes the required insert of the extender;
FIG. 2 is a perspective view that illustrates one side of the paver extended to the increased width for paving a wider slab, the other side of the paver not being shown and shows the light bracing members in position;
FIG. 3 is a plan schematic of the frame illustrating the principle of extension insertion for expanding the frame, the paver side bolsters not being shown;
FIG. 4A is a side elevation of the female telescoping member and a plan and elevation of the extender member illustrating apertures for the installation of pins to enable connection interior of the female telescoping tube of the extenders to the male member;
FIG. 4B is an elevation of the forward box beam of the paver frame illustrating apertures for insertion of pins to effect fastening of the extenders with the hidden lines showing apertures located on the inner female telescoping tube;
FIG. 5 is a plan schematic of the frame illustrating offset of the paver frame in expansion for positioning a reinforcing bar inserter at a position where interference with the frame member does not occur;
FIG. 6 is a detail illustrating the connecting end of the extender to the male telescoping member;
FIG. 7 is a detail of the male telescoping member connected to an extender, and applicable pins inserted through the female telescoping member, it being noted that line up pin holes may be required in the male telescopic member and extender connection for ease of pin hole line up;
FIG. 8 is a partial plan view of the frame illustrating the case where the extenders are attached and the frame is contacted to minimum dimension;
FIG. 9A and 9B are respective plan view and side elevations of the male telescoping member and extender separated from one another so that the gathering feature of this invention can be understood;
FIG. 10 is a side elevation of the single male member attached to the male telescoping member; and,
FIGS. 11A and 11B are respective side elevation section at the box beam illustrating the juxtaposition of the male telescoping member and extender interior of the box beam and a detail of the recess and securing leaf for the inserted fastener pins.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1A illustrates paver P proceeding in paving direction 15 for paving roadway or runway R. Paver P includes tractor frame F and paving kit K. Since the invention herein relates to the configuration of tractor frame F, paving kit K will be briefly discussed. In the description here, it will be assumed that conventional paving kit may be removed or attached from tractor frame F for the purposes of transport or to add other attachments without further discussion.
Paving kit K is conventional and includes spreader plow 18. Spreader plow 18 functions to spread concrete placed in paving direction 15 on what is to become roadway or runway R. There follows metering gate, vibrators, slipform pan 22 and trailing pan 24. It will be understood that paving kit K can be augmented with all sorts of accessories. Reinforcing bar inserters, tamper bars, side bar inserters and the like are typically added or taken off the machine as the job requires.
It will be understood that the width of the paving kit K is varied with extensions like the tractor frame F as the particular width of the job specifies. Such paving kit extensions come in all matter of widths. It is common to have one foot, two foot, three foot, five foot, and six foot extensions. In the conventional placement of these sections, the telescopic tractor frame is first expanded, and the requisite number and length of paving kit extensions installed. Since this process is conventional, it will not be further discussed herein.
The operation of a paver can be simply stated for purposes of this description. Typically, a system of grade level reference wires W are strung adjacent and parallel to the roadway or runway grade being constructed. Sensors 26 with wire feelers, one located at each corner of the machine attached to the frame, follow grade level reference wires W. Leveling sensors (not shown) on the frame independently adjusts the height of the frame relative to each of crawlers T 1 -T 4 through hydraulic cylinder C 1 -C 4 at each corner of the frame. The paving kit suspended from the frame thus is continually adjusted to maintain a preset elevation disposition relative to the wires as paving occurs.
Frame F can be best understood with a first reference to FIG. 1A. Frame F includes side relatively telescoping members S. These respective side relatively telescoping members S are fully set forth and described in Guntert et al U.S. patent application Ser. No. 08/450,242, filed May. 25, 1995 entitled FOUR TRACK PAVING MACHINE WITH TELESCOPING TRANSPORT COMPRESSION IN DIRECTION 0F PAVING MACHINE TRAVEL. An abbreviated description of the function of these side relatively telescoping members S will suffice.
Four track paver P is disclosed having a frame with side relatively telescoping members S or side bolsters which contract for transport to reduce the dimension of the machine in the direction of paving machine travel 15. The rectilinear frame includes four crawlers T 1 -T 4 , one at each corner of the frame. Each crawlers T 1 -T 4 is directly supported on its own hydraulic cylinder C 1 -C 4 and mounted for pivotal movement about the axis of the hydraulic cylinder. The frame telescopes at side relatively telescoping side bolster members S between the leading and trailing crawlers at the sides of the machine. When expanded, the paving machine has the full forward and rear dimension required for paving. When contracted, the paving machine has a profile allowing convenient transport with the crawlers rotated 90° or normal to the direction of travel to power the frame widening. Full details of this function of the machine can be realized by consulting the above reference patent application which is incorporated by reference into this patent application. Conventional four track paver side bolsters with pivoting arms can also be used with the present application. It is envisioned that the present application can also be used with two track paver provided external hydraulic cylinders are utilized to provide the power to telescope in the absence of four crawler tracks and the ability of turning the four crawlers 90° or normal to the direction of paving to power the frame widening.
The present application relates to the side to side paving expansion of paver P. This being the case, attention will now be directed to FIG. 3. This figure is advantageous because it focuses on the paving width extension of the paver telescopic tractor frame and does not show the appurtenant apparatus.
Rectilinear tractor frame F includes forward box Beam B F and rear box beam B R . Each forward box beam B F and each rear box beam B R defines leading interior female compartment 28 and trailing interior female compartment 30. Thus, side relatively telescoping members S and forward box beam B F and rear box beam B R define a rectilinear tractor frame F.
It is conventional with some pavers P to include telescoping expansion across the paving width. Accordingly, forward box beam B F and rear box beam B R each define forward female telescoping member F F at leading interior female compartment 28 and rear female telescoping member F R at trailing interior female compartment 30.
It is required that male telescoping members be received into the respective female telescoping members. This being the case, right forward male telescoping member 32 is received in forward female telescoping member F F of forward box beam B F . Similarly, left forward male telescoping member 34 is received in rear female telescoping member F R of forward box beam B F .
The trailing section of the frame is identically constructed. Right trailing male telescoping member 36 is supported in forward female telescoping member F F of rear box beam B R . Similarly, left trailing male telescoping member 38 is supported in rear female telescoping member F R of rear box beam B R .
Dimensions are important. Therefore, reference will be made to the dimensions important here utilized in the United States. It is envisioned that this invention will be adaptable to dimensions important to other parts of the world that incorporate Metric Dimensions.
Forward box beam B F and rear box beam B R are typically a nominal 12 feet in length. Respective right forward male telescoping member 32, left forward male telescoping member 34, right trailing male telescoping member 36, and left trailing male telescoping member 38 are also 12 feet in length. This enables the leading and trailing male telescoping members to be entirely received within forward box beam B F and rear box beam B R . It can therefore be quickly understood by the reader that the present machine has a capability of paving over a 12 foot span to match the minimum paving width generally paved in the United States. Even though the tractor frame might be limited to a minimum width of 12', when the telescopic frame is fully contracted, the paving kit may be arranged in a paving width less than 12'.
Expansion of paver P at any width between 12 and 25 feet can be readily understood. It is known that during telescoping movement or expansion of paver P, connection and disconnection of hydraulic jacking columns (hereinafter called cylinders) C 1 -C 4 is not desired. Accordingly, the respective cylinders C 1 -C 4 are all attached at the distal ends of respective right forward male telescoping member 32, left forward male telescoping member 34, right trailing male telescoping member 36, and left trailing male telescoping member 38. Crawlers T 1 -T 4 conventionally attach to hydraulic cylinders C 1 -C 4 . For the purposes of this illustration, FIG. 3 does not show the side bolsters and only shows the cylinders C 1 -C 4 and crawler tracks T 1 -T 4 attached to their respective corner. Presuming that crawlers T 1 -T 4 are rotated 90° by respective turning cylinders 40, it can be seen that powering of crawlers T 1 -T 4 can move to extend the respective male telescoping members 32, 34, 36, and 38. In a normal extension process, the respective male telescoping members 32, 34, 36, and 38 would all be extended in the range of six to six and one half feet. This would extend the paver tractor frame from 12 foot to a maximum range of a 25 foot span. In the prior art, this is the maximum paving width extension that such a paver would allow.
The reason for this maximum extension can be easily understood. It will be understood that male telescoping members 32, 34, 36, and 38 are in cantilever support when extended from the respective forward box beam B F and rear box beam B R . Further, the paver is heavy, weighing in the order of 75,000 pounds or more. It is therefore to be understood that extension of male telescoping members 32, 34, 36, and 38 substantially beyond a six foot extension is not prudent. Thus a certain minimum length of male telescoping member must remain engaged in the female box beam frame section to maintain the structural integrity of the tractor frame. Moreover, in the prior art and in most cases, power for the extension of the telescopic tractor frame was provided by hydraulic cylinders or screw jacks located either inside or outside the telescopic members and which were connected between the male and female telescopic tube. These hydraulic cylinders or screw jacks had the ability to extend the male telescoping members away from the female telescopic tube to its entire extended length or a portion of it, where in such cases, an extension to the extending cylinder or screw jack was required.
In the prior art, the only way the paver telescopic tractor frame could be extended beyond the maximum telescopic ability of 25' was to unbolt and hydraulically disconnect the cylinders C 1 -C 4 and crawler tracks T 1 -T 4 from each corner of the machine and add a fixed frame extension to the ends of the male telescopic members 32, 34, 36, and 38 and the cylinders C 1 -C 4 .
Having set forth this limitation, extenders E 1 -E 4 can now be discussed. This may be most conveniently done by considering the disposition of tractor frame F as illustrated in FIG. 3 and thereafter discussing the extension of the frame as illustrated in FIG. 5.
Before insertion of extenders E 1 -E 4 , it is required that tractor frame F be expanded to the approximately 25 foot span illustrated in FIG. 3. This defines clearance required for receipt of extenders E 1 -E 4 in two discrete aspects.
First, the respective forward female telescoping member F F and rear female telescoping member F R of forward box beam B F and rear box beam B R are open on the ends for receipt of extenders E 1 -E 4 . Second, hydraulic cylinders C 1 -C 4 and crawlers T 1 -T 4 , are sufficiently moved away from forward box beam B F and rear box beam B R so as to define clearance for insertion of extenders E 1 -E 4 .
It should be noted that insertion of extenders E 1 -E 4 is a relatively simple matter that can be handled by the on-site operating crew of the paver. Specifically, by utilizing a fork lift, boom truck or similar lifting apparatus, each of extenders E 1 -E 4 can be individually inserted. At the same time, detachment of heavy hydraulic cylinders C 1 -C 4 and crawlers T 1 -T 4 is not required.
Referring to FIG. 4A, right forward male telescoping member 32 is illustrated without attachment of either hydraulic cylinder or crawler. It defines single male connector plate 42 at its end opposite from where the hydraulic cylinder and crawler is attached. Single male connector plate 42 is bored by upper pin aperture 44 and lower pin aperture 46.
The construction of extender E 1 is analogous. It includes paired female connector plate members 52 which are in turn bored by upper pin aperture 54 and lower pin aperture 56.
Fastening of the member together is conventional. Referring to the details of FIGS. 6 and 7, such attached can be readily understood. Specifically, by placing pins N across the respective apertures 44, 54 and 46, 56, extenders E 1 -E 4 can be rigidly attached to their respective male telescoping members 32, 34, 36, and 38.
There remains to be understood how such pinning can occur within forward box beam B F and rear box beam B R . The detail of forward box beam B F in FIG. 4B provides elongate upper aperture 64 and elongate lower aperture 66 in forward box beam B F . By registering the respective ends of extenders E 1 -E 4 to the respective male telescoping members 32, 34, 36, and 38, ready access for the required insertion of pins N can occur.
It is necessary that the respective forward box beam B F and rear box beam B R have clamps for firm attachment to the respective male telescoping members 32, 34, 36, and 38. To this end, clamps L 1 -L 4 are illustrated only at forward box beam B F in FIG. 4B. To avoid confusing detail, these respective clamps are not set forth elsewhere in the drawings.
Further, a word about the practical aspects of inserting pins N. In a heavily loaded paver P, it will be understood that some gross manipulation of the paver will be required for precise pin placement. This being the case, clamps L 1 -L 4 can be manipulated, paver P and kit K can be raised and lowered and a portion of the tractor weight taken by four stanchions located at the four corners of the female telescopic tractor member, and both the male telescoping member and the particular crawler moved to effect pin placement.
It will further be understood, that expansion and contraction of paver P can occur through crawlers T 1 -T 4 . The paver P is designed so the crawler tracks on each side of the machine can be controlled together as a pair. This provides the power for driving the telescoping movement. In the case where this tractor frame is used in conjunction with two track machines, where four crawlers are not available for driving the telescoping movement, conventional external hydraulic cylinders as used in the prior art, connected between the male and female telescopic members, can be used to power the telescopic movement.
There remains to be considered the expanded disposition of tractor frame F as illustrated in FIG. 5. As shown in FIG. 5, paver P is expanded to a maximum design paving width of 34 feet. Normally, such expansion will be symmetrical; each of the male telescoping members 32, 34, 36, and 38 will extend the same distance. Since this is easily comprehended, we illustrate the case where eccentric expansion has occurred. A word of explanation of the need for eccentric expansion can be helpful.
As has been previously emphasized, paver P frequently includes installed accessories such as bar inserters, side bar inserters, and other accessories as the vagaries of any job may require. At the same time, the transverse spacing of such accessories may interfere with placement of the major structural members of tractor frame F such as side relatively telescoping members S. This being the case, eccentric expansion such as that illustrated in FIG. 5 can act to register attached accessories to their required location.
Referring to FIG. 5, it can be seen that extenders E 2 and E 4 protrude partially from forward box beam B F and rear box beam B R , respectively. On the other side, extenders E 1 and E 3 do not protrude at all from rear box beam B F and rear box beam B R , respectively. This gives the disclosed apparatus a flexibility of dimension that is highly practicable.
It is apparent, that when male telescoping members 32, 34, 36, and 38 are fully extended, cross bracing of paver P will be desired--if not required. Referring to FIG. 2, such cross bracing is illustrated. Specifically, with extenders E 1 -E 4 installed and male telescoping members 32, 34, 36, and 38 extended, two types of cross bracing can be utilized. Diagonal cross brace 68 and normal cross brace 70 can be used with conventional fastening as by bolts or pins occurring at the distal ends of the braces 68, 70 to male telescoping members 32, 34, 36, and 38. It is envisioned that one or both of the distal ends of the cross bracing may include a screw adjustable attachment bracket so that the length of the brace does not have to be exact.
There also needs to be considered the minimum contracted disposition of the tractor frame F as illustrated in FIG. 8 with the extenders attached. As shown in FIG. 8, paver P (not completely shown) is contracted to its minimum design paving width of 17'6" with the extenders E 1 -E 4 still attached. Because the female telescoping members B R , B F , F F , F R are all open on the end to receive extenders, the male telescoping members 32, 34, 36 and 38 can be contracted until they interfere with the side bolsters. In prior art, as stated above, the maximum range of telescopic ability of the tractor frame was six to six and one-half feet per side, or a telescopic range of 12'to 25'. Because of the opening on the ends of the female telescoping members, the male telescopic members may be contracted beyond the ends of the female tubes by approximately three feet on a side. Thus the resulting range of telescopic ability is 17'6" to 34', or eight and one quarter feet side.
The reader will understand that detail of attachment of paving kit K has been in the large part omitted. This omission is intentional as this attachment is standard and well understood by the prior art. It is further understood that this paving kit can be substituted with a concrete spreading/placing kit or a base spreading/finegrading kit.
It will be further understood that this invention is equally applicable to both two track and four track pavers. This being the case, it is understood that the tractor of this invention includes at least two crawler tracks with one crawler on either side of the paver. A tractor having four crawler tracks is included in this definition.
In the above specification, we have illustrated the preferred embodiment to include male and female telescoping members. The reader is to understand that these respective terms are used in the broadest possible sense. What is required is that the two members move relative to one another with cantilever support being taken by one member from an adjacent member. Thus, all types relatively sliding support and extension schemes are intended to be covered. These include conventional telescoping connection, and side-by-side members which slide relative to one another and provide in the extended position relative support to one another.
In development of this invention, it has been discovered that location of the pins between the male telescoping member and the extender needs to be facilitated. Accordingly, the now preferred interconnection between the extender and male telescoping member is illustrated in FIGS. 9A, 9B, 10, 11A and 11B.
Referring to FIGS. 9A and 9B, left forward male telescoping member 34 and extender E 1 is illustrated. Specifically, paired female flange members 52 are provided with locator pin L p . Locator pin L p is centered on the neutral axis of extenders E 1 .
Similarly, left forward male telescoping member 34 at single male flange 42 has locator aperture L A . Locator aperture L A , like locator pin L p is centered on the neutral axis of left forward male telescoping member 34. Locator aperture L A includes gathering surfaces G S flaring out from locator aperture L A . These respective gathering surfaces G S cause left forward male telescoping member 34 and extenders E 1 to come into registration as illustrated in FIG. 11A.
In actual operation, the respective male telescoping members such as left forward male telescoping member 34 are moved outward until upper pin aperture 44 and lower pin aperture 46 register within respective elongate upper aperture 64 and elongate lower aperture 66. Thereafter, the extenders, such as extenders E 1 is typically picked by lifting apparatus central of the extender and inserted to forward box beam B F , Insertion continues until locator aperture L A centers on locator pin L p . Once centering occurs, the distal end of extenders E 1 is moved up and down until centering of pins N in either the upper or lower position can occur.
Stopping here, and assuming that one of pins N is in place with locator aperture L A registered to locator pin L p , the remain apertures will by definition be centered. Insertion of the remaining pin is all that is required to occur.
Referring to FIGS. 11A and 11B, some details can be considered. First, in the installation of single male flange 42 to left forward male telescoping member 34, firm welded connection is required. For this reason, U-shaped weld indentations 72 are made between left forward male telescoping member 34 and single male flange 42.
Second, it is necessary that pins N be secured in such a manner that they do not interfere with the box beams such as forward box beam B F . Specifically, single male flange 42 is provided with recessed pin platform 74. Referring to FIG. 11B, it can be seen that pin N has attached fastening leaf 78 through which bolt 80 threads to fastening tap hole 76. Connection of pins N results with recessing of the pin so that interference with the respective box beams, such as forward box beam B F , does not occur.
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A conventional telescoping frame on a paving tractor is provided with fixed male extension members for insertion to and attachment with a telescoping frame member. The conventional telescoping frame includes paired forward and paired rear side-by-side female tube members. Each forward and rear tube member conventionally acts for the telescoping support of male extension members which attach directly to the cylinder and crawler via a side bolster. Within the limits of expansion, the male extension members co-acting with clamps acting through the female tube members provide for both movement of the point of crawler support and expansion of the paving width of the tractor frame. Into this combination, extenders are added for attachment to the supported end of the male extension members interior of the female telescoping members. During frame width expansion, the male telescoping members are expanded to register their ends interior of the female telescoping members to attachment access ports in the female telescoping member. The extenders are inserted, supported, and registered at complimentary attachment apertures with attachment to the males telescoping members taking place. Once attachment has occurred, further extension of the male telescoping members occurs. A simple system of pinned cross-bracing reinforces the extended frame with relatively light bracing members. Provision is made for extender gathering to the male telescoping member interior of the box beams to facilitate ready extender connection.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
This application is a continuation of application Ser. No. 170,494, filed July 21, 1980, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a method and apparatus for effecting the gravel packing of a plurality of spaced production zones provided in a subterranean well by a single trip of a work string incorporating the gravel packing apparatus into the well.
2. Description of the Prior Art
Of considerable magnitude in the production of hydrocarbons, such as oil and gas, from a producing well is the problem of sand flow into the well bore from unconsolidated formations. Production of sand with the flow of hydrocarbons will cause the well bore to gradually fill up with minute sand particles until production perforations in the casing and, oftentimes, the end of production tubing inserted therein, are covered, resulting in a significant reduction in fluid production. In many instances, sand production will cause the well to stop producing.
In addition to reduction of fluid production, flow of sand also may cause severe damage to equipment, such as pumps, chokes and the like. In flowing wells, fluid velocity may be sufficient to scavenge sand within the well bore and produce it with the fluid hydrocarbon, resulting in holes being cut in the tubing and flow lines.
One well known means of controlling flow of sand into the well bore is the placement of gravel on the exterior of a slotted, perforated, or other similarly formed liner or screen (hereafter referred to as "production screen") to filter out sand produced with the oil or gas, and thus prevent its entry into the well bore. It is important to size the gravel for proper containment of the sand. Additionally, the slotted liner or screen must be designed to prevent entry of the gravel itself into the production tubing.
Although other fluids have been used, treated and filtered production or nearby well or surface water, to which is generally added a desired concentration of calcium chloride or other active substance, is preferably used in most gravel packing processes during the cleaning or flushing procedure. The water is treated to remove contaminates such as cement particules, scale, and other foreign material generally resulting from the circulation of the water in the well bore.
Apparatus for gravel packing production zones of wells are well known, and a variety of apparatus is commercially available for effecting such operation. See for example, U.S. Pat. Nos. 3,901,318, 3,913,676 and 4,044,832.
All of such prior art devices have, however, required multiple trips of the work string incorporating the gravel packing apparatus into the well in order to effect the gravel packing of a plurality of production zones.
It would be economically desirable where multiple production zones are to be gravel packed in a subterranean well, that the required multiple gravel packing operations should be capable of being accomplished in a single trip of the work string into the production zone of the well. The present invention affords such means and method.
SUMMARY OF THE INVENTION
The present invention provides an apparatus for effecting the sequential gravel packing of a plurality of vertically spaced production zones within a subterranean well having casing in place therein. The apparatus comprises primary sealing means, such as a hydraulically set packer, which is adapted for setting in the casing at a position above the production zones. A plurality of sets of production screens and valve means selectively movable between open and closed positions are provided, the valve means being equal in number to the production zones, the valve means being carriable in the well with the primary sealing means and extending in series therebelow. Production zone isolation means, such as a packer, are connected between each said set and are expansible into sealing engagement with the casing intermediate the adjacent production zones. A tubular control mandrel is provided and is carriable on a conduit in the well with the primary sealing means and is movable within all of the sets. The control mandrel includes a single cross-over means for diverting gravel carrying fluid from the interior of the mandrel to the exterior thereof. A plurality of vertically spaced sealing means are provided on the control mandrel for successively isolating each set from the others when the cross-over means on the control mandrel is positioned in proximity to each of the valve means. Means on the control mandrel are provided for opening the valve means by longitudinal movement of the control mandrel in a first direction and closing the valve means by longitudinal movement of the control mandrel in a second direction. Means are provided for supplying gravel carrying fluid to the interior of the control mandrel whereby each successive production zone may be gravel packed by successively moving the conduit and the mandrel assembly to cooperate with each of the sets, without retrieving the conduit from within the well during the sequential gravel packing of the well.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1a, 1b, 1c, 1d and 1e together constitute a schematic quarter section vertical elevational view of the zone isolation, production screen and sliding sleeve portions of a gravel packing apparatus of the present invention in a preferred form for the packing of two production zones in a single trip, FIG. 1a being the lowermost portion of the apparatus and FIGS. 1b, 1c, 1d and 1e respectively being successive upward continuation views.
FIGS. 2a, 2b, and 2c together constitute a schematic quarter section vertical elevational view of a control mandrel assembly that is insertable within the gravel packing apparatus of FIG. 1 to control the direction of fluid flow and provide the required seals, FIG. 2a being the bottom of the tool, and FIGS. 2b and 2c respectively being successively upward continuation views.
FIGS. 3a, 3b, and 3c, together constitute a schematic quarter section vertical elevational view of the packing apparatus of FIG. 1 with the mandrel assembly of FIG. 2 inserted within the gravel packing apparatus in position after the run in of the complete tool through the well casing to a selected depth, FIG. 3a being the lowermost portion of the apparatus and FIGS. 3b and 3c being successive upward continuation views.
FIGS. 4a, 4b, 4c, 4d and 4e together constitute a schematic quarter section, vertical elevational view of the gravel packing apparatus with the elements thereof shown in the positions occupied in the initial gravel packing of the lowermost production zone, FIG. 4a being a view of the bottom of the apparatus, and FIGS. 4b, 4c, 4d and 4e respectively constituting successive upward continuation views.
FIGS. 5a, 5b, 5c, 5d and 5e are views respectively similar to FIGS. 4a-4e, but with the control mandrel assembly shifted upwardly to complete the gravel packing of the lower production zone.
FIGS. 6a, 6b and 6c constitute views respectively similar to FIGS. 4b, 4c and 4d, but illustrating the position of the control mandrel assembly during the gravel packing of the upper production zone.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 1, there is shown positioned within a well casing 1 an exterior apparatus for gravel packing two vertically spaced production zones, the interior portion or control mandrel, being shown in FIGS. 2a, 2b and 2c. The production zones are respectively represented at the vertically spaced sets of casing perforations 1a and 1b.
In the specific example to be described, wherein only two production zones 1a and 1b are involved, the required apparatus is assembled in vertically stacked relationship below a zone isolation means, such as a packer 10. The packer 10 is provided with an expandable packing element 11 for effecting a sealed engagement with the interior wall of the casing 1 at a region above the upper production zone. The packer 10 has a plurality of expandable slips 12 which engage the interior wall of the casing 1 to hold the packer 10 in a fixed position with respect to the casing 1. The packer 10 may be of any one of several well known, commercially available packers, such as the SC-1 packer manufactured and sold by Baker Sand Control Division, Baker International Corporation, of Houston, Tex. The particular type of packer is not critical, so long as it is capable of effecting a seal with the internal surface of the casing 1.
To the bottom of the packer 10 is affixed in conventional fashion to a mill-out extension 20, which is merely a sleeve-like element incorporated to provide adequate tubular conduit length below the packer 10 with a full diameter opening so that, in the event it is decided to retrieve the packer 10, the bottom of the retrieving tool can be accommodated.
Proceeding downwardly, a cross-over sub 25 effects the connection of the bottom of the mill-out extension 20 to a reduced diameter seal bore unit 30. As will be later described, the internal bore surface 31 of the seal bore 30 cooperates with annular sealing elements provided on the control mandrel 200 to control the fluid flow during gravel packing operations.
An extension sleeve 35 connects the seal bore unit 30 with the top of a sliding sleeve unit 40 and properly spaces such sliding sleeve unit relative to the seal bore unit. The sliding sleeve unit 40 is of conventional construction and in effect amounts to a sliding valve, operable by the mandrel 200, for controlling radial ports 47 to selectively permit fluid to communicate between the interior 41 of the sliding sleeve and the casing annulus 1c defined between the outside periphery of the gravel packing apparatus and the internal diameter of the casing 1.
The bottom end of the sliding sleeve unit 40 is connected to the top end of another seal bore unit 50, having an internal sealing surface 51, which, in cooperation with seals on the control mandrel 200, effects the direction of the flow of fluid from the interior of the gravel packing assembly to the exterior during the gravel packing operation.
The lower end of the seal bore unit 50 is secured to the top end of a shear-out safety joint 60 which permits release of component parts of the apparatus including the upper packer in the event that the apparatus becomes stuck in the well bore. The shear-out safety joint 60 may be of conventional construction.
The shear-out safety joint 60 is connected to the top end of a tubular section 65 which in turn is connected to the top end of the uppermost production screen 70 which, when the packer 10 is set, axially straddles the perforations 1b within the uppermost production zone. Again, the production screen 70 is of conventional construction and it is effective to filter out sand and other particulates from the produced fluid, permitting the filtered produced fluid to enter the interior of the gravel packing apparatus and through the production string, to the top of the well.
The lower end of the production screen 70 is connected to the top end of a seal bore 75 having an internal sealing surface 76 which functions in cooperation with sealing elements provided on the control mandrel 200, to direct fluid flow during gravel packing of the upper production zone immediate the casing perforations 1b. The lower end of sealing bore unit 75 is connected to the top end of a tell-tale screen 80, which is employed to insure that the gravel placement in the upper production zone 1b extends to the bottom of the intended longitudinal interval for gravel packing.
The bottom end of the tell-tale 80 is secured to a seal bore 90, the internal sealing surface 91 of seal bore 90 cooperating with sealing elements on the control mandrel 200 to, during gravel packing of the upper production zone, act as an isolator between the upper production zone and the lower production zone and, during the gravel packing of the lower production zone 1a, to act as a director of fluid.
The lower end of the seal bore unit 90 is connected to the top of a left-hand threaded connector sub 95 which, in turn, is threadably connected to a lower zone isolation means, such as packer 100 having a packing element 101.
The components below and including the isolation packer 100 constitute one "set" of gravel packing apparatus. The packer 100 may be of any one of a number of well known type of packers which effect a sealing engagement of a packing element 101 with the internal diameter of the casing 1. Its primary function is to isolate the upper production zone, particularly the casing annulus 1c, from the lower production zone, both during the gravel packing operation through the lower production zone and thereafter during production operations. Preferably, the packer 100 is set by fluid pressure transmitted down the tubing string, and into a self-contained setting mechanism.
The lower portion of the packer 100 is affixed to a large diameter sleeve-like extension 105 and the lower portion of the extension 105 is secured to the top end of a sliding sleeve 110. The function of sliding sleeve 110 is to provide temporary communication through radial ports 111 between the interior of the assembly and the annulus 1c between the o.d. of the assembly and the i.d. of the casing 1.
The lower end of the sliding sleeve 110 is affixed to the top end of a seal bore 120 having an internal sealing surface 121, which, in cooperation with sealing elements provided on the control mandrel 200, directs the flow of gravel and completion fluid to the lower production zone 1a.
The bottom end of the seal bore 120 is connected to a shear-out safety joint 130, which may be identical to the shear-out safety joint 60. Such safety joint is incorporated solely for purposes of retrieval of the apparatus. It permits the convenient retrieval of all apparatus above the shear-out safety joint 130 along with the top half of such shear-out safety joint. The bottom half of the safety joint 130 may be retrieved when the lower screen and liner assembly is retrieved.
The lower end of the shear-out safety joint 130 is affixed to the top end of a tubular section 135 and the lower end of the tubular section 135 is connected to the top end of a lower production screen 140.
The bottom end of the production screen 140 extends to a seal bore 150 having an internal sealing surface 151 to cooperate with seals provided on the control mandrel 200, to direct fluid flow through the lowermost tell-tale screen 160 which is connected to the bottom end of the seal bore 150 and, like the tell-tale screen 80 provided in the upper production zone, insures that the gravel placement has extended downwardly past the bottom of the screen interval.
The lower portion of the tell-tale screen 160 is conventionally connected to the top end of a cross-over sub 165 which merely effects a necessary reduction in diameter between the threaded connections on a standard tell-tale screen 160 and a snap latch 170 connected to the bottom end of the cross-over sub 165. The snap latch 170 is provided to engage the top end of a lower packer 180 which is anchored in the casing 1 at a predetermined position below the lowermost end of the perforations 1a. The external seals 171 provided on the body portion of the snap latch 170 are received in the bore 181 of packer 180 to eliminate any fluid flow across the bore 181 of the packer 180.
Referring now to FIGS. 2a, 2b and 2c, there is shown a control mandrel assembly 200 which is inserted within the aligned bores defined by the exterior gravel packing apparatus components shown in FIGS. 1a through 1e.
Now referring to FIG. 2a, the lowermost component of the control mandrel 200 is a check valve 220 which prevents fluid flow through the bottom end of the mandrel 200. This plug thus effectively prevents fluid transmission from within the control mandrel 200 to any area below the zone that is being gravel packed at a particular time. Immediately above the check valve 220 are a plurality of spaced external seals 225. During the gravel packing operation of the upper production zone, (FIG. 6a) the seals 225 cooperate with the interior surface 91 of the seal bore unit 90.
Immediately above the external seals 225, there is provided a plurality of flow passageways 228 which take fluid returns from the lower tell-tale screen 160 when the control mandrel 200 is shifted to the position shown in FIG. 4a.
Above the flow passageways 228 there is provided a second set of external seals 230 which cooperate with the internal bore surface 151 of the seal bore unit 150 to direct fluid flow down through the lowermost tell-tale screen 160 during gravel packing operations in the lower production zone when the control mandrel 200 is positioned as in FIG. 4a.
Immediately above the seal units 230 there is provided a length of tubular conduit section 235. Above the section 235 is mounted a collet-configured shifting tool 240 which cooperates with the sliding sleeve apparatus 110 or 40 to effect the longitudinal movement of the sliding sleeve from one of open and closed positions to the other position as the control mandrel 200 is shifted longitudinally.
Immediately above the shifting tool 240 there is provided an indicating collet 250 which engages the shoulder 122 of the seal bore 120 and the shoulder 52 of the seal bore 50, to provide a signal to the operator at the surface to determine where the cross-over tool is located relative to the sliding sleeves 110 or 40. Additionally, when the control mandrel 200 is elevated to effect the gravel packing of the lower production zone, the indicating collet 250 engages the shoulder 122 on the seal bore 120. The indicating collet 250 may be of conventional construction, being radially compressible to move downwardly past a constricted shoulder, but requiring the application of a substantial tension force to compress the collet to permit it to pass upwardly through the restricted shoulder 122 of the seal bore 120, or shoulder 52 of the seal bore 50.
Immediately above the indicating collet 250, there is provided a series of external seals 255 which function as the bottom seal assembly in the cross-over tool 260. They are provided to prohibit flow going out the cross-over port 261 and down the interior of the screen liner assembly. The cross-over port 261 directs fluid from the flow passageway 262 of the cross-over tool 260 through the port 111 of the sliding sleeve 110 during gravel packing of the lower production zone, or through the port 47 of the sliding sleeve 40, during gravel packing of the upper production zone, to the casing annulus 1c, thence to the exterior of the production screen 140 or 70, respectively. The cross-over tool 260 may be of the same general configuration as that described in U.S. Pat. No. 4,044,832, and incorporates an inner tubular member 263 having the flow passageway 262 communicating with a concentric work string 300 (FIGS. 4d and 4e) which is run from the surface of the well interior of the tubular work string 5.
A fluid annulus 264 is defined between center tubular section 263 and the outer wall of the cross-over tool 260, and permits fluid transmission to the top of the well through the interior of the mandrel assembly 200 and from the flow passageways 228.
At the upper end of the cross-over tool 260, the annulus 264 communicates through radial ports 265 with the annulus 202 (FIG. 3c) between the control mandrel assembly 200 and the interior of the liner assembly.
The internal bore 201 of the control mandrel 200 is provided with an internally projecting ball valve seat 204 in the vicinity of the lowermost seal elements 255. A ball 203 is positioned on the seat 204 and is run into the well initially with the control mandrel 200 to act as a check valve during reverse circulation operations.
Above the cross-over port 261 there is provided a plurality of axially spaced external seals 270. These seals cooperate with the sealing surface 91 provided in the seal bore 90 (FIG. 4c) above the sliding sleeve 110 during the gravel packing of the lower zone, and with seal bore 30 in the upper zone (FIG. 5d) to prohibit fluid flow out of the cross-over port 261 and directly back up to the top of the well.
Above the seals 270, the control mandrel assembly 200 is provided with a second indicating collet 280 to indicate to the operator at the surface the relative position of the cross-over tool 260 with respect to the sliding sleeve assemblies 110 and 40. The indicating collet 280 is a compression indicator which engages the top of a seal bore, such as 90 and 30, as the control mandrel 200 is moved down.
Above the indicating collet 280, the control mandrel 200 is provided with a collet-like closing tool 285 employed to close the sliding sleeve 110 prior to setting the packer 100.
The top end of the closing tool 285 is affixed to the bottom end of an extended length of pipe 288 on top of which is mounted the setting tool 290 for the packer 10 including a seal ring 291. Above setting tool 290 is mounted a seal bore unit 295 which surrounds seal rings 301 provided on a concentric work string 300 which extends to the bore 262 of the cross-over tool 260. The setting tool 290 and the entire assembly including and below the packer 10 are run into the well on a tubular work string 5.
All of the apparatus illustrated in FIGS. 1a-1e will be hereinafter referred to as the outside screen and liner assembly. All of this apparatus is assembled to the bottom end of the packer 10 prior to insertion of the apparatus in the well.
In the same manner, all of the apparatus shown and described in connection with FIGS. 2a-2c will hereinafter be referred to as the mandrel assembly, and this assembly is inserted within the outer screen and liner assembly. Lastly, the work string 300 (FIGS. 4c, 4d and 4e) is run within the control mandrel assembly 200 at the appropriate time.
OPERATION
Prior to running the gravel packing assembly in the well, the lower packer 180 is anchored in the casing 1 as previously mentioned, at a pre-determined position below the lower production zone perforations 1a. Upon running in the entire gravel packing assembly into the well, the snap latches 172 provided on the snap latch 170 on the bottom of the screen and liner assembly are engaged with cooperating elements on the packer 180 and the external seals 171 of the snap latch 170 are sealingly engaged in the bore 181 of the packer 180, as shown in FIG. 3a. In this position the extreme bottom end of the control mandrel 200 represented by the check valve 220 is positioned below the packer 180 (FIG. 3a). The setting tool 290 now is in position to engage the packer 10. The packer 10 is set by manipulation of the setting tool 290, in a known and conventional manner.
The control mandrel assembly 200 now is moved upwardly a sufficient distance to set the cross-over tool 260 carried by control mandrel 200 in position to permit the pressure of fluid in the work string 300 to be increased to hydraulically set the packer 100. In this position, the seals 255 cooperate with seal bore surface 121 and the ports 111 of the sliding sleeve 110 are closed.
With both the upper packer 10 and the packer 100 set, the control mandrel assembly 200 is moved to the position illustrated in FIGS. 4a-4e wherein the lower locating collet 250 is somewhat below the shoulder 122 of the seal bore 120. In this position, the cross-over tool 260 will have its port 261 commuicating with the annulus 202 between the control mandrel 200 and the screen and liner assembly just above the sliding sleeve 110, whose port 111 will be in the open position. Gravel carrying fluid can thus be introduced into the aforementioned annulus to flow around the perimeter of the lower production screen 140 and downwardly around the tell-tale screen 160. The flowpath is downwardly through the wash pipe 300 into the central bore 262 of the cross-over 260, through radial port 261 into the annulus 202, through the radial port 111 in the sliding sleeve 110 and into the annulus 1c. Return fluid flows through tell-tale screen 160, through the passageways 228 into the annular passage 264 of the cross-over tool 260, through the ports 265 into the annulus 202 (above the seal bore 90), and then into the casing annulus above the packer 100.
The flow of such fluid which, of course, contains aggregate in the size and amount appropriate for the particular well formation, will continue until the gravel covers the lower tell-tale screen 160. This will result in a detectable increase in back pressure of the packing fluid which will indicate to the operator at the surface that the gravel has been applied to the lower end of the screen interval. After this operation, the control mandrel 200 is picked up, as shown in FIGS. 5a-5e, and fluid is continued to be pumped through the wash pipe 300 to pack the production screen 140, with the return fluid being routed through the lower production screen 140.
The control mandrel 200 now is moved to the position illustrated in FIGS. 6a, 6b and 6c wherein the check valve 220 of the control mandrel 200 is now placed above the packer 100, and the series of seals 225 surrounding the check valve of the control mandrel 200 are in sealing engagement with the inner sealing surface 91 of the seal bore 90. The raising of the mandrel 200 obviously effects the closing of the port 111 of the lower sliding sleeve assembly 110 through the action of the shifting tool 240 on such sliding sleeve.
The port 261 of the cross-over tool 260 is now positioned just above the open port 47 of the upper sliding sleeve assembly 40. The locating collet 250 is positioned just below the shoulder 52 of the seal bore 50. The seal rings 255 below the cross-over tool 260 are in sealing engagement with the inner surface 51 of the seal bore 50. Thus, the upper production zone, represented by the casing perforations 1b is completely isolated from the lower production zone and the gravel packing apparatus is in the same relationship with work string 300 as previously described in connection with the packing of the lower production zone.
The gravel carrying fluid can now be introduced through the work string 300 into the bore 262 of the cross-over tool 260 of the control mandrel 200, where it will flow outwardly through the port 261 of the cross-over tool 260 into the annulus 202 between the mandrel assembly 200 and the inner wall of the screen and liner assembly through the open port 47 of the sliding sleeve 40. Hence, gravel is packed around the periphery of the tell tale screen 80. When sufficient gravel has been supplied so that the pack covers the tell-tale screen 80, the back pressure of the gravel pack fluid will increase and provide a pressure signal to the operator that the packing has been completed down to the bottom of the desired screen interval.
As before, the control mandrel 200 is then raised to complete the packing of the production screen 70, which will be signalled by a pressure increase.
The control mandrel 200 may now be completely removed from the well, thus closing the ports 47 of the sliding sleeve assembly 40, and the well is ready for production with the gravel packing of the two production zones having been accomplished with a single trip of the aforedescribed gravel packing apparatus into the well.
It should be noted that the distance between the lower tell-tale screen of each gravel packing set and the sliding sleeve of each gravel packing set has to be substantially identical. This is a necessity because of the fixed distances between the sealing elements and the cross-over port of the cross-over tool incorporated in the mandrel assembly. Additionally, to successfully gravel pack a plurality of production zones in a single trip, the lengths of the individual production zones have to be substantially identical.
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 the disclosure. Accordingly, modifications are contemplated which can be made without departing from the spirit of the described invention.
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An apparatus is provided for gravel packing a plurality of zones within a subterranean well. Primary sealing means are adapted for setting in casing at a position above the zones. A plurality of sets of production screens and valve means are provided, the valve means being equal in number to the zones to be packed and being carriable in the well with the primary sealing means. Zone isolation means are connected between each said set and expansible into sealing engagement with the casing. A control mandrel includes a single cross-over means for diverting gravel carrying fluid. A plurality of vertically spaced sealing means are defined on the cross-over means for successively isolating each set from the others when the cross-over means is positioned in proximity to each valve means. Valve opening means are provided on the control mandrel and are operable by longitudinal movement of the mandrel to positions for opening and closing the valve means. Means for supplying gravel carrying fluid to the interior of the control mandrel is provided whereby each successive production zone may be gravel packed by successively moving the conduit and the mandrel assembly to cooperate with each of the sets, without retrieving the conduit from within the well.
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RELATED APPLICATION
This application is a continuation-in-part of my United States patent application Ser. No. 847,962 filed Nov. 2, 1977 now abandoned for: METHOD AND APPARATUS FOR LOGGING INCLINED EARTH BOREHOLES USING THE MEASURED ACCELERATION OF THE WELL LOGGING INSTRUMENT, which is a continuation-in-part of my U.S. application Ser. No. 838,686 filed Oct. 3, 1977 now U.S. Pat. No. 4,109,521, issued Aug. 29, 1978.
BACKGROUND OF THE INVENTION
This invention relates generally to apparatus for logging earth boreholes and specifically to methods and apparatus utilized to assist well logging instruments in traversing highly deviated earth boreholes.
In the practice of obtaining lithological measurements of subsurface formations there is an attendant problem of moving a logging instrument through an earth borehole, and in particular one which is inclined from the vertical and may contain numerous irregularities and obstructions which impede movement of the instrument to such an extent that it may descend under gravity. In such wells there may also be a comparable problem in retrieving the instrument because it may become stuck, or alternatively, the logging cable becomes stuck. This latter circumstance often occurs when the cable, by its longitudinal movement, "key seats" itself in the mud cake layer which covers the surface of permeable rock formations. In fact the cable may slice into the rock itself, being plastered against the borehole wall by hydraulic forces in the borehole. Often the cable will be broken before sufficient pulling force is applied to cause the cable and attached instrument to move upwardly. In descending, the force of gravity is insufficient to overcome these same effects and the instrument may move discontinuously or become stuck.
In descending, the matter of primary concern is that the bottom of the well or other objective point in the borehole be reached expeditiously with minimum loss of time. Economy of time is important because of the extremely high cost of drilling operations involving slant holes. These in general are drilled from large expensive drilling platforms situated offshore or in hostile and remote locations. Normally the drilling operation is interrupted while logging operations are conducted; so the "rig time" expended while logging may be an important factor in the cost of the overall operations.
As many as 10 to 30 wells are drilled from a single platform, each well directed outwardly from a central vertical hole to form a cluster that uniformly taps the objective reservoir over a preselected area. To control these directionally drilled wells and assure that they reach and penetrate the objective zone often requires more and different types of well logs than conventionally drilled wells. Various prior art methods for traversing such deviated boreholes have been devised.
One such prior art method is called "pump down" logging. This method involves the use of logging instruments which are small in diameter such that they will pass through the drill pipes. With the drilling bit removed, drill pipe is inserted into the hole to a depth above the portion of the hole desired to be logged. At this point, the drill pipe is kept more or less stationary while mud fluids are continuously circulated. The drill pipe is slowly reciprocated longitudinally to avoid its becoming stuck in the hole due to key seating or other hydraulic forces like those discussed previously in respect to the logging cable.
A logging instrument, attached to the conventional logging cable is placed in the top end of the drill pipe and is carried to the bottom by the descending column of mud fluids. The logging cable is meanwhile paid out by the cable winch to allow the tool to descend. When the instrument has reached the bottom of the drill pipe and emerges into the "open" hole, it may fall under gravity or it may become stuck just as in normal operations depending on the conditions of the hole and its inclination. If it becomes stuck, the necessary procedure has been to withdraw the instrument from the hole, add more sections of pipe to the drill pipe string and try again. In some cases it has been found impossible to obtain "open hole" logs of lower portions of steeply inclined boreholes because no satisfactory method was available for overcoming these obstacles. In fact, due to the fact that so much time is consumed in "pump down" logging, with its attendant hight cost, the decision is often made to proceed with a minimum number of logs, or even with none at all. This results in the possible consequence that an unproductive well will result.
A more recent prior art method is the placing of a means of motivating power within the logging instrument itself. A command generated at the surface is used to initiate the motive power to apply force for causing the instrument to move within the borehole. Various methods of accomplishing this are known in the art. An example of such art is disclosed in applicant's above-mentioned U.S. Pat. No. 4,109,521. However, even with motive means within the instrument, problems may occur in causing the instrument to traverse the borehole. For example, if the instrument is being lowered into the borehole and becomes stuck, by the time it is realized at the surface that downward tool movement has stopped and the motive means commanded on, the logging cable may have been played out to overrun the tool and may kink or twist so that when the motive means engages, the cable may be pinched or otherwise damaged. Also, when the instrument together with the lower portion of the cable cease to move, their stuck condition quickly begins to worsen due to continued depositions of mud cake wherever mud filtrate can enter permeable formations. This effect causes the cable and instrument to be more forcefully plastered against the borehole wall and progressively more difficult to disengage. Alternatively, as the instrument is being raised within the borehole, it may become stuck and prior to receipt on the surface of an indication of this condition, the cable may be stretched to an extent which may either snap the cable or at least pull it from its connection with the instrument.
Yet another objectional consequence of discontinuous or non uniform movement of the logging instrument relates to the requirement while logging to produce a record of the logging parameters on a linear depth scale. This is accomplished by a means old in the art whereby the recorder is driven by movement of the sheave wheel over which the cable travels. If the sheave movement is not synchronous with the instrument movement, then the logged parameters will be erroneously recorded with reference to the depth scale. This is particularly prevalent when logging downward in a well, and for this reason in the prior art it is exceptional to undertake a logging operation while going into a well with a logging device. In fact it is sometimes preferred to log while moving downward, as for example when excessively high temperatures are to be encountered. In such case, by logging downward it is possible to obtain a log of the greatest possible portion of the well before the instrument fails. In another case, if the instrument contains a neutron source initiated below a gamma ray measuring device, then radioactivity may be induced in formation elements and detected by the gamma ray measuring device only if the instrument is moving downward. Thus it may be desirable in some cases to log in both directions in order to obtain two differing measurements. In yet another case, a complex instrument may comprise so many measuring devices that it is not practical to perform all the measurements simultaneously. In such case a selected group of measurements may be made going into the hole and the remainder may be made on the way out.
The instant invention, by providng correct correlation between measured parameters and depth in the hole makes is feasable to produce logs of acceptable quality while logging in either direction by overcoming the problems of the prior art due to discontinuous and non uniform drag caused by friction, viscous and hydraulic forces, obstacles in the borehole, and the like.
The present invention overcomes the deficiencies of the prior art and novel means and apparatus are disclosed for providing synchronized cable playout to facilitate movement of the logging instrument within the borehole and for the generation of command signals for initiating a motive force contained within the logging instrument to facilitate movement thereof within the borehole.
SUMMARY OF THE INVENTION
The present invention contemplates a means for determining the rate of movement of the logging instrument and the downward force at the cable head. The latter indicates whether gravitational force on the mass of the instrument is sufficient to overcome friction and other forces tending to prevent movement of the tool. If so, the tool will descend except for the restraining force of the cable. When coming out of the hole, this apparatus will indicate the presence and magnitude of resisting or sticking forces by increases in the indication of weight over and above the actual weight of the tool.
By means of the signal from the accelerometer it is old in the art at the surface to observe changes in the velocity of the tool. By integrating the signal from an axial acceleration measuring device, the velocity of the instrument may be continuously computed whereby the rate at which the cable is wound onto or unwound from the drum may be controlled. This control is in response to the signals received from the subsurface instrument. Drum rotation is monitored and the rotation rate compared with a preselected rotational rate. When cable drum rotation slows to a rate equal to or less than the preselected rate, an electric signal is generated and transmitted to motive means situated in the logging instrument, the signal initiates operation of the motive means to propel the instrument in the desired direction within the well.
It is therefore the primary object of the invention to achieve smooth and expeditious movement of the logging instrument through the borehole.
This and other objects, features and advantages of the present invention will be apparent from the following detailed description taken with reference to the figures of the accompanying drawings, wherein:
FIG. 1 is a schematic view illustrating the apparatus according to the present invention traversing a deviated earth borehole.
FIG. 2 illustrates schematically, partly in block diagram, comparison and control features of the invention depicted in FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawing in more detail, and in particular to FIG. 1, there is illustrated schematically a logging operation conducted in accordance with the invention. A well 13, which has been drilled into a portion of the earth's surface 12 has disposed within it a subsurface well logging instrument 30'. Instrument 30' includes a logging module 31 which may be an induction, electric, acoustic or any of the types of conventional logs well known in the art. Cable 32 supports the instrument 30' in the well and contains the required conductors for electrically connecting the instrument 30 with surface apparatus. The cable is wound onto and unwound from cable drum 33 for raising or lowering the instrument 30' to traverse the well. During the traversal, the signals from well logging modules 31 are sent up cable 32. Through slip rings 34 on the end of drum 33, the signals are conducted by the lines indicated generally at 35 to the surface electronics 36. A recorder (not illustrated) within the surface electronics 36 is driven through the transmission 38 by means of measuring reel 39, over which cable 32 is drawn, so that the recorder moves and correlates with depth. Instrument 30' includes an accelerometer 140 for measuring the acceleration of the well logging instrument 30' within the borehole. Additionally, the surface electronics section 36 has incorporated therein a velocity indicator 46 which measures the velocity of either the drum 33 or the cable 32 by means of a sensor 44 which is connected to velocity indicator circuit 46 by means of the conductor 45, the purpose of which will be discussed hereinafter in more detail.
Referring now to FIG. 2, an embodiment of the present invention is described which incorporates a subsurface accelerometer 140 located within the well logging instrument (not illustrated) and which has its output connected to a subsurface velocity circuit 141 whose output in turn is connected to the input of a comparator circuit 142 which drives an actuator 143, for example, the control module for controlling the motive means illustrated in FIG. 1. The output of the subsurface instrument velocity circuit 141 is also connected by means of a conductor 144 located within the well logging cable 146 to the earth's surface. A surface velocity circuit 150 which provides a signal indicative of the velocity of the well logging cable at the surface as hereinbefore described has its output connected to a comparator circuit 151. The surface velocity output signal is also conducted by means of conductor 153 which passes through the slip rings 34 on the end of the hoist drum 33 and is conducted to the subsurface instrument by means of the well logging cable 32 along the conductor 145 to the second input of the comparator circuit 142. The signal which passes along the conductor 144 through the well logging cable 32 is taken off the slip rings 34 and is connected into another input of the surface comparator circuit 151 by means of the conductor 152. The output of the surface comparator circuit 151 is connected into the cable hoist control circuit 149 which drives the motor and gear box 148 which in turn drives the hoist drum 33.
In the operation of the apparatus and circuitry illustrated in FIG. 2, it should be appreciated that as the subsurface accelerometer 140 measures the acceleration of the well logging instrument and which consequently produces a signal indicative of the subsurface velocity through the circuit 141, the subsurface velocity is thus compared with the velocity of the cable at the surface by means of the subsurface comparator 142. Whenever a significant difference is exhibited between the two velocities, the actuator 143 is actuated to thus make, or at least attempt to make, the well logging instrument proceed through the borehole at a greater velocity.
The subsurface velocity of the well logging instrument is also compared with the velocity of the cable at the earth's surface in the surface comparator circuit 151 to control the movement of the hoist drum 33. Thus, if the well logging instrument continues to slow down, even though the actuator 143 has been providing additional motivation for the well logging instrument, the surface comparison circuit 151 will produce a greater output signal which causes a reduction in the rotational movement of the drum 33 and thus will cause the well logging cable to be payed out more slowly. Through the combined apparatus and circuitry illustrated in FIG. 2, the well logging instrument will strive to motivate itself whenever it starts to slow down because of the borehole conditions and even should it start to slow down, despite the activitation of the actuator 143, the cable hoist will also slow down in order to avoid too much cable being paid out. Whenever the instrument starts to speed up, the surface comparator circuit 151 will produce a lesser signal which will in turn cause the hoist drum to speed up and stay with the well logging instrument.
Additionally, there is a strain gauge (not shown) coupled to the cable head which is used to monitor tension caused by weight placed on cable 32 by the subsurface instrument and which develops a signal functionally related thereto which is coupled to surface comparator 151. As hereinafter explained in greater detail, the signal thus derived from the strain gauge is also utilized to develop control and command signals.
Referring now to FIGS. 1 and 2, the instrument 30' is placed into the well at the surface where a section of pipe (not shown) called surface casing is always installed. The instrument 30' will readily descend this cased portion of the hole. The signal from the accelerometer is continuously fed to surface comparator 151 in surface electronics 46 which drives a signal indicative of the instruments downward velocity. The signal from the strain gauge (not shown) at the cable head is also fed continuously to the surface electronics 46. This weight indicating signal and the aforementioned velocity indicating signal are each fed into surface comparator 151 which derives command signals to control the cable winch and the motive power means in the logging instrument.
The surface comparator 151 acts to produce uniform movement of the subsurface instrument downward in the borehole. It will react to changes in either the velocity of the tool or the downward force at the cable head. If, for example, the tool velocity is suddenly diminished but the force at the cable head remains constant, then the tool is not stuck, but some retarding force on the cable is responsible for the reduced speed. The surface comparator's response will be to reduce the rate of rotation of the winch such that is exactly equals the speed of the movement of the downhole tool. If this speed reduction causes the rate of descent to be less than a predetermined minimum, then the surface comparator 151 will actuate the instrument motive power means to attempt to increase tool speed. When the surface comparator 151 senses that an increased downward force is measured at the cable head, the winch speed will be increased. The velocity indicator will then establish whether the tool speed did in fact increase to keep pace with the pay out of of the cable.
In summary of operation, the velocity of the instrument is constantly monitored and the rate of cable pay out is kept equal to tool speed. Whenever tool speed is less than the desired minimum, the means for subsurface motive power is actuated and/or the rate of cable pay out at the winch is increased. If increasing cable pay out does not coincide with an equal increase in tool speed, the winch rate is again reduced.
To assure that the logging cable does not overrun the tool, the length of cable in the hole is measured by conventional means as the cable passes over the sheave. This cable length is compared with the distance the subsurface tool moves as computed in the surface electronics 36 from the data received from the accelerometer 140. The total length of cable in the hole is measured by conventional means as the cable passes over the sheave. This cable length is compared with the distance the subsurface tool moves as computed in the surface electronics 36 from the data received from the subsurface accelerometer 140. The total length of cable payed out should always exceed the depth of the instrument in the hole by a predetermined fraction, e.g., 0.1% to 1.0%, so as to assure that there is sufficient slack line to permit tool movement but insufficient to risk its overrunning the tool.
When the instrument is to be withdrawn from the hole, usually during the logging operation, it will again be desirable to move at a constant predetermined speed. In this case again the computer panel will act to keep the winch take up in synchronism with tool movement. In particular, it will act to stop the winch whenever the tool stops in order to avoid pulling the cable out of the cable head. In the prior art this function has been sometimes achieved by controlling or stopping the winch in response to an indication of weight derived by a weight indicator at the suspended sheave wheel over which the cable travels. It will be appreciated that this method of the prior is inadequate for the reason that such an indication of increased weight due to a tool becoming stuck does not occur until the entire cable has been stretched taut and will thereafter quickly reach the breaking point. By contract the present invention contemplates control of the winch in response to the subsurface signals that are communicated to the surface as soon as the sticking occurs. Thereby the system is enabled to react before any indication is detectable at the sheave and thereby before a dangerous situation can develop.
Thus, there has been illustrated and described herein the preferred embodiment of the present invention which provides method and apparatus for synchronizing cable pay out to movement of the logging instrument through the borehole and for initiating commands to activate motive means contained within the logging instrument to facilitate movement thereof through the borehole. However, those skilled in the art will recognize that obvious modifications can be made to the preferred embodiment without departing from the spirit of the invention.
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An improved technique is provided for comparing the velocity of an elongated well logging instrument traversing an inclined earth borehole with the playout velocity of the well logging cable at the earth's surface to control both the cable hoist drum rotation and the rate of movement of the subsurface instrument and thus insure cable playout is in equilibrium with the logging instrument movement. Method and apparatus are described for detecting any reduction in movement of the logging instrument through the borehole and for reducing the velocity of the logging cable playout in response thereto by reducing drum rotation. Further, when the velocity of cable playout slows to a preselected value, a monitoring circuit generates control signals which actuate a means of power attached to or integral with the logging instrument which, upon initiation, apply a force to move the logging instrument upward or downward within the borehole.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] The present application claims the filing benefits of U.S. provisional application Ser. No. 61/806,672, filed Mar. 29, 2013, which is hereby incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates generally to an apparatus and method for improving the control and productivity of a concrete screeding machine during the leveling and smoothing of freshly poured concrete that has been placed over a surface.
BACKGROUND OF THE INVENTION
[0003] Screeding devices or machines are used to level and smooth uncured concrete to a desired grade. Known screeding machines typically include a screed head, which includes a vibrating member and a grade setting device, such as a plow or auger device. The screed head is vertically adjustable, such as in response to a laser leveling system, to establish the desired grade at the vibrating member. Examples of such screeding machines are described in U.S. Pat. Nos. 4,655,633; 4,930,935; 6,227,761; 7,044,681; 7,175,363; and 7,396,186, which are hereby incorporated herein by reference in their entireties.
SUMMARY OF THE INVENTION
[0004] The present invention provides a screeding machine that comprises a screed head having a vibrating member and a grade setting device. The grade setting device comprises an auger device that has at least two separate spiral or helical flightings disposed on and around and at least partially along a rotatable shaft or body of the auger. The helical flightings are staged or configured or arranged so that at least a portion of the auger has a first flighting portion or region having a first longitudinal spacing between adjacent fins or vanes of the helical flighting or flightings and a second flighting portion or region having a second longitudinal spacing between adjacent fins or vanes of the helical flighting or flightings.
[0005] According to an aspect of the present invention, an auger may have three separate and distinct flightings or vanes that are helically disposed along a rotatable shaft or body of the auger. A first one of the flightings may be helically disposed substantially along the entire length of the body, while a second one of the flightings may be helically disposed along a shorter length of the body, such as, for example, along about two-thirds of the length of the body that is encompassed by the first flighting, with the second flighting being spaced from the first flighting. Optionally, a third flighting may be helically disposed along a shorter length of the body, such as, for example, along about one-third of the length of the body that is encompassed by the first flighting (and thus, for example, about half of the length of the body that is encompassed by the second flighting), with the second flighting being spaced from the first and second flightings. In such a configuration, the spacing between the first, second and third flightings may be substantially uniform (i.e., the longitudinal spacing between the first flighting and second flighting is the same as the longitudinal spacing between the second flighting and the third flighting, and is the same as the longitudinal spacing between the third flighting and the first flighting.
[0006] Optionally, the longitudinal spacing along the body between adjacent portions of the flightings may be uniform along the body. Thus, the second flighting may only extend partially along a middle region (such as, for example, a middle third) of the body and may be disposed mid-way between the adjacent flighting portions of the first flighting. At a third portion of the body, the second flighting may terminate and a third and fourth flighting may be disposed equally spaced from one another and from the first flighting to provide three flightings at the third portion of the body.
[0007] Thus, the present invention provides a staged flighting auger device that has different flighting configurations along its length. For example, at one end or portion of the auger (such as a downstream portion or region or discharge end of the auger), the auger may have a tighter or closer configuration of flightings or vanes, and at another end or portion of the auger (such as an upstream portion or region or end of the auger), the auger may have a more spaced apart configuration of flightings or vanes. The denser configuration is at the downstream end of the auger with the more spaced flighting configuration being at the upstream end of the auger, such that, as more concrete is moved by the auger and the concrete starts to build up as it is moved by the auger, the denser spacing flighting configuration enhances movement of the larger volume of concrete.
[0008] These and other objects, advantages, purposes and features of the present invention will become apparent upon review of the following specification in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a perspective view of a concrete leveling and screeding machine that incorporates the improved operator controls and control systems and screed head apparatus design improvements and features of the present invention;
[0010] FIG. 2 is a perspective view of an auger having staged flighting in accordance with the present invention;
[0011] FIG. 3 is a perspective view of another auger having staged flighting in accordance with the present invention;
[0012] FIG. 4 is another perspective view of the auger of FIG. 3 ;
[0013] FIG. 5 is a perspective view of another auger having staged flighting in accordance with the present invention;
[0014] FIGS. 6-9 are plan views of the auger of FIG. 5 ;
[0015] FIG. 10 is a perspective view of an end region of an auger of the present invention, showing an internal bearing mount for mounting the auger at the screed head in accordance with the present invention;
[0016] FIG. 11 is another perspective view of the auger of FIG. 10 , showing the auger mounted at an auger support beam of the screed head;
[0017] FIG. 12 is a sectional view of the end region of the auger of FIG. 10 ;
[0018] FIG. 12A is an enlarged sectional view of the area A in FIG. 12 ; and
[0019] FIG. 13 is a perspective view and partial sectional view of the auger and internal bearing mount of FIGS. 10 and 11 , shown with the auger mounted at the auger support beam.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0020] Referring now to the drawings and the illustrative embodiments depicted therein, a screeding machine 10 includes a wheeled unit 12 with a boom 14 extending therefrom and supporting a screeding head or assembly 16 at an outer end thereof ( FIG. 1 ). The wheeled unit 12 is drivable to a targeted area at a support surface with uncured concrete placed thereat, and the wheeled unit may rotate about a base portion to swing the boom and screeding head to a targeted location. The boom 14 is extendable and retractable to move the screeding head 16 over the placed concrete, while the screeding head 16 is operable to establish a desired grade of the concrete surface and smooth or finish or screed the concrete. In the illustrated embodiment, the screeding head includes a plow 18 , a grade setting device or auger 20 and a vibrating member 22 ( FIG. 3 ). The screeding machine includes a plurality of stabilizers 24 that are extendable and retractable to support and stabilize the machine on the support surface during the screeding operation. The auger 20 of screeding head 16 comprises a staged flighting or vane configuration with multiple spiral or helical flightings or vanes staged along the auger, such that the auger has a coarser or less dense or more spaced distribution at or near the upstream end of the auger and a denser distribution or configuration of vanes at the downstream or discharge end or region of the auger, so that the auger of the present invention has improved or enhanced efficiency and provides enhanced movement of concrete to the discharge end of the auger, as discussed below.
[0021] Screeding machine 10 and the screeding head or assembly 16 may be similar in construction and/or operation as the screeding machines and screeding heads described in U.S. Pat. Nos. 4,655,633; 4,930,935; 6,227,761; 7,044,681; 7,175,363; and/or 7,396,186, and/or U.S. Publication Nos. US-2007-0116520 and/or US-2010-0196096, which are all hereby incorporated herein by reference in their entireties, such that a detailed discussion of the overall construction and operation of the screeding machines and screeding heads need not be repeated herein. For example, the screeding machine may comprise or may utilize aspects of a Somero SXP-D LASER SCREED™ screeding machine. However, clearly this example is not intended to limit the scope of the present application and clearly aspects of the present invention are suitable for use on other types of screeding machines. For example, the screeding head and auger device of the present invention may be suitable for use on a smaller screeding machine, such as a machine of the types described in U.S. Pat. Nos. 6,976,805; 7,121,762; and/or 7,850,396, which are hereby incorporated herein by reference in their entireties. Optionally, although shown in FIG. 1 as having a plow 18 , the screed head may not include a plow, whereby the auger establishes the desired grade of concrete ahead of the vibrating member.
[0022] As shown in FIG. 2 , auger 20 comprises a mounting shaft 24 , which protrudes from a generally cylindrical body or shaft 26 , which has flightings or vanes 28 spirally or helically disposed therearound and therealong. The auger has an upstream end or region 20 a , where the flightings may be more coarsely or less densely distributed or spaced, and a downstream end or region 20 b , where the flighting or flightings may be more densely distributed or spaced. In the illustrated embodiment of FIG. 2 , flightings 28 comprise a first helical flighting or vane 30 that is disposed helically around the body 26 and along a first portion of the body 26 (such as substantially the entire length of the body). A second helical flighting or vane 32 is disposed helically around the body 26 and along a second portion of the body (such as, for example, about two-thirds of the length of the body), with the second portion being a reduced amount of the first portion. A third helical flighting or vane 34 is disposed helically around the body 26 and along a third portion of the body (such as, for example, about one-third of the length of the body), with the third portion being a reduced amount of the second portion.
[0023] Thus, the first portion of the body 26 has a coarse or spaced apart distribution of the flighting therealong, while the second portion of the body has a reduced spacing or distribution of the flighting therealong and the third portion of the body has a further reduced spacing of the flighting therealong. In the illustrated embodiment of FIG. 2 , at the second body portion (such as a middle third of the body), the second flighting is spaced from the first flighting at about one-third of the way between the corresponding portions of the first flighting (so that the second flighting is not centered between the first flighting portions. The third flighting is then disposed at a middle region between the second and first flighting so that, at the third portion of the body, the three flightings 30 , 32 , 34 are spaced equidistantly along the body.
[0024] In the illustrated embodiment of FIG. 2 , the flightings 30 , 32 , 34 have the same pitch and thus are disposed generally parallel to one another along the respective portions of the body 26 . For example, the auger may comprise a nine inch diameter auger with the flighting having a pitch of about nine inches per revolution. The first flighting 30 extends continuously and helically around and along the body, while the second flighting 32 starts at a start portion 32 a (that may be about one-third of the length of the body from the upstream end 20 a of the auger) and extends continuously and helically around and along the body from its start portion 32 a to the downstream or discharge end 20 b of the auger, and the third flighting 34 starts at a start portion 34 a (that may be about two-thirds of the length of the body from the upstream end 20 a of the auger) and extends continuously and helically around and along the body from its start portion 34 a to the downstream or discharge end 20 b of the auger. The auger thus provides a finer or reduced spacing distribution of flightings or vanes at the downstream or discharge end of the auger as compared to a middle region of the auger, which provides a finer or reduced spacing distribution of flightings or vanes at the middle region of the auger as compared to the upstream region of the auger (where a coarser or greater spacing between the flighting is provided).
[0025] Optionally, the auger of the present invention may have discontinuous flightings or flighting portions therealong, so that the flightings are spaced equidistant apart along each portion or region of the auger or body. For example, and with reference to FIGS. 3 and 4 , an auger 20 ′ comprises a body 26 ′ with staged flightings 28 ′ disposed therealong. In the illustrated embodiment, the first helical flighting or vane 30 ′ is disposed helically around the body 26 and along a first portion of the body 26 (such as substantially the entire length of the body), while a second helical flighting or vane 32 ′ is disposed helically around the body 26 and along a second portion of the body (such as, for example, about a middle one-third portion of the body), with the second flighting 32 ′ starting at an end 32 a ′ (that is about one-third of the length of the body from the upstream end 20 a ′ of the auger) and ending at an end 32 b ′ (that is about two-thirds of the length of the body from the upstream end 20 a ′ of the auger). At the third portion or region (the downstream region) of the body and auger, a third flighting 34 ′ and a fourth flighting 33 ′ are disposed helically around the body 26 ′ and along the third portion of the body (such as, for example, about one-third of the length of the body at the downstream or discharge end of the auger). As shown in FIG. 3 , the second flighting 32 ′ is disposed midway between the first flighting 30 ′ so that the vanes or flightings have equidistant spacing or uniform spacing along the second or middle region of the auger, while the third and fourth flightings 34 ′, 33 ′ are disposed equidistant from one another and from the first flighting 30 ′ at the third or downstream portion or region of the auger, so the flightings have equidistant spacing or uniform spacing along the third or downstream region of the auger. The ends of the respective flightings 30 ′, 32 ′, 33 ′, 34 ′ may comprise angled or tapered ends (such as end 32 a ′ in FIG. 3 ) or may be squared or sharp cut ends (such as the end 32 a ″ in FIG. 4 ), without affecting the scope of the present invention.
[0026] Optionally, and with reference to FIGS. 5-9 , an auger 20 ″ may have flightings 28 ′ along the body 26 ′ similar to auger 20 ′, discussed above, with a transitional flighting or vane element 36 ″ established between the end 32 b ′ of the second flighting 32 ′ and the start or end 33 a ′ of the fourth flighting 33 ′. As can also be seen in FIGS. 5-9 , the third flighting 34 ′ starts at 34 a ′ at or near where the transitional element 36 ″ is disposed. In the illustrated embodiment, for example, the auger 20 ″ comprises a nine inch diameter auger and all four flightings 30 ′, 32 ′, 34 ′, 33 ′ have a pitch or lead of nine inches per revolution, with the exception of the transitional section or element 36 ″. The transitional section or element 36 ″ in this example has a pitch of about 15 inches per revolution and is only about one quarter of a revolution in effective length, thus smoothly and continuously joining the second flighting 32 ′ with the fourth flighting 33 ′ to provide a continuous flighting over the upstream two-thirds of the auger. The transitional section or element 36 ″ thus allows for an auger with equal spacing of the flightings along the auger (such as about nine inches between the flights of the first flighting, and about 4.5 inches between the flights of the first and second flightings, and about three inches between the flights of the first and fourth flightings and the fourth and third flightings and third and first flightings).
[0027] Thus, the staged flighting or variable flighting arrangement or configuration of the auger of the present invention provides a coarser or larger spacing of flights or vanes at or near an upstream end of the auger and a finer or closer spacing of flights or vanes at or near a downstream or discharge end of the auger. Thus, during operation of the auger, as the auger is rotated while engaging the concrete surface and excess concrete at the desired grade (with the auger being rotatably driven, such as via a hydraulic motor or the like at an end of the auger, in a direction opposite to the direction of travel of the screed head assembly), the coarser spacing of the upstream end flightings may start to move concrete along the auger and towards the discharge end of the auger. As the concrete accumulates as it moves along the auger, the spacing between the flightings decreases to enhance movement of the additional concrete moved along the auger from the upstream end, and the spacing between the flightings decreases more at or near the discharge end of the auger to further accommodate accumulated concrete and enhance movement of the concrete at or near the discharge end of the auger.
[0028] Although shown and described as an auger having three distinct portions or regions with different flighting spacings or gaps, clearly more or less portions may be provided along the auger while remaining within the spirit and scope of the present invention. For example, an auger may only have two flighting sections, with an upstream half of the auger (or other portion or fraction of the auger) having a single flighting arrangement and the downstream half of the auger (or other portion or fraction of the auger) having a dual flighting arrangement. Optionally, for example, an auger may have four or more flighting sections, such as with a single flighting extending the full length of the auger, a second flighting extending about three quarters of the length of the auger, a third flighting extending about half of the length of the auger and a fourth flighting extending about one quarter of the length of the auger. The flightings may be uniformly spaced or the spacing may only be uniform at the first and fourth quarters, and the auger may include transitional sections to join different flighting sections together, such as discussed above, while remaining within the spirit and scope of the present invention. Optionally, the auger may have one or more flightings extending substantially along the length of the auger, with the pitch of the flightings varying from a coarser or larger pitch at or near the upstream end of the auger to a finer or smaller pitch at or near the downstream or discharge end of the auger.
[0029] Thus, the present invention provides a staged or varying flighting auger, which provides an increased concrete carrying capacity as excess concrete increasingly accumulates toward the discharge end of the auger. The auger of the present invention may also provide a reduced auger weight from “all full length flights”, because the flights or flightings are added along the direction of concrete flow and movement where they are most needed. The weight of extra flighting is eliminated at the upstream end (in other words, at the starting end of the auger, where overlap normally occurs over the previous pass).
[0030] The present invention may also provide for reduced auger flighting wear at the discharge end of the auger. Current augers typically need to be flipped end-to-end to maximize useful life due to uneven wear. The present invention avoids this and thus provides a machine-operator maintenance benefit.
[0031] The preferred multiple, staged flighting configuration of the present invention provides a uniform and substantially constant pitch (such as about 9 inches or thereabouts) along the auger. Optionally, the auger of the present invention may provide one or more flightings with a varying pitch of the flighting or flightings along the auger. However, a varying pitch (having a smaller or reduced pitch at or near the discharge end of the auger to provide a denser or closer spacing arrangement of the flighting at or near the discharge end of the auger) may slow down the lateral velocity of the concrete as the flights or vanes get closer together and the concrete moves towards and reaches the end of the auger. The multi-flight staged configurations of the present invention preferably provide equal pitch flighting that provides enhanced concrete movement.
[0032] The auger may be mounted at the screed head via any suitable mounting means. Optionally, the auger may be mounted at the screed head via an internal bearing mounting assembly, which rotatably mounts the auger body to a fixed shaft via an internal bearing that is received in the end of the hollow auger body. For example, and with reference to FIGS. 10-13 , an auger 120 (such as any of the staged flighting augers discussed above or a conventional single flighting auger or the like) includes a cylindrical body portion 126 with flighting 128 helically disposed therealong. At an end of the auger, such as at the downstream or discharge end of the auger in FIGS. 10-13 , an auger mounting assembly 140 is disposed to rotatably mount the respective end of the auger at an auger support beam or element 142 of the screed head 116 . The auger mounting assembly comprises a stationary or fixed shaft 144 that protrudes from a bolt on end cap or attachment plate 146 , with a mounting bracket or structural support 148 attached to and extending radially outwardly and upwardly from the fixed shaft 144 for attaching at the auger support beam 142 (as shown in FIGS. 11 and 13 ).
[0033] As best shown in FIGS. 12 and 13 , auger mounting assembly 140 includes an internal bearing 150 , with a race 150 a fixedly attached or locked to the fixed shaft 144 , and with an outer bearing surface rotatably engaged with an inner sleeve 152 that is inserted into or received in the hollow end of the body 126 , such as via an outer race 150 b of the bearing assembly 150 . In the illustrated embodiment, a lubrication port or grease fitting 154 is provided at the bearing assembly 150 and inside the body and inboard of the end cap 146 , which is bolted or fastened or attached to the inner sleeve 152 to attach the end cap 146 at the body 126 and seal or enclose the bearings within the auger body. The end cap may be removed to access the grease fitting 154 as desired.
[0034] Thus, the mounting assembly 140 of the present invention provides a sealed bearing within the auger body. The sleeve 152 is inserted into the auger body and may be press fit or welded thereto to fixedly attach the sleeve to the body. In the illustrated embodiment, the sleeve includes a raised shoulder 152 a at its outboard end to limit insertion of the sleeve into the body, and the raised shoulder portion may have an outer surface that is generally flush with the outer surface of the body, whereby the flighting 128 may extend over the outer surface of the raised shoulder portion of the sleeve (such as shown in FIGS. 10-13 ). The bearing assembly (with the fixed shaft attached thereto) is inserted into the sleeve and the end cap 146 is attached or fastened to the sleeve to retain and seal the bearing within the sleeve 152 and auger body 126 .
[0035] The potential benefits of the internal bearing mount of the present invention include that the relatively thin vertical structural support and relatively reduced diameter of the stationary shaft at the discharge end of the auger offers less resistance to the movement of concrete away from the end of the auger. Known current pillow-block type bearings are mounted externally at the rotating shafts of current augers and tend to have a higher cross-sectional area than what is provided by the internal bearing mount of the present invention. Also, with the bearing mounted internally inside the auger body or tube, there is reduced exposure to concrete and stone aggregate at the bearings. Current designs typically require a plastic collar on the shaft between the bearing and the end of the auger to help prevent stones from jamming between the rotating parts and destroying the grease seals of the bearings. The internal bearing mount of the present invention may also allow a shaft seal to be included between the stationary shaft and rotating end cap of the auger (not currently shown), further protecting the actual grease seals of the bearing itself. Also, exposure to pressure washing of the screed head at the end of the day by machine operators tends to reduce the life of bearings whenever water gets inside the bearings. The bearings need to be greased to help force out any water after pressure washing is complete. However, the internal bearing mount of the present invention may help reduce the likelihood of failures from water contamination. Optionally, the internal bearing mount of the present invention may include a type of access port with a sealed, yet removable, access cover at the grease fitting to ease the greasing when greasing may be desired or necessary.
[0036] The opposite end of the auger (such as the upstream end of the auger) may be mounted via any known mounting means and may be rotatably driven via a hydraulic motor and known pillow-block bearing supporting the auger (not shown). However, optionally, the auger motor may be mounted internally inside the auger itself. In such a configuration, the shaft of the auger motor may remain stationary with the flow of pressurized hydraulic fluid traveling through ports and internal passageways of the stationary motor shaft.
[0037] Changes and modifications to the specifically described embodiments can be carried out without departing from the principles of the present invention, which is intended to be limited only by the scope of the appended claims as interpreted according to the principles of patent law.
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A screeding machine for screeding a concrete surface having a partially cured concrete area and a newly placed concrete area includes a wheeled unit and a screeding head attached at the wheeled unit. The wheeled unit has a plurality of wheels for moving the wheeled unit over a support surface. The screeding head assembly includes a grade setting device and a vibrating member and is movable over the concrete area via the wheeled unit. The grade setting device includes an auger device having a longitudinal body and at least one flighting helically disposed around and along the body. The spacings between respective longitudinally adjacent vane portions of the at least one flighting vary longitudinally along the auger device.
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CROSS REFERENCE TO RELATED APPLICATION
The present application claims priority to U.S. Provisional Patent Application Serial No. 60/137,731 filed on Jun. 7, 1999, entitled “Method And Apparatus For Fracturing Brittle Materials By Thermal Stressing”.
FIELD OF THE INVENTION
The present invention relates to methods and apparatus for fracturing rock, ceramics, concrete and other materials of low elasticity. The invention relates in particular to methods and apparatus for fracturing rock for purposes of mining, excavation, and demolition.
BACKGROUND OF THE INVENTION
Mining and excavation of rock is commonly carried out using explosives. Typically, sticks of explosive are placed in holes drilled into the rock and then detonated, thereby explosively fragmenting a portion of the rockface being worked on. The rock debris created by the explosion is cleared away, and preparations begin for another blast.
The blasting method described above is time-consuming and expensive. Each blast takes a considerable time to set up and carry out. A large number of holes must be drilled into the rockface, then the explosives placed in the holes must be carefully interconnected with fusing apparatus to ensure that they detonate simultaneously. The resultant blast can throw rock debris large distances, unless the configuration of the blast is such that heavy and expensive blasting mats can be put in place to cushion the explosion and prevent the blast debris from flying away. As with any operation employing explosives, the blasting method also is inherently hazardous to the persons involved.
Accordingly, there is a need for rock mining and excavation methods which are faster and more efficient and thus less expensive than conventional blasting methods. There is also a need for rock mining and excavation methods which eliminate or substantially reduce the safety hazards associated with conventional rock blasting practices.
One possible alternative to conventional mining methods is to fracture the rock by means of thermal stress. It is well known that solid materials can fracture due to internal stresses induced by a large and sudden temperature change. A simple example of this is the shattering of a piece of glassware plunged into cold water after having been heated. Similarly, rock will shatter if it undergoes a temperature rise great enough and sudden enough to induce internal tensile stresses exceeding the inherent tensile strength of the rock. This would be a desirable result for purposes of rock mining and excavation. Material near the surface of a rock mass would be heated rapidly, and resultant thermal stresses would fracture the rock. The fractured material would be removed, then the process would be repeated on the fresh rock thus exposed, and so on until a desired amount of rock has been removed.
The practical difficulty with this concept, of course, is how to create such a sufficiently sharp and intense temperature rise in the surficial zone of a rock mass, before the heat thus transferred to the rock can be dissipated by conduction throughout the rest of the rock mass. One obvious aspect of the solution is to use an extremely hot source of heat. Conventional flame-heat sources, however, are not capable of achieving the desired result. An acetylene-oxygen flame, for example, can achieve a maximum temperature of approximately 3,100 degrees Celsius, but tests have indicated that even a flame this hot is not effective for producing thermal stresses intense enough to fracture rock.
U.S. Pat. No. 4,027,185 issued to Nodwell et al. on May 31, 1977, U.S. Pat. No. 4,700,102 issued to Camm et al. on Oct. 13, 1987, and U.S. Pat. No. 4,937,490 issued to Camm et al. on Jun. 26, 1990, the contents of which are incorporated herein by reference, disclose closely similar arc lamps capable of generating white light at temperatures as high as 12,000 degrees Celsius, considerably hotter than the temperatures which can be achieved with flame heat. These arc lamps have been developed and used for such applications as simulating, for purposes of scientific experiments, the high temperatures produced by nuclear explosions. The white light generated by these arc lamps is hot enough to heat rock high enough and quickly enough to produce thermal-stress-induced fracture, and in fact is capable of heating an object a great deal faster than a flame source.
This can be illustrated by the well-established heat transfer equation for radiant heat, as follows:
Q=σE F A (T 1 4 −T 2 4 )
wherein:
Q=amount of heat transferred
σ=Stefan-Boltzmann constant
E=emissivity
F=shape factor
A=area
T 1 =temperature of heat source
T 2 =initial temperature of heat absorber (i.e., object being heated)
This equation may be used to compare the amounts of heat transferred to an object by a white light source and by a flame source. Factors σ, E, F, and A will be constant for each case. Given that T 1 will be far greater than T 2 in either case, it is evident on inspection that the term (T 1 4 −T 2 4 ) may be reduced to merely T 1 4 without significant loss of accuracy. It follows, therefore, that:
Q L /Q F =T IL 4 /T IF 4 =(T IL /T IF ) 4
where:
Q L =amount of heat transferred to heat absorber by light source
Q F =amount of heat transferred to heat absorber by flame source
T IL =temperature of light source
T IF =temperature of flame source
Therefore, if the temperature of the light source is 12,000 degrees Celsius, and the temperature of the flame source is 3,100 degrees Celsius, the heat transfer from the light source will be (12,000/3,100) 4 or 225 times that of the flame source.
White light arc lamps of the type taught by Nodwell et al. and Camm et al. feature a hollow, elongate quartz arc chamber positioned within an elongate concave reflector. The reflector is hollow, so that liquid coolant may be circulated through the reflector to prevent it from becoming overheated under the intense heat generated by the arc chamber. For proper operation, this type of arc lamp requires an extremely clean environment. Even tiny amounts of dust or dirt on the quartz arc chamber or the reflector can cause the lamp to fail, or to function with significantly reduced effectiveness.
For these reasons, white light arc lamps have typically been used only in controlled environments such as experimental laboratories. If used, unmodified, for thermal-stress-induced fracturing of rock, they would likely malfunction because of the dirty air typically associated with rock mining and excavation operations. One apparent possible solution to this problem would be to enclose the arc chamber and reflector inside a translucent cover, thereby shielding them from airborne particles while allowing light to pass through. The solution cannot be quite this simple, however; airborne particles would build up on the cover, melt under the intense heat from the lamp, and interfere with the transmission of light from the lamp. Therefore, any cover over the arc chamber and reflector would have to be kept extremely clean, even in a dirty environment.
Accordingly, there is a need for an improved white light arc lamp, the arc chamber and reflector of which will remain clean and effectively dust-free even in environments having significant concentrations of airborne particulate matter. As well, there is a need for an improved white light arc lamp having means for keeping the arc chamber and reflector clean in dirty environments while also ensuring effectively unimpeded transmission of light from the arc lamp to a target object.
BRIEF SUMMARY OF THE INVENTION
In one aspect, the present invention is the use of high-intensity white light to induce thermal stress fracture in brittle materials such as rock, ceramics or concrete. In another aspect, the present invention is a method of fracturing brittle materials such as rock, ceramics or concrete, comprising the step of directing white light generated by a high-intensity arc lamp upon a mass of the brittle material until the material fractures due to induced thermal stresses.
In another aspect of the invention, the invention comprises a high intensity arc lamp for generating and directing high intensity light toward a target object, said arc lamp having an arc chamber and comprising:
(a) a convex reflector enclosure which partially encloses the arc chamber and which comprises an air inlet;
(b) an air plenum associated with the enclosure;
(b) a source of air for introduction into the air plenum;
(c) filtering means for filtering particulate matter from the air before it is introduced into the air plenum;
(d) a fan for forcing air from the air plenum through the air inlet segmented reflector and past the arc chamber, so as to create an air shield travelling outwardly away from the arc chamber and the reflector and deflecting airborne particulate matter away from the arc chamber and the reflector; and
(e) cooling means for cooling the reflector and peripheral surfaces of the air plenum.
Preferably, the convex reflector is divided into at least two segments which are spaced apart and the air inlet is the space(s) between the segments of the reflector. More preferably, the convex reflector comprises at least three longitudinal segments thereby providing at least two longitudinal air inlets between the longitudinal segments.
In another aspect, the invention comprises an apparatus for shielding the arc chamber and reflector against the entry and build-up of airborne particulate matter, for use in a high-intensity arc lamp having an elongate arc chamber positioned within an elongate concave reflector, said apparatus comprising:
(a) a translucent cylindrical shield mounted to the arc lamp so as to encircle and enclose the arc chamber and reflector, with the longitudinal axes of the translucent cylindrical shield and the arc chamber being substantially coincident or parallel;
(b) means for rotating the translucent cylindrical shield about its longitudinal axis; and
(c) means for continuously cleaning the surfaces of the translucent cylindrical shield as it rotates.
In yet another aspect, the invention comprises an apparatus for shielding the arc chamber and reflector against the entry and build-up of airborne particulate matter in a high-intensity arc lamp having an elongate arc chamber positioned within an elongate concave reflector, said apparatus comprising:
(a) a first shield chamber associated with one longitudinal edge of the reflector;
(b) a second shield chamber associated with the other longitudinal edge of the concave reflector;
(c) a translucent planar shield approximately as long and slightly more than twice as wide as the open side of the reflector, and positioned such that it completely closes off the open side of the reflector, thereby enclosing the arc chamber, and such that the portion of the translucent planar shield not thus positioned across the open side of the reflector at a given time will be housed within either the first or second shield chamber;
(d) means for moving the translucent planar shield in a reciprocating fashion in its own plane, such that it alternately extends partially into the first shield chamber and then partially into the second shield chamber while at all times being positioned across and closing off the open side of the reflector and enclosing the arc chamber;
(e) means within the first shield chamber and second shield chamber for cleaning the surfaces of the translucent planar shield as it moves alternately into or out of the first and second shield chambers.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the invention will now be described with reference to the accompanying drawings, in which numerical references denote like parts, and in which:
FIG. 1 is a schematic isometric drawing of a high-intensity arc lamp known in the prior art.
FIG. 2 is a schematic drawing of a high-intensity arc lamp equipped with the air shield and reflector apparatus of the present invention.
FIG. 3 is a schematic drawing of a high-intensity arc lamp equipped with an embodiment of the translucent cylindrical shield apparatus of the present invention.
FIG. 4 is a schematic drawing of a high-intensity arc lamp equipped with an embodiment of the translucent planar shield apparatus of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 schematically depicts a high-intensity arc lamp (also called a “white light lamp”) known in the prior art, generally indicated by the reference number ( 20 ). This device has an elongate light bulb referred to as an arc chamber ( 22 ), and a concave reflector ( 24 ) disposed substantially co-axially around the arc chamber ( 22 ). Light generated by the arc chamber ( 22 ) is focussed by and reflected outwardly from the reflector ( 24 ). The arc chamber comprises a cylindrical quartz tube within which a high intensity arc discharge between two electrodes is provided. Such arc chambers ( 22 ) are well known in the art. Suitable arc chambers may be as described in the Nodwell, et al. and Camm, et al. patents referred to above or may be available from Vortek Industries, Vancouver, British Columbia.
The reflector ( 24 ) directs the light to the target and must be water cooled to withstand the heat generated by the arc chamber. In one embodiment, the reflector defines internal water cooling passages (not shown) and baffles designed to allow water to flow through the reflector and cool the reflector.
Arc lamps having arc chambers which generate sufficient radiant heat energy may be used to fracture rocks. The lamp may be positioned close to the rock or rock surface which is to be fractured and turned on until the rock fractures. The distance from the lamp to the rock and the focus of the light may be adjusted to suit the needs of the application. In one embodiment, the distance between the arc chamber and the surface of the rock to be fractured may be about 10 centimeters to about 100 cm or more. The distance will depend on the size and susceptibility to heat stress of the rock, the power of the arc lamp and the length of time of exposure. The time of exposure may vary from a few seconds to 30 minutes or more.
As referred to above, it is very important to keep particulate matter such as dust and debris away from the arc chamber ( 22 ) and reflector ( 24 ). In one embodiment, this is accomplished by flowing a clean air stream past the reflector and arc chamber as an air shield so that dust and debris cannot get to the arc chamber and reflector.
FIG. 2 conceptually illustrates one embodiment of an air shield apparatus of the present invention, being a modification of the prior art high-intensity arc lamp described above. This apparatus has a segmented reflector ( 25 ) made with a number of reflector segments ( 25 a ) which define air passages ( 26 ) between them. An air plenum ( 30 ) positioned behind the segmented reflector ( 25 ) carries air from a compressed air source (not shown). The air is forced through the air passages ( 26 ), and is directed over, around, and outwardly away from the arc chamber ( 22 ), all as conceptually indicated by arrows “A”. The air is forced over, around, and away from the arc chamber ( 22 ) with sufficient velocity to deflect airborne particulate matter away from the arc lamp and thus to prevent such matter from coming in contact with the arc chamber ( 22 ).
In the preferred embodiment, a fan ( 32 ) is provided to increase the velocity of the air flowing through the air plenum ( 30 ). As well, an air filter ( 34 ) is interposed between the plenum ( 30 ) and the fan ( 32 ) in order to minimize or eliminate particulate matter which might be present in the compressed air, and which otherwise might come into contact with the arc chamber ( 22 ) and impair its function. Also in the preferred embodiment, cooling means (not shown) will be provided in association with the air plenum ( 30 ) to cool the air passing therethrough, so as to provide enhanced cooling of the segmented reflector ( 25 ) and the arc chamber ( 22 ).
In an alternative embodiment utilizing the air shield (not shown), the reflector may be unitary and air may be flowed past the reflector and arc chamber along the longitudinal axis of arc chamber. The specific direction of air flow is unimportant so long as clean or filtered air flows past the reflector and arc chamber and ultimately towards the potential source of dust or debris so that the air stream acts as a shield.
In another aspect of the invention, the arc lamp may be shielded from dust and debris by a transparent shield. However, as noted above, the arc lamp must be modified to keep the shield clean and free of dust and debris.
FIG. 3 illustrates an embodiment of this aspect of the present invention, in which a high-intensity arc lamp, having an arc chamber ( 22 ) and a water-cooled reflector ( 24 ), is fitted with a translucent cylindrical shield ( 40 ). The cylindrical shield ( 40 ) is mounted to the arc lamp so as to enclose, and to rotate substantially coaxially around, the arc chamber ( 22 ) and the reflector ( 24 ). As it rotates, the cylindrical shield ( 40 ) passes continuously through a shield-cleaning chamber ( 42 ) formed between two semi-cylindrical members ( 41 a , 41 b ). FIG. 3 shows the cylindrical shield ( 40 ) rotating counterclockwise, as indicated by arrow “R”, but it could be rotating clockwise with substantially the same effectiveness. Also, the cylindrical shield ( 40 ) need not rotate continuously in one direction. In one embodiment, the cylindrical shield may stop and reverse itself after making a full turn or a half turn. The object is to periodically clean the shield in the cleaning chamber ( 42 ) and to return it in position in front of the arc lamp. The speed of rotation may be varied in accordance with the conditions. In extremely dirty conditions, it may be necessary to rotate the shield ( 40 ) at a higher speed.
The cylindrical shield ( 40 ) provides a physical barrier preventing airborne particulate matter from coming in contact with the arc chamber ( 22 ). Undesirable accumulation of particulate matter on the cylindrical shield ( 40 ) is prevented or minimized by the continuous cleaning action of the shield-cleaning chamber ( 42 ). Disposed within the cleaning chamber ( 42 ) may be cleaning elements (not shown) in contact with the shield ( 40 ) such as wiper blades or soft cloths which clean the shield as it rotates within the cleaning chamber ( 42 ). The cylindrical shield may be slightly pressurized from the inside with a source of clean or filtered air so as to prevent particulate matter from entering inside the cylindrical shield. This configuration would also accommodate expansion and contraction of the air resulting from the heat generated by the arc chamber during operation.
The cylindrical shield ( 40 ) may be rotated by a chain or belt (not shown) driven by an electric or hydraulic motor or by any other suitable mechanical means for rotating the shield.
FIG. 4 illustrates a further embodiment of the shielding apparatus of the present invention. In this embodiment, a high-intensity arc lamp is fitted with an upper shield chamber ( 52 ) disposed along the upper edge of the reflector ( 24 ) of the arc lamp, plus a lower shield chamber ( 54 ) disposed along the lower edge of the reflector ( 24 ). A translucent planar shield ( 50 ) is movably positioned within continuous slots (not shown) in the upper shield chamber ( 52 ) and the lower shield chamber ( 54 ). The planar shield ( 50 ) is dimensionally configured such that it will can slide as far as possible into the upper shield chamber ( 52 ), as conceptually indicated by arrow “Q”, without being fully withdrawn from the lower shield chamber ( 54 ), and vice versa. Accordingly, the planar shield ( 50 ) at all times will completely span the space between the upper and lower edges of the reflector ( 24 ), thereby shielding the arc chamber ( 22 ) from contact with airborne particulate matter, regardless of the position of the planar shield ( 50 ).
Means are provided for reciprocating the planar shield ( 50 ) between the upper and lower shield chambers ( 52 , 54 ), each of which in turn includes means for cleaning the planar shield ( 50 ) as it moves in and out of the shield chambers. The shield chambers ( 52 , 54 ) may include wiper blades or soft cloths (not shown) to contact and clean the shield as it reciprocates in and out of the shield chamber. The reciprocating movement of the planar shield ( 50 ) and the continuous cleaning action of the upper and lower shield chambers ( 52 , 54 ) prevent or minimize undesirable accumulation of particulate matter on the planar shield ( 50 ), thereby preventing or minimizing physical interference with the transmission of light from the arc chamber ( 22 ) through the planar shield ( 50 ). As with the other embodiment, the enclosure created by the planar shield ( 50 ) may be slightly pressurized with a source of clean or filtered air to prevent ingress of particulate matter during operation.
The shield ( 50 ) may be reciprocated using any suitable mechanical means (not shown) such as an electric motor and a suitable configuration of gears to cause reciprocal vertical motion of the shield.
It will be readily seen by those skilled in the art that various modifications of the present invention may be devised without departing from the essential concept of the invention, and all such modifications and adaptations are expressly intended to be included in the scope of the claims appended hereto.
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A method of fracturing or breaking rock includes the step of directing high intensity white light at the rock to induce thermal stress sufficient to fracture the rock. An approach for generating high intensity white light includes an elongate arc chamber and an elongate concave reflector. The arc chamber and reflector may be shielded from airborne particulate matter by an air shield or a rotating or reciprocating translucent shield.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
FIELD OF THE INVENTION
The field of this invention relates to tools useful for shifting sleeves and similar equipment downhole.
BACKGROUND OF THE INVENTION
Sliding sleeves are frequently employed in downhole operations. The sliding sleeves are incorporated in tubing or casing, and when properly positioned in the wellbore such sleeves need to be shifted to open or close ports to accomplish a wide variety of downhole operations. Generally, sleeves have had an internal groove at either end so that a shifting tool could be oriented in one direction to engage one of the grooves and oriented in the well in an inverse orientation to engage the other groove on the shifting sleeve so that movement in the opposite direction could be achieved. These internal shifting grooves on sliding sleeves were engaged by dogs or collets that generally were radially loaded with coil or leaf springs so that they could pass over the end of the shifting sleeve and spring back into the shifting groove for a connection to the sleeve to move it in one direction or the other. Typical of such prior designs are U.S. Pat. Nos. 4,917,191; 5,211,241; 5,183,114; 5,305,833; 5,090,481; and 5,156,210.
The drawback of prior designs is that, as they are biased further outward radially, the motive force keeping them in that position decreases as the coil or leaf spring extends further and further. As a result, the force keeping the dogs, which engage the shifting sleeve in the engaged position, decreases as the dogs move radially outwardly, allowing the springs which drive them to expand. In many prior designs, the dogs were retained in a retracted position until the shifting tool reached the desired location, at which point a retainer would be moved out of the way, allowing the dogs to move outwardly into the shifting grooves on the sliding sleeve.
These prior designs had the drawbacks of not only a reduced pushing force on the dogs as they moved outwardly radially, but also the inherent unreliability of the small coil or leaf springs that had to be used in a very confined space in applications that called for a significant biasing force. Frequently, these springs would be subject to premature failure due to stress cracking or attack from surrounding contaminants.
The use of springs behind the locking dogs to drive them further outwardly also entailed designs which had fairly large profiles, making that type of layout difficult to use in applications requiring smaller diameters where a more compact design was necessary.
The apparatus of the present invention was developed to address the shortcomings of these prior designs. In the present design, a pivoting linkage is employed to engage the shifting grooves in the shifting sleeve. As the linkage expands further outwardly, a greater locking force is applied to the shifting groove. Jarring movements further increase the grip of the shifting tool of the present invention on the shifting sleeve. Additionally, the layout of the components is such that the pivoting linkage can be placed in an expanded position as the shifting tool is lowered toward the shifting sleeve, thereby allowing the linkage to compress as required to clear any obstructions along the way while springing out when finally contacting the groove on the shifting sleeve. The present design moves away from the leaf or small wire springs that had been previously used, and instead adopts a hydraulic actuation system which further involves the use of larger coil springs which provide greater flexibility to adjust the resulting force on the pivoting linkage when contacting the shifting sleeve.
SUMMARY OF THE INVENTION
A shifting tool is provided which is preferably hydraulically actuated. A built-up hydraulic force overcomes a retaining piston, which in turn frees up a pivoting linkage whose movements are opposed by a coil spring. The coil spring urges the pivoting linkage outwardly where contact can be made with the internal groove on a shifting sleeve. The shifting tool can be run in with the linkage in the expanded position since the parts are configured to allow the linkage to retract to clear any internal obstructions before reaching the shifting grooves in the shifting sleeve. The pivoting action of the grip on the groove in the shifting sleeve increases the gripping force when jarring occurs. The parts are configured so that there is a minimum of movement of shifting pans which have seals to further reduce potential wear on these pressure seals. A compact design is provided which can be useful on sleeves with a range of internal bores. The coil springs used in the preferred embodiment, which act against the linkage, can be easily replaced to adjust the force of engagement with the internal groove on the shifting sleeve.
DETAILED DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view of the shifting tool in the run-in position.
FIG. 2 is the view in FIG. 1, with the tool in the shifted or engaged position with the groove on the sliding sleeve.
FIG. 3 is similar to the view of FIG. 1, but with hydraulic pressure applied as the tool is being run in to indicate that the tool can assume the run-in position when it encounters an obstruction during run in.
FIG. 4 illustrates the apparatus A in section view, showing in more detail the position of the components when it is engaged in the sleeve.
FIG. 5 is the view of FIG. 4 after an emergency shear release, showing the movement of the parts after the pin is sheared.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The apparatus A is shown in the run-in position in FIG. 1. It has a mandrel 10 having a central passageway 12. A ball seat 14 is disposed in passage 12 and is formed to accept a ball or sphere 16 so as to obstruct passage 12 for subsequent pressure build-up. While a ball and seat combination has been described, other mechanisms for obstructing or restricting the passage 12 to facilitate pressure build-up are within the purview of the invention, such as an orifice which creates backpressure when flow is pumped through it.
A lateral port 18 communicates with variable-volume cavity 20. Seals 22, 24, and 26 effectively seal cavity 20. Seals 24 and 26 are located in retaining piston 28. Retaining piston 28 has an outwardly oriented shoulder 30 which is aligned with a shoulder 32 of linkage piston 34. Spring 36 is mounted over mandrel 10 and is supported by ring 38, whose position is retained by retainer 40 against shoulder 42 on mandrel 10. One end of spring 36 bears on ting 38 while the other end bears on retaining piston 28. Sleeve 44 is mounted over mandrel 10, with seal 22 therebetween to sealingly close off one end of cavity 20. Sleeve 44 has an inwardly-oriented shoulder 46, which is aligned with the bottom 48 of linkage piston 34. In the preferred embodiment, springs 36 and 50 are coil springs, with spring 36 being stiffer than spring 50. Spring 50 is disposed between bottom 48 and shoulder 46, and is normally retained in the compressed position shown in FIG. 1 due to the greater force extended against retaining piston 28 by spring 36. Because of this force imbalance, shoulder 30 firmly provides a travel stop to the linkage piston when its shoulder 30 engages shoulder 32 on the linkage piston.
As shown in FIG. 1, the linkage piston 34 can be made of several components and includes an upper segment 52 which contains a depression 54 adjacent its end. Adjacent the depression 54 is a projection 56. Projection 56 is mounted into depression 58 on link 60. Link 60 has a projection 63 which extends into depression 54 of upper segment 52. As can be seen by comparing FIGS. 1 and 2, link 60 translates when the linkage piston 34 is allowed to move, as will be explained below. Link 60 is pivotally connected to link 62 at pin 64. Link 62 is pivotally connected to link 66 by pin 68. Finally, link 66 is fixedly pinned at pin 70 for rotation about pin 70. However, longitudinally pin 70 is stationary. It should be noted that the distance from the centerline 73 to the pin 68 is greater than the distance between the centerline 73 and the pin 64. As a result of this centerline distance difference, translational movement of linkage piston 34 puts an outward force on pin 64, encouraging it to move in the manner illustrated in FIG. 2.
Link 66 has a special shape so that it may engage a groove 72 in the sleeve 74 which is to be shifted. In the position shown in FIG. 2, the sleeve 74 can be urged downwardly to either open or close an opening in a casing (not shown). Those skilled in the art will appreciate that sleeve 74 has a groove similar to groove 72 at its other end. The apparatus A can be inserted in a reverse orientation to that shown in FIG. 2 so that it may engage the similar groove on the sleeve 74 located at the other end of the sleeve from groove 72 for movement of the sleeve in an opposite direction. The apparatus A can be run in the orientation shown in FIG. 2 and at a later time rerun in the wellbore in a reversed orientation to move the sleeve 74 in the opposite direction. Alternatively, an assembly can be put together so that the apparatus A can be stacked upon itself, with one of the assemblies oriented in a manner shown in FIG. 2 and the other in a reversed orientation. In that situation, one or more ball seats, such as 14, can be provided, having differing dimensions to allow sequential operations of various assemblies of the apparatus A at different times as desired. Restricting orifices can be used as an alternate.
Referring now to FIGS. 1 and 2, it should be noted that the link 66 has an outwardly facing groove 75 which is defined by surfaces 76, 78, and 80. The angle between the surfaces 76 and 78 is close to a 90° angle ranging to an acute angle. The angle between surfaces 78 and 80 is obtuse. As a result, surface 76, along with surface 82, defines a projection 84 which, when link 66 is rotated to the position shown in FIG. 2, extends into groove 72 of sleeve 74. In the retracted or first position shown in FIG. 3 for link 66, surface 78 is oriented with a negative slope, indicated in FIG. 3 by arrows 108. When link 66 rotates to engage sleeve 74, surfaces 82 and the bottom 86 of groove 72 windup facing each other in a parallel or nearly parallel orientation to facilitate grip on the sleeve 74. It should be noted that the angle or movement of link 66 is fairly small, in the range of approximately 10°, at the time surface 82 extends into groove 72. At that time, it is preferred that the alignment of surface 82 is parallel to surface 86 which forms a part of groove 72. With the parts so configured, the rotational motion of link 66 puts surface 82 into groove 72 in the same orientation as if the groove 75 translated radially outwardly. The angular rotation of link 62 is greater than the angular rotation of link 66 and is in the order of approximately 30° in the position shown in FIG. 2 in the preferred embodiment. The translational movement of link 60 is quite small, in the order of three eights of an inch. This minimal longitudinal movement of linkage piston 34 reduces wear on seals 24 and 26. It should be noted that prior designs involving shifting sleeves, which in one way or the other were used in conjunction with spring-loaded dogs, involve longitudinal movements of such sleeves of as much as two inches and more, which caused a greater wear rate on the sealing mechanisms involved.
In the preferred embodiment, it is desirable to have the groove 75 in alignment with projection 88 which forms the end of the sleeve 74 to be shifted. When the links 62 and 66 are extended to the position shown in FIG. 2 and are aligned as previously described, jarring motions in the direction of arrow 89 further increased the grip of the linkage, comprised of links 62 and 66, to the sleeve 74.
It should be noted that while one linkage and actuating mechanism have been illustrated, a plurality of linkages distributed around the circumference of the tool is contemplated. Each of the linkages has an equivalent to the links illustrated in FIGS. 1 and 2. Each such linkage is in turn connected to upper segment 52 of the linkage piston 34 for tandem actuation. When disposed, as in the preferred embodiment, at 90° intervals and simultaneously actuated by the linkage piston 34, the outward movement of the identical linkages 62 and 66 acts to centralize the apparatus A within the sleeve 74, as well as to distribute the forces all around the sleeve 74 to facilitate its movement in the uphole or downhole direction with an application of a uniform force around its circumference.
In operation, the passage 12 should be obstructed so that hydraulic pressure can be built up in passageway or port 18. This is accomplished by dropping a ball or sphere 16 onto a ball seat 14 or in any other way obstructing the passage 12. A restricting orifice which creates a backpressure is another way to build pressure. Pressure is built up from the surface which communicates with variable-volume cavity 20 through the port 18. Upon an increase in pressure, as represented by arrow 90, the retaining piston 28 shifts from the position shown in FIG. 1 to the position shown in FIG. 2. In so doing, it compresses the spring 36. Once the force applied by spring 36 on retaining piston 28 is defeated, spring 50 is now free to move the linkage piston 34 until such time as shoulder 32 again contacts shoulder 30 on the retaining piston 28 or link 66 contacts the groove 72, whichever occurs first. As long as the pressure is maintained in port 18, the retaining piston 28 is taken out of consideration and the linkage piston 34 is free to translate against the opposing force of spring 50. Accordingly, the apparatus A may be run into the wellbore under pressure, such as when it is run on a coiled tubing. If any obstructions are encountered as the apparatus A is run into the wellbore, the obstructions would then impact link 66 and force it back toward the position shown in FIG. 1 from the position shown in FIG. 2, temporarily overcoming the force of spring 50. Once the obstruction is cleared, the link 66 can then rotate back outwardly under the force applied indirectly through spring 50 through the linkage. FIG. 3 illustrates running in while under pressure, with arrow 90 indicating pressure applied. It can be seen that there is a gap between shoulders 30 and 32. This is because the link 66 is pushed back into the run-in position when hitting an obstruction 92 schematically illustrated in FIG. 3. It can be readily appreciated that as long as the pressure represented by arrow 90 is maintained, link 66 will again rotate radially outwardly in a counterclockwise manner once it clears the obstruction 92. In the position shown in FIG. 3, the piston 34 has a range of motion available represented by the gap between shoulders 30 and 32.
There is an emergency release feature which is also illustrated in FIGS. 2, 4 and 5. As shown in FIGS. 4 and 5, mandrel 10 has a top sub 94 to which is connected an outer sleeve 96. Extending through outer sleeve 96 is a bore 98. A guiding sleeve 100 is disposed between outer sleeve 96 and anchor sleeve 102. Anchor sleeve 102 supports pin 70 to which link 66 is connected. At its lower end, guiding sleeve 100 extends over link 60 to guide it in its longitudinal movement. Guiding sleeve 100 further has a recess 104 which is aligned with bore 98 of sleeve 96. A shear screw 106 extends through bore 98 into recess 104 to secure the position of guiding sleeve 100. As shown in FIG. 4, the guiding sleeve 100 is locked against anchor sleeve 102, which would otherwise translate but for the existence of shear screw 106. When an emergency release is desired, a sufficient downward jarring force is applied while the apparatus A is in the position shown in FIG. 4. When sufficient stress is transmitted through the top sub 94 to the outer sleeve 96, the shear pin 106 can shear. Once that occurs, the assembly of the guiding sleeve 100 and anchor sleeve 102 are free to translate toward top sub 94. Once this occurs, pin 70 moves longitudinally toward top sub 94, thus retracting the linkage by allowing link 66 to rotate in a clockwise direction. It should be noted that the outer sleeve 96 further promotes the clockwise rotation of link 66 when shear pin 106 is sheared since movement of pin 70 toward top sub 94 rotates link 66 into alignment with outer sleeve 96 so that link 66 can advance under sleeve 96. Eventually, when sufficient clockwise rotation of link 66 has occurred to disengage from the groove 72 of sleeve 74, the apparatus A may be retrieved. Pulling upon top sub 94 facilitates this disengagement. It should also be noted that in the emergency release procedure, shear pin 106 is sheared which encourages the entire linkage to move toward and partially within outer sleeve 96, thereby instituting the clockwise rotation of link 66 to facilitate the disengagement from the groove 72 of sleeve 74. These motions are illustrated in more detail in FIGS. 4 and 5. The use of coil springs reduces failure which occurred in prior designs using leaf or small wire springs. Using the pivot action of links 66 and 62 increases the mechanical advantage of the force applied by spring 50. A more compact design is presented which can service a range of sleeve sizes. Wear on seals 24 and 26 is minimized as a very small longitudinal movement is magnified by a far greater radial movement of links 62 and 66.
The foregoing disclosure and description of the invention are illustrative and explanatory thereof, and various changes in the size, shape and materials, as well as in the details of the illustrated construction, may be made without departing from the spirit of the invention.
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A shifting tool is provided which is preferably hydraulically actuated. A built-up hydraulic force overcomes a retaining piston, which, in turn, frees up a pivoting linkage whose movements are opposed by a coil spring. The coil spring urges the pivoting linkage outwardly where contact can be made with the internal groove on a shifting sleeve. The shifting tool can be run in with the linkage in the expanded position since the parts are configured to allow the linkage to retract to clear any internal obstructions before reaching the shifting grooves in the shifting sleeve. The pivoting action of the grip on the groove in the shifting sleeve increases the gripping force when jarring occurs. The parts are configured so that there is a minimum of movement of shifting parts which have seals to further reduce potential wear on pressure seals. A compact design is provided which can be useful on sleeves with a range of internal bores. The coil springs used in the preferred embodiment, which act against the linkage, can be easily replaced to adjust the force of engagement with the internal groove on the shifting sleeve.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Patent Application No. 61/045,062, filed on Apr. 15, 2008, which is incorporated by reference herein in its entirety.
TECHNICAL FIELD
[0002] The present invention is directed to methods and apparatus to inject high energy density substances into subterranean environments where they react. More specifically, this invention is directed to methods and apparatus to inject high energy density fluids like reactive mono-propellants and other hypergolic fluids into subterranean environments through wellbores into the earth.
BACKGROUND OF THE INVENTION
[0003] When a fluid, such as oil and natural gas, is being produced from a subterranean reservoir through a wellbore the reservoir's ability to produce such fluids is often enhanced by processes that inject fluids and solids from the surface through a wellbore into subterranean reservoirs. There is one field of work that uses these fluids and is known to those familiar with the art of oil and gas production as stimulation fluids or hydraulic fracturing fluid, and the process involving these fluids is often referred to as hydraulic fracturing job or stimulation job. It is commonly believed that fracturing the subterranean rock in the reservoir will enhance hydrocarbon production from the well. This is accomplished by pumping the fluids at very high pressures that are greater than the fracture pressure of the subterranean reservoir, thus cracking the rock.
[0004] In early days explosives like nitroglycerin were dropped in wells to break up, crack, or otherwise stimulate the subterranean rock to produce fluids. These explosives had the limitation of only cracking the rock near the wellbore. Therefore, the idea of extending the fractures and cracks in the rocks far afield from the wellbore was developed using the injection of high pressure hydraulic fracturing fluids. The fluids injected as stimulation or fracture fluids are often mixed at surface with a variety of chemicals and solids prior to injection. Many fluid types are used including freshwater, saltwater, nitrogen, carbon dioxide, hydrogen peroxide, monopropellants, hydrogen fluoride, acids, bases, surfactants, alcohols, diesel, propane, liquid natural gas, with many combinations of these fluids and many more fluids. Some of these fluids are blended with solids like sand, bauxite, ceramic proppants, propellants, proppants, and/or catalysts and the fluid and solids are pumped as a slurry into the wellbore and reservoir rocks.
[0005] There are further chemicals and fluids mixed at the surface and injected with stimulation processes like acid stimulation jobs or steam injection stimulations to improve the reservoir's ability to produce back the injected stimulation fluids to surface and enhance the reservoir production of hydrocarbon fluids. This is because the stimulation fluids remaining in the rock matrix of the subterranean reservoir or the chemicals transported by the fluids reduce the reservoirs ability to produce commercial hydrocarbon fluids. Additionally, those familiar with the art of stimulation or fracture technology in the oil and gas industry often mix at surface viscosifier agents and/or cross-linkers to the stimulation fluid, enhancing the fluid's ability to transport solids into the reservoirs. What is needed is a method and apparatus to add large amounts of heat generated inside the well during well stimulation as opposed to generating heat at surface and transporting the heat down the well.
[0006] Further, current industry practice of adding to stimulation fluids chemicals such as hydroxypropyl guars, polyacryl imides, and cellulose gelling agents reduces the hydraulic friction between the fluids being pumped and the well conduits that transport the fluids from surface to the subterranean reservoir. These are often referred to as friction reducer chemicals. As the oil and gas industry continues to find more gas and oil in lower permeability rocks, and in ever lower pressured “resource plays,” like shale gas and coal bed methane, shale oil, and tar sands, it becomes ever more important to find substances to pump into the reservoir rock to enhance the hydrocarbon production by reducing the detrimental effects of the chemicals added for friction reduction.
[0007] Moreover, there is a problem with these methods when the fluids, particularly water, are produced back from the wells because they must be treated to re-use in subsequent wells or safely and environmentally disposed. There are many detrimental issues with this produced back fluid. For example, while flowing back from the subterranean environment, injected fluids containing friction reduction chemicals, gelling agents, scale inhibitors surfactants, crosslinkers, and hydrogen sulfide gas often contain bacteria that feed on the gels and poly acrylimdes and thus are not suitable for surface disposal or re-injection into subsequent wells during a subsequent stimulation, enhanced oil recovery method, or hydraulic fracture treatment. In the case of hydrogen sulfide gas production while flowing fluids from the wells, the ability to neutralize and treat this gas in the wellbore system would be a great improvement over the current art of flowing to facilities where the hydrogen sulfide (H 2 S) gas is stripped out with various ammine solutions. Moreover, the lack of water resources in areas of large hydrocarbon recovery restricts the use of water as a treatment fluid.
[0008] Before the current invention, methods to enhance production of hydrocarbons from wells used by those familiar with the art of treating stimulation fluids mixed friction reducers, gelling agents, cross linkers, and/or surfactants into water at surface prior to injecting the fluid and chemicals down a well casing or tubing. These chemicals are typically batch mixed into the stimulation fluids to be injected at the surface into large holding tanks, known as frac tanks, or the chemicals are added “on the fly” at surface to the stimulation or fracture fluid by injecting them into the discharge of a large centrifugal pump at the surface. The mixed fluid is then pumped through high pressure pumps and injected into the well and the reservoir at very high pressures and normally high injection rates thereby exceeding the fracture pressure of the reservoir rock. Hence the stimulation or rock fracturing is largely done with hydraulic forces.
[0009] This process, often referred to as “hydraulic fracturing,” is thought to crack or break the subterranean rock in the reservoir giving the reservoir more conductivity for the production of reservoir fluids like oil and gas. The objective is to put as much energy out away from the wellbore into the formation rock well beyond the wellbore to crack rock far field from the wellbore thereby improving the fluid conduction path from the far afield rock to the wellbore. Using current methods the hydraulic energy is highest at the wellbore where the stimulation or fracture chemicals enter into the well, and the energy available to crack and stimulate becomes progressively less as the stimulation and fracture fluids travel out beyond the wellbore. The typical method of treating heavy oil, tar sands, and depleted light oil reservoirs is to heat fresh water into steam and inject the steam into the wellbore once again concentrating most of the energy injected into the reservoir rock to near the wellbore. This stimulation or enhanced oil recovery method requires large amounts of fresh water, and the process loses considerable amounts of the heat energy in the transportation of the steam from surface to the subterranean environment.
[0010] A still further method of fracturing or stimulating subterranean rock reservoirs or stimulating subterranean reservoirs has been the dropping of explosives into the wells or injecting liquid and solid propellants, like nitroglycerin, dynamite and high grades of hydrogen peroxide, directly into reservoir rock. Hydrogen peroxide is known to decompose into hot water and oxygen in many reservoir rocks where the rocks act as a catalyst for the decomposition and no oxygen is required. The problem with this method is the very rapid and uncontrolled decomposition rate of hydrogen peroxide near the wellbore and the unpredictability of the reactivity of the reservoir rock as a catalyst.
[0011] It is desirable to use fluids with large chemical energy storage that do not require an oxygen environment to combust or decompose so that more chemical energy is available in the subterranean environment and may be placed far underground and far afield from the wellbore out into the reservoir to stimulate the subterranean reservoir with energy other than solely hydraulic energy, like heat and the expanding products of the fluids combustion and decomposition in the presence of catalyst, ignitors, and geothermal temperatures.
[0012] When a fluid, such as oil and natural gas, is being produced from a subterranean reservoir the reservoir energy depletes with time. It has been found that by the injection of certain fluids from the surface such as, nitrogen, water, steam, carbon dioxide, flue gas, air, and combinations of these fluids into a depleted or mature hydrocarbon reservoir the production of hydrocarbons from the depleted reservoir can be enhanced. There is one field of work that uses these fluids and is known to those familiar with the art of oil and gas production as Enhanced Oil Recovery, EOR. It is also known that the injection of heat can greatly enhance the injected fluid's ability to recover hydrocarbons from the depleted or mature reservoirs. This is particularly the case in “steam floods” and “steam assisted gravity drainage methods”, known as SAGD to those in the field of EOR, which uses injected steam from the surface but suffer from the heat loss as the steam is injected from surface and heat is lost along the length of the well and the surface pipe infrastructure in a field thereby delivering less heat energy to the subterranean reservoir. What is needed is a method to generate heat in-situ.
[0013] It has been found that by the injection of certain fluids like air, natural gas, oxygen, and combinations of these fluids into a depleted or mature hydrocarbon reservoir the production of hydrocarbons from the depleted reservoir can be enhanced by igniting the oil, natural gas, coal, tar sand, shale oil, shale gas, or kerogen located in-situ in the reservoir. The field of work that uses these burning fluids is known to those familiar with the art of oil and gas production as Fire Flooding or In-Situ retorting. It is known that the placement of heat in-situ can greatly enhance the fuel in-situ to ignite. This is particularly the case in tar sands and shale oil reservoirs. What is needed is a method to generate heat in-situ in the reservoir as far from the wellbore as possible with ignitable fluids or with fluids that will assist in the ignition of the in-situ reservoir fluids.
[0014] Additionally, enhanced oil recovery projects, in-situ retorting of shale oil, fire floods, and fracture and stimulation treatments are often performed in parts of the world that have high ambient surface temperatures, where the use of explosive and reactive fluids like hydrogen peroxide becomes more dangerous as these fluids become more reactive as their temperature increases at surface. Likewise, enhanced oil recovery projects, in-situ retorting, fire floods, fracture, and stimulation treatments are often performed in parts of the world that have low surface temperatures, such that the reactive fluids like hydrogen peroxide might freeze, rendering them unpumpable. Currently, when using water as the work fluid this cold condition is easily resolved by heating the working fluid, e.g. water, with heat exchangers for stimulation or EOR projects. The methods to maintain the temperatures on the surface of highly reactive mono-propellants for example is not currently available. What is needed are methods and apparatus to allow for the temperature control of high energy density fluids to allow them to be injected safely at well sites into wells.
[0015] For example currently, a hot oiler truck comes to the well that is to be stimulated with water fracture based fluids and, by burning propane on the truck's heat exchangers and passing the working fluid to be pumped into the well, the truck heats up the working fluid on the truck such that heated fluid passes through heat exchangers on the truck and at the same time passes the working fluid, usually water, to be used for the stimulation treatment over the truck's heat exchanger and then re-circulates the fracture treatment water back to a heated holding tank. In this way the fracture treatment water is heated in cold weather such that it can be pumped and does not get solid on the surface. However, this heating method of pumping the fluids into a heat exchanger on a truck that is burning propane is exceedingly dangerous when the fluids to be pumped are mono-propellants like hydrogen peroxide or hydrazine.
[0016] A still further need to transmit large amount of energy beyond the wellbore in an interval is known to those familiar with the art of enhanced oil recovery, EOR, and in-situ retorting of hydrocarbons. This need to get energy out into the subterranean reservoirs beyond the wellbore can also be extended to the new and evolving field of enhanced gas recovery, EGR, and fluid sequestering like CO2. In both EOR and EGR, there is a need to get energy down wellbores and out into the reservoir. Indeed, the method of horizontal wells for steam flooding was developed to allow the steam energy to contact larger portions of the subterranean reservoir.
[0017] A still further method of enhanced oil recovery, or indeed subterranean in-situ retorting of oil is to place large heaters in the earth to heat hydrocarbons and kerogens such that they can be produced from the subterranean intervals. Subterranean heaters, however, cannot heat large areas of the subterranean reservoir far afield from the wellbore because the heater is located in wellbore and the earth is a great heat sink. To improve the heating of the subterranean reservoir, one must drill either a large number of heater wells and add exceeding large amounts of heat in these wells from surface or drill very expensive and long horizontal wells in which heaters are placed. In all cases the desire is to get energy, and in the case of enhanced oil and gas recovery, heat energy large distances from the wellbore. In the case of oil shale, the immense amount of heat needed to remove the oil from the shale is not cost effective, hence a method is needed to ignite and to feed oxygen to the oil shale, using the in-situ generated heat from the combustion of some of the oil shale or kerogen to heat the oil shale reservoir. However, getting oxygen to the oil shale is not easy due to the shale's low inherent permeability which makes the injection of oxygen into the rock away from the wellbore very difficult. What is needed is a fluid that can heat the rock, ignite in the rock, and deliver oxygen to the rock while assisting in the burning of in-situ fluids.
[0018] What is needed is a method to transmit large amounts of energy beyond the wellbore in a subterranean interval being stimulated to enhance oil or gas production. A further need is to accomplish this far field from the injection wellbore for enhancement effect in the subterranean reservoir with substances that will not reduce the permeability of the reservoir or otherwise inhibit the reservoir to produce fluids back to the wellbore and to the surface. A further need is to reduce the environmental damage done on the surface of the earth and sea by the flow back to surface of stimulation and fracture fluids containing chemicals and bacteria. A still further need is to have available methods and apparatuses to safely handle and control the rate of reaction of reactive fluids and solids such as propellants, catalyst, and fuels pumped into subterranean environments like reservoir rocks at outdoor well sites that may have cold and hot surface environments. Many wells are located in locations on the earth where the surface temperatures are below the sublimation temperatures of many reactive mono-propellant fluids like hydrogen peroxide or hydrazine. What is needed is a method to keep these reactive high energy density substances, like liquid propellants, from freezing at well sites with cold surface temperatures.
BRIEF SUMMARY OF THE INVENTION
[0019] The present invention is directed to new methods and apparatuses to treat subterranean reservoirs through wellbores with reactive high energy density substances. This invention teaches methods and apparatuses that allow substances such as mono-propellants, oxidizers, catalysts, and fuels to be injected into subterranean environments to release large amounts of energy into the subterranean environment by controlling their temperature, thus allowing these fluids to be injected safely.
[0020] In one aspect of the present invention, surface vessels, conduits, and/or pumps are designed to perform a process that maintains the highly reactive substances and their transport fluids in a low reactive state by controlling their temperature while at surface.
[0021] In a further aspect of the present invention highly reactive high energy density substances are frozen into solid form and mixed into cold fluids to allow the solid substances to be delivered to a well site, pumped and transported as a slurry into the well and out into the reservoir with the transport fluids that keep the substances cold. The invention further teaches methods to blend the substances with fuels, oxidizers, mono-propellants, and catalysts at low temperatures to keep the blend in a low reaction state.
[0022] In another aspect of the present invention highly reactive high energy density fluids are heated, and monitored to maintain them in a liquid state on surface at a well site where cold surface environment temperatures are below the propellants freezing point, to allow the propellant to be pumped as a liquid into the well.
[0023] In a still further aspect of the present invention a method is presented to form solid reactive materials from liquid reactive materials using cold solids to seed the formation of the reactive fluids.
[0024] In a still further aspect of the present invention a method is presented to ignite highly reactive high energy density fluids in a down hole reaction chamber connected to a coiled tubing thereby directing said fluids to be pumped from an appropriately temperature controlled surface storage vessel, through surface lines, through a coiled tubing string disposed in a well through a wellhead sealing pack off elastomeric device with a reaction chamber on the coiled tubing distal end that atomizes high energy density fluid and ignites the fluid allowing the coiled tubing to articulate in the well bore the position of the reaction chamber while pumping the fluid from surface thereby releasing heat and or decomposition products from the reaction chamber into the subterranean environment.
[0025] In a still further aspect of the present invention a method is presented to provide energy to a subterranean environment by directing a reactive high energy density fluid from a surface storage vessel (that is optionally temperature controlled), through surface lines, through a conduit such as a coiled tubing string disposed in a wellbore, and into the wellbore where the fluid decomposes or reacts. In some embodiments, upon exiting the conduit, the fluid enters a down hole reaction chamber connected to the conduit. In the reaction chamber, the high energy density fluid is ignited, and may atomized to assist in ignition. The reaction chamber can have a one-way valve that allows the fluid and/or reaction/decomposition products to exit the chamber and enter the formation, but prevents flow in the reverse direction.
[0026] The method can include reciprocating the reaction chamber (such as by reciprocating the conduit) to release heat or reaction/decomposition products along a length of the wellbore. At or near the wellhead, the conduit can be directed through an appropriate pack off elastomeric device to provide a seal.
[0027] In another aspect, a method is provided for the in situ treatment of hydrogen sulfide, comprising pumping a reactant that reacts with hydrogen sulfide to produce desirable products such as elemental sulfur into a wellbore via a stainless steel (as opposed to carbon steel) conduit and reacting the reactant with the hydrogen sulfide to produce desirable products. In some embodiments, the reactant comprises hydrogen peroxide and the product comprises elemental sulfur.
[0028] The foregoing has outlined rather broadly the features and technical advantages of the present invention in order that the detailed description of the invention that follows may be better understood. Additional features and advantages of the invention will be described hereinafter which form the subject of the claims of the invention. It should be appreciated by those skilled in the art of hydrocarbon production enhancement from wells that the conception and specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures and methods for carrying out well hydrocarbon production enhancement. For example the well production enhancement for enhanced oil recovery, in-situ processing of shale oil, coal, coal bed methane, shale gas, and tar sands, as well as other well enhancement fields, can use the methods and apparatuses of this invention. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the invention as set forth in the appended claims. The novel features which are believed to be characteristic of the invention, both as to its organization and method of operation, together with further objects and advantages will be better understood from the following description when considered in connection with the accompanying figures. It is to be expressly understood, however, that each of the figures is provided for the purpose of illustration and description only and is not intended as a definition of the limits of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] For a more complete understanding of the present invention, reference is now made to the following descriptions taken in conjunction with the accompanying drawing, in which:
[0030] FIG. 1 is a schematic showing the well site and equipment of the present invention;
[0031] FIG. 2 is a schematic of the well site and equipment of the present invention;
[0032] FIG. 3 is a schematic of an apparatus used to ignite monopropellants in a subterranean environment in a reaction chamber attached to a stainless steel coiled tubing while reciprocating the reaction chamber; and,
[0033] FIG. 4 is a schematic of hydrogen sulfide gas sweetened in-situ.
DETAILED DESCRIPTION OF THE INVENTION
[0034] As used herein, “a” or “an” means one or more. Unless otherwise indicated, the singular contains the plural and the plural contains the singular.
[0035] In many aspects and embodiments, the present invention uses reactive high energy density substances that can deliver a relatively high amount of energy per unit weight. Examples of such substances include 10% hydrogen peroxide, 100% hydrogen peroxide, hydrazine mixtures, and other substances.
[0036] In the embodiment of FIG. 1 , tank 1 holds a reactive fluid 50 and has shroud 3 located around inner tank 2 . Many reactive fluids may be used, including but not limited to hydrogen peroxide, hydrazine, monopropellants, hydrogen fluoride, hypergolic fluids (i.e., combustible without an ignition source), acids, bases, alcohols, diesel, propane, liquid natural gas, and combinations thereof. The reactive fluid 50 is preferably stored, monitored, and temperature controlled inside inner tank 2 . Located inside tank shroud 3 are heat exchanger tubes 4 connected to a heat exchanger 5 , which is preferably outside reactive fluid tank 1 . Heat exchange tubes 4 are also located inside inner tank 2 . The heat exchange permits safe temperature control of a reactive fluid, preferably cooling it to a temperature to retard its reactivity, but keeping it above a temperature such that it can be pumped into the well. This allows a reactive fluid to be introduced to a well in a activity-reduced state so that it can be directed to the outer parts of the reservoir 28 before reacting completely. In some embodiments, temperature control is required to heat the reactive fluid, such as when the ambient temperature would freeze the fluid to a point where it cannot be pumped.
[0037] In one embodiment, heat exchanger fan 6 blows air across heat exchanger tubes 4 in heat exchanger 5 , and is driven by prime mover 7 . Other means of heat exchange are also in the scope of this invention. In one embodiment, the tank shroud 3 is filled with a suitable fluid, and heat exchanger tubes 4 are submersed in the reactive fluid. The reactive fluid is enclosed by shrouds filled with dilution fluids like water that allows for dilution of the reactive fluid in the event of a leak. In one embodiment, the fluid filling tank shroud 3 is water, and for convenience this disclosure may refer to water. Of course, other fluids can be used that provide either heat exchange or safety via dilution, or preferably, both. Heat exchanger 5 , tank 1 , inner tank 2 , shroud 3 , and tubes 4 are not limited to the geometries, orientations, or structure disclosed in the FIG. 1 and FIG. 2 , but rather can be any form suitable for the objects of this invention.
[0038] The water in shroud 3 can be circulated from water tank 10 through pump 11 with the water returning from tank shroud 3 to water tank 10 . In one embodiment, tank 1 can be instrumented with temperature monitoring sensors 8 , and in one embodiment the sensors are optical fibers 8 , disposed inside tubes 4 and tubes 9 located inside tank 1 , both in tank shroud 3 and inside inner tank 2 . Optical fibers 8 can be used as temperature sensors themselves and are preferably monitored with an Optical Time Domain Reflectometer machine (“OTDR”) 12 that launches light down the fibers and interprets the backscatter light back to the machine to give continual distributed temperature profiles from the optical fibers 8 . This device is often referred to as an OTDR Distributive Temperature System (“OTDR DTS”). Additionally, the circulation of water from tank 10 through tank 1 in shroud 3 allows for an even heat to be maintained in the reactive fluid inside inner tank 2 . Thus, FIG. 1 shows the adding or removing of heat from the reactive fluid using a heat transfer fluid in tank 1 . Additionally, FIG. 1 shows the continuously monitoring of the temperature of shroud 3 and fluid inside inner tank 2 . For example, monitoring the temperature using optical fibers 8 interrogated with OTDR DTS machine 12 .
[0039] The embodiment of FIG. 1 has a hot oiler truck 13 that can heat the water in tank 10 , but other heating systems can be used. The hot oiler truck puts energy, Q in , into the system. The water can be transferred from the tank 10 through suction line 14 by pump 15 . The water is heated in hot oil truck 13 by burning propane on the truck and passing the water from tank 10 across the hot heat exchangers of truck 13 and then returning the heated water to tank 10 . The heated water from tank 10 can then be transferred to tank 1 through pump 11 and line 16 . The water from tank 1 is returned to tank 10 through line 17 to water tank 10 . Temperature sensors such as optical fibers 18 can monitor the temperature in tank 10 via methods such as an OTDR DTS machine 12 . Thus, the reactive fluid is indirectly heated by hot oil truck 13 using the fluid from tank, 10 which increases the safety of the temperature control process.
[0040] Thus FIG. 1 demonstrates how heat can be added to or removed from the reactive fluid 50 in tank 1 by using heat exchanger tubes 4 from the water in tank 10 . In some cases, the water in tank 10 is heated from the heat exchanger on truck 13 . The temperature of shroud 3 and the fluid inside inner tank 2 can be monitored continuously using temperature sensors, such as optical fibers interrogated with an OTDR DTS machine 12 .
[0041] The embodiment in FIG. 1 shows a reactive fluid being transferred from tank 1 where the reactive fluid 50 is stored and maintained at a temperature sufficiently above its solid temperature to allow transport downhole but sufficiently below a temperature such that its action is reduced. In one embodiment, the chilled reactive fluid travels through injection pump 19 through a shrouded suction conduit 16 A, which has water or other fluid circulated inside its shroud from water tank 10 . Water is delivered to shroud of conduit 16 A, via pump 11 and water line 16 , and the water returns from the shroud through line 17 .
[0042] In one embodiment, pump 19 is enclosed in shroud 20 , which may use fluid from tank 10 in a manner similar to other shrouds described above. Pump 19 is powered by any known means, but preferably by hydraulic power pack 21 and controlled remotely from a frac van 22 with hydraulic controls via hydraulic control line 23 . Hydraulic control pack 21 is powered by prime mover 24 that is preferably monitored and controlled remotely from the frac van 22 by hydraulic control line 25 . The use of hydraulic power increases safety when working with reactive fluids.
[0043] Injection pump 19 pressurizes the reactive fluid and the substances from tank 1 and injects them into (preferably shrouded) high pressure conduit 26 for injection into well 27 and out into subterranean reservoirs 28 . In a manner similar to other shrouds described, shrouded high pressure conduit 26 can have water supplied from tank 10 via pump 11 and line 29 , and water is returned to water tank 10 through line 34 . In one embodiment, wellhead 30 is shrouded with wellhead shroud 20 , which receives a fluid such as water from tank 10 through line 29 A, and the fluid returns to tank 10 through line 31 .
[0044] Thus FIG. 1 demonstrates how a temperature controlled reactive fluid is transferred from a temperature controlled tank and injected into well 27 and into subterranean reservoirs 28 . The water and other fluids in the shrouded conduits and pumps maintains the high pressure reactive fluid at a desirable temperature and maintains a means to capture and dilute any reactive fluid that may leak out from the inner high pressure conduit. In some embodiments, shrouds will serve to cool the reactive fluid, while in other embodiments they will serve to heat the reactive fluid. Thus, a reactive fluid is maintained at a proper temperature in a surface vessel located at a well site, tank 1 , and the reactive fluid is then injected at the desirable temperature into well 27 to allow the injected reactive fluid and substances to reach the subterranean reservoirs 28 in a low reactive state, thereby allowing the reactive fluid to be injected far afield beyond the wellbore, 40 , before the fluid and the substances react and release chemical energy. The position beyond the wellbore is shown in FIG. 1 as element 40 .
[0045] In one embodiment, the temperature of the reactive fluid is continually monitored in the well using at least one temperature sensor such as optical fiber 32 using the OTDR DTS machine 12 . Thus, FIG. 1 shows an exemplary embodiment that illustrates that the down hole temperature of an injected reactive fluid can be controlled from surface by adding or removing heat at surface from the fluid in tank 1 through the heat exchanger 5 . It is clear to those familiar with the art of well treatment that multiple injection pumps 19 can be used to inject reactive fluid from multiple reactive fluid tanks 1 and the temperature controlled by multiple heat exchangers 5 and injected through multiple surface shrouded conduit lines 26 into single well 27 allowing higher injection rates into subterranean reservoirs 28 .
[0046] In another embodiment shown in FIG. 2 , a reactive fluid can be mixed with other materials in mixer 36 . In one embodiment, temperature controlled tank 1 holds a cold fluid, like liquid nitrogen or liquid CO 2 , which is delivered to blender vessel 36 through pump 35 . Tank 1 can be temperature controlled by any known manner. A reactive material, like solid 90% hydrogen peroxide, is transferred into blender vessel 36 from tank 33 and the materials from tank 1 and tank 33 are then mixed into a pumpable form, such as a slurry, in blender vessel 36 and injected into well 27 through high pressure injection pump 19 and far into the subterranean reservoirs.
[0047] In another embodiment a reactive fluid like hydrogen peroxide can transferred from tank 1 at a controlled temperature, and solids like sand, ceramics, bauxite, proppants, and/or catalyst, can be added from tank 33 through a pump 240 into blender vessel 36 . Other reactive fluids and solids can be used as are known in the art. In embodiments where the temperature of the fluid in vessel 36 is desired to be cold, solids from tank 33 are preferably cool or cold. The solids and reactive fluid are mixed and injected into the well 27 and out into the reservoir 28 . Thus, reactive fluids are delivered into the reservoir 28 at a low temperature, increasing the distance the reactive fluid can be placed beyond the wellbore, releasing energy into the far field of subterranean reservoir 28 .
[0048] In another embodiment a reactive fluid is transferred from tank 1 at a controlled temperature, and very cold solids can be added from tank 33 into blender vessel 36 . The solids preferably have a temperature lower than the freezing point of the reactive fluid from tank 1 , thereby causing the reactive fluid to freeze around and in the solids. The solids thusly coated with reactive fluid are pumped out of blending vessel 36 into well 27 and into the subterranean reservoirs 28 . Thus, reactive fluids are delivered into the reservoir 28 at a low temperature, greatly increasing the distance the reactive fluid can be placed beyond the wellbore, releasing energy into the far field of subterranean reservoir 28 .
[0049] For example, the fluid in blender vessel 36 is kept cool by adding cold fluids, such as, cryogenic fluids, liquid nitrogen, methanol, or water, from tank 38 through pump 39 to the shroud of vessel 36 . Heat can be removed from mixing vessel 36 in heat exchanger 5 . Likewise, if the surface environmental temperatures are lower than the reactive fluids freezing point, blender 36 can be heated via a shroud or other heat exchanging system, which receives fluid such as hot water from tank 38 . Hot oiler truck 13 can heat the water in tank 38 using the propane burners and a heat exchanger on hot oiler truck 13 . If desired, the slurry leaving blender vessel 36 can be further temperature controlled before well injection by adding or removing heat via a heat exchange fluid in tank 37 , which can be controlled in any known manner, preferably with hot oiler truck 13 when heat, Q IN , is required.
[0050] Once the injected fluid and solid warms up in the subterranean reservoir 28 and releases energy, Q out , e.g., by igniting, the in-situ energized fluid in the reservoir can be flowed back to the well surface through a line to a surface tank. This high temperature reaction in the reservoir and the reaction products will combine and further enhance the in-situ hydrocarbons' ability to flow from the well.
[0051] FIG. 3 shows a schematic of an apparatus used to ignite monopropellants in a subterranean environment in a reaction chamber attached to a stainless steel coiled tubing while reciprocating the reaction chamber. In FIG., the reaction chamber, 310 has an igniter, 302 , located in reaction chamber 310 and is connected to an electrical power transmission cable, 309 . The electrical power transmission cable is interwoven in the continuous coiled tubing and the cable is connected to a battery and/or capacitor, 301 . The battery and/or capacitor is positioned near the reaction chamber 310 . The coiled tubing, 307 , is lowered from a reeling device 311 or drum, through an elastomeric seal, 308 . The elastomeric seal is located at the surface and separates the surface environment from the subterranean well environment containing the reaction chamber. The reactor chamber 310 is positioned in the well, 312 , inside a well casing 306 . In one aspect of the present invention, the igniter 302 inside the reaction chamber 310 is powered using electrical power from a surface source 313 and/or a subterranean source 301 . Monopropellant fluid 315 is then pumped from a vessel 314 on surface with at least one pump 316 and the monopropellant fluid is transmitted through a swivel joint 317 and through the coiled tubing 309 on reel 311 . The fluid is then ejected from atomizers 303 located inside the reaction chamber 310 . Within the reaction chamber, 310 , the atomized fluid is ignited using the igniter 302 . The igniter is initiated using transmitted electrical power from the surface source 313 , and/or the down hole source 301 to the igniter. Once the monopropellant 315 is ignited in the reaction chamber, the combustion products 316 are transmitted out of the reaction chamber 310 into the well casing 306 along with the heat produced by the combustion reaction within the chamber. The elastomeric seal 308 allows for the reciprocation of the coiled tubing 309 from surface. The coiled tubing is reciprocated from the surface to the reaction chamber 310 inside the well 312 while simultaneously pumping the monopropellant 315 into the coiled tubing 307 . The coiled tubing is directed through the coiled tubing injector head 321 , the elastomeric seal 308 and into the well casing 306 . Also, the coiled tubing transports the electrical power to the igniter in the reaction chamber 310 . Another function of the coiled tubing is to dispose the combustion products 316 and to direct the heat into the surrounding subterranean reservoir 304 . While simultaneously flowing well fluids 318 from a subterranean reservoir 304 through perforations 305 , directing combustion products 316 to surface and igniting monopropellant fluids 315 in the reaction chamber 310 , the surface injector head 321 reciprocates the coiled tubing 309 in the well.
[0052] In FIG. 3 , a Optical Time Domain Reflectometry machine, 319 , directs light down an optical fiber 320 which is disposed in the coiled tubing 309 . Directing light from the source 319 into the optical fiber 320 and monitoring the back scatter light reflected back to the optical machine, a computer 319 uses algorithms to analyze the reflected light and to determine the temperature profile of the well. Since an optical fiber is used, the entire length of the optical fiber 320 is capable of being used as a sensor.
[0053] Now directing your attention to the FIG. 4 which illustrates hydrogen sulfide gas sweetened in-situ. In FIG. 4 , a stainless steel continuous tube, 401 , is disposed inside a production tubing 402 . The production tubing is also disposed in a well casing 403 . The well casing has a packer 404 located on the production tubing. This packer seals the well casing 403 above the packer 404 from fluids in the casing below the packer 404 . Hydrogen peroxide fluid 405 is disposed in a temperature controlled vessel 406 , and pumped into the stainless steel coiled tubing 401 . As the hydrogen peroxide is pumped into the stainless steel coiled tubing, hydrogen peroxide is forced out an injection valve 407 . This injection valve is located at the distal end of the coiled tubing 401 which provides a means for mixing the hydrogen peroxide 405 with hydrogen sulfide fluids 408 being produced in the subterranean reservoir. The mixing of the hydrogen peroxide with the hydrogen sulfide allows the subterranean hydrogen sulfide fluid being produced from the reservoir to react with the hydrogen peroxide fluid 405 being injected into the well 312 . As stated above, the hydrogen peroxide is injected through the coiled tubing 401 . This subterranean fluid mixing serves to remove hydrogen sulfide gas from the flowing well fluid 408 . Because the fluid is flowing, the reaction products resulting from the reaction of hydrogen peroxide 405 and the well fluids with hydrogen sulfide gas 408 flows to the surface and these products are directed out of the well into a flow line 409 at surface.
[0054] In another embodiment, at least one hypergolic component is pumped down a wellbore. In yet another embodiment, at least two hypergolic components are separately pumped down a wellbore released such that they will mix in the wellbore. For example, a first reactive substance such as hydrogen peroxide is pumped from the surface into the wellbore and reservoir using one conduit, and a second substance that will spontaneously ignite with the first substance, such as ammonia, is pumped from the surface into the wellbore and reservoir using a separate conduit. The two substances will mix in the wellbore and subterranean formation forming a hypergolic fluid. The substances may, in some embodiments, be temperature, pressure controlled, and/or shrouded as described in any one of the above embodiments.
[0055] In any of the embodiments, the containers and conduits can be made from any material known in the art, such as stainless steel. The containers and/or conduits can, if desired, be passivated, coated with films, chemical films, or metal oxides, and/or otherwise treated to enhance the overall process. If a surface is passivated, it is desirable to test the surface for passivation at various times. In some embodiments, pressure monitoring and/or testing is desired for certain containers and/or conduits.
[0056] In another embodiment, a method provides energy to a subterranean environment by directing a reactive high energy density fluid from a surface source (such as a temperature controlled vessel), through surface lines, through a conduit (such as a coiled tubing) disposed in a wellbore, and into the wellbore where the fluid decomposes, ignites, or reacts to form products that comprise elemental oxygen. The energy of this reaction heats the surrounding formation. In addition, the elemental oxygen product reacts with in situ hydrocarbons to propagate additional reactions into the formation, which can generate heat, decompose heavy hydrocarbons and kerogen into lighter hydrocarbons, and increase the productivity of the well.
[0057] In an another aspect of the present invention, acoustical and/or seismic energy is transmitted from the surface to the reaction chamber. This energy is used to ignite an explosive in the reaction chamber. In an alternate and/or specific example, acoustical energy is used to heat at least one element in the reaction chamber.
[0058] In some embodiments, upon exiting the conduit, the fluid enters a down hole reaction chamber connected to the conduit. In the reaction chamber, the high energy density fluid is ignited, and atomized to aid the ignition. The reaction chamber can have a one-way valve that allows the fluid and/or reaction/decomposition products to exit the chamber and enter the formation, but prevents flow in the reverse direction. In some cases, the method includes reciprocating the reaction chamber (such as by moving the conduit) to release heat or reaction/decomposition products along a length of the wellbore. At or near the wellhead, the conduit is directed through an appropriate pack off elastomeric device to provide a seal.
[0059] In another embodiment, a method is provided for the in situ treatment of hydrogen sulfide. Hydrogen sulfide is a dangerous chemical with many undesirable qualities. Hydrogen peroxide reacts with hydrogen sulfide to produce elemental sulfur and other products. Moreover, hydrogen peroxide reacts with or interacts with many materials found in oxides of metals and subterranean minerals, with a very reactive catalyst being iron oxide. Hence the injection or transport of hydrogen peroxide into wells with iron or carbon steel tubulars, frac lines, or well heads is highly dangerous, and becomes exceedingly dangerous as the percentage of active hydrogen peroxide is increased.
[0060] In some embodiments, the current method uses a stainless steel (as opposed to carbon steel) conduit to carry substances, such as hydrogen peroxide, that react with hydrogen sulfide to produce desirable products, such as elemental sulfur. The reactant is delivered into a wellbore via a stainless steel conduit, where it reacts with the hydrogen sulfide to produce desirable products. Thus, as fluids are produced back, they contain less (or no) harmful hydrogen sulfide, which increases safety and saves time and money because the need to treat the hydrogen sulfide is reduced or eliminated. In any or all of the embodiments, the conduit is a continuous conduit, meaning that it is not made up from repeated threaded joints.
[0061] Although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the invention as defined by the appended claims. Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, composition of matter, means, methods and steps described in the specification. As one of ordinary skill in the art will readily appreciate from the disclosure of the present invention, processes, machines, manufacture, compositions of matter, means, methods, or steps, presently existing or later to be developed that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein may be utilized according to the present invention. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps.
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The invention relates to methods and apparatuses for the subterranean injection of reactive substances like propellants into wellbores and subterranean reservoirs. These methods and apparatuses controls the temperature of a reactive substance for safe handling at surface and controls the decomposition rate of the substances in the subterranean environment. In addition, these methods and apparatuses provide a means for safe dilution of reactive fluids in the event of a leak or spillage of the reactive substance.
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BACKGROUND OF THE INVENTION
[0001] The present invention relates generally to latches.
[0002] Latches are known in the art and are provided for the latching and the opening of a member such as a door or panel.
[0003] In addition, it is oftentimes desired that the lock cylinder of latches generally have the capability of being opened with a master key in addition to a lower level security key. This is particularly true in the case of marine applications where the individual members of a crew need access to individualized areas which the captain of the vessel also needs access to. However, there may be locked areas which are only to be accessible by the captain of the ship. In such cases, the captain would need a high level security key or master key to access his areas and also the crews areas.
[0004] In many prior art lock cylinders, the door or panel in which the lock cylinder was installed needed to be as thick as a significant portion of the length of the key which is inserted into the lock cylinder. This resulted in very long lock cylinders which oftentimes would protrude from the back side of the door or panel due to the length of the lock cylinders. Accordingly, due to space limitations it is desired to have a door or closure member which can accommodate a lock cylinder which is thin or in other words where the length of the axis of the lock cylinder is as short as possible so that the lock cylinder when installed in the door does not protrude from the front or back of the door.
[0005] A need therefore exists for a lock cylinder for a latch having a master key capability which can be accommodated in doors of a thickness which prior art lock cylinders could not be accommodated in.
[0006] Previously, in order to secure a door or panel with a high degree of security, users were required to operate deadbolt locks which consume valuable space around a door and frame.
[0007] A need exists for a low profile, high security, ergonometric latch assembly which can be opened by rotation of a knob on one side of the latch assembly or a lock which is accessible by key turned by a user on the other side of the latch.
[0008] The present invention has been developed in view of the foregoing and to overcome the deficiencies of the prior art.
SUMMARY OF THE INVENTION
[0009] In accordance with the present invention, it is an object of the invention to provide an ergonometric hook latch which has an easy to use manual lock on one side of the hook latch when the latch is installed either directly in a door or panel, and a second lock on the other side of the hook latch which uses a key. The latch can be actuated by rotation of a knob of the latch or by unlocking of the hook latch through the use of a key.
[0010] It is an object to provide an improved lock cylinder having master key capability which is readily adaptable to different thicknesses of doors or closure members.
[0011] Another object of the present invention is to provide a door lock that is easy to operate.
[0012] A further object of the invention is to provide a lock cylinder which has a very low profile or thickness and which can be used in applications where space and thickness is a limiting factor.
[0013] It is a further object of the invention to provide a lock cylinder which can be fitted with two different annular rings, one of which is designed to operate the lock cylinder with only a master key and another which is to operate the lock cylinder with either a master key or a low level security key.
[0014] It is another object of the present invention to provide a hook latch for fastening to a keeper which is able to be mounted in any of the following configurations: clamshell, flush-mounted, mortise mounted, and surface mounted.
[0015] A further object of this invention is to provide such a lock cylinder with structural components which offers ease of assembly, and reliable operations.
[0016] The objects of the present are realized in a hook latch for fastening and unfastening a closure member to a keeper in a latched position. The hook latch is moveable between the latched position and an open position. The hook latch comprises a rotation means which preferably comprises a knob connected to a cam shaped protuberance which acts upon an actuator plate and a locking plate. Upon rotation of either the knob or the key which is inserted in a lock cylinder which has a locking ring having a cam-shaped protuberance, the cam-shaped protuberances displace both the actuator plate and the locking plate. When the locking plate is displaced from the open position, first and second pawls which are each fixed at a rotation point at one end of each of the first pawl and second pawl are also rotatable about the rotation point. Due to the presence of a pawl pin in each of the first pawl and second pawl, the displacing motion of the actuating plate casues a rotation of each of the pawls into the latched position such that the first and second pawl can engage a keeper.
[0017] When the rotation of the knob about a first axis or key about a second axis causes the shaped protuberances on the locking ring and the rotation means to extend closest to the opposing axis, the engagement of the protuberances on the locking plate extend the locking plate into an extended position against the urging of a biasing means or coil spring mounted on a biasing means support on the locking plate. As the rotation means is rotated a prong on the actuator plate rides over a detent on the locking plate to a position where the locking plate and actuator plate are in the latched position wherein the locking plate detent prevents motion of the actuator plate back to the open position. The actuator plate is prevented from moving to the open position by interference of the actuator plate prong with the detent on the locking plate until the detent is withdrawn by the withdrawal of the locking plate detent upon rotation of the rotation means or key by a user. Accordingly, accidental motion of the first pawl or second pawl in the latched position or unauthorized tampering with the first or second pawl would not result in the hook latch being opened due to the interference of the actuator plate prong with the detent of the locking plate.
[0018] The objects of the present invention are also realized in a lock cylinder configured for a key. Master key functionality is attained by adding an annular ring to the basic lock cylinder structure and modifying the profile of the low level security key. A separate key profile for each key is provided to provide the master key capability. A portion of one of the bits of the master key is machined deeper than the low level security key and has a key stop where the bit abuts the stem. When the lock cylinder is provided with a master annular ring, the lock cylinder can only be operated by the master key and not the limited access low level security key due to the presence of a tab on the master annular ring provided on the front of the lock cylinder which prevents entry of the limited access or low level security key into the lock cylinder. The master key can also operate the lock cylinder when the lock cylinder is fitted with a low level security annular ring which does not have the tab which is present on the master annular ring.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] The features, advantages and operation of the present invention will become readily apparent and further understood from a reading of the following detailed description of the invention with the accompanying drawings, in which like numerals refer to like elements, in which:
[0020] FIG. 1 is a side elevational view of the low level security key for use with one embodiment of the present invention;
[0021] FIG. 2 is a front elevational view of the lock cylinder for use with one embodiment of the present invention having a low level security annular ring;
[0022] FIG. 3 is a side elevational view of the master key for use with one embodiment of the present invention;
[0023] FIG. 4 is a front elevational view of the lock cylinder for use with one embodiment of the present invention having a master annular ring;
[0024] FIG. 5 is a perspective view of the lock cylinder and low level security key for use with one embodiment of the present invention in a locked state shown with a low level security annular ring;
[0025] FIG. 6 is a perspective view of the lock cylinder and low level security key for use with one embodiment of the present invention in an unlocked state shown with a low level security annular ring;
[0026] FIG. 7 is a rear elevational view of the lock cylinder and low level security key for use with one embodiment of the present invention in a locked state shown with a low level security annular ring;
[0027] FIG. 8 is a side elevational view of the lock cylinder and low level security key for use with one embodiment of the present invention in a locked state shown with a low level security annular ring;
[0028] FIG. 9 is a side elevational view of the lock cylinder and low level security key for use with one embodiment of the present invention in an unlocked state shown with a low level security annular ring;
[0029] FIG. 10 is an exploded view of the lock cylinder for use with one embodiment of the present invention without either a master annular ring or a low level security annular ring;
[0030] FIG. 11 is an exploded view of the lock cylinder and low level security key for use with one embodiment of the present invention in a locked state shown with a low level security annular ring;
[0031] FIG. 12 is a top plan view of the low level security annular ring for use with one embodiment of the lock cylinder of the present invention;
[0032] FIG. 13 is a perspective view of the low level security annular ring for use with one embodiment of the lock cylinder of the present invention;
[0033] FIG. 14 is a perspective view of the lock cylinder for use with one embodiment of the present invention shown without a low level security annular ring or a master annular ring;
[0034] FIG. 15 is a side view of the lock cylinder for use with one embodiment of the present invention shown without a low level security annular ring or a master annular ring;
[0035] FIG. 16 is a perspective view of hook latch of the present invention in the latched position installed in a door in a clamshell configuration, the hook latch having a knob a key inserted;
[0036] FIG. 17 is a side view of the hook latch of FIG. 17 in the latched position;
[0037] FIG. 18 is a perspective view of hook latch of the present invention in the open position installed in a door in a clamshell configuration, the hook latch having a knob a key inserted;
[0038] FIG. 19 is a side view of the hook latch of FIG. 18 in the open position;
[0039] FIG. 20 is an exploded view of the hook latch of the present invention in a clamshell configuration;
[0040] FIG. 21 is a top plan view partially cut away of the hook latch of the present invention latched to a keeper 35 ;
[0041] FIG. 22 is a bottom plan view partially cutaway of the hook latch of the present invention latched to a keeper;
[0042] FIG. 23 is an exploded view of the hook latch of the present invention in the latched position;
[0043] FIG. 24 is an exploded view of the hook latch of the present invention in the open position with the hook latch cover plate and hook latch frame removed;
[0044] FIG. 25 is a bottom plan view of the hook latch of the present invention in the latched position with the hook latch cover plate and hook latch frame removed;
[0045] FIG. 26 is a side view of the hook latch of the present invention in the latched position with the hook latch cover plate and hook latch frame removed;
[0046] FIG. 27 is a top plan view of the hook latch of the present invention in the latched position with the hook latch cover plate and hook latch frame removed;
[0047] FIG. 28 is a perspective view of the hook latch of the present invention in the latched position with the hook latch cover plate and hook latch frame removed;
[0048] FIG. 29 is a perspective view of the hook latch of the present invention in the open position with the hook latch cover plate and hook latch frame removed;
[0049] FIG. 30 is a bottom plan view of the hook latch of the present invention in the open position with the hook latch cover plate and hook latch frame removed;
[0050] FIG. 31 is a side view of the hook latch of the present invention in the open position with the hook latch cover plate and hook latch frame removed;
[0051] FIG. 32 is a top plan view of the hook latch of the present invention in the open position with the hook latch cover plate and hook latch frame removed;
DETAILED DESCRIPTION OF THE INVENTION
[0052] FIGS. 16-19 show the hook latch of the present invention in a clamshell configuration in a door 29 . Rotation of the key 1 or knob 41 actuates the latch and first and second pawl move from the latched and unlatched position. FIG. 20 shows the knob stem 48 which actuates rotation means 33 which in turn actuates rotation means protuberance 34 seen in FIG. 22 where the hook latch latches door 29 to frame 30 .
[0053] In FIG. 22 , rotation of the low level security annular ring 7 by a key (not shown) rotates actuator 28 such that locking ring protuberance 34 of locking ring 32 has displaced actuator plate 37 into the extended position in which first pawl 38 and second pawl 39 are latched.
[0054] In the exploded views of FIGS. 23 and 24 of the hook latch, it can be seen that the rotation of a knob which in turn rotates rotator 49 in yoke 55 causes rotation means protuberance 34 in first actuator plate aperture 50 to displace actuator plate 37 such that the first pawl 38 and second pawl 39 rotate to the latched position. This is achieved by the rotation of first pawl 38 about first pawl rotation pin 56 which causes first pawl actuation pin 57 which is connected to first pawl 38 at first pawl actuator pin aperture 64 to move in actuator plate slot 63 . First pawl 38 rotates about first pawl rotation pin aperture 58 in cover plate 46 and first pawl aperture 65 .
[0055] The second pawl 39 rotates in a similar way as first pawl 38 . Rotation of second pawl 39 about second pawl rotation pin 61 causes second pawl actuation pin 60 which is connected to second pawl 39 at second pawl actuator pin aperture 66 to move in actuator plate slot 63 . Second pawl 39 rotates about second pawl rotation pin aperture 59 in cover plate 46 and second pawl aperture 67 .
[0056] As the rotation means 33 is rotated actuator plate prong 68 on the actuator plate 37 rides over a locking plate detent 69 on the locking plate 36 to a position where the locking plate 36 and actuator plate 37 are in the latched position wherein the locking plate detent 69 prevents motion of the actuator plate 37 back to the open position as seen. The actuator plate 37 is prevented from moving to the open position by interference of the actuator plate prong 68 with the locking plate detent 69 on the locking plate 39 until the locking plate detent 69 is withdrawn by the withdrawal of the locking plate detent 69 upon of the key or knob by a user to move the latch to the open position. Accordingly, accidental motion of the first pawl 38 or second pawl 39 in the latched position or unauthorized tampering with the first pawl 38 or second pawl 39 would not result in the hook latch being opened due to the interference of the actuator plate prong 68 with the locking plate detent.
[0057] The latching means also comprises a biasing means 70 here a coil spring which biases the latch to the open or latched position.
[0058] The latch can be maintained in the open position by action of the locking plate detent 69 upon the actuator plate prong 68 as seen in FIG. 29 .
[0059] As seen in FIG. 25 , when the knob 41 is rotated actuator plate corner 71 and actuator plate guide 72 ensure that the locking ring protuberance moves in concert with rotation means protuberance 34 .
[0060] As seen in FIG. 23 , motion of the actuator plate 37 is stopped by engagement of actuator plate stop 53 with actuator plate frame stop 54 .
[0061] The hook latch can be locked and unlocked in two different ways: by either the use of a key, most preferably by low level security key 1 or master key 12 as shown in FIGS. 1 and 3 .
[0062] The lock plug 8 can be provided for access by the low level security key 1 or the master key 12 as described in detail below.
[0063] The above described invention permits a user to rotate front handle 66 or rear handle 67 and actuate the actuator in the direction of the pawl actuator 31 and allows the user to latch a door or panel in which the latch assembly is installed to a keeper.
[0064] In a preferred embodiment of the present invention, the hook latch is adapted for use with a low level security key and/or a master key.
[0065] As seen in FIG. 1 , low level security key 1 has grip portion 3 to be held by a user of the low level security key 1 and a stem 2 extending from the grip portion 3 . Individual bittings 4 are formed on at least one of the bits of the low level security key 1 . Stem 2 of the key 1 which is preferably cylindrical in cross section extends from the grip portion 3 to the bits of the low level security key 1 . As shown in this embodiment the low level security key 1 , one end of the low level security key 1 is in a star profile as seen in FIG. 7 and has three bitted bits 5 . The fourth bit which forms part of the remaining portion of the star profile is the low level security key stop bit 15 which terminates in a low level security key stop 6 . Low level security key 1 is dimensioned and configured to be inserted into lock cylinder 13 which has low level security annular ring 7 as seen in FIG. 5 until low level security key stop 6 contacts low level security annular ring 7 which thereby prevents further insertion of low level security key 1 into lock plug 8 .
[0066] The low level security key stop 6 has a depth equal to the difference between the distance from the top of the low level security key stop bit 15 to the axis of low level security key 1 and the distance from the top of the low level security key stop 6 to the axis of the low level security key, wherein the depth of the low level security key stop 6 is less than the depth of the master key stop 16 .
[0067] When the lower level security key 1 or master key 12 is inserted, one or more of the bitted bits 5 engage tumblers (not shown) in the lock plug 8 and lock shell 10 which in the locked state extend from lock plug apertures 24 in the lock plug 8 into corresponding lock shell apertures 24 in lock shell 10 . After insertion of the low level security key 1 , the bitted bits 5 push and align the tumblers which are preferably biased by a biasing means such as a coil spring into positions such that none of the tumblers contacts simultaneously both the lock plug 8 and the lock shell 10 thereby permitting rotation of the lock shell 10 relative to lock plug 8 . A user then turns grip portion 3 of the low level security key 1 in a clockwise direction as seen in FIG. 6 to unlock the lock plug 8 from the lock shell 10 .
[0068] Lock cylinder 13 of FIG. 2 which is shown with low level security annular ring 7 also accommodates master key 12 of FIG. 3 as the depth of master key stop 16 is sufficiently deep as measured from the top of the master key stop 16 to the top of the master key stop bit 25 to permit passage of the master key 12 into the lock plug 8 until master key stop 16 is prevented from being inserted further into the lock plug 8 by contact with ring stop 9 on low level annular ring 7 . The master key stop 16 has a depth equal to the difference between the distance from the top of the master key stop bit 25 to the axis of the master key 12 and the distance from the top of the master key stop 16 to the axis of the master key 12 . Therefore, lock cylinder 13 when provided with the low level annular ring 7 can be operated with either the master key 12 or low level security key 1 .
[0069] In FIG. 4 , the same lock plug 8 and lock shell 10 as seen in FIG. 2 is provided, however a master annular ring 17 is shown screwed to the front of the lock plug 8 by screws 19 . The master annular ring 17 is different from the low level annular ring 7 of FIG. 2 in that the master annular ring 17 has a tab 18 which prevents insertion of low level security key 1 into lock plug 8 . The low level security key 1 is prevented from being inserted into the lock plug 8 by the contact of low level key stop 6 against tab 18 . On the other hand, master key 12 can be inserted into lock plug 8 in FIG. 4 because of the greater depth of master key stop 16 which permits passage of the master key stop bit 25 below tab 18 . Accordingly, master key 12 can function as a master key which has the capability of opening both the lock cylinder 13 when it is provided with a low level security annular ring 7 and the lock cylinder 13 when it is provided with a master annular ring 17 .
[0070] In the same way if a user were to try to insert the low level security key 1 in the lock cylinder 13 while the lock cylinder 13 is fitted with a master annular ring, the bit 15 would be blocked from entering the lock cylinder 13 by tab 18 on the master annular ring 17 .
[0071] FIGS. 10 and 11 show an exploded view of the lock cylinder 13 of the present invention having shell 10 and lock plug 8 . In order to provide for mounting of the lock cylinder 13 in a latch, prongs 14 are provided mounted in an apertures 20 in the lock shell 10 . Also, the lock shell 10 is provided with grooves in which plates 21 are fitted to keep biasing means, i.e. coil springs, and tumblers in the lock shell 10 and lock plug 8 . Lock plug 8 is also fitted with ring support 22 which serves to maintain the relative position of either the master annular ring 17 or the low level security annular ring 7 . In a preferred embodiment, the lock shell 10 is fitted with a ball bearing aperture 23 in which ball bearing 27 is located together with a biasing means (not shown) such as a coil spring. The ball bearing 27 in the ball bearing aperture 23 is biased toward the lock plug 8 which has a detent (not shown) in which a portion of the ball bearing 27 will rest when the lock plug 8 is properly aligned with lock shell 10 .
[0072] Preferably, the lock plug 8 is located concentric to and rotatable inside of and relative to said lock shell 10 , and said lock plug 8 is configured for insertion of said master key 12 or said low level security key 1 .
[0073] Low level security annular ring 7 as shown in FIGS. 12 and 13 has a ring stop 9 which contacts key stop 6 when the low level security key 1 is used and which contacts master key stop 16 when the master key 12 is used. The ring stop 9 can be of any shape which permits insertion of the master key 12 and the low level security key 1 into the lock plug 8 but acts as a stop against a portion of the master key stop 16 or low level security key stop 6 respectively. The tab 18 of the master annular ring 17 can be of any shape, thickness or configuration which permits insertion of the master key 12 up to the master key stop 16 but which does not permit insertion of the low level security key 1 due to contact of the low level security key stop bit 15 against the tab 18 .
[0074] Tab 18 extends into an interior portion of the ring formed by the master annular ring 17 and the tab 18 permits insertion of the master key stop bit 25 into the lock plug 8 until the master key stop 16 contacts the tab 18 on the master annular ring 17 .
[0075] Actuator 28 on master annular ring 17 or low level annular ring 7 which are both preferably in the form of a ring actuate the means by which the latch or lock in which the lock cylinder 13 is unlocked when a user unlocks the lock cylinder 13 and rotates either the master key 12 or low level security key 1 .
[0076] As can be seen by a comparison of FIG. 1 and FIG. 3 , a master key and a low level security key can preferably be provided which can have identical bittings on the bits of the two keys. However, when the basic lock cylinder configuration of a lock plug and lock shell is provided with a master annular ring then only the master key can open the lock cylinder. However, the lock cylinder can be opened by a low level security key or master key when the lock cylinder is fitted with the low level security annular ring.
[0077] Many changes can be made in the above-described invention without departing from the intent and scope thereof. It is therefore intended that the above description be read in the illustrative sense and not in the limiting sense. Substitutions and changes can be made without departing from the scope and intent of the invention.
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A hook latch for fastening and unfastening a closure member to a keeper in a latched position. The hook latch is moveable between the latched position and an open position. The hook latch comprises a rotation means which preferably comprises a knob connected to a cam shaped protuberance which acts upon an actuator plate and a locking plate. Upon rotation of either the knob or the key which is inserted in a lock cylinder which has a locking ring having a cam-shaped protuberance, the cam-shaped protuberances displace both the actuator plate and the locking plate.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to excavation apparatus of the type which employs high velocity air to loosen soil and a pneumatic vacuum to remove the loosened soil, and in particular to excavation apparatus having an improved air lance nozzle with a blade-shaped orifice, an improved air lance adapted to be rotated during excavation, and an improved pneumatic vacuum system including a multistage venturi ejector adapted to be fitted on a material collection container.
2. Discussion of Related Art
The concept of vacuum excavation has been discussed in a number of prior patents. U.S. Pat. Nos. 4,776,781, 4,936,031, 5,140,759, and 5,361,855 all disclose pneumatic soil excavation systems in which a jet of air is directed against a mass of soil by a hand-held nozzle to cause the mass to break up, and in which the loosened soil is collected by entraining it in an air flow carried by a pipe or conduit, and depositing the entrained soil at a site away from the excavation.
The theory underlying the concept of vacuum excavation is well-known. Essentially, application of supersonic jets of air causes local fracturing of the soil and rapid release of expanding high pressure air trapped within the soil at the local fracture sites. The fracturing and gas-release properties of the soil are not shared by man-made structures buried within the soil, such as natural gas lines, water pipes, sewer lines, and the like, and thus these structures are unaffected by the supersonic air jets.
Loosening of the soil by local fracturing and rapid expansion of gases trapped in the soil rather than by direct impact means that the air delivery device generates relatively low reaction forces and can be manipulated by a single person. Vacuum excavation therefore increases productivity relative to hand-excavation methods, i.e., shovels, without sacrificing precision, significantly reducing visible alteration of local landscaping or paving. In addition, the use of a high vacuum for material collection causes an effective evacuation of solid material from difficult to reach areas such as beneath or behind pipes, where shovels cannot fit or are difficult to maneuver.
Despite these advantages, however, the conventional vacuum excavation systems have a number of disadvantages that have prevented their widespread use. On the air lance side of the apparatus used in the conventional systems, the disadvantages include difficulties in handling the air lance, which conventionally must be “bounced” up and down to loosen layers of soil across an area of the excavation, and the need for a larger air supply than is available from the type of air compressor commonly used by contractors to operate pneumatic equipment. On the material collection side of the conventional vacuum excavation apparatus, the disadvantages include both the high initial cost of the vacuum generating equipment, and high maintenance costs.
One of the reasons for the large air consumption on the air lance side of the apparatus is the low resistance provided by the conventional cylindrical nozzle or pipe nipple. Because of this problem, nearly all companies currently performing vacuum excavation are forced to use high volume (100 cubic feet per minute (cfm) or greater) high pressure compressed air for soil breakup.
In order for an air lance to be an effective digging tool, the air must exit the lance at supersonic velocity which creates a shock wave in the air, and in order to create a shock wave at the tip of a ¼ inch pipe nipple, a high volume of high pressure air is needed. The typical air lance consists of ¾ or 1 inch internal diameter pipe with a reducer and a ¼ inch internal diameter pipe nipple at the digging end, and is supplied by a vehicle-mounted engine driven air compressor having an airflow rating of 180 cfm or greater. Since the most commonly available compressor has a rating of 185 cfm, the conventional cylindrical air lance requires the full power of the compressor, leaving the compressor unavailable for use as an air supply for a vacuum system, or to power other equipment, thus necessitating a separate engine driven vacuum pump.
On the vacuum collection side of the conventional vacuum excavation apparatus, most vacuum excavation systems employ vacuum pump and engine systems that require use of positive displacement blowers and various stages of filtration or cyclonic separation between the collection container and the positive displacement blowers, as the blowers are very susceptible to internal damage from particulates passing into the motive sections. Motors to drive the positive displacement blowers in the conventional vacuum pump and engine systems vary but generally range between 15 and 50 hp, with some systems making use of power take off linkage from the vehicle on which the unit is mounted.
In addition to being expensive and difficult to maintain, such systems are difficult to transport, and generally can only effectively access locations less than 25 feet from the vacuum source. The V-belts, filters, and internal combustion engines associated with vacuum pump/engine systems require complicated maintenance, which is compounded by the typically dirty and dusty work environments in which they are used, with those systems utilizing truck mounted hoppers being especially difficult to clean. In addition, conventional excavation systems of this type have poor water handling capabilities, since water can contaminate the vacuum generating equipment and especially the filters. Such systems can obviously not be taken indoors or up to work zones in high rise buildings.
While systems have also been proposed which use venturi-type ejectors to generate the vacuum and thereby reduce maintenance costs by eliminating the need for complex filtration or cyclonic separation systems, the conventional venturi systems require high air volumes (450 CFM or more) to generate an effective suction, and therefore require the use of large high cost air compressors and high volume connection hoses, which negates the advantage of simplicity offered in theory by the venturi engine concept.
The ultimate effect of these disadvantages is that, in order to begin using a conventional vacuum excavation system, an initial investment of greater than $100,000.00 is required, with significantly increased operating costs to be expected during the life of the system. This puts the cost of vacuum excavation apparatus out of reach of virtually all private contractors, not to mention others who might benefit from an inexpensive air lance and material removal system. On the other hand, the apparatus of the invention, as described below, currently has a cost of approximately one fourth the minimum cost of the conventional systems, and far lower transportation and maintenance costs.
SUMMARY OF THE INVENTION
It is accordingly an objective of the invention to provide an improved vacuum excavation system having greater versatility, lower maintenance, and lower initial costs than conventional vacuum excavation systems.
It is a second objective of the invention to provide a vacuum excavation system which uses a single portable air compressor of the type commonly used to operate tools at construction sites, as opposed to a dedicated positive displacement blower, or unusually large air compressor.
It is a third objective of the invention to provide a vacuum excavation system which can be maintained by daily cleanup of the vacuum engine, pickup pipe or hose, and collection drum, and in which the portable air compressor can be remotely located. The system has no need for filters or cyclonic separators between the vacuum source and the collection stream.
It is a fourth objective of the invention to provide a vacuum excavation system with improved water handling capabilities, and which can therefore be used for utility vault drainage, eliminating the need for a trash pump, and which can provide dewatering apparatus capable of 200 gpm transfer at 15 foot lift.
It is a fifth objective of the invention to provide a vacuum excavation system which occupies a reduced footprint and is modular.
These objectives are achieved by making three principal improvements to the conventional systems:
The first principal improvement involves an improved air lance nozzle which provides reduced air consumption by replacing the ¼ inch cylindrical pipe nipple of conventional systems with an elongated blade-like structure that achieves supersonic airflow through the use of a slit having a gap of only 0.01 or 0.02 inches and a width of approximately 1.5 inch.
The second principal improvement is to combine the blade style orifice of the improved nozzle with an air lance made of thin wall tempered pipe and a T-shape handle to enable rotation of the lance, a swivel adapter on the air supply hose, and a lever style valve placed at the fingertips of the operator, to enable spinning of the air lance, in place of the conventional technique of bouncing the nozzle up and down on the soil. This provides improved control for digging of larger holes, and enables digging of pilot holes by rotation of the lance without the need for vacuum removal of the soil.
The third principal improvement is to combine the improved nozzle and air lance structure with the use of a separate vacuum structure featuring a highly efficient multistage venturi ejector which generates the vacuum at the spoil container near the excavation site, permitting the use of a remote compressor and eliminating the need for separate engines and extensive filtering between the vacuum pump and the excavation.
The invention thus provides a vacuum excavation system which incorporates a low air consumption lance, a highly efficient multi-stage vacuum generation system in which the compressor is isolated from the waste stream, and a highly portable material collection system. The system can be powered entirely by one 185 cfm portable air compressor, available from local tool rental firms if one is not owned, so that nearly any contractor, utility company, or design firm can easily outfit themselves for vacuum excavation, at a cost for the excavation system less the air compressor of less than one tenth that of a conventional system, and the compressor can easily be carried by a ½ ton pickup truck and located at distances greater than 200′ from the excavation site using standard 1″ compressed air hose to connect the compressor to the vacuum engine which drives the collection system, rather than being limited to a location 25′ from the vacuum equipment.
A benefit of the preferred nozzle is that it can be used to bore a small “pilot hole” quickly and with little effort even in the hardest soils. This is accomplished by placing the nozzle on the ground, providing 90 psi compressed air, and rotating the nozzle 180 degrees back and forth. Because the blade style orifice of the nozzle is wider than the pipe connecting it to the tee handle, the spoil and compressed air can escape upward through the resulting annulus between the sides of the hole and the pipe, clearing the way for further progress of the lance assembly. The device has been found to easily bore 1″ pilot holes to depths of over twenty feet. When performing vacuum excavation to locate utilities, it is very advantageous to perform 1″ pilot holes to search for the utility instead of digging full size 12″ holes with the lance and vacuum combination.
The curved face of the nozzle reduces contact wear on the orifice and helps to guide the lance straight downward through the soil. The blade effect of the nozzle also permits it to move rocks out of the way by simply spinning the air lance with the tee-shaped handle. Without the tee-shaped handle the nozzle loses much of its effectiveness because it becomes very difficult to spin the lance assembly. Other air lance designs require the operator to bounce the nozzle up and down on the soil, whereas the preferred design uses rotation, which requires much less effort, especially when the excavation is over six feet deep and the air lance is heavy due to the long pipe needed between the tee-shaped handle and the nozzle. At 90 psi, the nozzle of the invention consumes about 45 SCFM of compressed air. To perform the same amount of excavation work, a round orifice design would have to consume 90 to 150 SCFM.
The three stage vacuum engine of the preferred embodiment of the invention thus has several advantages related to practicality, the first of which is that conventional ejectors do not produce sufficient flow through a 4″ hose to be effective, and a 4″ hose is the minimum size of hose necessary to clear spoil from an excavation. In addition, the invention provides spoil containment in accordance with local regulations, and can operate effectively with a minimal 167 CFM air source. A single stage venturi of the type used in prior vacuum (excavation) systems would not produce enough flow through a 4″ pick-up hose to be effective, whereas the multi-stage venturi engine of the invention generates over 800 cfm of flow through the same 4″ hose.
Finally, the use of an air lance separate from the vacuum pick up allow both to be easily lengthened for use on deep excavations, in addition to permitting the digging of pilot holes which do not require use of a vacuum pick-up.
The potential applications for the system are widespread, including underground utility exploration, roadwork cleanup, valve box maintenance, water and gas leak detection and repair, pipeline corrosion prevention system installation and repair, gutter cleaning, residential and commercial chimney cleaning, smokestack cleaning, hazardous waste recovery, directional drilling mud removal, leaf collection, aggregate transfer, general high volume wet and dry vacuuming, and numerous others which will occur to those skilled in the art.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view showing the overall excavation system of the preferred embodiment.
FIG. 2 is a plan view of an air lance constructed according to the principles of the preferred embodiment of the invention.
FIG. 3 is a plan view of a nozzle for the air lance of FIG. 2 .
FIG. 4 is a side view of the nozzle illustrated in FIG. 3 .
FIG. 5 is an end view of the nozzle illustrated in FIGS. 3 and 4 .
FIG. 6 is an isometric view of a drum head adapter for use in the excavation system of the preferred embodiment of the invention.
FIG. 7 is a cut-away view of a vacuum engine constructed according to the principles of the preferred embodiment of the invention.
FIG. 8 is a plan view of a foot controlled valve for use with the excavation system of the preferred embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As shown in FIG. 1 , the vacuum excavation system of the invention includes an air lance 1 arranged to direct air at supersonic speeds at a material to be excavated, and a material pickup hose 2 arranged to remove the loosened dirt from the excavation. The material pick-up hose 2 can be an ordinary hose, PVC pipe, or combinations of hoses and pipes, preferably having at least a 4″ diameter for soil excavation applications, although hose 2 is illustrated in FIG. 1 as being fitted with a PVC extension pipe or wand 3 , pipe 3 being replaceable with longer or shorter extension pipes depending on the depth of the excavation.
The pickup hose is connected to a vacuum engine 4 , described in greater detail below, which in turn is attached to an airtight material collection drum 5 via a drum head adapter 6 , also described in more detail below. The air supply for the vacuum engine and the air supply for the air lance are both supplied by ¾″ standard compressed air hoses 7 and 8 from a single portable air compressor 9 , with the vacuum engine 4 being operated by a foot operated air valve 10 . Although illustrated as being just a few feet away, compressor 9 can easily be located more than 200′ away from the vacuum engine 4 and air lance 1 , the only limitation being the ability of the standard hoses to carry a sufficient flow of compressed air from the compressor to the lance and vacuum engine.
As illustrated in more detail in FIG. 2 , the air lance includes a pipe 11 having a flat taper nozzle 12 at the digging end, and a transversely extending pipe 13 at the opposite end, pipe 11 and pipe 13 being in communication to provide an airflow path between the air supply hose 8 and the nozzle 12 . Pipe 13 serves as at least part of the handle 15 for the air lance, with handle 15 and pipe 11 forming a “T” or tee shape. Of course, since a portion of the handle 15 is not directly in the air path, it does not need to be formed of pipe, although the use of a t-fitting 16 is used to connect pipe 13 to pipe 11 easily enables a capped portion of pipe 17 to be coupled to the fitting to complete the handle.
Preferably, one end of pipe 13 is provided with a swivel fitting 14 to connect the air lance with the compressed air supply hose 8 while permitting rotation of the air lance without kinking of the air supply hose. Fitting 14 may be in the form of a “Chicago”-type female fitting, with the connection being provided with a lever style valve 14 ′ to permit operator control of the air supply.
As illustrated in FIGS. 3-5 , the improved nozzle includes a cylindrical extension 18 arranged to be coupled to the end of pipe 11 by any convenient means such as an annular weld, and a flattened end 19 which forms an elongated structure having a blade type orifice 20 with a gap width of significantly less than the ¼ inch diameter of the conventional cylindrical nozzle, and preferably on the order of approximately 0.01 to 0.02 inches and a length approaching 1.5 inches. As a result, the air in the pipe 11 , which has an internal diameter of ¾ inches and a cross-sectional area of 0.44 in 2 , is forced through an area tat the gap of 0.015 to 0.03 in 2 to create a sheet of jetted air focused directly in front of the nozzle, and thereby accelerated to supersonic velocity, creating a shock wave which fractures and causes loosening of the soil as described above.
Preferably, the nozzle lip 21 is given a concavity as seen looking down on the flattened surface in FIG. 3 . The concavity is not believed to have an effect on the airflow, but serves to reduce contact wear on the orifice and helps to guide the air lance straight downward through the soil.
In operation, the air lance is set on the ground in a vertical orientation and the handle 11 twisted back and forth to dig a small diameter probe hole to a depth limited only by the length of the air lance with very little operator exertion. This is useful in exploration efforts to locate buried utilities and avoids the digging of large holes. Once the underground utility 9 is encountered, the larger hole can be dug by combining the air lance and the pneumatic vacuum system described below. Any size hole can be created, allowing for simple inspection for size and condition or a very complicated repair, and the blade effect of the nozzle also permits it to move rocks out of the way by simply spinning the air lance with the tee handle.
As indicated above and shown in FIG. 1 , the vacuum system comprises a tube or wand 3 , a flexible conduit 2 , a container 5 in the form of an airtight drum, and a pressure or flow responsive engine or injector device 4 that pulls air and loosened soil from the excavation hole successively through the wand 3 , the flexible conduit 2 , and into the drum 5 . In this arrangement, the excavated soil separates from the air stream during passage of the air through the drum to the intake of the vacuum engine, thereby at least partially isolating the vacuum engine from the source of contamination, while the one-way nature of the air supply completely isolates the compressor.
As illustrated in FIGS. 1 and 6 , the vacuum engine 4 is attached to the drum 5 via an adapter 6 which is made up of a lid 22 adapted to fit over the drum and form an airtight seal to ensure maximum airflow through the drum. The evacuation hose 2 enters the drum through an intake conduit 23 , hose 2 having in the preferred embodiment an outer diameter of approximately 4.0″ and being attachable to intake conduit 23 by any suitable hose attachment means. Intake conduit 23 is angled relative to the plane of the lid and located off the axis of the drum. A second opening 24 in adapter 6 is shaped to conform to the base of the vacuum engine 4 to provide an air outlet and is provided with a mounting flange and gasket arrangement 25 , including fastening means 26 , which receives and secures the base of the engine and seals opening 24 . Fastening means 26 are preferably arranged so as to permit easy removal and installation of the engine to facilitate cleaning and maintenance, while the adapter as a whole preferably includes means, including seals and attachment fittings (not shown) as well as, for example, carrying handles 27 (only one of which is shown), to facilitate both attachment to and removal from the collection drum so that drums can be replaced as they become full. The design of the system is such that very little debris passes through the drum into the engine itself. Nevertheless, the engine can easily be removed from the adapter for cleaning with brushes or high power spray washing with a radial spray nozzle.
The vacuum engine 4 , as shown in FIG. 7 , is made up of a housing 30 containing at a front end a nozzle 31 that converts high pressure air entering from hose 7 into a jet. The jet of air draws air from the drum via opening 24 and through the open base 32 of the engine as it passes sequentially through a series of venturi tubes 33 , 34 , and 35 with pressure equalizing check valves 36 and 37 to provide a three stage suction arrangement pulling the soil collection stream through conduit 2 and into the drum.
As the high pressure air jet from nozzle 31 passes through a first chamber 38 into the opening 39 of venturi tube 33 and then into reduced diameter section 40 , it draws air at a relatively high pressure from the drum through chamber 38 , as indicated by arrow A. This air is injected into the opening 41 of second venturi tube 34 , enters reduced diameter section 43 and draws air from the drum via second chamber 44 through check valve 36 , as indicated by arrow B, and the output of venturi tube 34 enters the opening 45 and reduced diameter section 46 of venturi tube 35 to draw air from the drum through chamber 47 via check valve 37 , as indicated by arrow C. Finally, the combined airstream, which by this stage is relatively low in pressure, is exhausted through opening 47 of venturi tube 35 and through a low impedance filter 48 as necessary for filtering any particulates still present in the airstream. For typical soil excavation applications, filter 48 may, for example, take the form of a 250 micron filter bag.
As is apparent from FIG. 7 , venturi tubes 33 - 35 increase in length and diameter from the first stage at the front of the engine to the third stage at the exhaust end of the engine, while the shapes of the chambers 38 , 44 , and 47 are such that the openings at the bottoms of the chambers become progressively larger as the main airstream loses velocity due to the increasing size of the venturi tubes, and the upper portions of the chambers are extended to accommodate the lengths of the venturi tubes. The relative volumes and exact shapes of the chambers are actually a matter of convenience given the constraints resulting from the lengths of the venturi tubes and the size of the opening at the bottom of the engine, but it is possible that the shapes of the chambers could have some effect on the airflow and be adjusted accordingly.
Check valves 36 and 37 are in the form of pressure sensitive check valves associated with each chamber to control air passage from the drum to the last chamber by moving in response to pressure differences in the chamber and the pressure in the container.
More specifically, the check valves remain open when the system is operating with low resistance, as is the case during most vacuum pickup functions of loose debris, the flow of air from the intake nozzle 31 taking along with it air from the chamber surrounding the venturi tube it passes through, so that the initial quantity of pressurized air together with the air brought with it will flow out from the first chamber through the first venturi tube into the second chamber. The quantity of flowing air through the nozzles will increase from chamber to chamber and thus the sub-pressure in the chambers will become greater.
When greater impedance develops in the material handling hose, however, air pressure levels within the three chambers changes until the pressure differential increases sufficiently to cause the third stage check valve 37 to close. Under this condition, only the first two stages are supplying vacuum to the collection drum, so that the overall airflow is reduced while the vacuum level at this point is much higher than in the free flow situation due to the higher pressure in the first two stages. As greater impedance develops, such as occurs during liquid pick-up, air pressure levels within the three stages again changes and reaches a point where the check valve governing airflow into the second stage shuts off so that stage one is the sole supplier of vacuum to the collection drum. The air pumping pressure and volume of the injector will thus automatically match the system requirement at each instant.
By way of example, a suitable engine of the type described above may have a length of 65″ from front to back, a width of 8″, and a height from the open base to the top of the engine of 9.5″, with the adapter being arranged to fit on a 55 gallon open top drum. A suitable material for the housing is aluminum, which will result in an engine with the above dimensions having a weight of 18 pounds. This relatively small and light engine, which has no moving parts except for the check valves, provides an air consumption of 167 cfm @ 110 psi input, a static lift of 23 in Hg @ 110 psi input, and a no load vacuum airflow of 850 cfm. The operating characteristics of the three stages are as follows: 0-23 in. Hg. lift, 167 to 358 cfm throughput for the first stage consisting of chamber 38 and venturi tube 33 ; 0-8 in. Hg. lift, 167 to 566 cfm throughput for the second stage consisting of chamber 44 and venturi tube 43 ; and 0 to 23 in. Hg lift, 167 to 850 cfm throughput for the third stage consisting of chamber 47 and venturi tube 46 , which is conveniently formed by the housing 30 .
It will of course be appreciated by those skilled in the art that the size, operating characteristics, and construction of the engine are given by way of example only and that details such as the size, weight, and materials of the engine may be freely varied to meet the requirements of applications other than soil excavation, such as roadwork cleanup, gutter cleaning, chimney and smoke cleaning, hazardous waste recovery, directional drilling mud removal, leaf collection, aggregate transfer, and other applications which may occur to those skilled in the art, without departing from the scope of the invention.
To reduce overall compressed air consumption, foot operated valve, as shown in FIG. 8 , controls the compressed air supply to the vacuum engine in an essentially on/off mode of operation, allowing more efficient use of the compressed air by permitting the operator to instantly turn the vacuum on and off. The valve includes a pedal 50 , valve 51 with air hose fittings 52 , and a protective cage 53 , and also serves as a safety mechanism by allowing air to pass when foot pressure is applied. Optionally, to prevent operators from bypassing this safety feature, the air connection at the back of the vacuum engine can be provided with a JIC threaded fitting, instead of the Chicago type quick connections used for the other air connections throughout the system.
Having thus described various preferred embodiments of the invention, those skilled in the art will appreciate that variations and modifications of the preferred embodiment may be made without departing from the scope of the invention. It is accordingly intended that the invention not be limited by the above description or accompanying drawings, but that it be defined solely in accordance with the appended claims.
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A vacuum excavation system which incorporates a low consumption air lance, a highly efficient multi-stage vacuum generation system effectively isolated from the waste stream and the air source, and a highly portable material collection system. The air lance includes a cylindrical main body which narrows to a flat taper nozzle at the digging end, and a tee-shaped handle with a swivel type air fitting at one end, while the vacuum generation system is a multi-stage ejector fitted onto a collection drum and consisting of successive venturi tubes with pressure equalizing check valves on the second and higher stages, the material collection system consisting of the drum and hoses or pipes connected to the drum through a separate opening. The system can be powered entirely by one 185 cfm portable air compressor, available from local tool rental firms if one is not owned, so than nearly any contractor, utility company, or design firm can easily outfit themselves for vacuum excavation, at a cost for the excavation system less the air compressor of less than one tenth that of a conventional system.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
a. Field of the Invention
The present invention relates to a working platform lifting apparatus for an aerial ladder truck for fire fighting purposes used for operations at high altitudes, for example, for extinguishing a fire in a multistory building or for saving a person who has been left behind the scene of a fire.
B. Description of the Prior Art
Heretofore, an aerial ladder truck equipped with a working platform movable up and down along the extensible ladder has been known in the art. The conventional aerial ladder truck of this type, however, has the disadvantage that the extending and contracting operation of the ladder and the raising and lowering operation of the working platform interfere with each other. As a result, the operations and mechanisms of the ladder and working platform are very complicated. Further, in a safety aspect of the working platform, there are problems which must be solved.
SUMMARY OF THE INVENTION
The present invention is intended to make the extending and contracting operation of the ladder and the raising and lowering operation of the working platform free from interference with each other. Further, even if the driving system for the working platform goes wrong, the platform can be manually raised or lowered.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic side view of the entire apparatus of the present invention;
FIG. 2 is a view explanatory of operation;
FIG. 3 is a front view of a winch;
FIG. 4 is a right-hand side view of FIG. 3;
FIG. 5 is a left-hand side view of FIG. 3;
FIG. 6 is a view of a hydraulic circuit for a brake removing hydraulic cylinder;
FIG. 7 is a view of control means for the solenoid valve shown in FIG. 6;
FIG. 8 is a side view of a mechanism for raising and lowering a working platform;
FIG. 9 is a fragmentary side view of a ladder showing the uppermost section thereof; and
FIG. 10 is a view of an electric circuit for automatic stop means associated with said uppermost ladder section.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In FIG. 1, the character 1 designates an aerial ladder truck; 2, a turntable; 3, a ladder supporting structure set up on the turntable 2; and 4 designates a ladder equipped with means whereby it is extended and contracted and means whereby it is vertically swung.
A winch 6 is mounted on the turntable 2 and a wire 7 withdrawn from the winch extnds in zigzags passing successively around a pulley 8 mounted on a ladder pivot, a pulley 9 at the front end of the first ladder section, a pulley 10 at the rear end of the second ladder section, a pulley 11 at the front end of the second ladder section, a pulley 12 at the rear end of the third ladder section, a pulley 13 at the front end of the third ladder section, a pulley 14 at the rear end of the fourth ladder section, a pulley 15 at the front end of the fourth ladder section, a pulley 16 at the rear end of the fifth ladder section and a pulley 17 at the front end of the fifth ladder section, the front end of said wire being tied to the working platform 5. In addition, for a ladder having six or more ladder sections, the wire 7 may be likewise arranged.
Because of the arrangement of the wire 7 described above, the extension and contraction of the ladder 4 will not cause the working platform 5 to be raised or lowered. This will now be described in more detail with reference to FIG. 2.
Referring to FIG. 2 illustrating the relation between the first and second ladder sections, if the second ladder section is extended through a distance L, the pulleys 10 and 11 will be displaced also through the same distance L. As a result, the distance between the pulleys 10 and 11 is decreased by the same amount L. On the other hand, the distance between the pulley 11 and the working platform 5 is increased by the same amount L. The net result is that without the wire 7 changing in length or being paied out, the ladder alone is allowed to extend or contract while holding the working platform 5 in its stopped position. It will be apparent that the ladder can be likewise contracted. The same applies to a ladder having three or more ladder sections.
After the ladder 4 is extended, the working platform 5 may be raised or lowered.
As shown in FIG. 3, the winch 6 comprises a winding drum 6a having a shaft 6b rotatably supported in bearings 6c and 6d, one end of said shaft 6b being connected to a worm gear speed reduction mechanism 6f through a coupling 6e, said mechanism being connected to a hydraulic motor 6g. The input shaft 6h of the worm gear speed reduction mechanism 6f, as shown in FIG. 4, is connected at one end thereof to the hydraulic motor 6g and is adapted to receive a handle 6i which may be used to manually rotate the wire winding drum 6a to wind or unwind the wire to raise or lower the working platform 5 in the event of a breakdown occurring to the hydraulic circuit of the motor 6g.
As shown in FIG. 3, a brake drum 6j is connected to the other end of the wire winding drum 6a. The brake drum is provided with a band 6k, as shown in FIG. 5. One end of the brake band is fixed in position, while the other end is connected to a movable arm 6l to which a brake applying spring 6m and a brake removing hydraulic cylinder 6n are connected. As will be later described, it is so arranged that when the working platform 5 is raised or lowered, the brake is removed in connection with such raising or lowering operation and that when the working platform is brought to a stop, the hydraulic cylinder 6n becomes inactivated, allowing the brake applying spring 6m to brake the brake drum 6j. The brake is especially designed to be effective on the lowering side of the working platform 5.
FIG. 6 shows the hydraulic circuit of the brake removing hydraulic cylinder 6n. Thus, the cylinder 6n is supplied with high pressure working oil from a hydraulic pump 18 through a solenoid valve 19. When the solenoid valve 19 is not energized, the hydraulic cylinder 6n is not supplied with oil and communicates with an oil tank 20, allowing the piston to move freely in the cylinder.
As shown in FIG. 7, the solenoid valve 19 is placed in an electric circuit to a switch 22 which is on-off controlled by the operation of an operating lever 21 for raising or lowering the working platform. Thus, the lever 21 is provided with a cam 23 opposed to said switch 22 and having a recess 24, the arrangement being such that when the lever 21 is in its neutral position, the recess 24 is opposed to the switch 22 to open the latter and that when the lever is moved to its raising or lowering position, the switch 22 is closed.
With the arrangement described above, when the working platform 5 is raised or lowered, the solenoid valve 19 is energized, whereby the brake removing hydraulic cylinder 6n slackens the brake band 6k. Further, means is provided whereby when the working platform 5 reaches its uppermost position, the operating lever 21 is automatically brought back to its neutral position, as will be described below.
As shown in FIG. 8, the operating lever 21 is installed in a control tower 25 mounted on the turntable 2. Also installed in the control tower 25 is an operating valve 26 having a spool 27 connected to a lever 28. The levers 21 and 28 are interconnected by a link 29. The operating valve 26 serves to control the hydraulic circuit of the hydraulic motor 6g of the winch 6 shown in FIGS. 3 and 4.
Positioned close to said operating valve 26 is an automatic stopping hydraulic cylinder 30 which is controlled by a solenoid valve 31 which, in turn, is on-off controlled by limit switches 32 and 33 positioned at the front end of the ladder 4 (see FIG. 9). The limit switches 32 and 33 are adapted to be closed when the working platform 5 reaches its uppermost position. The electric circuit of the solenoid valve 31 is arranged in the manner shown in FIG. 10, comprising pilot lamps 34 and 35, a buzzer 36 and manual switches 37 and 38 which are normally closed. In this condition if the working platform 5 is raised and approaches the front end of the ladder 4, the lower limit switch 32 is closed, whereby the pilot lamp 34 is lit and the buzzer 36 is rung while the solenoid valve 31 is energized. As a result, the solenoid valve 31 is switched so that working oil from a pump 39 is fed into one of the chambers of the hydraulic cylinder 30. This condition corresponds to the lower chamber of the hydraulic cylinder 30 being filled with working oil in FIG. 8. Therefore, the piston rod 30a of the hydraulic cylinder 30 is upwardly moved to push up the lever 28 so that the operating lever 21 is shifted from its raising position back to its neutral position. As a result, the operating valve 26 is shifted to its neutral position to stop the upward movement of the working platform 5. The stoppage of the working platform 5 at its uppermost position is effected in two steps. Thus, the first step takes place at its usual uppermost position and the second step is taken only when it is desired to further raise the working platform 5 beyond said position. If the limit switch 32 at the first step is closed, the working platform 5 is automatically stopped. In this condition, if it becomes necessary to further raise the working platform, this may be achieved by opening the manual switch 37 shown in FIG. 8 and then shifting the operating lever 21 shown in FIG. 8 to its raising position. As a result, the working platform 5 is raised until it closes the limit switch 33 at the second step, whereupon the solenoid 31 and the buzzer 36 are energized and the working platform is automatically stopped.
Since the operation of the working platform 5 described above is controlled at the control tower 25, it would be difficult to ascertain whether the working platform reaches its uppermost position. To overcome this difficulty, the automatic stop mechanism has been employed only at the uppermost position of the working platform.
The automatic stopping hydraulic cylinder 30 does not interfere with the operation of the operating lever 21 to its lowering position.
As has been described thus far, according to the present invention, the ladder and the working platform can be operated independently of each other and their operations and mechanisms can be greatly simplified. Further, since the working platform can be automatically stopped at its uppermost position, the safety is high as compared with a system in which the operator has to ascertain such stoppage visually. Since the brake is automatically applied whenever the working platform is stopped, safety is assured, at whatever position along the ladder the working platform may be stopped. Particularly, since the brake acts more effectively on the lowering side of the working platform, the safety is further increased. Moreover, even if an accident occurs to the hydraulic drive system of the working platform, it is still possible to raise or lower the working platform by means of a handle.
Whiles there have been described herein what are at present considered preferred embodiments of the several features of the invention, it will be obvious to those skilled in the art that modifications and changes may be made without departing from the essence of the invention.
It is therefore to be understood that the exemplary embodiments thereof are illustrative and not restrictive of the invention, the scope of which is defined in the appended claims and that all modifications that come within the meaning and range of equivalency of the claims are intended to be included therein.
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A working platform lifting apparatus for an aerial ladder truck, wherein the working platform movable up and down along the ladder is arranged so that it does not interfere with the extension and contraction of the ladder, that when it is stopped at any desired position it is automatically braked, that when it reaches its uppermost position it is automatically stopped and that in an emergency it can be lowered manually. Other merits and details of the construction will be made clear.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
[0001] It is widely known that a hand trowel is a flat-bladed tool with a handle and flat metal blade, used by masons and others for leveling, spreading, or shaping substances such as cement, plaster, or mortar. Also appreciated is the fact that the work output required by the user finishing a work surface with a hand trowel is decreased significantly if some other additional energy input is provided on the trowel, such as a vibration or a sonic energy generator. It is also agreed upon that vibration and/or sonic energy added to a hand trowel makes the trowel increasingly efficient over those trowels where the user alone provides the only work input. Thus, the trend in hand trowel construction is to increase the efficiency of the hand trowel and decrease the work input required by the user by increasing the work input to the hand trowel using an alternative energy source.
[0002] Therefore, what is needed is an orbital vibrating hand trowel that combines the use of vibration energy with the orbital movement of the trowel for quickly and efficiently finishing a work surface, while demanding less physical input by the user.
[0003] Another purpose of the present invention is to provide an apparatus that is inexpensive to manufacture, easy to use, free from electrical cords (cordless), rechargeable and capable of being fitted to various sized and operational float bodies, as well as significantly reducing the physical work input provided by the user and time requirement to finish a surface.
BRIEF SUMMARY OF THE INVENTION
[0004] Therefore it is a primary object, feature, or advantage of the present invention to improve over the state of the art.
[0005] It is a further object, feature, or advantage of the present invention to provide a hand trowel that is comfortable to operate.
[0006] It is a still further object, feature, or advantage of the present invention is to provide a hand trowel that does not fatigue the user.
[0007] Another object, feature, or advantage of the present invention to provide a hand trowel that is adaptable to accommodate a float body of various sizes and applications.
[0008] Yet another object, feature, or advantage of the present invention to provide a hand trowel that uses orbital translation in combination with vibration of the float for efficiently finishing a work surface.
[0009] A further object, feature, or advantage of the present invention to provide a hand trowel for finishing off cement.
[0010] It is a further object, feature, or advantage of the present invention to provide a hand trowel for finishing off a plaster surface.
[0011] Another object, feature, or advantage of the present invention is to provide a hand trowel for finishing off mortar.
[0012] Yet another object, feature, or advantage of the present invention is to provide hand trowel wherein the electrical components are encased in the handle for protection from the work environment.
[0013] A still further object, feature, or advantage of the present invention is to provide a hand trowel wherein the motor and electrical leads from the battery and/or switch to the motor are quickly accessible.
[0014] Another object, feature, or advantage of the present invention is to provide a hand trowel wherein a switch for selectively applying power to the motor is operatively located on the handle.
[0015] Yet another object, feature, or advantage of the present invention is to provide a hand trowel wherein the battery is a replaceable, chargeable NiCad battery.
[0016] A further object, feature, or advantage of the present invention is to provide a hand trowel wherein the battery encased in the handle is chargeable using a DC connector operatively positioned on the handle.
[0017] Another object, feature or advantage of the present invention is to provide a hand trowel wherein the motor is positioned in the handle and is replaceable without undue labor and time involvement.
[0018] Yet another object, feature, or advantage of the present invention is to provide a hand trowel wherein an eccentric mass is attached to the shaft of the motor.
[0019] A still further object, feature, or advantage of the present invention is to provide a hand trowel wherein a housing having an aperture for receiving the eccentric mass is attached to the float.
[0020] Another object, feature, or advantage of the present invention is to provide a hand trowel wherein the diameter of the aperture in the housing is approximately the diameter of the eccentric mass.
[0021] Still another object, feature, or advantage of the present invention is to provide a hand trowel wherein the motor is a high-speed motor with high-speed bearings.
[0022] Yet another object, feature, or advantage of the present invention is to provide a hand trowel wherein slack between the sidewall of the aperture and the eccentric mass allows for rotation of the eccentric mass with the aperture.
[0023] A still further object, feature, or advantage of the present invention is to provide a hand trowel wherein rotation of the eccentric mass within the aperture affects orbital translation of the float.
[0024] Another object, feature, or advantage of the present invention is to provide a hand trowel that is collapsible for cleaning, storing, repairing and maintaining.
[0025] Yet another object, feature, or advantage of the present invention is to provide a hand trowel wherein the eccentric mass has an aperture for receiving and attaching to the shaft of the motor.
[0026] Still another object, feature, or advantage of the present invention is to provide a hand trowel wherein the aperture for housing the eccentric mass is fitted with a high-speed bearing to facilitate transfer of orbital movement and vibration from the eccentric mass to the float body.
[0027] A still further object, feature, or advantage of the present invention is to provide a hand trowel wherein the aperture in the eccentric mass is off-center for producing vibration and an orbital movement during rotation of the eccentric mass.
[0028] Another object, feature, or advantage of the present invention is to provide a hand trowel wherein off-center rotational movement of the eccentric mass within the aperture in the housing causes the housing to vibrate and translate in an orbital pattern which in-turn is transferred to the float body thereby providing vibration and orbital translation of the float body in a plane parallel to the float body.
[0029] Yet another object, feature, or advantage of the present invention is to provide a hand trowel wherein the eccentric mass has a first stage having a first diameter and a second stage having and second diameter and the second diameter being larger than the first diameter for driving the adaptor body about an orbital pathway.
[0030] Still another object, feature, or advantage of the present invention is to provide a hand trowel wherein the shaft from the motor is supported by a high-speed bearing to facilitate rotation of the shaft and the attached eccentric mass.
[0031] According to one aspect of the present invention an orbital vibrating hand trowel, is disclosed. The trowel has a body having a first and second opposite end and a handle between the ends for grasping. The trowel also includes a motor and power source within the body. The power source is in electrical communication with the motor. An eccentric mass is connected to the motor and an adapter body is connected to a float body. The adapter body has an aperture for housing the eccentric mass. The eccentric mass rotates within the aperture of the adaptor body to move and vibrate the adaptor body and attached float body in an orbital path along a horizontal plane with respect to the float body for finishing a work surface.
[0032] According to another feature of the present invention, the handle having a switch positioned thereon for switching power on and off from the power source to the motor.
[0033] According to another feature of the present invention, the power source positioned within the handle is a rechargeable power source.
[0034] According to another feature of the present invention, the handle having a DC connection positioned thereon for communicating power to the power source for recharging the power source.
[0035] According to another feature of the present invention, rotation of the eccentric mass thereby affects translation of the float body along the orbital path.
[0036] According to another feature of the present invention, rotation of the eccentric mass thereby affects vibration of the float body along the horizontal plane with respect to the float body.
[0037] According to another feature of the present invention, the diameter of the aperture in the adaptor body is approximately the diameter of the eccentric mass.
[0038] According to another feature of the present invention, the aperture in the adaptor body having a collar for securing the eccentric mass within the aperture.
[0039] According to another feature of the present invention, the eccentric mass having a dimensional center and an aperture positioned off center of the dimensional center for connecting to a shaft on the motor.
[0040] According to another feature of the present invention, the eccentric mass is removably attached to the shaft of the motor.
[0041] According to another feature of the present invention, the diameter of the aperture in the adaptor body varies to accommodate variation in the diameter of the eccentric mass.
[0042] According to another feature of the present invention, the adaptor body having at least one pilot hole for securing the float body to the adaptor body using a screw.
[0043] According to another feature of the present invention, the float and adaptor body follows the lateral translation of the eccentric mass along the orbital pathway.
[0044] According to another feature of the present invention, the first end of the body housing the motor therein.
[0045] According to another feature of the present invention, the second end of the body having a spacer connected thereto, the spacer being connected to the float body.
[0046] According to another feature of the present invention, the spacer having at least one pilot hole for securing the spacer to the second end of the body.
[0047] According to another feature of the present invention, the spacer and the adaptor body having the same thickness.
[0048] According to another feature of the present invention, the spacer having at least one screw for connecting the spacer to the float body.
[0049] According to another feature of the present invention, the float body having a first and second opposite end and an elevated rib running the length of the float body, the first end being connected to the adaptor body and the second opposite end being connected to the spacer.
[0050] According to another feature of the present invention, the float body being pivotable about the spacer on the second end to thereby assist orbital translation and vibration of the float body about the first end.
[0051] According to another aspect of the present invention, an orbital vibrating hand trowel, is disclosed. The trowel has a motor within a handle. The trowel includes an eccentric mass connected to the motor and an aperture within an adaptor body attached to a float body. The aperture is for housing the eccentric mass. Rotation of the eccentric mass within the aperture affects orbital translation and vibration of the attached float body for finishing a work surface.
[0052] According to another aspect of the present invention, an orbital vibrating hand trowel for finishing a work surface, is disclosed. The trowel has a body for gripping and housing a motor. The trowel includes a housing having an aperture and adapted for attachment to a float body. An eccentric mass is connected to the motor and received within the aperture for affecting orbital translation and vibration of the float for finishing the work surface.
[0053] One or more of these and/or other objects, features, or advantages of the present invention will become apparent from the specification and claims that follow.
BRIEF DESCRIPTION OF THE DRAWINGS
[0054] FIG. 1 is an isometric view of the present invention.
[0055] FIG. 2 is a cross-sectional view of the present invention taken along line 2 - 2 of the isometric view in FIG. 1 .
[0056] FIG. 3 is an exploded cross-sectional view of the housing and eccentric mass of the present invention taken along line 3 - 3 in FIG. 2 .
[0057] FIG. 4 is an exploded plan view of the housing and eccentric mass of the present invention taken along line 3 - 3 in FIG. 2 .
[0058] FIG. 5 is a top plan view of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0059] The present invention includes a number of aspects all of which have broad and far-reaching application. Although specific embodiments are described herein, the present invention is not to be limited to these specific embodiments.
[0060] FIG. 1 is an isometric view of the present invention. In FIG. 1 , one embodiment of the trowel 10 is shown as having generally a body 12 having a first end 14 and a second opposite end 16 and handle 18 extending between the two ends 14 , 16 for gripping. The first end 14 of the body 12 further comprises a motor cap 20 providing quick access and protection for a motor positioned within the body 12 . The second end of the body 12 has pilot holes 17 allowing passage of a screw for attaching the body 12 to the spacer 24 . The spacer 24 is in-turn connected to the float body 30 . The body 12 also comprises a switch 26 for selectively providing power to a motor. Also included on the body 12 is a DC connector 28 for charging or providing power to a power source housed within the body 12 . An adaptor body 22 is connected to the first end 14 of the body 12 . In addition, the adaptor body 22 is attached to the float body 30 . Both the spacer 24 and the adaptor body 22 may be separate pieces or part of the body 12 . The float body 30 has a first end 32 and an opposite second end 34 and an elevated rib 36 running between the ends 32 , 34 for connecting to the body 12 . The float body 30 is preferably a float for finishing a surface consisting of a workable material, such as concrete or plaster. The float body 30 may be of different shapes and sizes thereby accommodating different tasks. The float body 30 may be interchangeable. It is preferred that the spacer 24 on the second end 16 of the body 12 and the adaptor body 22 on the first end 14 of the body 12 are of equal thickness. However, the spacer 24 and adaptor body 22 may have a different thickness to accommodate manufacturing and application needs. Furthermore, the thickness of the spacer 24 and adaptor body 22 may be varied jointly or separately to accommodate a different size and shape float body 30 . The thickness of the spacer 24 and the adaptor body 22 may also be varied to change the pitch of the handle 18 on the body 12 with respect to the float body 30 . Both the adaptor body 22 end the spacer 24 are attached to the float body 30 along the elevated rib 36 . It is preferred that the body 12 be constructed of a high impact material capable of protecting the device from the abuse commonly associated with commercial grade tools. Additionally, it is preferred that the body 12 of the trowel 10 be constructed of a material that is easy to grip and non-fatiguing.
[0061] FIG. 2 is a cross-sectional view of the present invention taken along line 2 - 2 of the isometric view in FIG. 1 . In FIG. 2 , one embodiment of the trowel 10 is shown as having a body 12 . Within the body 12 is a power source 19 . It is preferred that the power source be a rechargeable NiCad battery or any other power source which permits stand-alone operation of the trowel 10 , where stand-alone operation means without a power cord being attached. Thus, any power source that is rechargeable, durable and provides stand-alone operation of the trowel is suitable as a power source. The power source 19 is in electrical communication with the motor 15 positioned in the first end 14 of the body 12 . The motor is preferably a commercial or industrial grade motor. The motor also should be a high-speed motor with high-speed bearings suitable for the wears of use in a commercial or industrial setting. The motor is preferably a sealed motor if exposed to work elements, but may have an impervious casing if protected within the body of the trowel. The power source 19 is also in electrical communication with the switch 26 for selectively providing power from the power source 19 to the motor 15 . The switch 26 may be a variable power switch for varying the speed of the motor 15 and subsequently the orbital rotation and vibration of the float body 30 . The switch 26 may be lockable to permit sustained operation of the trowel 10 without having to depress or continually hold the switch in the on position. The power source 19 and the motor 15 are encased within the body 12 and protected from being interrogated by elements external to the trowel 10 . The power source 19 and the motor 15 are both accessible within the body 12 . By removing the motor cap 20 electrical communication to motor 15 from the switch 26 and the power source 19 can be verified and remedied. The body 12 of the trowel 10 may be a single piece or a multi-piece body thereby permitting easy access to the internal workings of the trowel 10 . The second end 16 of the body 12 comprises pilot holes 17 for inserting a screw 25 for securing the spacer 24 to the body 12 . An additional pilot hole 17 is placed within the spacer 24 for securing the float body 30 to the spacer 24 using a screw 25 . The pilot hole 17 within the spacer is intentionally oversized with respect to the size of the screw 25 so as to allow transitional movement of the float body 30 with respect to the spacer 24 while yet keeping the float body 30 attached to the spacer 24 . Thus, as the first end 32 of the float body 30 is translated along an orbital pathway, the second end 34 translates in reciprocating fashion along the same axis of the body 12 and about the oversized pilot hole 17 in the spacer 24 . The spacer may be constructed of numerous materials and in numerous ways. It is preferred that the attachment used to affix the body 12 of the trowel 10 to the float body 30 be rigid and strong yet permit translation of the float body 30 forward and backwards with respect to a line of axis collinear with the length of the body 12 .
[0062] Also illustrated by FIG. 2 is the first end 14 of the body 12 that houses the motor 15 . The motor has a shaft 21 extending downward toward the float body 30 and an eccentric mass 23 attached thereto. The eccentric mass 23 is housed within the aperture 38 in the adaptor body 22 . high-speed bearing may be used to the form the inner liner of the aperture 38 to ease the stress on the motor 15 and friction on the eccentric mass 23 , as well as increase the efficiency of the trowel 10 . Using a high-speed bearing to form the aperture 38 would also diminish the amount of wear and tear on the eccentric mass 23 gyrating within the aperture 38 . The diameter of the aperture 38 in the adaptor body 22 is approximately the diameter of the eccentric mass 23 , where the eccentric mass has two different stages; the first stage 52 having a first diameter 54 and the second stage 56 having a second diameter 58 . The difference between the diameters of the eccentric mass 23 and the aperture 38 within the adaptor body 22 is sufficient to allow rotational movement of the eccentric mass 23 within the aperture 38 . The adaptor body 22 has also a collar 40 for retaining the eccentric mass 23 within the aperture 38 , as best shown by FIG. 3 . Also within the adaptor body 22 are pilot holes 17 . Screws 25 are placed within pilot holes 17 for securing the adaptor body 22 to the float body 30 . The eccentric mass 23 is preferably attached to the shaft 21 of the motor using set screw 48 , but may be attached using a keyway and key, or simply by a press-fit.
[0063] FIG. 3 is an exploded cross-sectional view of the housing and eccentric mass of the present invention taken along line 3 - 3 in FIG. 2 . Similarly, FIG. 4 is an exploded plan view of one embodiment of the housing and eccentric mass of the present invention taken along line 3 - 3 in FIG. 2 . Both FIG. 3 and FIG. 4 illustrate how rotation of the eccentric mass 23 within the aperture 38 in the adaptor body 22 effects orbital translation and vibration of the float body 30 . In particular, the motor 15 rotates shaft 21 having the eccentric mass 23 attached thereto, using set screw 48 . The eccentric mass 23 is attached to the shaft 21 by inserting the shaft 21 of the motor 15 into the aperture 42 within the eccentric mass 23 . The aperture 42 in the eccentric mass 23 has an offset center 46 from the actual or true dimensional center 44 of the eccentric mass 23 , as best illustrated by FIG. 4 . The center offset 46 of the aperture 42 within the eccentric mass 23 affects orbital movement of the eccentric mass 23 about the true or actual dimensional center 44 of the eccentric mass 23 . Movement of the adaptor body 22 and the attached float body 30 occurs as the eccentric mass 23 rotates orbitally keeping the outer periphery 50 of the second stage 56 of the eccentric mass 23 in continuous contact with the aperture wall 60 thereby pushing the adaptor body 22 radially outward along the rotating orbital point of contact between the aperture wall 60 and the outer periphery 50 of the second stage 56 of the eccentric mass 23 . Thus, the rotation of the eccentric mass 23 within the aperture 38 effects translation of the adaptor body 22 along an orbital path. Additionally, the rotation of the eccentric mass 23 induces a vibration into the adaptor body 22 attached to the float body 30 . Thus, when a user activates the motor 15 using the switch 26 the eccentric mass 23 begins to rotate within the aperture 38 thereby effecting orbital translation and vibration of the adaptor body 22 . The orbital translation and vibration of the adaptor body 22 attached to the float body 30 effects orbital translation and vibration of the float body 30 , as the adaptor body 22 is attached to the float body 30 .
[0064] FIG. 5 is a top plan view of the present invention. In FIG. 5 , the orbital vibration and translation of the float body is illustrated. The movement of the rotation of the eccentric mass 23 within the aperture 38 in the adaptor body 22 causes the float body 30 to translate in an orbital manner about the actual or true dimensional center 44 of the eccentric mass 23 . The float body 30 is permitted to translate back and forth with respect to the body 12 and along a line of axis that is collinear with the length of the body 12 . Additionally, by offsetting the aperture 42 from the actual or true dimensional center 44 causes a vibration to resonate from the eccentric mass 23 into the float body 30 . Thus, the combination of the orbital translation of the float body 30 as well as the vibration introduced in the float body 30 allows the user to efficiently and quickly close off or finish a surface of workable material such as cement, plaster, mortar, or any other shapeable, spreadable, or levelable substance.
[0065] The present invention contemplates numerous other options in the design and use of the trowel.
[0066] These and/or other options, variations, are all within the spirit and scope of the invention.
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The orbital vibrating hand trowel has a body with first and second opposite ends and a handle between the ends for grasping. The body houses a motor and power source. An eccentric mass is connected to the motor. An adapter body is connected to a float body. The adapter body has an aperture for housing the eccentric mass such that rotation of the eccentric mass within the aperture of the adaptor body moves and vibrates the adaptor body and attached float body in an orbital path along a horizontal plane with respect to the float body for finishing a surface.
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BACKGROUND OF THE INVENTION
FIELD OF THE INVENTION
As insurance rates rise, so to has the effort to reduce damage to property and personnel on the highway by providing guard rails which have deformable cell portions which absorb energy and direct the automobiles back onto the roadway, the magnitude of the damage done to passengers and property can be minimized.
It is therefore an object of this invention to provide a means for transforming automobile kinetic energy by deforming a guard rail cell or a plurality of them, and thereby redirecting the car so as to keep it on the roadway.
It is a further object of this invention to provide a guard rail cell which is capable of easy replacement upon deformation, and at a low cost.
These and other objects will become apparent when considering the appended drawings and specification.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a three quarter perspective view of the invention including guard rail and post;
FIG. 2 shows a sectional view taken along the lines 2--2 of FIG. 1;
FIG. 3 shows a sectional view of the structure shown in FIG. 2 looking downward along the lines 3--3 of FIG. 2; and
FIG. 4 shows a further sectional view of the cell looking along the lines 4--4 of FIG. 3.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, in which similar reference numerals in the drawings refer to like parts throughout, the overall guard rail system is generally denoted by numeral 1.
The guard rail assembly comprises a rail member 2 carried by a post member 5 and cell member 3 which are attached by a bolt 4. The guard rail 2 generally has a W-shaped configuration and is supported by cell 3 and bolt 4. Cell 3 is of substantially cylindrical configuration, and has grooves 6 disposed on its outer circumference. The cell 3 is carried by post 5 which may be made of wood or any other material which is well known in the art.
FIG. 3 best depicts damping capabilities of the cell, and disposed within the cell is a conical void. This conical void is truncated at its extremities defined by the inner walls 8 of the cell member. Extending outwardly from this truncated conical void and terminating on the inner wall portion of the cell is the energy absorbing material or cushion 7.
The bolts 4 connect the rail 2 to the post 5 extending between a pair of cells 3 and supports the cells 3 by passing through brackets 9 attached to opposite ends of adjacent cells 3.
The outer wall or housing defined by numeral 3 preferably made from tin, such as a number 10 tin can, and the inner cushion or damping material is preferably formed of a cenentious material which has been expanded with vermiculite particules.
An alternative embodiment, and one which has different properties then that which has been discussed above, would embrace a cylindrical void in the center of the cell rather than a conical one. A cylindrical void would be useful for example when a higher force was anticipated in the deformation of the cell, and could be used for example on a highway having higher speeds which would therefore require greater damping in the cell member. The tapered cylinder however would start to crush with less pressure than the straight cylinder.
Another means for varying the energy absorbtion capabilities of the cell is in the formulation of the damping material 7. The cement is preferably made from approximately 50% portland cement and 50% casting plaster, and it is combined with the vermiculite particles. The particles of vermiculite are preferably one quarter to one thirty second of an inch in diameter. Using the example of a number 10 tin can which is 6 inches in diameter and 7 inches long, a damping compound using 6 pounds portland cement and 6 pounds of casting plaster to each cubic foot of expanded vermiculite combined with sufficient water to make a workable mix will provide an adequate and desirable damping compound formulation. The damping material fills approximately two thirds of the space in the can and after compression the outer dimension of the can will have been reduced to 2 inches in length. Therefore the 33% space allocated towards the void is necessary to provide space for the crushed material and the deformation of the cell without having the can break its seams.
The damping compound is placed in the can, and then dehydrated to remove moisture. A suitable mold is utilized to provide the contour of the inner void as desired and specified above. After the moisture has been removed a vacuum is applied to the can and the can is then sealed.
Upon impact, the vacuum stabilizes and pulls the sides inward, and causes the can walls to wrinkle inward as the can decreases in length, thereby producing a well defined collapsed container of solid material. This compaction is assisted not only by the vacuum maintained within the cell, but also by the ribs 6 which are circumferentially disposed about the cell member. These ribs encourage clean and neat folds as the can decreases in length.
As stated above the aggregate mix of vermiculite preferably has particle size of a quarter to a thirty second of an inch and when crushed will reduce the particle size by perhaps 80%. Other sizes can be considered but only at the expense of the compression range and resistance needed for this energy disposing cell.
The vacuum which is applied and maintained in the can provides the additional benefit when the compression has been applied. The walls of the cell will be pulled inwardly fairly evenly. Without evacuation of the cell seam rupture is increased and outward dispersion of the damping material is more likely. This would result in a smaller damping action for a given cell size.
The conical shape of the void on the inside of the can encourages distortion of the cell structure upon impact as seen in FIG. 3 from left to right. When the cell has been crushed to its limit the resulting structure will be a can of perhaps one third the original size having the damping material displaced to the right hand portion of the cell with associated distortion. Having the conical configuration provides a large crush distance to can length ratio and promotes progressive crushing of material rather than disintegration all at one time.
Having thus described the preferred embodiment of the invention it should be understood that numerous structural modifications and adaptations may be resorted to without departing from the spirit of the invention.
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Disclosed herein is a cell used preferably with a guard rail to absorb the impact of a vehicle which crashes into the rail. The cell converts the kinetic energy of the automobile and absorbs it by distortion of the cell. The effect of the cushion is that it redirects the vehicle back to the roadway without causing severe damage to the vehicle guard rail or posts.
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RELATED APPLICATIONS
[0001] This patent application claims the benefit of priority from co-pending U.S. Provisional Patent Application Serial No. 60/364,880 filed on Mar. 13, 2002.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to curtain walls used for building exteriors and, more particularly, but not by way of limitation, to the construction and assembly of sill and mullion sections of such curtain walls along with the curtain wall panels associated therewith.
[0004] 2. Description of the Related Art
[0005] Curtain walls are typically constructed of extruded aluminum frame support members having generally U-shaped channels (although other shapes may apply) for supporting a plurality of panel members that serve as the exterior of a building. Such panel members are most often panes of glass, and often double pane glass sections, but other paneled building materials such as aluminum, granite, slate, or concrete are also utilized. Such panel members are often of identical size and shape. However, near doors, opening windows, or other access points into the building, panel members of different sizes and shapes may be utilized.
[0006] More specifically, such curtain walls generally include a horizontal sill member having at least one portion forming a channel at the bottom of a wall section, a horizontal head member having a downwardly facing channel at the top of a wall section, and a plurality of vertical mullions running between the sill and head members. Panel members are supported by the channels of the sill member and the head member, and the vertical joints between adjacent panel members are formed at the mullions. In some designs, the mullions are disposed interiorly of the sill member, the head member, and the panel members so that only the joint between adjacent panel members, and not the mullions themselves, are visible from the exterior of the building. The designs do, however, vary, depending upon the desired aesthetics of the curtain wall construction.
[0007] In another curtain wall construction, multiple panel members are typically arranged side-by-side and are secured and sealed between a sill member and a head member, with their vertical joints overlapping at a mullion. This vertical joint must then be sealed from both the interior and exterior of the building using both resilient gaskets, sealant tapes, sealant, and/or structural silicone, as described for reference purposes below.
[0008] An existing solution is set forth and shown in U.S. Pat. No. 6,158,182 and assigned to the assignee of the present invention. Referring now to FIG. 1, a schematic, cross-sectional view of a sill member 10 of an exemplary curtain wall is shown. The sill member 10 secures a curtain wall to a structural support surface such as a concrete slab 12 . The concrete slab 12 may be at ground level or comprising a floor surface of a high rise building. Although not shown in FIG. 1, a head member similar to the sill member 10 secures the curtain wall to a concrete slab between floors of a building or other building structures, and a plurality of mullions span between the sill member 10 and the head member. The sill member 10 is typically formed as an integral aluminum extrusion. The sill member 10 also generally includes a channel section 14 , an anchoring section 16 disposed interiorly of a channel section 14 , and a cover 18 .
[0009] Still referring to FIG. 1, the channel section 14 and the cover 18 cooperate to secure the panel member 20 to the sill member 10 . More specifically, the channel section 14 includes a base 14 a and two legs 14 b and 14 c that form a upwardly facing U-shaped channel. A support member 22 rests on the top surface of the base 14 a . The exterior leg 14 b has a groove 24 proximate the upper end of its interior surface facing the panel member 20 , and the interior leg 14 c has a support surface 26 proximate the upper end of its interior surface. The cover 18 has a downward projecting leg 28 that engages a groove 30 on the exterior surface of the interior leg 14 c . The cover 18 also has two tongues 32 , 49 , one proximate to each end of the cover 18 . The panel member 20 is placed within the channel section 14 on an upper surface of a setting block 34 . An exterior and interior gasket 36 , 38 are located at the upper end of the exterior and interior legs 14 b , 14 c . The gaskets 36 , 38 operate to hold the panel member 20 in the channel section 14 . The setting block 34 is disposed on the top surface of the support member 22 . The exterior gasket 36 has a tongue 36 a that engages the groove 24 of the exterior leg 14 b . The exterior gasket 36 is typically pre-installed in groove 24 of the exterior leg 14 b during the manufacture of the sill member 10 . The interior gasket 38 has a groove 38 a that engages the tongue 32 of the cover 18 and the support surface 26 of the interior leg 14 c . The channel section 14 further includes a plurality of support legs 40 below base 14 a.
[0010] The anchoring section 16 includes a base 16 a , an interior leg 16 b , and a plurality of support legs 42 below the base 16 a . The base 16 a has a plurality of holes 44 spaced along its length for receiving fasteners 46 to secure the sill member 10 to the structural support surface 12 . The interior leg 16 b has a groove 48 for receiving the tongue 49 of the cover 18 . The cover 18 stabilizes the interior gasket 38 that presses against the panel member 20 and also conceals the base 16 a of the anchoring section 16 so that the fasteners 46 are not visible. A drawback of this example is that the panel member 20 cannot be installed until the cover 18 is placed over the fasteners, due to the fact that the cover 18 is needed to hold the interior gasket in place against the panel member 20 . Therefore, the entire structure must be inspected before the panel member 20 is installed as discussed in more detail below.
[0011] The following technique is typically used to install the panel member 20 of such a curtain wall. First, the sill member 10 is laid on a shim 56 in the proper position on the concrete slab 12 and is used as a template to drill holes into the concrete slab 12 for each fastener 46 . One should note that the shim 56 does not run continuously along the length of the sill member 10 . Instead, the shim 56 is used at low points of the concrete slab 12 to level the sill member 10 , if necessary. The sill member 10 is removed from the shim 56 , and a hole 50 with a larger diameter is drilled in the place of each of the holes drilled using the sill member 10 . A structural insert 52 is secured within each of the holes 50 via epoxy or other conventional means. Each insert 52 has an internally threaded hole 54 for receiving fasteners 46 . The sill member 10 is repositioned on the shim 56 and secured to the concrete slab 12 using fasteners 46 . A sealant 58 is disposed continuously on the concrete slab 12 along both the exterior and interior sides of the shim 56 . A head member similar to the sill member 10 is secured to part of the building structure using the above-described techniques. Vertical mullions are secured between the sill member 10 and the head member at appropriate intervals along the curtain wall. The vertical mullions are attached at each side to sill members 10 . The support member 22 is disposed on the base 14 a of the sill member 10 , and the setting block 34 is disposed on the support member 20 . The panel member 20 is then installed from the exterior of the building, typically first being tilted into the channel section of the head member, and then being dropped into the channel section 14 of the sill member 10 . The cover 18 is installed in the sill member 10 , and a glazing stop is installed in the head member of the curtain wall. The interior gasket 38 is disposed on the tongue 32 of the cover 18 of the sill member 10 , and a similar gasket is disposed on the tongue of the glazing stop of the head member.
[0012] While such curtain walls, and other conventional curtain walls, have proved to be reliable commercial building systems, they suffer from several drawbacks. For example, installing the panel members at the building site also requires inspections during the process. These inspections must be performed by building code enforcement personnel, whose schedule may or may not be compatible with time schedules for the contractor erecting such curtain walls.
[0013] Another solution is set forth and shown in U.S. patent application Ser. No. 10/099,070, assigned to the assignee of the present invention, and incorporated herein by reference. Referring now to FIG. 2, a side cross-sectional view a sill assembly 100 of the '070 patent application is shown. By first installing a sill flashing 112 directly upon a support surface 155 such as a concrete slab, the remaining portions of the curtain wall may be assembled at the factory prior to delivery to the field for installation. An outside cap 108 , an interior cover 110 , and a sill member 106 are adapted for resting upon and mounting to the sill flashing 112 .
[0014] The curtain wall as set forth in the '070 patent application is assembled by first temporarily fastening, with a fastener 153 , the sill flashing 112 to the support surface 155 of a building at the job site. The sill member 106 is mounted to two vertical mullions (not shown) at opposite ends of the sill member 106 . An outside cap 108 is secured to the sill member 106 and provides a groove for attaching an exterior gasket 151 . The exterior gasket 151 presses against the exterior of the panel member 150 to secure the panel member 150 set on the top surface of a setting block 200 placed in a channel of the sill member 106 . The sill member 106 , outside cap 108 , panel member 150 , and setting block 200 may be preassembled at a factory prior to being shipped to the job site. However, the sill flashing 112 must be temporarily secured at the job site prior to fastening the sill member 106 and other components permanently to the support surface 155 . After the sill flashing 112 has been temporarily secured to the support surface 150 and the sill member 106 , outside cap 108 , panel member 150 , exterior gasket 151 , and setting block 200 have been assembled at the factory and shipped to the job site, then the sill member 106 is permanently secured to the sill flashing 112 and the support surface 155 with at least one fastener 152 . Building code enforcement personnel then inspect the securement of the sill assembly 100 . Once approved, then the interior cover 110 is secured to the sill flashing 112 and the sill member 106 .
[0015] The '070 patent application allows for some pre-assembly to occur at the factory, however, the sill assembly must to be split into two pieces, namely the sill member 106 and the sill flashing 112 , in order to allow the pre-assembly of the sill member 106 with other components.
[0016] For this reason, it would be greatly advantageous to provide a curtain wall system construction that maximizes the ability for pre-assembly without sacrificing the structural integrity of the overall curtain wall system.
SUMMARY OF THE INVENTION
[0017] The present invention relates to curtain walls used for building exteriors and the assembly of a building curtain wall with a sill and mullion assembly permitting the substantially flush mounted panel members therewith. More particularly, one aspect of the present invention relates to a curtain wall system including a first vertical mullion operable to attach to a first sill member and a second vertical mullion operable to interlock with the first vertical mullion. The present invention also relates to a mullion cap for attaching to a bottom surface of a vertical mullion. The mullion cap includes a substantially planar bottom plate having an upper surface, a lower surface, a front edge, and a back edge. The mullion cap further includes an attachment face located on the upper surface of the substantially planar bottom plate. The attachment face is operable to attach to the vertical mullion.
[0018] In another aspect, the present invention includes a curtain wall system comprising a first vertical mullion operable to attach to a first sill member, and a second vertical mullion operable to interlock with the first vertical mullion. The first vertical mullion may also include a protrusion and the second vertical mullion may include a groove for interlocking with the protrusion. In one aspect, the first sill member attaches to the first vertical mullion via at least one screw spline and screw. The second vertical mullion may also be further operable to attach to a second sill member, while the first sill member may be formed as a single extrusion. The curtain wall system may also include a mullion cap for attaching to a bottom surface of at least one of the first and second vertical mullions. In one aspect, the mullion cap attaches to the first vertical mullion. The vertical mullions may also include a securement clip for attaching the vertical mullions to one another. The securement clip may be fastened to an interior surface of a second vertical mullion. The securement clip includes an extension that abuts a securement face located on an interior surface of the first vertical mullion.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] For a more complete understanding of the present invention, and for further objects and advantages thereof, reference is made to the following description taken in conjunction with the accompanying drawings in which:
[0020] [0020]FIG. 1 (Prior Art) illustrates a side cross-sectional schematic view of a sill member of a conventional curtain wall;
[0021] [0021]FIG. 2 illustrates a side cross-sectional view of a sill assembly of a curtain wall system;
[0022] [0022]FIG. 3 illustrates a perspective view of a sill and mullion assembly according to an embodiment of the present invention;
[0023] [0023]FIG. 4 illustrates an enlarged perspective view of a mullion cap as shown in accordance with an alternate embodiment of the present invention;
[0024] [0024]FIG. 5 illustrates an enlarged top view of the vertical mullion and mullion cap as shown in FIG. 4,
[0025] [0025]FIG. 6 illustrates a bottom view of the mullion cap as shown in FIG. 4;
[0026] [0026]FIG. 7 illustrates a bottom exploded view of a sill and mullion assembly including the mullion cap of FIG. 4 according to an alternate embodiment of the present invention;
[0027] [0027]FIG. 8 illustrates a bottom perspective view of the sill and mullion assembly including the mullion cap of FIG. 5;
[0028] [0028]FIG. 9A illustrates a top view of a securement clip of the mullion assembly of an alternate embodiment of the present invention;
[0029] [0029]FIG. 9B illustrates a perspective view of a securement clip of the mullion assembly of FIG. 9A,
[0030] [0030]FIG. 10A illustrates a top view of the engaged securement clip of the mullion assembly of FIG. 9A;
[0031] [0031]FIG. 10B illustrates a perspective view of the engaged securement clip of the mullion assembly of FIG. 10A;
[0032] [0032]FIG. 11 illustrates a perspective view of the sill and mullion assembly according to an alternate embodiment of the present invention; and
[0033] [0033]FIG. 12 illustrates a side cross-sectional view of the sill and mullion assembly including the mullion cap of FIG. 5.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0034] In the present embodiment, as shown in FIG. 3, a curtain wall assembly 250 of a preferred embodiment of the present invention is illustrated. Vertical mullions 300 , 302 are extruded in a shape permitting direct interengagement one with the other. One of the vertical mullions 300 is formed to provide a groove 304 on its rearward face for receiving a protrusion 306 of another of the vertical mullions 302 . The groove 304 and protrusion 306 are arranged so that the vertical mullions 300 , 302 are angled with respect to each other and then rotated until the rearward faces of both vertical mullions 300 , 302 are aligned in a planar fashion as described in more detail in FIGS. 7 and 8. Although the preferred embodiment of the present invention describes the interlocking mechanism of the vertical mullions as a groove 304 and protrusion 306 , any means of interlocking the two vertical mullions 300 , 302 together may be used. For example, a male and female snap arrangement may be employed, as well as two protrusions from the rearward faces of the vertical mullions 300 , 302 which may be secured together with additional fasteners. The interlocking vertical mullions 300 , 302 permit a restricted amount of movement to allow for thermal expansion and contraction while preventing failure under extreme stresses that may be exhibited by a hurricane or other natural disasters.
[0035] Sill members 308 are constructed as a single extrusion for direct engagement with the vertical mullions 300 , 302 via screw splines 310 . The sill members 308 are further constructed to provide a channel 312 for receiving a panel member (not shown) such as glass, granite, or other building material. The sill members 308 are fastened to the vertical mullions 300 , 302 which are then interlocked. The sill members 308 also provide various other grooves within the channel 312 for receiving components used to stabilize or secure the panel member. In the preferred embodiment, the interior surface of a forward leg 312 a of the channel 312 includes two grooves 314 , 316 while the interior surface of an intermediate leg 312 b includes a groove 318 , a support leg 320 , and an upper protrusion 322 . These grooves 314 , 316 , 318 , the support leg 320 , and the upper protrusion 322 may be oriented in a variety of ways to aid in the securement of various components placed in the channel 312 . In an alternate embodiment, the grooves 314 , 316 , 318 , support leg 320 , and upper protrusion 322 are eliminated and the components may be placed directly on the upper surface of a base 312 c of the channel 312 . The face opposite the groove 318 and support leg 320 of the intermediate leg 312 b includes a groove 324 in addition to a groove 326 disposed on the interior surface of a rearward leg 328 . In the preferred embodiment, the screw splines 310 are oriented between the intermediate and rearward legs 312 b and 328 .
[0036] Referring now to FIGS. 4 - 6 , a mullion cap 400 may be used with the curtain wall assembly 250 of the present invention. The mullion cap 400 may also be eliminated in an embodiment of the present invention. The mullion cap 400 includes a bottom plate 402 that is substantially planar and substantially rectangular in shape, however, other orientations may be used depending on the configuration of the vertical mullions 300 , 302 and the sill members 308 . On an upper surface of the bottom plate 402 , an attachment face 404 is located approximately near the center of the bottom plate 402 . In the preferred embodiment, sides of the attachment face 404 do not extend to the outside edges of the bottom plate 402 . In alternate embodiments, the attachment face 404 may be located at a position other that near the center of the bottom plate 402 and may also have sides that extend to or beyond the edges of the bottom plate 402 . Also in the preferred embodiment, the attachment face 404 includes an aperture 406 for securement to at least one of the vertical mullions 300 , 302 . A lower surface of the bottom plate 402 is substantially planar as illustrated in FIG. 6, although other orientations are possible.
[0037] As shown in the top view of FIG. 5, a fastener 500 is utilized to secure the attachment face 404 of the mullion cap 400 to a vertical face 502 of the vertical mullion 302 . The attachment face 404 may also be oriented in another direction to facilitate securement to another face of the vertical mullion 302 . As shown, the bottom plate 402 abuts the lower surface of the vertical mullion 302 and extends on both sides of the vertical face 502 . The bottom plate 402 may also be fabricated to be flush with the vertical face 502 instead of extending past the vertical face 502 .
[0038] [0038]FIGS. 7 and 8 illustrate the process of interlocking the vertical mullions 300 , 302 together, as well as the securement of the mullion cap 400 to the bottom surface of the vertical mullions 300 , 302 . The vertical mullions 300 , 302 are angled with respect to each other and sealant 700 is placed on bottom edges of the vertical mullions 300 , 302 , as well as an upper surface of the mullion cap 400 . The mullion cap 400 is secured to the bottom surface of the vertical mullions 300 , 302 . An end dam 702 may also be utilized in the preferred embodiment and attached to the vertical mullion 300 that is not secured to the mullion cap 400 . The end dam 702 is secured to a vertical face of the vertical mullion 300 in a similar fashion to that of the mullion cap 400 . The sealant 700 placed on the upper surface of the mullion cap 400 marries the end dam 702 to the mullion cap 400 , thereby providing a water tight seal. As shown in FIG. 8, the groove 304 may be placed over the protrusion 306 and rotated into position. In an alternate embodiment, the vertical mullions 300 , 302 may be rotated into position and then the sealant 700 may be applied. Then the mullion cap 400 may be secured to the bottom surface of the vertical mullions 300 , 302 .
[0039] Now referring to FIGS. 9A and 9B, a securement clip 900 according to an alternate embodiment of the present invention is described. To further enhance the structural integrity of the interlocking vertical mullions 300 , 302 during negative pressure loading, a securement clip 900 may be added to an internal face of the vertical mullion 300 including the groove 304 . In a first embodiment of the securement clip 900 , the securement clip 900 is formed of a single aluminum extrusion and is fashioned with an extension 904 at one end of the securement clip 900 . Although in the preferred embodiment a single aluminum extrusion is utilized, other configurations and material may be used to form the securement clip 900 . Other configurations may include multiple pieces and may span only a portion of the interior face. The securement clip may also be integrally formed with the vertical mullion 300 . The securement clip 900 abuts the internal face of the vertical mullion 300 from a side 906 of the groove 304 to a leg 908 oriented at or near a corner 910 of the vertical mullion 300 . The leg 908 abuts at least a portion of the extension 904 . The extension 904 includes a curved end portion for fastening against a securement face 902 of the opposite vertical mullion 302 with the protrusion 306 . The securement face 902 protrudes from an interior surface at or near a corner 912 of the vertical mullion 302 . The extension 904 of the securement clip 900 is operable to contact the securement face 902 as shown in FIGS. 10A and 10B.
[0040] As illustrated in FIGS. 10A and 10B, the curved end portion of the extension 904 abuts the securement face 902 to further secure the vertical mullions 300 , 302 . When the vertical mullions 300 , 302 are interlocked, the respective corners 910 , 912 are oriented near each other to facilitate engagement between the extension 904 and the securement face 902 . As shown, the leg 908 is oriented to protrude rearward of the corners 910 , 912 of the vertical mullions 300 , 302 and supports the extension 904 of the securement clip 900 . When the securement clip 900 is engaged, the leg 908 may rest on the interior surface of the vertical mullion 302 near the securement face 902 .
[0041] [0041]FIG. 11 illustrates the curtain wall assembly 250 once the vertical mullions 300 , 302 have been rotated into place and the mullion cap 400 has been secured to the vertical face 502 of the vertical mullion 302 and a bottom surface of the end dam 702 . Once rotated into position, the rear faces of both vertical mullions 300 , 302 are substantially planar. Depending on the interlocking mechanism utilized, one of the rear faces may be slightly inset with respect to the other rear face. As shown and discussed with reference to FIG. 5, in the preferred embodiment, the bottom plate 402 of the mullion cap 400 substantially covers the lower surface of the curtain wall assembly 250 from the edge of the sill member 308 attached to one vertical mullion 302 to the edge of a second sill member 308 attached to the other vertical mullion 300 that is interlocked with the first vertical mullion 302 . The mullion cap 400 , as installed, creates a water tight seal for the vertical mullions 300 , 302 . The interlocking vertical mullions 300 , 302 also provide addition structural support and do not pull apart when loaded with extreme stresses such as those experienced during natural disasters.
[0042] Referring now to FIG. 12, a curtain wall assembly 250 including a panel member 1000 secured in the channel 312 of the sill member 308 is illustrated. A setting chair 1002 may be fashioned with two legs 1004 , 1006 operable to sit in the grooves 316 , 318 of the forward leg 312 a and the intermediate leg 312 b , respectively. A setting block 1008 rests on an upper surface of the setting chair 1002 . The panel member 1000 has a lower surface that rests on the upper surface of the setting block 1008 . As noted above, the setting block 1008 may also rest on an upper surface of the base 312 c of the channel 312 . An exterior gasket 1010 attaches to the forward leg 312 a via the groove 314 . The exterior gasket 1010 aids in the stabilization and securement of the panel member 1000 in the channel 312 . On the interior side of the panel member 1000 , a plug 1012 is supported by the support leg 320 of the intermediate leg 312 b . On the upper face of the plug 1012 , structural silicone 1014 is utilized to create a water tight and structural seal between the panel member 1000 and the intermediate leg 312 b . In an alternate embodiment, in place of the plug 1012 and the structural silicone 1014 , a gasket similar to the exterior gasket 1010 may be utilized. The panel member 1000 is stabilized and secured via the exterior gasket 1010 , the setting chair 1002 , the setting block 1008 , the plug 1012 , and the structural silicone 1014 . The assembly of the panel member 1000 within the channel 312 may take place at the factory or other alternate site.
[0043] The curtain wall assembly 250 may be assembled at the factory and then shipped to the job site. The assembly required at the job site is the attachment of the sill member 308 to a support structure 1016 of the building via at least one fastener 1018 . The fastener 1018 secures the bottom surface of the sill member 308 to the support structure 1016 . Once the sill member 308 is secured, an assembly cover 1020 is placed over the exposed portion of the sill member 308 . Preferably, the assembly cover 1020 includes two legs 1022 , 1024 , one disposed at each end of the assembly cover 1020 . The forward leg 1022 is operable to fit in the groove 324 located on the intermediate leg 312 b and the rearward leg 1024 is operable to fit in the groove 326 located on the rearward leg 328 . The assembly cover 1020 may also be fastened to the sill member 308 by other securement means such as fasteners or snaps. By allowing direct access to the fully assembled and secured curtain wall assembly 250 , an inspector may easily view the securement of the sill member 308 to the support structure 1016 . Once viewed, the assembly cover 1020 may be secured to the sill member.
[0044] It is thus believed that the operation and construction of the present invention will be apparent from the foregoing description. While the curtain wall assembly shown and described have been characterized as being preferred it will be obvious that various changes and modifications may be made therein without departing from the spirit and scope of the invention.
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Disclosed is a curtain wall assembly used for building exteriors. The curtain wall system includes a first vertical mullion operable to attach to a first sill member and a second vertical mullion operable to interlock with the first vertical mullion. A mullion cap may be attached to a bottom surface of at least one of the vertical mullions. The mullion cap includes a substantially planar bottom plate having an upper surface, a lower surface, a front edge, and a back edge. The mullion cap further includes an attachment face located on the upper surface of the substantially planar bottom plate. The attachment face is operable to attach to the vertical mullion.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
FIELD OF THE INVENTION
[0001] The invention relates to an improved releasing slip for use with a hold down tool/bridge plug/packer for lowering into a wellbore. In particular, the releasing slip of the invention has a low friction face to facilitate ease of release.
BACKGROUND OF THE INVENTION
[0002] A production packer is a standard component of completion hardware in oil and gas wells. Production packers are used to provide a seal between the outside of production tubing and the inside of a casing, liner, or wellbore wall. When recovering oil and gas from a well, in many geological formations it is necessary to isolate the zone containing the oil and gas producing formation from the remainder of the underground structure so as to prevent contamination of the oil and gas producing zone from salt water or other undesirable contaminants.
[0003] Packers may be lowered into the well and expanded to isolate the oil and gas producing zone. Packers may be placed above and below the producing zone, or, if the producing zone is near the bottom of the well, a single packer may be placed above the producing zone. Packers are typically provided with slips for providing gripping engagement with the wall of a wellbore. Once a packer is set, the packer may experience forces that could displace the packer in the casing. One example of such a force is pressure from the formation.
[0004] In some circumstances, it may be desirable to utilize a hold down tool or bridge plug in the well to assist in keeping a packer in position. A hold down tool/bridge plug typically includes a plurality of slips that may be selectively forced into tight engagement with a wall of the well bore.
[0005] One difficulty associated with the use of conventional slips or gripping members is that the slips that are engaged with the wellbore can be extremely difficult to release when it is desired to release the tool.
[0006] An innovative oil well hold down tool is taught in U.S. Pat. No. 3,356,141 to Albert K. Kline (the '141 patent). The system taught in the '141 patent provided for one or more slips to be released prior to release of all the loaded slips, depending on the circumference of the tool used. The early releasing slips have become known as “releasing slips”. When the releasing slip or slips are released, normally by pulling up against them or their mounting device, the tool as a whole is then free to move laterally in the well slightly. The lateral movement of the tool is enough to lessen or remove entirely the bite of the remaining slips. The tool can then be moved up the well, or relatched and then moved further down the well and reset, or removed entirely.
[0007] There are numerous uses of the releasing slip principle taught by the '141 patent. Applicant's company manufactures several tools utilizing the teachings of the '141 patent. For example, one tool addressed improvements to the invention of the '141 patent related to the releasing slips. The device was used to assist in the release of hold down tools that have mechanically, as opposed to hydraulically, loaded slips above the pack-off portion of the tool.
[0008] One drawback of hold down tools utilizing prior art designs is that, when engaged, the slips bite into the casing wall while the hold down tool is performing its functions. Therefore, during release, even the releasing slips provide resistance, which causes problems including that the biting surfaces of the releasing slips become worn fairly quickly, requiring their replacement. An additional difficulty is that during higher pressure operations, the releasing slips can provide sufficient resistance that release becomes difficult and may also cause other problems. These problems may include overstressing the pulling unit topside, parting of the tubing that is used to transfer the tension from the pulling unit to the tool, rupture or permanent deformation of the mounting device for the slips, and ultimately, an inability to remove the tool at all.
SUMMARY OF THE INVENTION
[0009] This present invention replaces the releasing slips with a part or parts that have no biting effect on the casing. In one embodiment, the surface of the releasing slip of the present invention is entirely smooth. When pulled upwards, the releasing slips of the present invention move up much more easily, allowing the tool to move laterally, thereby partially unloading the remaining slips, and thus allowing the remaining slips to more easily release. The releasing slips in this case are, in practice, used as a wedge, which allow the remaining slips to function normally. The releasing slips of the invention are not required to provide biting capability for the hold down tool to perform its function. The releasing slips of the invention allow the tool to release much more easily, especially in severe applications.
[0010] A second embodiment of the present invention utilizes one or more hardened carbide pieces or other suitable material on the contacting face of the releasing slip of the invention. The smooth surface of the hardened piece or pieces are preferably configured such that the piece or pieces lay flat against a wall, thereby providing greatly reduced resistance to release. The carbide pieces are harder than any standard grade of casing, which greatly reduces wear on the part.
[0011] In the case of larger diameter tools, more than one releasing slip may be used in the circumferential arrangement of the upper slips. Preferably, the releasing slips cover somewhat less than half the circumference of the tool so that the tool can move laterally in the wellbore when the releasing slips are released or disengaged from the wellbore wall. The biting slips preferably also encompass less than half the circumference. As an example, a hold down tool of the present invention may use two releasing slips and four biting slips, although other numbers of slips and ratios of releasing slips to biting slips may be functional. In a preferred embodiment, the releasing slips are wider than the biting slips and the biting slips encompass less than 180 degrees of tool circumference.
[0012] There are several advantages of the present invention. Most importantly, a tool utilizing the inventive slips significantly reduces the problems described above with respect to removal of the tool. The monetary benefit associated with the tool includes the relatively smaller benefits associated with improved service life of the releasing slips and also the substantially larger benefits associated with avoiding an inability to release the tool.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a partially sectioned elevation view of a packer being placed in a hole, attached to a hold down tool, in which the invention is embodied.
[0014] FIG. 2 is the structure of FIG. 1 attached at a desired position within a well bore.
[0015] FIG. 3 is an isometric view of a slip housing base of the hold down tool of FIG. 1 .
[0016] FIG. 4 is an isometric view of the slip housing of FIG. 3 shown with slips installed therein.
[0017] FIG. 5 is an isometric view of a biting slip for installation into the slip housing of FIG. 4 ,
[0018] FIG. 6 is an isometric view of a releasing slip for installation into the slip housing of FIG. 4 .
[0019] FIG. 7 is an isometric view of a releasing slip of FIG. 4 with carbide pieces on a wall engaging face of the releasing slip.
[0020] FIG. 8 is a partial cut-away view of a retrievable bridge plug in which the invention is embodied.
[0021] FIG. 9 is a partial cut-away view of a packer in which the invention is embodied.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] Referring first primarily to FIGS. 1 and 2 , shown is well bore 10 having a wall 12 . A packer 14 is shown lowered into well bore 10 . Packer 14 includes an expansible element such as packer slips 15 for selectively engaging wall 12 . A hold down tool 16 is connected to packer 14 . Hold down tool 16 includes a cone assembly 18 . Cone assembly 18 has an upwardly facing cone 20 and an outer casing 22 . Outer casing 22 defines a j-slot 24 having a long vertical section 26 and a short horizontal section 28 . Cone assembly 18 further defines an internal abutment 30 .
[0023] A coupling member 32 is attached to an upper end of hold down tool 16 . A tubing string 34 is connected to coupling member 32 for supporting hold down tool 16 and packer 14 within well bore 10 .
[0024] A spring 36 is located above hold down tool 16 . Spring 36 has an upper end in abutment with coupling member 32 . A cylindrical mandrel 38 extends downwardly inside cone assembly 18 . Mandrel 38 defines a protuberance 40 and has a lower end 42 . Mandrel 38 further has a pin 44 protruding from an outer surface. Pin 44 is provided for extending into j-slot 24 .
[0025] Mandrel 38 and cone assembly 18 are releasably connected together via pin 44 and j-slot 24 . When pin 44 is positioned in long vertical section 26 of j-slot 24 , mandrel 38 may be moved downwardly (as shown in FIG. 2 ) until lower end 42 of mandrel 38 seats on internal abutment 30 of cone assembly 18 .
[0026] Slip housing 46 is located above cone assembly 18 . Slip housing 46 is made up of a slip housing cover 48 ( FIGS. 1 , 2 , 4 ) and a slip housing base 50 ( FIGS. 3 , 4 ). Slip housing base 50 is slidably mounted on mandrel 38 . Slip housing cover 48 and slip housing base 50 define an annular space therebetween. Slip housing base 50 has an upper end in engagement with a lower end of spring 36 . Spring 36 urges slip housing base 50 against protuberance 40 on mandrel 38 . Slip housing base 50 has a lower end defining a flange portion 52 . Flange portion 52 defines a plurality of downwardly facing openings 54 ( FIG. 3 ).
[0027] A plurality of slips 56 are carried within slip housing 46 and are sized to be received within openings 54 of slip housing base 50 . Slips 56 each have an extension 58 ( FIGS. 4-7 ) on an upper end for locating in the annular space between the slip housing cover 48 and the slip housing base 50 . Slips also have a wall engaging face 60 ( FIGS. 4-7 ). Slips 56 further define a slip neck 61 ( FIGS. 5-7 ). Slips 56 are loosely received within openings 54 of slip housing base 50 wherein flange portions 52 of slip housing base 50 that are located between openings 54 provide supportive engagement with slip necks 61 .
[0028] Slips 56 are comprised of biting slips 62 ( FIGS. 4 , 5 ) and releasing slips 66 ( FIGS. 4 , 6 , 7 ). Faces 60 of biting slips 62 have a plurality of wickers or teeth 64 to facilitate gripping engagement with wall 12 of bore 10 . Faces 60 of releasing slips 66 have smooth surface 68 to facilitate ease of release. In an alternative embodiment, smooth surface 68 of releasing slip 66 may be impregnated with one or more hardened carbide pieces 70 to reduce wear on face 60 of releasing slips 66 .
[0029] Slip housing base 50 functions to selectively urge slips 56 downwardly when mandrel 38 is moved downwardly. Slips 56 are oriented vertically and are positioned circumferentially above upwardly facing cone 20 of hold down tool 16 . Therefore, when slips 56 are moved downwardly with mandrel 38 , slips 56 engage the upwardly facing cone 20 . Upwardly facing cone 20 then forces engagement faces 60 proximate the lower ends of slips 56 outwardly into engagement with wall 12 of well bore 10 .
[0030] When it is desired to release the slips 56 , mandrel 38 is moved upwards. The force of the mandrel moving upward is first transmitted through slip housing base 50 . Flange portion 52 of slip housing base 50 lifts slips 56 upwards. Slip necks 61 may be of different lengths, so that flange portion 52 does not engage slips simultaneously.
[0031] Referring now to FIG. 8 , a bridge plug 100 is shown utilizing the slips of the invention. Bridge plug 100 includes a tubular housing 102 . Tubular housing 102 is made up of lower mandrel 104 , connecting rod 106 that is threadably received on an upper rod of lower mandrel 104 , and an upper mandrel 108 that is threadably received on an upper end of connecting rod 106 . A pulling head cap 110 is threadably received on an upper end of upper mandrel 108 .
[0032] A control body 112 surrounds lower mandrel 104 . A plurality of drag blocks 114 are supported by control body 112 . Drag blocks 114 are biased outwardly by drag block springs 116 .
[0033] A lower cone member 118 surrounds lower mandrel 104 . Lower cone member 118 has a cone section 120 and a lower cylindrical section 122 . A plurality of lower slips 124 surround lower cylindrical section 122 of lower cone member 118 . Plurality of lower slips 124 are located below cone section 120 of lower cone member 118 .
[0034] An element retainer 126 is threadably received on an upper end of lower cone member 118 . Packing and seal sleeve 128 and attached packing element 130 are adjacent to connecting rod 106 in an abutment with element retainer 126 . An upper cone member 132 is threadably received on an upper end of packing and seal sleeve 128 .
[0035] A slip sleeve 134 is provided above upper cone member 132 . A plurality of upper slips 136 surrounds slip sleeve 134 . Upper slips 136 are made up of releasing slips 138 and biting slips 140 . A thrust spring 142 is provided having a lower end in engagement with slip sleeve 134 . A spring ring 144 is affixed to upper mandrel 108 . Spring ring 144 is in engagement with an upper end of thrust spring 142 .
[0036] In practice, when packing element 130 engages a wall of a wellbore, packing element 130 moves upwardly with regard to tubular housing 102 with attached upper cone member 132 . Upper cone member 132 contacts upper slips 136 and forces slips 136 into engagement with a wall of the wellbore.
[0037] Referring now to FIG. 9 , shown is a packer 200 utilizing the releasing slips of the invention. Packer 200 includes a mandrel 202 . A top sub 204 is threadably attached to an upper end of mandrel 202 . A control body 206 surrounds mandrel 202 . A plurality of drag blocks 208 are supported by control body 206 . Drag blocks 208 are biased outwardly by drag block springs 210 .
[0038] A lower slip sleeve 212 is threadably attached to an upper end of control body 206 . A lower cone member 214 surrounds lower slip sleeve 212 . A plurality of lower slips 216 surround lower slip sleeve 212 . The plurality of lower slips 216 are located below lower cone member 214 .
[0039] An element retainer 218 is threadably received on an upper end of lower cone member 214 . A packing and seal sleeve 220 as well as a packing element 222 are in threaded communication with element retainer 218 .
[0040] An upper cone member 224 is threadably received on an upper end of packing and seal sleeve 220 . An upper slip support 226 is located above upper cone member 224 . A plurality of upper slips 228 surround upper slip support 226 . Upper slips 228 are made up of releasing slips 230 and biting slips 232 . A slip spring 234 is provided for biasing each of upper slips 228 outwardly. An upper slip housing assembly 236 is located above upper slips 228 .
[0041] In practice, when packing element 222 engages a wall of the wellbore, packing element 222 moves upwardly with regard to mandrel 202 . Attached upper cone member 224 moves upwards as well. Upper cone member 224 contacts upper slips 228 and forces slips 228 into engagement with a wall of the wellbore.
[0042] When pulled against for release, as described above, releasing slips 66 ( FIGS. 4 , 6 , 7 ), 138 ( FIG. 8 ), 230 ( FIG. 9 ) are easily lifted and disengaged from wall 12 since releasing slips 66 , 138 , 230 have a low friction wall engaging face, as can best be seen in FIGS. 6 and 7 . Once releasing slips 66 , 138 , 230 are lifted, tool 16 , 100 , 200 is able to move laterally, thereby partially unloading the remaining biting slips 62 ( FIGS. 4 , 5 ), 140 (FIG, 8 ), 232 ( FIG. 9 ), which allows biting slips 62 , 140 , 232 to more easily release. Therefore, releasing slips 66 , 138 , 230 function as a wedge to force biting slips 62 , 140 , 232 to securely engage wall 12 . Releasing slips 66 , 138 , 230 are not required to provide biting capability for tool 16 , 100 , 200 to perform its function. Releasing slips 66 , 138 , 230 of the invention allow tool 16 ( FIGS. 1 , 2 ), 100 ( FIG. 8 ), 200 ( FIG. 9 ) to release much more easily, especially in severe applications.
[0043] In one embodiment, hardened pieces 70 ( FIG. 7 ), such as hardened carbide disks or pieces of other suitable material protrude from contacting face 60 of releasing slip 66 , or from a contact face of releasing slips 138 , 230 . Smooth surface 68 of a hardened piece 70 or pieces 70 are preferably configured such that the piece or pieces 70 lay flat against wall 12 , thereby providing greatly reduced resistance to release. The carbide pieces 70 are harder than any standard grade of casing, which greatly reduces wear on releasing slip or slips 66 , 138 , 230 .
[0044] In the case of larger diameter tools 16 , 100 , 200 , more than one releasing slip 66 , 138 , 230 may be used in the circumferential arrangement of the slips 56 . Preferably, releasing slips 66 , 138 , 230 cover somewhat less than half the circumference of tool 16 , 100 , 200 , so that tool 16 , 100 , 200 can move laterally in wellbore 10 when releasing slips 66 , 138 , 230 are released or disengaged from wall 12 . Consequently, biting slips 62 , 140 , 232 preferably encompass more than half the circumference of tool 16 , 100 , 200 .
[0045] Thus, the present invention is well adapted to carry out the objectives and attain the ends and advantages mentioned above as well as those inherent therein. While presently preferred embodiments have been described for purposes of this disclosure, numerous changes and modifications will be apparent to those of ordinary skill in the art. Such changes and modifications are encompassed within the spirit of this invention as defined by the claims.
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Releasing slips for use with a downhole tool, a tool for deploying downhole in a well utilizing the releasing slips and a well in which a downhole tool is deployed utilizing the releasing slips of the invention is described herein. The tool has a plurality of slips for selective engagement with a wall of a wellbore. The slips include releasing slips and biting slips. The releasing slips have a low friction surface, e.g., a substantially smooth surface for engaging the wall of the wellbore. The smooth wall engaging face of the releasing slips facilitate easy release of the slips, thereby facilitating easy removal of the downhole tool. The slips may include a plurality of hardened members that protrude from the wall engaging face of the releasing slips to reduce wear on the face of the releasing slip.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
This is a division of U.S. Patent Application Ser. No. 111,468, filed Oct. 22, 1987, now U.S. Pat. Ser. No. 4,771,504.
The present invention provides a leaf loading method including the steps of picking up material from the ground by operating a rotary beater having a plurality of lifting elements and a rotary broom having a plurality of bristles, delivering leaves between the beater and the broom in opposite directions, guiding material from between the beater and the broom toward an auger disposed rearwardly of the broom, transferring leaves from the auger into a thrower by rotating the auger, and discharging leaves by operating the thrower. The guiding step may include utilizing a shroud which fully covers an upper side of the beater and partially covers an upper side of the broom. The guiding step may further include utilizing a housing which overlies an upper side of the auger and part of the upper side of the broom. The picking up step may include arranging the beater and the broom so that each has a lower side thereof disposed adjacent the ground, and the transferring step may include utilizing an opening in a side wall of the housing to provide communication between the auger and the thrower.
BRIEF DESCRIPTION OF THE DRAWINGS
In the course of the following detailed description, reference will be made to the attached drawings in which:
FIG. 1 is a top plan view, with portions broken away, of a leaf loading machine embodying the principles of the present invention;
FIG. 2 is a right side elevational view of the machine of FIG. 1;
FIG. 3 is a left side elevational view of the machine of FIG. 1;
FIG. 4 is an enlarged sectional view taken along line 4--4 of FIG. 1;
FIG. 5 is a left side elevational view of the leaf loading machine with the machine being shown in a transport position in solid line form and an operating position in dashed line form;
FIG. 6 is a left side elevational view of the leaf loading machine with its rotary pickup beater being shown at its minimum displacement above the ground in solid line form and at its maximum displacement above the ground in dashed line form;
FIG. 7 is an enlarged side elevational view of one of the sweeping elements in a rotary pickup broom of the leaf loading machine;
FIG. 8 is a sectional view taken along line 8--8 of FIG. 7;
FIG. 9 is an enlarged side elevational view of one of the lifting elements in the pickup broom of the leaf loading machine;
FIG. 10 is an end elevational view as seen along line 10--10 of FIG. 9;
FIG. 11 is an enlarged side elevational view of a central spider support structure in the pickup broom of the leaf loading machine;
FIG. 12 is a sectional view taken along line 12--12 of FIG. 11; and
FIG. 13 is an exploded view of one of ten groupings of sweeping and lifting elements in the pickup broom of the leaf harvesting machine.
DETAILED DESCRIPTION OF THE INVENTION
In the following description, right hand and left hand references are determined by standing at the rear of the machine and facing in the direction of forward travel. Also in the following description, it is to be understood that such terms as "forward", "left", "upwardly", etc., are words of convenience and are not to be construed as limiting terms. In General
Referring now to the drawings, and particularly to FIGS. 1-3, there is shown an improved leaf loading machine, being indicated generally by numeral 10 and comprising the preferred embodiment of the present invention (the right side of the machine being shown in FIG. 2 and the left side in FIG. 3 when one is standing to the rear of the machine and facing in the direction of forward travel).
The machine 10 is provided with a mobile frame, generally indicated at 12, which includes a left longitudinal frame member 14 and a pair of laterally spaced inner and outer right longitudinal frame members 16,18 which members 14,16,18 all extend fore-and-aft and are interconnected by forward and rearward transverse frame members 20,22. The longitudinal frame members 14,16,18 are respectively supported by left and right ground wheels 24,26 being rotatably mounted by an elongated axle 28 extending between and mounted at its opposite ends to left and right bracket plates 30,32 fixed in upright orientations to the rear portions of the left and outer right longitudinal members 14,18.
At the right front portion of the mobile frame 12, a pair of inner and outer beams 34,36 are fixed upstanding on the front ends of respective inner and outer longitudinal frame members 16,18. A tongue assembly 38 is pivotally mounted at its rear portion by an elongated pivot pin 40 connected to and extending between the upper ends of the beams 34,36. The tongue assembly 38 extends forward from the beams 34,36 and has a hitching means 42 on its forward end adapting the machine 10 to be secured to a drawbar 44 (FIG. 5) of a towing vehicle (not shown), such as a truck located at the front of the machine 10, for towing the machine 10 along surfaces of streets, roadways, parks or other areas to be cleaned.
In addition to the mobile frame 12, the leaf loading machine 10 basically includes a rotary beater 46 on the frame 12 extending transversely of the direction of travel and a main rotary pickup broom 48 on the frame 12 also extending transversely of the direction of travel and disposed rearwardly of and in tandem relation to the beater 46. Covering the upper side of the beater 46 is a shroud 50 open at its front and rear ends and composed of a pair of spaced left and right side walls 52,54 interconnected by a top wall 56. Overlying and enclosing the upper side of the main pickup broom 48 is a housing 58 open at its front end and composed of a pair of spaced left and right side walls 60,62 interconnected by a top wall 64 and closed at the rear end of the housing 58 by a rear wall 66. The housing 58 is fixed on and extends between and above the left and inner right longitudinal frame members 14,16 of the mobile frame 12.
Thus, the beater 46 and main pickup broom 48 are disposed with their lower sides adjacent to the ground and their upper sides spaced below respective top walls 56,64 of the shroud and housing 50,58. The auxiliary beater 46 and main broom 48 have respective elongated central tubular members 68 and 70 rotatably mounted at their respective opposite ends to and extending between respective side walls 52,54 and 60,62 of the shroud 50 and housing 58 by which the beater 46 and broom 48 can counterrotate relative to one another so as to deliver leaves from the ground upwardly therebetween. The leaves are then deflected rearwardly over the main broom 48 by the respective top walls 56 and 64 of the shroud 50 and housing 58.
Also, the leaf loading machine 10 includes means on the mobile frame 12 for receiving the leaves delivered from the ground by the beater 46 and main pickup broom 48 and deflected rearwardly over the broom 48 toward the rear wall 66 of the housing 58. The receiving means preferably takes the form of a transfer auger 72 disposed transversely on the mobile frame 12 rearwardly of and in tandem with the broom 48 and a discharge blower 74 coaxially aligned with and disposed at a discharge end of a central shaft 76 of the auger 72. The auger 72 at the left end of its shaft 76 is rotatably mounted to the left side wall 60 of the housing 58. The thrower 74 is mounted on the inner and outer right longitudinal frame members 16,18 adjacent the right side wall 62 of the housing 58.
An opening 78 in the housing right side wall 62 provides communication of the auger 72 with an impeller 80 rotatably mounted between the housing right side wall 62 and an outer side wall 82 of a casing 84 of the blower 74. The auger 72 rotates and coacts with a stationary arcuate shaped trough 86, which underlies the auger 72 and is fixed between the housing side and rear walls 60,62,64, to transfer the leaves laterally from left to right in FIG. 1 to the thrower impeller 80. The impeller 80 rotating at high speed in the blower casing 84 propels the leaves through the casing 84 and out a discharge spout 88 extending upwardly from the casing 84 to a storage location, such as the truck which tows the machine 10.
The motive power for the beater 46, main pickup broom 48, transfer auger 72 and discharge thrower 74 of the leaf loadingmachine 10 is derived from an engine 90 mounted on a rear superstructure 92 fixed to the longitudinal frame members 14,16,18 of the mobile frame 12 and overlying the ground wheels 24,26 thereof. A power train leading from a rotating drive shaft 94 of the engine which mounts a flywheel 96 provides rotary driving power to the above-described operating components of the machine 10.
More particularly, the power train includes drive and driven sheaves 98,100 respectively mounted on the engine drive shaft 94 and the thrower impeller 80 and a continuous belt 102 extending between an drivingly entrained about the sheaves 98,100. A belt tightener mechanism 104 is disposed adjacent the belt 102 and actuatable by a handle 106 pivotally mounted on the superstructure 92. The power train also includes a jack shaft 108 rotatably mounted a bracket 110 fixed upright on the outer right longitudinal frame member 18 and having a large diameter sprocket 112 and a pair of small diameter sprockets 114 attached respectively on outer and inner ends of the jack shaft 108. Another small diameter sprocket 116 is attached on the outer end of the impeller 80 adjacent the sheave 110 thereon with a drive chain 118 extending between and drivingly entrained about the sprockets 112,116.
For powering the main pickup broom, the dual sprockets 114 on the inner end of the jack shaft 108 are drivingly coupled to dual sprockets 120 on the right end of the broom central tubular member 70 by a pair of continuous drive chains 122. For powering the beater 46 and the transfer auger 72, a pair of inner and outer sprockets 124,126 are attached side-by-side to the left end of the broom central tubular member 70. Respective drive chains 128,130 extend between and drivingly couple the outer and inner sprockets 126,124 with sprockets 132,134 respectively attached on the left ends of the beater central tubular member 68 and the auger shaft 76. A pair of drive chain take-up idler sprockets 136 are rotatably mounted on the left side wall 60 of the housing 58 adjacent the outer sprocket 126 on the broom central tubular member 70. The idler sprockets 136 allow adjustable movement of the beater 46 toward and away from the broom 48 while still providing drive coupling therebetween by the chain 128 and also provide for counterrotation of the beater 46 and broom 48 such that they move toward one another, as depicted by the arrows in FIG. 4, at their respective lower sides.
The machine 10 also has a brush stripper 138 with an elongated shaft 140 and diametrically opposed radially projecting combs 142. The shaft 140 is rotatably mounted between the left and right housing side walls 60,62 so as to locate its combs 142 rearwardly and tangentially to the main pickup broom 48. The power train also includes a large diameter sprocket 144 attached on the left end of the auger shaft 76 and a small diameter sprocket 146 attached to the left end of the brush stripper shaft 140. A drive chain 148 extends between and drivingly couples the sprockets 144,146. The relative speeds of the operating components of the machine 10 can readily be determined by comparing the relative sizes of the respective sheaves and sprockets of the power train associated therewith.
Rotary Beater and Pickup Broom
One important feature of the improved leaf harvesting machine 10 relates to the composition of, and cooperation which occurs between, the beater 46 and main pickup broom 48. As best seen in FIG. 4, in addition to its central tubular member 68, the pickup beater 46 includes a number of elongated angle members 150 being L-shaped in cross section and a plurality of elongated lifting elements 152 attached in spaced relation along each of the angle members 150. The angle members 150 are circumferentially spaced about and rigidly fixed to the central tubular member 68 so as to extend tangentially therefrom. The lifting elements 152 are angularly spaced about and generally extend in swept back radial fashion from a central mounting structure 154 formed by the angle members 150 and central tubular member 68 of the beater.
Also, the beater 46 includes a stripper assembly 156 composed of a plurality of spaced apart U-shaped stripper segments 158 which extend parallel to one another and downwardly around the lower side of the central mounting structure 154 and are attached at their upper ends by bolts 160 to flanges 162 fixed on the underside of the top wall 56 of the beater shroud 50. The lifting elements 152 are aligned with the spaces between the stripper segments 158 so as to extend through the spaces and beyond the stripper segments 158 during travel through the lower portion of an endless path of travel P(1) as the beater central mounting structure 154 is rotated counterclockwise as viewed in FIG. 4. During travel through the upper portion of the endless path P(1), the lifting elements 152 withdraw inside of the stripper segments 158 whereby the segments 158 cause stripping of any material clinging to the lifting elements 152. Preferably, the lifting elements 152 take the form of resiliently yieldable, semirigid spring type fingers or tines which move in the endless path P(1) and are capable of engaging and loosening up densely packed piles of leaves and of lifting the leaves upwardly from the ground.
As best seen in FIGS. 1, 4, and 7-13, in addition to its central tubular member 70, the pickup broom 48 includes a spider 164, and pluralities of brushing or sweeping elements 166 and lifting elements 168 axially slidably mounted on the spider 164. The spider 164 is composed of three bars 170 spaced radially from and extending generally parallel to the central tubular member 70 by a plurality of triangular-shaped plates 172. The plates 172 are axially spaced from one another along the central tubular member 70 and attached thereto and to the bars 170 so as to define with the central tubular member 70 and bars 170 a central spider support structure 174 having an overall equilateral triangular configuration.
As best seen in FIGS. 4, 7, 8 and 13, each of the brushing or sweeping elements 166 of the broom 48 is composed of a central ring 176 having a multiplicity of resiliently flexible elongated fiber bristles 178 arranged in a row, anchored thereto and extending radially therefrom. The central ring 176 has a wavy, undulating or convoluted shape defining three pairs of alternating, axially spaced lobes A and B which, depending upon the angular orientation of one ring 176 relative to an adjacently positioned ring 176, allow placement of the rings 176 either in sync or out of sync with one another. In other words, when the rings are "in sync" with one another, the three pairs (or six) lobes A,B of each ring are nested together in close packed contacting relation with their rows of bristles 178 disposed adjacent one another. After rotation of one ring 176 sixty degrees relative to the adjacent ring 176, the rings are "out of sync" such that only three lobes A displaced one hundred twenty degrees apart are contacting and their rows of bristles 178 are axially spaced at the locations of the other three spaced apart lobes. Both the "in sync" and "out of sync" relationships of the sweeping elements 166 can be seen in FIG. 1. Two pairs of radially inwardly extending spaced drive pins 180, 182 fixed on the ring 176 of each sweeping element 166 and circumferentially spaced from one another by approximately one inch interfit with any of the bars 170 of the spider support structure 174 to prevent the sweeping element 166 from rotating relative thereto once the ring 176 has been slidably installed over the spider support structure 174. Rotation of the spider support structure 174 thus causes rotation of the plurality of sweeping elements 166 therewith in an endless path P(2) in which the outer tips of the fiber bristles 178 engage and sweep the loosened leaves across the ground.
As best seen in FIGS. 4, 9, 10 and 13, each of the lifting elements 168 of the broom 48 is composed of a triangular shaped plate 184 and a plurality of resiliently-yieldable, semi rigid spring type fingers or tines 186 angularly-spaced thereabout one hundred twenty degrees from one another. The tines 186 are mounted by bolts 188 to each of three angular brackets 190 fixed on the respective three segments 192 of the plate 184. Installation of the lifting element 168 over the spider support structure 174 of the broom 48, as best seen in FIG. 4, involves aligning the bars 170 of the spider support structure 174 with the interior corners formed by the plate segments 192 and then sliding the plate 184 on the bars 170.
As shown in FIG. 13, one lifting element 168 is grouped with six sweeping elements 166 with a subgroup of three sweeping elements 166 on each opposite side of the lifting element 168. Ten of such groups are positioned along the spider support structure 174 of the broom 48. The sweeping and lifting elements 166,168 are installed from the right end of the structure 174 as viewed in FIG. 11. A stop plate 194 is provided on the left end of the structure 174.
The three sweeping elements 166 of each subgroup on each side of the lifting element 168 are oriented to assume an "in sync" or nesting relation to one another. However, the inner ones of the sweeping elements 166 of the two subgroups are oriented "out of sync" with each other, allowing the lifting element 168 to be positioned therebetween with its corners 196 formed by the plate segments 192 being disposed between the three spaced lobes B of the sweeping element rings 176. In such manner, the lifting element tines 186 are interspersed with the fiber bristles 178 of the sweeping elements 166 and, upon rotation of the spider support structure 174, move in an endless path P(3) to engage and lift upwardly from the ground the leaves being swept by the sweeping elements 166. It will be observed in FIG. 4 that the tines 186 of the lifting elements 168 are slightly shorter in length than the bristles 178 of the sweeping elements 166. Thus, the diameter of endless path P(3) is less than that of endless path P(2).
Therefore, upon counterrotation of the beater 46 and main pickup broom 48 such that the beater and broom rotate toward one another at their respective lower sides which are located adjacent the ground, the respective sweeping elements 166 and lifting elements 152,168 thereof cooperate to positively and consistently deliver leaves from the ground upwardly between the beater and broom 46,48 to the transfer auger 72. Because of the interspersed relationship of the tines 186 within the mass of bristles 178, when the load becomes heavy the more rigid tines 186 take over the load carrying function from the fiber bristles 178. If the tines 186 were not present, the bristles 178 would merely deflect and not lift the load. The tines 186 by being spring-type are forgiving and so will resilient yield when passing over rocks and other immovable objects.
Adjustable Mounting of Rotary Beater
Another important feature of the improved leaf harvesting machine 10 relates to means mounted on the mobile frame 12 which, in turn, adjustably mounts the beater 46 for movement along a linear path toward and away from the main pickup broom 48 for presetting the positional relationship of the beater 46 relative to the broom 48. More specifically, the adjusting means includes a releasable and slidably adjustable attachment arrangement, generally designated 198, for presetting the position of the endless path P(1) of the beater lifting elements 152 relative to the endless paths P(2),P(3) of the pickup broom sweeping and lifting elements 166,168. As seen in FIG. 4, the slightly overlapping relation between the peripheries of the respective endless paths P(1) and P(2) of the beater lifting elements 152 and pickup broom sweeping elements 166 is preferred. Also, a substantially tangential relation between the peripheries of the respective endless paths P(1) and P(2) of the pickup beater lifting elements 152 and pickup broom lifting elements 168 is preferred.
As best seen in FIGS. 1-6, the adjustable beater attachment arrangement 198 includes a pair of left and right elongated arms 200,202 pivotally mounted at their rear end portions to the outer left and right ends of the broom central tubular member 70 and slidably coupled via elongated slots 204 defined in their front end portions to outer left and right ends of the beater central tubular member 68. Left and right plates 206,208 are fixed to the front portions of the respective left and right arms 200,202 and extend above and below the arms. A pair of spaced slots 210 are formed in each of the plates 206,208 above and below the arms 200,202. The slots 210 receive releasable fasteners 212 which extend through holes in the left and right shroud side walls 52,54 being alignable with the respective slots 210. Thus, the position of the beater 46 relative to the broom 48 is adjusted by first unloosening the fasteners 212. Next, the beater 46 and shroud 50 therewith are slid toward the broom 48 (with the outer ends of the beater central tubular member 68 sliding along the slots 204 in arms 200,202) until the desired position is reached. Then, the fasteners 212 are retightened.
Still another important feature of the improved leaf loading machine 10 relates to means pivotally mounted on the mobile frame 12 and mounting the beater 46 for swinging movement toward and away from the ground about the main pickup broom center 48. In particular, the beater mounting means takes the form of the above-described beater support and attachment arrangement 198 which pivotally mounts the beater 46 to the axis of the broom 48 and a height adjustment mechanism 214 coupled between the beater shroud 50 and the mobile frame 12. Particularly, the height adjustment mechanism 214 includes a bracket 216 fixed on the top wall 56 of the shroud 50 having an elongated lost motion slot 218, a cylinder 220 having a central threaded bore 222 pivotally mounted by a bracket 224 fixed on the front edge of the housing top wall 64, and an elongated threaded rod 226 extending through the cylinder 220 with a handle 228 defined on the upper end thereof. The height adjustment mechanism 214 is actuatable by rotating the handle 228 to preset a minimum displacement of the beater above the ground, as seen in FIG. 6. The presence of the slot 218 permits a lost motion type pivotal movement of the beater shroud 50 and the beater 46 therewith to a maximum displacement above the ground (as seen in dashed line form in FIG. 6) to allow the beater 46 to rise up over immovable obstacles encountered on the ground.
Conversion Between Transport and Operating Positions
Yet another feature of the improved machine relates to a conversion arrangement 230 for raising and lowering the beater 46 and main pickup broom 48 between operating and transport positions shown respectively in dashed and solid line forms in FIG. 5. Specifically, as best seen in FIGS. 1-6, the tongue assembly 38 of the machine 10 which is pivotally mounted by the pin 40 about a generally horizontal axis to the upright beams 34,36 includes a lever member 232 of the conversion arrangement 230 extending rearwardly from the beams. The arrangement 230 also includes a conversion mechanism 234 coupled between the rear end of the lever member 232 and a bracket 236 attached on the right longitudinal members 16,18 of the mobile frame 12.
The handle 238 on a threaded rod 240 of the conversion mechanism 230 being threaded through a coupler 242 pivotally attached at 244 to the rear end of the lever member 232 is turned to rotate the rod 240 and causing pivoting of the tongue assembly 38 about the axis defined by pivot pin 40 and relative to the mobile frame 12 between first and second articulated conditions seen in FIG. 5. When the tongue assembly clevis 42 is attached to the drawbar 44 of a towing vehicle, selected actuation of the conversion mechanism 230 will respectively lower and raise the mobile frame 12 and the auxiliary pickup beater 46 and main pickup broom 48 mounted thereon between the operating and transport positions.
Other Features
In addition to the rotary brush cleaner 140 described earlier, the leaf loading machine 10 also incorporates an arcuate shaped carryover recovery plate or chute 246 fixed to and extending between the housing side walls 60,62 rearwardly of the lower side of the main pickup broom 48. The function of the chute 246 is to facilitate return of carried over material along the endless path P(2) of the broom 48 so that another attempt can be made at removing it from the street surface. Further, as an option a rotary curb brush 248 mounted to the beater left support arm 200 by a swing arm 250 and powered by a hydraulic motor 252 can be used on the machine 10.
It is thought that the present invention and many of its attendant advantages will be understood from the foregoing description and it will be apparent that various changes may be made in the form, construction and arrangement of the parts thereof without departing from the spirit and scope of the invention or sacrificing all of its material advantages, the form hereinbefore described being merely a preferred or exemplary embodiment thereof.
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In a leaf loading method, leaves are picked up from the ground by operating a rotary beater and a rotary broom. The leaves are then delivered between the beater and the broom by rotating the beater and the broom in opposite directions. Next, the leaves are guided from between the beater and the broom toward an auger disposed rearwardly of the broom. Finally, the leaves are transferred from the auger into a thrower by rotating the auger and then the leaves are discharged by operating the thrower.
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BACKGROUND
[0001] Technical Field
[0002] The present invention relates to systems for improving the operation of pool skimmers, particularly those used in outdoor swimming pools, and methods of using the same.
[0003] Background of the Invention
[0004] With reference to FIGS. 1-3 , in the prior art, it is known to remove debris in swimming pools 110 through the use of skimmers 100 . As known to those of ordinary skill, swimming pools 110 generally consist of a basin (or swimming area) 121 , the perimeter of which is defined by a plurality of sidewalls 120 and the bottom of which is defined by a floor 122 . The floor 122 usually includes a bottom drain 101 .
[0005] Skimmers 100 generally include a rectangular skimmer opening 135 located in a sidewall 120 of the swimming pool 110 , a moveable skimmer weir 170 located inside the skimmer 100 that pivots on a hinge 155 within the skimmer 100 and moves in response to changes in the water levels of the swimming pool 110 and a rectangular skimmer faceplate 145 . The faceplate 145 surrounds the skimmer opening 135 , has a thickness 148 of about 1-3 inches and is secured to the pool sidewall 120 via one or more fasteners (e.g., screws) 146 inserted through fastener apertures 147 . Some pools, particularly many concrete and gunite pools, lack a faceplate 145 surrounding the skimmer opening 135 . The skimmer weir 170 pivots between a vertical position (shown in phantom line 170 A in FIG. 2 ) in which the skimmer weir 170 is generally parallel to the sidewall 120 (and perpendicular to the ground) and prevents large debris from flowing through the skimmer 100 (more precisely, beyond the skimmer weir 170 ) and a horizontal position (shown in phantom line 170 B in FIG. 2 ) in which the skimmer weir 170 is generally perpendicular to the sidewall 120 (and parallel to the ground) and allows large debris to flow through the skimmer 100 until the debris reaches a filter or debris basket 160 . The passageway or throat through which water flows through the skimmer 100 is denoted by numeral 196 and the top of the throat is denoted by 197 . As known to the those of ordinary skill, the skimmer weir 170 of a conventional skimmer 100 often occupies a position between its two end pivot points (i.e., between the vertical 170 A and horizontal 170 B positions), as shown in FIG. 2 . Water enters the skimmer 100 through the opening 135 , flows through throat 196 and over the skimmer weir 170 , and through a filter or debris basket 160 , which collects debris. Optionally, the top of the throat 197 includes a downwardly extending flange 198 , which prevents the skimmer weir 170 from rotating beyond the vertical 170 A. Ultimately, the filtered water exits the skimmer 100 through drain/exit aperture 199 is then pumped back into the basin 121 of the swimming pool 110 through water jets 165 located in the pool sidewalls 120 . Pools may include a series of pumps 190 , valves 192 and 194 and pipes 180 , 181 , 182 and 193 . Typically the water jets 165 create a counter-clockwise or clockwise 183 circulation in the basin 121 of the pool 110 , as shown in FIG. 3 . Pools 110 may contain one or more skimmers 100 , depending on pool size and the year the pool was built. For example, some U.S. municipalities require that municipal pools have one skimmer per 400 square feet of swimming area.
[0006] Usually, the skimmer opening 135 and skimmer weir 170 are located several inches below the top overhang 130 of the pool. (The distance from the pool top overhang 130 to the top of the skimmer opening 135 is labeled as 140 . The distance from the pool top overhang 130 to the top edge 171 of the skimmer weir 170 is labeled as 150 ). Most, if not all, of the debris typically found in the basins 121 of swimming pool 110 is less dense than water and hence is located in the top layer of the water located in the basin 121 of the swimming pool 110 . Thus, for this reason, skimmer manufacturers instruct swimming pool owners to keep the water level in the basin 121 of the pool 110 approximately two-thirds (⅔) of the way up the faceplate 145 (i.e., below the top edge 171 of the skimmer weir 170 ) so that the skimmer 100 filters the top, debris-containing layer of the pool water. Unfortunately, keeping the water at the manufacturer's recommended level is problematic for several reasons. First, the owner may want to keep the water level in the basin 121 of the pool 110 near the top overhang 130 of the pool 110 for aesthetic effect (i.e., a full pool). Second, if a rainstorm increases the water above the manufacturer's recommended level, the owner must remove some of the water from the pool 110 via a drain so that the water returns to the recommended level. This creates a time burden on the pool owner unless the drainage is automatic and, in any case, is environmentally unfriendly and costly, as pool water and chemicals in the pool water are wasted when the pool is drained.
[0007] Some devices in the prior art seek to address some of these water loss issues; however these prior art devices are costly and create hazards in the pool. For example, the Ecoskim™ device (Ecoskim Pty Ltd., Australia), which is disclosed in U.S. Pat. No. 7,993,515 to Davies, is a swimming pool cleaning device that includes an outer body with an outlet to the pool pump line, a hollow mating member, which floats within the outer body so that its top rim is at the surface of the pool and a litter basket which fits within the floating member. The device further includes an inlet that attaches to a hose, which moves about the swimming pool, and a backing plate that fits over the opening of a swimming pool skimmer and prevents water from entering the skimmer opening. The Ecoskim™ device costs approximately $700 U.S. Dollars and relies on the use of a mobile hose, which poses a hazard to children swimming in the swimming pool.
[0008] Thus, there is a need for cheap and safe devices that improve the operation of swimming pool skimmers.
BRIEF SUMMARY
[0009] The present disclosure provides several systems for increasing the range of a pool skimmer that has a skimmer opening located in a sidewall of a swimming pool.
[0010] One such system includes:
[0011] a) a swimming pool comprising a basin configured to hold water and a plurality of sidewalls defining a perimeter of the basin;
[0012] b) a skimmer comprising a skimmer opening located in one of the sidewalls, the skimmer opening in fluid communication with the basin; and
[0013] c) a weir assembly located in the basin and adjacent to the skimmer opening, the weir assembly abutting the one sidewall and comprising a plurality of fastener apertures and a weir located in the basin, the weir configured to move in response to changing water levels in the basin, the weir assembly configured to deliver water from the basin to the skimmer opening.
[0014] Optionally, the weir is configured to move above the skimmer opening so that water located above the skimmer opening can enter the skimmer. Optionally, the weir assembly further comprises a vacuum release door and a vacuum release opening, the vacuum release door configured to move between a closed position wherein the vacuum release door closes the vacuum release opening and an open position wherein the vacuum release door allows water located in the basin to enter through the vacuum release opening and enter the skimmer opening.
[0015] Optionally, the vacuum release door is located in the weir. Optionally, the weir assembly further comprises a hinge attaching the vacuum release door to the weir assembly and the vacuum release door is moveable (more particularly pivotable) along the hinge. Optionally, the weir assembly comprises a top half and a bottom half and the vacuum release opening is located in the bottom half of the weir assembly. Optionally, the weir assembly has a height of at least about 4 inches and a width of at least about 4 inches, e.g., a height of from about 4 to about 14 inches and a width of from about 4 inches to about 24 inches.
[0016] Optionally, the weir assembly further comprises a plate abutting the pool sidewall, the plate comprising the plurality of fastener apertures, the plate preventing water in the basin from entering the skimmer opening without passing over the weir. Optionally, the plate comprises a flat portion abutting the one sidewall. Optionally, the plate further comprises a plate opening located between the weir and the skimmer opening, the plate opening configured to feed water to the skimmer opening, and further wherein the weir at least partially covers the plate opening. Optionally, the weir further comprises a top, the top comprising an opening configured to feed water from the basin to the plate opening. Optionally, the plate opening has a cross-sectional area from about 4 square inches to about 50 square inches (more preferably from about 16 square inches to about 40 square inches).
[0017] Optionally, the system further comprises a plurality of fasteners attaching the weir assembly to the one sidewall. Optionally, the system further comprises a pool pump in fluid communication with the skimmer, the skimmer further comprises a throat and a water exit aperture/drain that feeds water from the skimmer to the pool pump, the throat located between the skimmer opening and the water exit aperture/drain, and the system further comprises an adjustable frame located in the throat, the adjustable frame having an adjustable length and an adjustable height.
[0018] Optionally, the system further comprises a plurality of fastener apertures located in the adjustable frame and a plurality of fasteners attaching the adjustable frame to the weir assembly, each of the plurality of fasteners passing through a fastener aperture located in the weir assembly and a fastener aperture located in the adjustable frame. Optionally, the weir assembly further comprises a floor located at a bottom of the weir assembly, the floor abutting the one pool sidewall, the floor configured to inhibit water located in the basin from entering the skimmer opening from below the floor. Optionally, the weir assembly further comprises a motor configured to move the weir in response to changing water levels in the basin. Optionally, the weir assembly further comprises a track configured to allow the weir to move in response to changing water levels in the basin. Optionally, the system further comprises a power source configured to power the motor. Optionally, the weir assembly further comprises a top and the top comprises a solar panel configured to power the motor. Optionally, the system further comprises a water level sensor configured to sense the water level in the basin, and a processor connected to the water level sensor and configured to move the weir in response to data concerning the water level in the basin received from the water level sensor. Optionally, the basin is filled with water, and the weir comprises a top and a float located adjacent to the top, the float configured to allow the top of the weir to float in the water. Optionally, the weir is buoyant in water.
[0019] The present invention also provides a method of using a pool skimmer system to increase the range of a pool skimmer, the method comprising:
[0020] a) providing the pool skimmer system; and
[0021] b) flowing water from the basin over the weir (i.e., at least partially over the weir) and into the skimmer opening.
[0022] In other embodiments, the present disclosure provides a system that includes at least one track attached to the sidewall and adjacent to the skimmer opening. The track has a track length generally perpendicular to the ground. The first system also includes a weir attached to the track and moveable in a generally vertical position along the track length in response to changing water levels in the pool (more particularly, water levels in the pool basin). The weir preferably is configured to feed water located in the pool (more particularly, in the basin) to the skimmer opening. Preferably, water from the pool flows through a weir recess in the weir and into the skimmer opening. In some embodiments, the weir recess is located in a quarter sphere portion of the weir. Preferably, the system includes two tracks and each track has a track length, a track recess surface extending along the track length, and a sidewall surface configured to face, preferably, abut (and optionally, to attach, directly or indirectly to) the pool sidewall and disposed at about a 90 angle relative to the track recess surface. Optionally, the weir includes a vacuum release opening and a vacuum release door that is configured to move between a closed position in which the door seals the opening and an open position in which the door allows water to enter through the opening. Optionally, the track sidewall surfaces include fastener apertures to attach the track directly or indirectly to the pool sidewall or to the adjustable frame described above. Preferably, the first system includes a weir fastener for immobilizing the skimmer weir (i.e., the weir located inside the skimmer throat). Optionally, the track and weir are comprised of clear plastic.
[0023] Another system generally relates to a deflector that faces, preferably abuts (and optionally is attached, directly or indirectly to), the sidewall and that extends outwards into the pool and above the skimmer opening. The deflector further includes an opening. The opening may be centrally located or may be a side opening that is positioned to capture water circulating in a clockwise or counter-clockwise fashion (depending on the circulation pattern of water within the pool, more particularly, within the basin). The opening feeds water to the skimmer opening. As with the prior embodiment, preferably the skimmer weir is immobilized by a weir fastener or removed. Preferably, the deflector does not move within the swimming pool other than to slightly deform in response to pressure applied to the deflector. Preferably, the opening spans substantially the entire height of the deflector and at least above the skimmer opening.
[0024] Preferably, the deflector includes fastener apertures and fasteners for attaching the deflector directly or indirectly to the sidewall or to the adjustable frame. Preferably, the deflector is attached to a skimmer faceplate that is attached to the pool sidewall. Preferably, the deflector includes a solid, water impermeable floor, which may abut the sidewall, and a top opening so that water flows through only the side or top openings. Preferably, the deflector extends into the pool (more particularly the pool basin) a distance of about 1 inch to about 18 inches so that the deflector does not interfere with swimmers in the pool and the deflector has a height of at least 8 inches (e.g., about 8 inches to about 20 inches).
[0025] In another embodiment, the present disclosure provides a system for improving the range of a pool skimmer, the system comprising:
[0026] a) a swimming pool comprising a basin configured to hold water and a plurality of sidewalls defining a perimeter of the basin;
[0027] b) a pool skimmer, the pool skimmer comprising a skimmer opening located in one of the sidewalls and a skimmer interior; and
[0028] c) a deflector adjacent to the sidewall comprising the skimmer opening and extending into the basin, the deflector having a rear facing the skimmer opening and comprising a first opening in fluid communication with the skimmer and configured to feed water through the skimmer opening, a front opposite the rear, a left side, a right side, and an interior defined by the front, the rear, and the left and right sides, at least one of the front, the left side and the right side comprising a second opening configured to deliver water from the pool basin to the deflector interior and the first opening, the second opening having a width of at least about 1 inch and a height of at least about 1 inch.
[0029] Optionally, the second opening has a height of from about 4 inches to about 12 inches and a width of from about 1 inch about 6 inches. Optionally, the second opening extends above the skimmer opening. The second opening may extend above the skimmer opening at least about 1 inch, preferably about 2 to about 6 inches. Optionally, the rear of the deflector is substantially flat. Optionally, the rear of the deflector is attached to a plate comprising a gasket abutting the pool sidewall. Optionally, the deflector further comprises a weir configured to at least partially cover the second opening, the weir configured to move upwards and downwards in response to changing water levels in the pool basin. Optionally, the weir is configured to move above the skimmer opening. Optionally, the weir is configured to move upwards and downwards in an arc. Optionally, the deflector further comprises at least one track adjacent to the second opening and further wherein the weir is configured to move along the track. Optionally, the deflector is generally circular. Optionally, the weir further comprises at least one wheel and the at least one wheel is configured to move along the track. Optionally, the deflector further comprises two tracks located on opposite sides of the second opening, and further wherein the weir further comprises at least two wheels located on opposite sides of the weir and each wheel is configured to move along a track. Optionally, the tracks are curved and each track forms an arc. Optionally, the second opening is on the left side of the deflector, and the deflector further comprises a third opening on the right side of the deflector, the second and third openings each having a height of from about 4 inches to about 12 inches and a width of from about 1 inch about 6 inches, and the deflector further comprises two tracks adjacent to the second opening and two tracks adjacent to the third opening. Optionally, the weir further comprises at least two wheels located on opposite sides of the weir and each wheel is configured to move along a track adjacent to the second opening, and the deflector further comprises a third weir comprising at least two wheels located on opposite sides of the third weir and each wheel of the third weir is configured to move along a track adjacent to the third opening. Optionally, the weir is buoyant in water. Optionally, the weir comprises a top, a bottom, a tab extending from the top, and a float. Optionally, the float is attached to the tab. Optionally, the float comprises foam. Optionally, the weir comprises a top, a bottom, and a height extending from the top to the bottom, and the weir is curved along its height. Optionally, the weir is configured to move upwards and downwards along an arc in response to changing water levels in the pool basin. Optionally, the deflector further comprises a vacuum release door and a vacuum release opening, the vacuum release door configured to move between a closed position wherein the vacuum release door closes the vacuum release opening and an open position wherein the vacuum release door allows water located in the basin to enter through the vacuum release opening and enter the deflector interior and the first opening. Optionally, the deflector further comprises a hinge attaching the vacuum release door to the deflector and further wherein the vacuum release door is moveable along the hinge. Optionally, the deflector comprises a tab located exterior to the vacuum release door, the tab configured to prevent the vacuum release door from rotating beyond the tab. Optionally, the deflector comprises a top half and a bottom half and the vacuum release opening is located in the bottom half of the deflector. Optionally, the deflector further comprises a magnet to bias the vacuum release door in the closed position. Optionally, the deflector further comprises a bypass opening and a bypass door to removably close the bypass opening, the bypass door configured to move between a closed position wherein the bypass door closes the bypass opening and an open position wherein the bypass door allows water located in the basin to enter through the bypass opening and enter the first opening. Optionally, the bypass door is configured to rotate relative to the bypass opening. Optionally, the bypass door is generally circular in shape and is configured to rotate about a pivot point located in a center of the circle. Optionally, the bypass door is configured to move vertically relative to the bypass opening. Optionally, the system comprises a tube extending from the deflector rear and adjacent to the first opening, the tube having a front end attached to the deflector rear, a rear end, a hollow interior in fluid communication with the first opening, and a wall. Optionally, the tube wall comprises threads. Optionally, the system further comprises a nut comprising threads configured to mate with the tube wall threads. Optionally, the system further comprises a frame located inside the skimmer interior, the frame comprising an aperture receiving the tube, further wherein the nut is attached to the tube, and further wherein the frame is located between the nut and the skimmer opening. Optionally, the deflector further comprises at least one fastener configured to removably attach the deflector to the skimmer interior. Optionally, the fastener is a suction cup. Optionally, except for the first opening, at least 95% of the surface area of the skimmer opening is covered. Optionally, the deflector further comprises a substantially water impermeable floor.
[0030] Optionally, the deflector further comprises a top, the top comprising a top aperture. Optionally, the pool skimmer further comprises a skimmer weir located inside the pool skimmer interior and the skimmer weir is immobilized. Optionally, the pool skimmer does not have a skimmer weir in the skimmer interior.
[0031] In some embodiments, the present disclosure provides a method of using a system to increase the range of a pool skimmer that includes
[0000] a) providing the system; and
b) flowing water from the basin, through the second opening, through the deflector interior, through the first opening, through the skimmer opening, and into the skimmer interior.
[0032] In some embodiments, the present disclosure provides a pool skimmer system comprising:
[0000] a) a swimming pool comprising a basin configured to hold water and a plurality of sidewalls defining a perimeter of the basin;
b) a pool skimmer, the pool skimmer comprising a skimmer opening located in a sidewall and a skimmer interior,
c) two tracks located in the pool basin; and
d) a weir located in the pool basin, the weir configured to move upwards and downwards and regulate water entering the skimmer opening, the weir having opposite sides, each of the opposite sides having at least one wheel attached thereto, each of the wheels received in a track.
[0033] Optionally, the tracks are curved and the weir is configured to move in an arc upwards and downwards. Optionally, the skimmer interior further comprises a skimmer basket.
[0034] Optionally, the system further comprises a pump in fluid communication with the basin and the skimmer interior.
[0035] In some embodiments, the present disclosure provides a pool skimmer comprising:
[0000] a) a skimmer interior,
b) a front end comprising a top, a bottom, and a skimmer opening leading to the skimmer interior and comprising a top, a bottom, a left side, a right side, a width extending from the skimmer opening left side to the skimmer opening right side of at least about 2 inches and a height extending from the skimmer opening top to the skimmer opening bottom of from about 2 inches to about 16 inches (preferably about 5 inches to about 16 inches);
c) a rear end comprising a top comprising a top opening, a lid configured to removably close the top opening, a bottom comprising a bottom opening in fluid communication with the skimmer opening, a well located directly below the top opening, the bottom opening extending into the well, a skimmer basket located in the well and comprising a floor, a sidewall extending from the floor, at least one of the floor and the sidewall comprising a plurality of apertures; and
d) a middle portion located between the front end and the rear end and comprising a top, a bottom, and a throat in fluid communication with the skimmer opening and the rear end, wherein the top of the front end, the top of the rear end, and the top of the middle portion are within about 1 inch of each other when the top of the front end, the top of the rear end, and the top of the middle portion are positioned parallel to the ground.
[0036] Optionally, the top of the front end, the top of the rear end, and the top of the middle portion are within about 0.5 inches of each other when the top of the front end, the top of the rear end, and the top of the middle portion are positioned parallel to the ground.
[0037] Optionally, the height of the skimmer opening is from about 8 inches to about 14 inches. Optionally, the width of the skimmer opening is between about 3 and about 6 inches. Optionally, the pool skimmer further includes a weir configured to move upwards and downwards. Optionally, the weir is located adjacent to the skimmer opening (e.g., about 0 to about 6 inches from the skimmer opening). Optionally, the skimmer comprises a left track and a right track and the weir is configured is configured to move along the left and right tracks. Optionally, the weir further comprises at least one left wheel located in the left track and at least one right wheel located in the right track. Optionally, the weir further comprises a float. Optionally, the float comprises foam. Optionally, the weir is hingedly attached to the skimmer and is configured to pivot between a horizontal position in which the weir is parallel to the lid and a vertical position in which the weir is perpendicular to the lid. Optionally, the weir further comprises a vacuum release door and a vacuum release opening, the vacuum release door configured to move between a closed position wherein the vacuum release door closes the vacuum release opening and an open position wherein the vacuum release door allows water to enter through the vacuum release opening. Optionally the weir further comprises a hinge attaching the vacuum release door to the weir and further wherein the vacuum release door is moveable along the hinge. Optionally, the weir comprises a tab located exterior to the vacuum release door, the tab configured to prevent the vacuum release door from rotating beyond the tab. Optionally, the weir comprises a top half and a bottom half and the vacuum release opening is located in the bottom half of the weir. Optionally, the throat has a length of from about 3 inches to about 12 inches. Optionally, the throat is generally rectangular in shape.
[0038] Without being bound to any particular theory, it is believed that the apparatuses are relatively cheap to manufacture, safe, conserve water and chemical use, and allow for an aesthetically pleasing full pool.
BRIEF DESCRIPTION OF THE DRAWINGS
[0039] FIG. 1 illustrates a front, perspective view of a prior art skimmer and pool sidewall.
[0040] FIG. 2 illustrates a cross-sectional view of the prior art skimmer of FIG. 1 , taken along line 2 - 2 of FIG. 1 .
[0041] FIG. 3 illustrates a schematic view of water circulating in a clockwise fashion in a swimming pool with a prior art skimmer.
[0042] FIG. 4 illustrates a front, perspective view of a system of one embodiment of the present invention for increasing the range of a pool skimmer.
[0043] FIG. 5 illustrates a front, exploded view of the system of FIG. 4 .
[0044] FIG. 6 illustrates a rear, perspective view of the system of FIG. 4 .
[0045] FIG. 7 illustrates a side, elevational view of the system of FIG. 4 .
[0046] FIG. 8 illustrates a front, cut-away view of the system of FIG. 4 attached to the faceplate of a pool skimmer.
[0047] FIG. 9 illustrates a close-up, front, cut-away view of the system of FIG. 4 attached to the faceplate of a pool skimmer.
[0048] FIG. 10 illustrates a top view of the system of FIG. 4 .
[0049] FIG. 11 illustrates a front, perspective view of one embodiment of a deflector of the present invention.
[0050] FIG. 12 illustrates a rear, perspective view of the deflector of FIG. 11 .
[0051] FIG. 13 illustrates a top, plan view of the deflector of FIG. 11 .
[0052] FIG. 14 illustrates a side, elevational view of the deflector of FIG. 11 and a faceplate of a pool skimmer.
[0053] FIG. 15 illustrates a front, perspective view of another embodiment of a deflector of the present invention.
[0054] FIG. 16 illustrates a front, perspective view of another embodiment of a deflector of the present invention abutting a pool sidewall; in this embodiment, the deflector includes a weir.
[0055] FIG. 17 illustrates another front, perspective view of the deflector of FIG. 16 .
[0056] FIG. 18 illustrates a front, exploded, perspective view of the deflector of FIG. 16 ; FIG. 18 shows that the deflector is attached to an adjustable frame located inside the skimmer.
[0057] FIG. 19A is a front, elevation view of the adjustable frame of FIG. 18 .
[0058] FIG. 19B is a front, elevation view of another embodiment of an adjustable frame.
[0059] FIG. 20 is a front elevation view of the adjustable frame of FIG. 18 inside a skimmer, the deflector is not shown in FIG. 20 so that the frame is visible.
[0060] FIG. 21 is a front, perspective view of a weir assembly that abuts a pool sidewall; in FIG. 21 , the weir assembly includes a central plate and two side plates that cover a skimmer with a large opening.
[0061] FIG. 22 is a top, plan view of the weir assembly of FIG. 21 .
[0062] FIG. 23 is a front, exploded, perspective view of the weir assembly of FIG. 21 .
[0063] FIG. 24 is a front, perspective view of another embodiment of a weir assembly.
[0064] FIG. 25 is a left side, perspective view of a system of another embodiment of the present invention for increasing the range of a pool skimmer.
[0065] FIG. 26 is a left side, perspective, exploded view of the system of FIG. 25 .
[0066] FIG. 27 is a front, elevation view of the system of FIG. 25 .
[0067] FIG. 28 is a cross-sectional view of the system of FIG. 27 , taken along line 28 - 28 of FIG. 27 .
[0068] FIG. 29 is a right side, elevation view of the system of FIG. 25 .
[0069] FIG. 30 is a right side, partially cut-away view of the system of FIG. 25 ; the skimmer is partially transparent to better illustrate the threaded tube/pipe and nut.
[0070] FIG. 31 is a right side, perspective view of the system of FIG. 25 .
[0071] FIG. 32 is a right side, cross-sectional view of the system of FIG. 31 , taken along the line 32 - 32 of FIG. 31 .
[0072] FIG. 33 illustrates a front, perspective view of a skimmer of one embodiment of the present invention and a pool sidewall.
[0073] FIG. 34 illustrates a cross-sectional view of the skimmer of FIG. 33 , taken along line 34 - 34 of FIG. 33 .
[0074] FIG. 35 illustrates a front, perspective view of the skimmer of FIG. 33 .
DETAILED DESCRIPTION
[0075] The present disclosure provides several systems for increasing the range of a pool skimmer 100 . The first system is designated by the numeral 200 , is illustrated in FIGS. 4-10 , and generally relates to a weir 230 that moves along one or more tracks 210 . The second system is designated by the numeral 300 , is illustrated in FIGS. 11-18 and generally relates to a deflector 330 . A third system is designated by the numeral 500 , is illustrated in FIGS. 21-24 and also generally relates to a weir 530 that moves along one or more tracks 510 . A fourth system, related to the above systems, is shown in FIGS. 25-32 and also generally relates to a deflector 330 and optionally includes a weir 230 . FIGS. 19-20 generally relate to attachment mechanisms for the above systems. A fifth system is shown in FIGS. 33-35 and generally relates to a new design for a skimmer 100 . In the drawings, not all reference numbers are included in each drawing for the sake of clarity. The systems illustrated in FIGS. 4-32 may be used in conjunction with any suitable pool skimmer, and are preferably used with immobile skimmers that are located in swimming pool, pond, fountain, or spa sidewalls, such as the skimmer 100 illustrated in FIGS. 1-3 . As used herein, the term “pool” means a swimming pool, pond, fountain or spa. Typically, the pool 100 includes a basin (or swimming area) 121 , the perimeter of which is defined by a plurality of sidewalls 120 and the bottom of which is defined by a floor 122 . The floor 122 usually includes a bottom drain 101 , as described above. While, the systems illustrated in FIGS. 4-35 may be used in spas, it will be appreciated that the systems are preferably used in swimming pools, given that spas generally have a small surface area and are typically covered during rainstorms. While one pool 110 may use two or more different systems, generally, only one type of system will be used with any one skimmer 100 . In other words, a given skimmer 100 will typically be outfitted with only one of the systems. It will be appreciated that the systems may each comprise several embodiments as described herein.
[0076] Referring further to the first system 200 , as shown in FIGS. 4-10 , the system 200 generally includes one or more tracks 210 , typically two parallel tracks 210 . The track 210 includes a track length 215 and a track recess surface 220 . Preferably, the track 210 has a length 215 of at least about 6 inches (e.g., about 6-24 inches) and a thickness 216 that is substantially equal to the thickness 148 of the faceplate 145 (e.g., about 1-3 inches). The track recess surface 220 includes a track recess 225 extending along the track length 215 . When it is mentioned that the track recess 225 extends along the track length 215 , it is meant that the track recess 225 extends at least partially along the track length 215 . In a preferred embodiment, the track recess 225 extends substantially the entire track length 215 . More preferably, the track recess 225 extends the entire track length 215 so that the weir 230 can be installed from either the top or the bottom of the track 210 and so that the weir 230 can slide out of the bottom of the track 210 if struck in a downward motion as a safety feature. The track 210 further includes a sidewall surface 221 configured to face, preferably abut (and optionally attach (i.e., directly or indirectly to)) the pool sidewall 120 . In a particularly preferred embodiment, the sidewall surface 221 is configured to attach to the sidewall 120 by attaching to a skimmer faceplate 145 that is attached to the sidewall 120 . Preferably, the sidewall surface 221 is disposed at an angle of approximately 90 degrees relative to the track recess surface 220 . Preferably, the sidewall surface 221 includes one or more fastener apertures 222 for attaching the track 210 directly or indirectly to the pool sidewall 120 . Preferably, the fastener apertures 222 are configured to receive a fastener 223 (e.g., bolt, screw, etc.) so that the fastener 223 may attach the track 210 to the skimmer faceplate 145 . In a particular embodiment, the fasteners 223 are a plurality (e.g., four) of pan-head screws that are used to attach two tracks 210 to the skimmer faceplate 145 and the fastener apertures 222 are longer than the diameter of the pan-head screw 223 , as best seen in FIG. 8 , and counter-sunk for the seats of the pan-head screw 223 , which allows for the proper seating of the screws 223 and gives the flexibility of height adjustment of the track 210 . In some embodiments, the systems described herein include fastener aperture covers (not shown) that fit inside unused fastener apertures so that water and debris does not enter unused fastener apertures. In some embodiments, some or all of the fastener apertures described herein are threaded (e.g., nuts) and configured to receive a threaded rod.
[0077] The first system 200 , as previously noted, is particularly useful in conjunction with the typical skimmer 100 illustrated in FIGS. 1-3 . As previously noted, such skimmers 100 typically include a skimmer opening 135 and a skimmer weir 170 located inside the skimmer 100 (more particularly inside throat 196 ), which pivots between a vertical position (shown in phantom line 170 A in FIG. 2 ) in which the skimmer weir 170 is generally parallel to the sidewall 120 (and perpendicular to the ground) and prevents large debris from flowing through the skimmer 110 (more precisely, beyond the skimmer weir 170 ) and a horizontal position (shown in phantom line 170 B in FIG. 2 ) in which the skimmer weir 170 is generally perpendicular to the sidewall 120 (and parallel to the ground) and allows debris to flow through the skimmer 100 until the debris reaches a filter or debris basket 160 . For ease of reference, the skimmer weir 170 of a conventional skimmer 100 , located in the throat 196 , is referred to herein as the “skimmer weir” and the additional weir 230 , 313 and 530 , located exterior to the skimmer 100 in basin 121 and provided by the systems of FIGS. 4-32 , is referred to herein as the “additional weir.” However, it will be understood that systems of FIGS. 4-32 may include only the additional weir, given that skimmer weir 170 may be removed as described below.
[0078] In addition to the optional skimmer weir 170 , the first system 200 further includes an additional weir 230 . The additional weir 230 is configured to be received in the track recess 225 when the track 210 faces, preferably abuts, and (optionally is attached to) the sidewall 120 so that the additional weir 230 may move in a generally vertical direction (relative to the ground) along the track length 215 in response to changing water levels in the pool 110 (more particularly, the basin 121 ).
[0079] Preferably, the forces acting on the additional weir 230 keep at least a portion of the top edge 231 of the additional weir 230 (preferably at least weir recess portion 235 of top edge 231 as described below) at or near the top surface of water in the pool 110 during normal operation so that the additional weir 230 only allows the top, debris-containing layer of water in the pool 110 to enter skimmer the opening 135 . For example, preferably, at least a portion of the top edge 231 of the additional weir 230 is at or near the top surface of water in the pool 110 when the pool 110 (more particularly basin 121 ) is filled with water to the top of skimmer opening 135 . Preferably, a majority of the surface area of the additional weir 230 is submerged in the pool water during normal operation so that the additional weir 230 inhibits non-debris-containing water from entering skimmer opening 135 . Those of ordinary skill will appreciate that such forces will include at least the buoyancy of the additional weir 230 . The forces may also include the suction power of the skimmer 100 . Optionally, the additional weir 230 includes one or more sealed air jackets 240 to increase its buoyancy. Alternatively, the additional weir 230 may be comprised of foam. The system 200 may be comprised of any suitable material, including without limitation, clear plastic (e.g., clear injection molded plastic). Preferably, the track 210 is comprised of a resilient plastic to prevent deformation.
[0080] The track 210 extends at least above, and preferably above and below the skimmer opening 135 so that the top edge 231 of the additional weir 230 has the ability to move at least above (and preferably above and below) the skimmer opening 135 so that the additional weir 230 increases the range of the skimmer 100 .
[0081] As shown in FIGS. 4-10 , unlike U.S. Pat. No. 7,993,515 to Davies, preferably the first system 200 does not block all water from entering the skimmer opening 135 .
[0082] The first system 200 generally eliminates the need for the skimmer weir 170 as the additional weir 230 is responsible for skimming the top, debris-containing layer of the water in the pool 110 . Preferably, the first system 200 further includes a weir fastener 250 (e.g., a clip with two prongs) removably attached to the skimmer weir 170 for immobilizing the skimmer weir 170 at an angle other than 90 degrees relative to the ground (i.e., at a position other than the vertical position 170 A). Preferably, the weir fastener 250 has a bottom portion 251 that contacts the top edge 171 of the skimmer weir 170 and a top portion 252 that contacts the top wall 197 of the throat 196 of the skimmer 100 , as shown in FIG. 8 . In another embodiment, the skimmer weir 170 is removed so that it does not interfere with skimming by first system 200 .
[0083] A particular shape of the additional weir 230 will now be described. However, it will be understood that the shape described is merely exemplary and that the additional weir 230 may have any suitable shape. Preferably, as shown in FIGS. 4-10 , the additional weir 230 curves away from the pool sidewall 120 so that water may be stored (if even for a very short time) between the rear 232 of the additional weir 230 and the skimmer opening 135 . Preferably, the additional weir 230 extends between about 1-12 inches into the pool 110 (more particularly, basin 121 ) so that the additional weir 230 does not interfere with swimmers. In a particular embodiment, as shown in FIGS. 4-10 , the additional weir 230 comprises a quarter sphere portion 233 generally in the shape of a quarter of a sphere, and the quarter sphere portion 233 has a generally flat open top 234 . Preferably, the diameter 237 of the quarter sphere is generally parallel to the ground, it being understood that a quarter sphere has one diameter. Preferably, the additional weir 230 further includes a weir recess 235 located in the top edge 231 of the additional weir 230 . The weir recess 235 may be located adjacent to the lengthwise center 239 of the top edge 231 of the additional weir 230 . In such an embodiment, the weir recess 235 is the entry point of water entering beyond the additional weir 230 (and ultimately into the skimmer opening 135 ). Preferably, the weir recess 235 is not parallel to the pool sidewall 120 so that the weir recess 235 is optimized to capture the clockwise 183 or counter-clockwise circulation of the pool water.
[0084] In some embodiments, the additional weir 230 further includes a vacuum release door opening 260 and a vacuum release door 261 . The vacuum release door 261 is configured to move between a closed position wherein the vacuum release door 261 closes (more preferably seals) the opening 260 and an open position wherein the vacuum release door 261 allows water to enter through the vacuum release opening 260 . Without being bound to any particular theory, it is believed that a purpose of the vacuum release door 261 , which is ordinarily in the closed position, is that if a child were to push the top edge 231 of the additional weir 230 above the water level in the pool 110 (more particularly basin 121 ), a vacuum may be created between the additional weir 230 and the pool sidewall 120 due to suction of the additional weir 230 to the pool sidewall 120 caused by skimmer 100 . In addition, when the top edge 231 of the additional weir 230 is pushed above the water level in the pool 110 by the child, the water behind the additional weir 230 (i.e., between additional weir 230 and skimmer 100 ) will be drained into skimmer opening 135 without being replenished, causing water in the pool 110 to exert pressure on the additional weir 230 without a counter-acting force from water behind the additional weir 230 (because the water behind the additional weir 230 is drained). To alleviate such issues, these forces cause the door 261 to move to the open position, allowing water to enter and destroying the vacuum, thereby releasing the additional weir 230 from the sidewall 120 and relieving water pressure exerted on the additional weir 230 .
[0085] The vacuum release opening 260 and door 261 are generally the same shape and may be any suitable shape, such as generally circular or rectangular. Preferably, the vacuum release door 261 and opening 260 are located in the lower half of the additional weir 230 so that the door 261 and opening 260 still will be submerged when a child pushes the additional weir 230 upwards, given that a purpose of the door 261 and opening 260 is to allow water to pass through the opening 260 when a child pushes the additional weir 230 upwards. The vacuum release door 261 may use any suitable mechanism to bias the door 261 in the closed position, such as a spring 262 or magnet. If a spring 262 is used, the first system 200 may further include a nylon or plastic bolt 264 that passes through an aperture 267 in the additional weir 230 . The aperture 267 is slightly smaller than the shaft of the bolt 264 , which when pressed into position becomes rigid and tight and non-moveable. The vacuum release door 261 then slides onto the bolt 264 from the rear side. The forward end 263 of the spring 262 rests against the door 261 and the rear end 266 of the spring 262 rests against a washer 265 . A nylon or plastic nut 268 is placed to the rear of the washer 265 so that the washer 265 cannot move rearwardly (i.e., towards the sidewall 120 ) and the spring 262 applies a force to bias the door 261 in a closed position. In another embodiment, a magnet attached to the door 261 or additional weir 230 is used to bias the door 261 in a closed position. If a magnet is used, the door 261 may be hinged to the additional weir 230 .
[0086] Optionally, the first system 200 is provided as a kit.
[0087] The first system 200 may be installed by any suitable process. Optionally, the process includes:
[0088] a) removing skimmer faceplate fasteners 146 ;
[0089] b) placing two tracks 210 on the left and right sides of the skimmer opening 135 so that the track sidewall surfaces abut the faceplate 145 , the track lengths 215 are perpendicular to the ground, the track recess surfaces 220 of each track 210 face each other, and the faceplate fastener apertures 147 arc aligned with the track fastener apertures 222 ;
[0090] c) inserting the track fasteners 223 through the faceplate fastener apertures 147 and the track fastener apertures 222 so that track 210 is secured to faceplate 145 and the sidewall 120 ; and
[0091] d) positioning the additional weir 230 in the track recesses 225 so that additional weir 230 is moveable along track lengths 215 .
[0092] Steps a) through d) may be performed in any suitable order, including simultaneously. Preferably, the track fasteners 223 are slightly longer than the fasteners 146 that are conventionally used to attach the faceplate 145 to the pool sidewall 120 , given that the track fasteners 223 must pass through an additional material, namely the tracks 210 . The process may include additional steps, such as removing the skimmer weir 170 or providing a weir fastener 250 and immobilizing the skimmer weir 170 with the weir fastener 250 .
[0093] The second system is generally designated by the numeral 300 , is illustrated in FIGS. 11-18 , and generally relates to a deflector 330 that is external to the skimmer 100 . In some embodiments, as illustrated in FIGS. 11-15 , the deflector 330 is attached, directly or indirectly, to the sidewall 120 and extends outwards into the pool 110 and above the skimmer opening 135 . The deflector 330 further includes an opening 320 . The opening 320 may be positioned at or adjacent to the widthwise center of deflector 330 , as shown in FIG. 15 , or alternatively may be positioned at the left or right side of the deflector 330 , as shown in FIGS. 11-14 and 16-18 , so that it is positioned to capture water circulating in a clockwise or counter-clockwise fashion (depending on the circulation pattern in the pool 110 , more particularly, basin 121 ). The opening 320 feeds water to the skimmer opening 135 and may be adjacent to the sidewall 120 , as shown in FIGS. 11-14 . The deflector opening 320 may be any suitable shape, including generally oval-shaped and rectangular. Optionally, the opening 320 is adjacent to the deflector apex 390 , which is the furthest point that the deflector 330 extends outward from the sidewall 120 , as shown in FIG. 15 . Preferably, the deflector 330 extends outward from the sidewall 120 a distance of about 1 inch to about 18 inches so that the deflector 330 does not interfere with swimmers.
[0094] As with the prior embodiment, preferably the skimmer weir 170 is immobilized by a weir fastener 250 or the skimmer weir 170 is removed in the second system 300 . In some embodiments, the deflector 330 does not move within the pool 110 other than to slightly deform in response to pressure applied to the deflector 330 . Preferably, the deflector 330 is comprised of rubber. Preferably, the opening 320 spans substantially the entire height 335 of the deflector 300 , as shown in FIGS. 11-18 , and at least above the skimmer opening 135 . Preferably, the deflector 330 includes fastener apertures 310 located on flat portions 316 on opposite sides (i.e., the left and right sides) of the deflector 330 and the second system 300 further includes fasteners 315 for attaching the deflector 330 directly or indirectly to the sidewall 120 . Preferably, the flat portions 316 have a width 317 at least equal to the thickness 148 of the faceplate 145 . For example, the flat portions may have a width 317 of at least 0.5 inches and preferably 1-5 inches so the flat portions 316 lay flat on skimmer faceplate 145 . Preferably, the deflector 330 includes a solid, water impermeable floor 340 , which abuts the sidewall 120 below the skimmer opening 135 , and a top opening 350 so that water flows through only the side or top openings 320 and 350 —and not from the floor 340 . Preferably, the deflector 330 includes a curved portion 360 that extends outward from the sidewall 120 . Preferably, the deflector 330 has a height of at least 8 inches (e.g., about 8 inches to about 20 inches).
[0095] Optionally, the deflector 330 includes a left flap 370 and a right flap 380 and the opening 320 is located between the left and right flaps 370 and 380 , as shown in FIG. 15 .
[0096] It will be appreciated the second system 300 , like the first system 200 increases the range of a pool skimmer 100 and preferably does not block all water from entering the skimmer opening 135 , unlike U.S. Pat. No. 7,993,515 to Davies. Rather, the deflector 330 (more particularly openings 320 and 350 ) feeds water to the skimmer opening 135 .
[0097] However, unlike the first system 200 , which feeds only the top, debris-containing layer to skimmer opening 135 , the second system 300 , as described above, is less selective and generally feeds any water that is able to enter through the openings 320 and 350 to the skimmer opening 135 . To alleviate this, as seen in FIGS. 16-18 , the deflector 330 may further include an additional weir 313 that moves vertically in response to changing water levels in the basin 121 and the additional weir 313 at least partially covers the opening 320 so that the deflector 330 is selective in this embodiment and only feeds the top, debris-containing layer of water to the skimmer opening 135 . In some embodiments, the additional weir 313 travels along tracks 314 located on opposites sides of the opening 320 and optionally the system 300 further includes a motor 325 for moving the additional weir 313 along the tracks 314 and a power source 326 (e.g., battery and/or solar panels) for powering the motor 325 . In some embodiments, the opening 320 has a median width of at least about 1 inch (e.g., about 1 to about 6 inches), more preferably at least about 3 inches (e.g., about 3 to about 6 inches) and a height of from about 4 inches to about 12 inches (more preferably about 7 inches to about 12 inches). Preferably, the size of the opening 320 is relatively narrow to take advantage of the Bernoulli principle but is still large enough to allow debris to flow through. In some embodiments, as illustrated in FIGS. 16-18 , the additional weir 313 may be a single piece of plastic that moves like a reverse garage door to close opening 320 (i.e., unlike a typical garage door which moves laterally at the top, the additional weir 313 may move laterally along the floor 340 , as best seen in FIG. 17 ). In other embodiments, the additional weir 313 may be comprised of a series of panels that, for example, fold onto each other at the bottom of opening 320 like an accordion.
[0098] In some embodiments, the deflector 330 includes a vacuum release door 311 and vacuum release opening 312 having the same features as described above for the first system 200 (e.g., spring or magnet-operated system). Optionally, if the second system 300 includes an additional weir 313 , the vacuum release door 311 and vacuum release opening 312 may be located on the additional weir 313 , as shown in FIGS. 16-18 .
[0099] Optionally, to increase the suction power of the second system 300 , the deflector 330 includes a narrow channel behind deflector 330 and in front of skimmer opening 135 that has a smaller cross-sectional area than the cross-sectional area of the opening 320 . For example, in some embodiments, the cross-sectional area of the channel is from about 4 square inches to about 36 square inches at its narrowest point, more preferably from about 4 square inches to about 20 square inches. This allows the narrow channel to take advantage of the Bernoulli principle, which holds that velocity of water increases when water flows through a narrow constriction. It has been observed in the inventor's experimentation with similar systems that it is advantageous to locate a narrow constriction further into the pool basin 121 (i.e., further from sidewall 120 ) because doing so allows the suction power created by the constriction to extend further into the basin 121 (and thereby potentially increase the skimming radius of the skimmer 100 ). In other words, the suction force decreases as the distance from the constriction increases. In such embodiments, preferably the top of deflector 330 is closed (i.e., lacks top opening 350 ) and water enters through the opening 320 , into narrow channel and then into skimmer opening 135 . Optionally, the cross-sectional area of the openings 320 and channel may decrease gradually like a funnel to aid the flow of water and debris therethrough. In other embodiments, as opposed to a weir 313 that moves vertically, the opening 320 has a door (not shown) that can be moved by a user laterally over the opening 320 to partially close the opening 320 and reduce the size of opening 320 , and thereby take advantage of the Bernoulli principle.
[0100] In some embodiments, as opposed to being attached to the pool sidewall 120 , the first and second systems 200 and 300 are attached to the skimmer 100 via an adjustable frame 400 , as shown in FIGS. 16-18 . The adjustable frame 400 has an adjustable width and adjustable height to accommodate skimmer throats 196 of different sizes, and is generally positioned where skimmer weir 170 is typically positioned (e.g., behind downwardly extending flange 198 if the flange is present). Preferably, the skimmer 100 includes left and right flanges to the left and right sides of the skimmer weir 170 when the skimmer weir 170 is in vertical position 170 A, which provides an additional contact area for adjustable frame 400 . An example of such a skimmer is the Hayward SP1084 (Hayward Industries, Elizabeth, N.J.). In this embodiment, skimmer weir 170 is typically removed. In some embodiments the adjustable frame was a width of between about 4 to about 14 inches and a height of between about 2 and about 12 inches. The adjustable frame 400 is particularly useful for concrete and gunite pools, which unlike vinyl pools, typically lack a faceplate 145 and would require a significant amount of time to drill a fastener aperture into the sidewall 120 . Thus, instead of the fasteners 223 , 315 and 520 anchoring the tracks 210 , deflector 330 and plate 531 (described below) by attaching to the sidewall 120 , the fasteners 223 , 315 and 520 instead anchor the tracks 210 , deflector 330 and plate 520 by anchoring to the adjustable frame 400 . More particularly, the fasteners 223 , 315 and 520 pass through apertures 222 , 310 , and 521 as well as through fastener apertures 402 in the adjustable frame. Again, the adjustable frame apertures 402 may be slotted to allow a user to adjust the system and unused portions of the apertures 402 may be covered so that debris and water does not get trapped in the unused apertures 402 . In this embodiment, the adjustable frame 400 is typically prevented from moving forwardly within throat 196 due to the fact skimmers 100 typically have downwardly extending flanges 198 or other narrowings to prevent the skimmer weir 170 from over-rotating beyond the vertical position 170 A. And the adjustable frame 400 is typically prevented from moving rearwardly within throat 196 due to the fact that tracks 210 , deflector 330 and plate 531 abut the sidewall 120 . The adjustable frame 400 may be generally rectangular, include four sides 401 and may include adjustment knobs 403 on each side 401 to allow a user to adjust the frame's height and width, as shown in FIGS. 18-21 . In some embodiments, the adjustment knobs (e.g., nuts) 403 may themselves move along threaded rod 408 and the knobs 403 may push against corner pieces 404 , 405 , 411 and 412 and cause the distance between the pieces 404 , 405 , 411 and 412 to increase or decrease (thereby increasing or decreasing the width or height of frame 400 ). In other embodiments, as shown in FIG. 19B , each side 401 of the adjustable frame 400 includes a knob 403 having one end 413 attached to a right hand screw 408 and the other end 414 attached to a left hand screw 409 and each screw 408 and 409 is received in a threaded aperture 406 of a corner piece 404 , 405 , 411 and 412 so that rotation of the knob 403 in one direction (e.g., clockwise) rotates the right hand and left hand screws 408 and 409 further into both corner pieces of the side (and hence decreases the width of the frame 400 ) and rotation of the knob 403 in another direction (e.g. counterclockwise) rotates the right hand and left hand screws 408 and 409 out of the corner pieces of the side (and hence increases the width of the frame 400 ).
[0101] Optionally, the second system 300 is provided as a kit.
[0102] The second system 300 may be installed by any suitable process. Optionally, the process includes:
[0103] a) removing skimmer the faceplate fasteners 146 ;
[0104] b) positioning the flat portions 316 so they abut the faceplate 145 and the faceplate fastener apertures 147 are aligned with the deflector fastener apertures 310 ; and
[0105] c) inserting the deflector fasteners 315 through the faceplate fastener apertures 147 and the deflector fastener apertures 310 so that deflector 330 is secured to the faceplate 145 and sidewall 120 .
[0106] In other embodiments, the process includes:
[0107] a) removing skimmer weir 170 ;
[0108] b) positioning the adjustable frame 400 into the throat 196 and adjusting the frame's height and width so that the adjustable frame 400 cannot move forwardly within the throat 196 (i.e., towards sidewall 120 by, for example, placing the adjustable frame 400 in the same location vacated by the skimmer weir 170 );
[0109] c) positioning the deflector 330 so that the deflector rear faces, preferably abuts, the sidewall 120 and the deflector fastener apertures 310 are aligned with the expandable frame apertures 402 ; and
[0110] d) inserting the deflector fasteners 315 through the deflector fastener apertures 310 and the frame apertures 402 so that deflector 330 is secured to the frame 400 .
[0111] The above steps may be performed in any suitable order, including simultaneously, and may include additional steps (e.g., the first method may also include removing the skimmer weir 170 or providing a weir fastener 250 and immobilizing the first weir 170 with the weir fastener 250 .). Preferably, in the first method, the deflector fasteners 315 are slightly longer than the fasteners 146 that are conventionally used to attach the faceplate 145 to the pool sidewall 120 , given that the deflector fasteners 315 must pass through an additional material, namely the deflector 330 . Preferably, for the second method, the deflector fasteners 315 have a length of from about 6 to about 18 inches.
[0112] The present disclosure also provides a third system 500 that is similar in design and function as the first system 200 . In some embodiments, the third system 500 includes:
[0113] a) a swimming pool 110 comprising a basin 121 configured to hold water and a plurality of sidewalls 120 defining a perimeter of the basin 121 ;
[0114] b) a skimmer 100 comprising a skimmer opening 135 located in one of the sidewalls 120 , the skimmer opening 135 in fluid communication with the basin 121 ; and
[0115] c) a weir assembly 532 located in the basin 121 and adjacent to the skimmer opening 135 , the weir assembly 532 abutting the one sidewall 120 and comprising a plurality of fastener apertures 521 and an additional weir 530 located in the basin 121 , the additional weir 530 configured to move in response to changing water levels in the basin 121 , the weir assembly 532 configured to deliver water from the basin 121 to the skimmer opening 135 .
[0116] Optionally, the additional weir 530 is configured to move above the skimmer opening 135 so that water located above the skimmer opening 135 can enter the skimmer 100 . Optionally, the weir assembly 532 further comprises a vacuum release door 533 and a vacuum release opening 534 , the vacuum release door 533 configured to move between a closed position wherein the vacuum release door 533 closes the vacuum release opening 534 and an open position wherein the vacuum release door 533 allows water located in the basin 121 to enter through the vacuum release opening 534 and enter the skimmer opening 135 . (Again, the vacuum release door and opening 533 and 534 may have the same components as described with the first system 200 ). Preferably, the vacuum release door and opening 533 and 534 are external to the skimmer 100 (i.e., located in basin 121 ) and optionally, the vacuum release door 533 is located in the weir 530 . Optionally, the weir assembly 532 further comprises a hinge attaching the vacuum release door 533 to the weir assembly 532 and the vacuum release door 533 is moveable (more particularly, pivotable) along the hinge. Optionally, the weir assembly 532 comprises a top half and a bottom half and the vacuum release opening 534 is located in the bottom half of the weir assembly 532 . Optionally, the weir assembly 532 has a height of at least about 4 inches and a width of at least about 4 inches, e.g., a height of from about 4 to about 14 inches and a width of from about 4 inches to about 24 inches.
[0117] Optionally, the weir assembly 532 further comprises a plate 531 abutting the pool sidewall 120 (e.g. directly abutting the sidewall 120 or abutting faceplate 145 attached to the sidewall 120 ), the plate 531 comprising the plurality of fastener apertures 521 , the plate 531 preventing water in the basin 121 from entering the skimmer opening 135 without passing over the weir 530 . Optionally, the plate 531 comprises a flat, rear portion abutting the one sidewall 120 . Optionally, as shown in FIGS. 21-24 , the weir assembly 530 includes a central plate, a left plate and a right plate if the skimmer opening 135 is large, as is the case with skimmers such as the Hayward SP1091 widemouth (Hayward Industries, Elizabeth N.J.), whose opening is 11 and ⅝ inches wide. In other embodiments, e.g., with skimmers 100 such as the Hayward SP1084 (whose opening is 7⅝ inches wide), the skimmer opening 135 is relatively small and only a central plate is needed. Optionally, the plate 531 further comprises a plate opening 535 located between the weir 530 and the skimmer opening 135 , the plate opening 535 configured to feed water to the skimmer opening 135 , and the weir 530 at least partially covers the plate opening 535 . Optionally, the weir 530 further comprises a top 536 , the top 536 comprising an opening 537 configured to feed water from the basin 121 to the plate opening 535 . Optionally, the top opening leads to a narrow channel whose cross-sectional area decreases gradually like a funnel to aid the flow of water and debris therethrough and increase the suction power of the system 500 through the Bernoulli principle described above. Optionally, the top opening 537 has a width of, for example, from about 1 to about 6. Optionally, instead of feeding water directly to the skimmer opening 135 , the system 500 includes a pipe/tube 722 system, similar to that described below and illustrated in FIGS. 26, 30 and 32 and the pipe 722 has a first end attached to the plate 531 (adjacent to, preferably surrounding, the plate opening 535 and in fluid communication with the plate opening 535 ) and a second end located in the throat 196 .
[0118] Optionally, the system 500 further comprises a plurality of fasteners 520 attaching the weir assembly 532 (more particularly, the plate 531 ) to the one sidewall 120 . Optionally, the system 500 further comprises a pool pump 190 in fluid communication with the skimmer 100 , the skimmer 100 further comprises a throat 196 and a water exit aperture/drain 199 located below basket 160 that feeds water from the skimmer 100 to the pool pump 190 , the throat 196 located between the skimmer opening 135 and the water exit aperture/drain 199 , and the system 500 further comprises an adjustable frame 400 located in the throat 196 , as described above.
[0119] Optionally, the system 500 further comprises a plurality of fastener apertures 402 located in the adjustable frame 400 and a plurality of fasteners 520 attaching the adjustable frame 400 to the weir assembly 532 , each of the plurality of fasteners 520 passing through a fastener aperture 521 located in the weir assembly 532 and a fastener aperture 402 located in the adjustable frame 400 . Optionally, the weir assembly 532 further comprises a floor 539 located at a bottom of the weir assembly 532 , the floor 539 abutting the one pool sidewall 120 , the floor 539 configured to inhibit water located in the basin 121 from entering the skimmer opening 135 from below the floor 539 . Optionally, the weir assembly 532 further comprises a motor 540 configured to move the weir 530 in response to changing water levels in the basin 121 . Optionally, the weir assembly 132 further comprises a track 510 (e.g., one or more tracks) configured to allow the weir 530 to move in response to changing water levels in the basin 121 . The track(s) 510 may be generally perpendicular to the ground, in which case, the weir 530 moves vertically up and down, as shown in FIG. 24 . Alternatively, the track 510 may be circular, semi-circular or U-shaped, as shown in FIGS. 21 and 23 , in which case the weir 530 rotates around the circular, semi-circular or U-shaped track 510 . Optionally, the system 500 further comprises a power source 542 (e.g., batteries and/or solar panels) configured to power the motor 540 . Optionally, the top 536 of the weir assembly 532 comprises a solar panel configured to power the motor 540 . Optionally, the system 500 further comprises a water level sensor 543 configured to sense the water level in the basin 121 , and a processor 544 connected to the water level sensor 543 and configured to move the weir 530 in response to data concerning the water level in the basin 121 received from the water level sensor 543 . Optionally, the basin 121 is filled with water, and the weir 530 comprises a top 536 and a float 551 located adjacent to the top 536 , the float 551 configured to allow the top 536 of the weir 532 to float in the water. Optionally, the weir 532 is buoyant in water.
[0120] The Embodiments of FIGS. 25-32
[0121] FIGS. 25-32 illustrate another embodiment of a system for increasing the range of a pool skimmer. As will be appreciated, the system of FIGS. 25-32 is similar in both design and function to the system of FIGS. 16-20 .
[0122] Referring further to FIGS. 25-32 , the system includes
[0123] a) a swimming pool 110 comprising a basin 121 configured to hold water and a plurality of sidewalls 120 defining a perimeter of the basin 121 ;
[0124] b) a pool skimmer 100 , the pool skimmer 100 comprising a skimmer opening 135 located in one of the sidewalls 120 and a skimmer interior 700 ; and
[0125] c) a deflector 330 adjacent to the sidewall 120 comprising the skimmer opening 135 (preferably directly in front of the skimmer opening 135 ) and extending into the basin 121 , the deflector 330 having a rear 701 facing the skimmer opening 135 and comprising a first opening 706 in fluid communication with the skimmer 100 and configured to feed water through the skimmer opening 135 , a front 702 opposite the rear 701 , a left side 703 , a right side 704 , and an interior 705 defined by the front 702 , the rear 701 , and the left and right sides 703 and 704 , at least one of the front 702 , the left side and the right side 703 and 704 comprising a second opening 320 configured to deliver water from the pool basin 121 to the deflector interior 705 and the first opening 706 , the second opening 320 having a median width 707 of at least about 1 inch and a height 708 of at least about 1 inch. In some embodiments, the deflector rear 701 is open (like the deflector rear of FIG. 12 ). In other embodiments, the deflector rear 701 is closed, except for the first opening 706 (as shown in FIGS. 25-32 ). In FIGS. 25-32 (like FIGS. 16-24 ), the pool sidewall 120 is shown as transparent for ease of viewing the components of the system. Optionally, the deflector 330 extends into the basin 121 from about 1 inch to about 18 inches, more preferably from about 1 inch to about 12 inches, even more preferably from about 1 inch to about 6 inches so that the deflector 330 does not interfere with swimmers. In other words, preferably, the deflector front 702 is located no more than about 18 inches, preferably no more than about 12 inches and even more preferably no more than about 6 inches from the sidewall 120 .
[0126] Preferably, the first opening 706 is configured to deliver water through the skimmer opening 135 by feeding water through a tube/pipe 722 as best seen in FIGS. 29-32 . The tube/pipe 722 preferably extends from the deflector rear 701 and is adjacent to the first opening 706 . The tube/pipe 722 optionally is generally cylindrical in shape, has an open front end 723 (which preferably surrounds first opening 706 ), an open back end 724 , a hollow interior 725 in fluid communication with the first opening 706 , a wall 726 forming the outside of the pipe/tube 722 , an outer diameter of from about 1 inch to about 5 inches (more preferably about 2.5 inches to about 4 inches), a length extending from the front end 723 to the back end 724 of from about 1 inch to about 14 inches (more preferably about 2 inches to about 8 inches). Optionally, the tube/pipe 722 is threaded with threads 727 so that it can receive a nut 729 (as explained below). Optionally, an additional tube/pipe (not shown) is configured to attach to the back end 724 of the tube/pipe 722 for skimmers 100 having a longer throat 196 . For example, some skimmer throat 196 can be as short as few inches and others can be over 6 inches in length. The front and back end 723 and 724 of the tube/pipe 722 are both open so that the tube/pipe 722 delivers water and debris from the deflector interior 705 into the throat 196 and ultimately through the basket 160 and pump 190 . The first opening 706 can have any suitable size, and optionally, has the same height and width as the tube/pipe 722 (e.g., from about 1 inch to about 5 inches). Preferably, the surface area of the first opening 706 is at least 3.14 square inches (the same surface area of a 2 inch diameter pipe) so that sufficient water flows to the pool pump 190 (which is in fluid communication with the first opening 706 ) so the pump 190 does not draw air.
[0127] Optionally, the second opening 320 has a height of from about 4 inches to about 12 inches (more preferably about 7 inches to about 12 inches) and a median width of from about 1 inch to about 6 inches. Optionally, the second opening 320 extends above the skimmer opening 135 . The second opening 320 may extend above the skimmer opening 135 at least about 1 inch, preferably about 2 to about 6 inches. Optionally, the rear 701 of the deflector 330 is substantially flat. Optionally, the rear 701 of the deflector 330 is attached to a plate 709 comprising an aperture 733 for receiving the pipe/tube 722 and a gasket 710 abutting the one sidewall 120 so that the plate 709 creates a seal so that water must enter through the second opening 320 (instead of entering directly through the skimmer opening 135 ). Optionally, the deflector 330 further comprises an additional weir 230 configured to at least partially cover the second opening 320 , the additional weir 230 configured to move upwards and downwards in response to changing water levels in the pool basin 121 . Optionally, the additional weir 230 is configured to move above the skimmer opening 135 . Optionally, the additional weir 230 is configured to move upwards and downwards in an arc in response to changing water levels in the pool basin 121 . Optionally, the arc is circular, elliptical, ovoidal in shape and/or forms part of an circle, ellipse or oval. Optionally, the deflector 330 further comprises at least one track 210 adjacent to the second opening 320 and the additional weir 230 is configured to move along the track 210 . Optionally, the deflector 330 is generally circular. Optionally, the additional weir 230 further comprises at least one wheel 627 / 628 and the at least one wheel 627 / 628 is configured to move along the track 210 . Optionally, the deflector 330 further comprises two tracks 210 (e.g., a front track 210 A and a rear track 210 B) located on opposite sides of the second opening 320 , and the additional weir 230 further comprises at least two wheels 627 / 628 (e.g., two to six wheels 627 / 628 ) distributed on opposite sides of the additional weir 230 (e.g., the front and rear sides) and each wheel 627 / 628 is configured to move along a track 210 , as best seen in FIG. 28 . It has been observed that the movement of the additional weir 230 performs much better with the wheels 627 / 628 than without the wheels, due to reduced friction. Preferably, the wheels 627 / 628 are bearings. If included the bearings may include a plurality of balls (e.g., stainless steel or glass) located around a track that is made of a different material. Such bearings are known in the art and include the replacement C60 bearings for the POLARIS 280 robotic pool cleaner (available from Zodiac Marine & Pool, Vista Calif.) as well as KMS Bearings, Anaheim Calif. Optionally, the tracks 210 are curved and each track 210 forms an arc, as best seen in FIGS. 28 and 32 , so that the additional weir 230 moves upwardly and downwardly along an are in response to changing water levels in the pool basin 121 . In some embodiments, the second opening 320 is on the left side 703 of the deflector 330 , and the deflector 330 further comprises a third opening (not shown) on the right side 704 of the deflector 330 , the second 320 and third openings each have a height of from about 4 inches to about 12 inches and a median width of from about 1 inch about 6 inches, and the deflector 330 further comprises two tracks 210 adjacent to the second opening 320 and two tracks (not shown) adjacent to the third opening. This embodiment, though not shown, provides two options: first, the left and right side 703 and 704 can each have an additional weir 230 , which allows water to enter the deflector interior 705 through the second 320 and third openings, simultaneously); alternatively, the embodiment may include only one additional weir 230 , and only one of the second 320 and third openings is exposed at a time, in which case, the weir 230 moves along the tracks 210 adjacent to the exposed opening and the opening on the other side is blocked by a moveable plate or piece of foam that covers this opening. The alternative approach is preferable in some respects, as it allows a user to choose to have water enter through either the left side 703 or right side 704 of the deflector 330 (i.e., the second 320 or third opening), depending on the water circulation in the user's pool 110 . Preferably, the additional weir 230 is buoyant in water (meaning that the additional weir 230 does not fully sink in water) so that the additional weir 230 adjusts to changing water levels in the pool basin 121 . Optionally, the additional weir 230 comprises a top 231 , a bottom 712 , a tab 713 extending from the top 231 , and a float 714 . Optionally, the float 714 is attached to the tab 713 . Optionally, the float 714 comprises foam. It has been observed that good results are achieved (in terms of the additional weir 230 moving in response to changing water levels in the basin 121 ) when the float 714 is attached to the tab 713 , the tab 713 is immobile and the tab 713 is approximately perpendicular (e.g, about 60 to 90 degrees) to the water surface as the additional weir 230 moves around the tracks 210 so that the tab 713 floats like a boat. In such case, water flowing through the second opening 320 pushes the additional weir 230 downward so that the tab 713 is located about 2 inches underwater and only the top layer (2 inches) of pool basin 121 water enters through the second opening 320 when the pump 190 is turned on. In such embodiments, when the pump 190 is turned off, the additional weir 230 moves upwardly to inhibit the debris-containing water in the skimmer 100 from flowing through the second opening 320 when the pump 190 is turned off. As with the prior embodiments, the purpose of the additional weir 230 is that most of the debris in the pool basin 121 water is located on or just slightly below the surface (e.g., within about 2 inches of the surface), and thus, the additional weir 230 allows this top layer of water to enter the second opening 320 so that it can reach the pump 190 and filtration system and the sub-surface water is blocked by the additional weir 230 . In other embodiments, instead of relying on a floatation system to move the additional weir 230 , the system of FIGS. 25-32 includes a water level sensor 543 , a power source 542 , a processor 544 and a motor 540 to move the second weir 230 in response to changing water levels in the basin 121 , as described with respect to system 500 .
[0128] Optionally, the additional weir 230 is curved along its height/length 708 , as shown in FIGS. 25-26, 28 and 32 . In some embodiments, instead of using a track 210 , the deflector 330 further comprises a hub (not shown) and a spoke (not shown), the spoke having a first end attached to the hub and a second end attached to the additional weir 230 , and the hub is configured to rotate about a pivot point (which is preferably centrally located on the front 702 or rear 701 of the deflector 330 ) so that the attached additional weir 230 similarly rotates about the pivot point (like a ferris wheel), which is an alternate way to allow the additional weir 230 to move upwardly and downwardly along an arc in response to changing water levels in the basin 121 that, as with the embodiment above, minimizes friction. Optionally, the deflector 330 further comprises a vacuum release door 261 and a vacuum release opening 260 similar to that illustrated in FIGS. 4-7, 9-10, 16, 17, and 24 . Like these prior embodiments, the vacuum release door 261 is configured to move between a closed position wherein the vacuum release door 261 closes the vacuum release opening 260 (e.g., at least partially covers/closes the vacuum release opening 260 ) and an open position wherein the vacuum release door 261 allows water located in the basin 121 to enter through the vacuum release opening 260 and enter the deflector interior 705 and the first opening 706 . As with the prior embodiments, it has been observed that, in the event that the additional weir 230 is intentionally pulled above the top of the water located in the basin 121 (e.g., by a mischievous child), the vacuum release door 261 opens and allows water located in the basin 121 to bypass the second opening 320 , which is now covered by the intentionally raised additional weir 230 , so that the pump 190 does not draw air. It has also been observed that the vacuum release door 261 equalizes the water pressure pressing on the deflector 330 from the deflector interior 705 and the pool basin 121 so that the additional weir 230 falls naturally to just below the top of the water located in the basin 121 when the person stops pulling the additional weir 230 upwards. Optionally, the deflector 330 further comprises a hinge 624 attaching the vacuum release door 261 to the deflector 330 and the vacuum release door 261 is moveable along the hinge 624 . Optionally, the deflector comprises a tab 625 located exterior to the vacuum release door 621 , the tab 625 configured to prevent the vacuum release door 261 from rotating beyond the tab 625 so that the vacuum release door 261 does not rotate beyond the vertical. Optionally, the deflector 330 comprises a top half 626 and a bottom half 650 and the vacuum release opening 260 is located in the bottom half 650 of the deflector 330 , which allows the vacuum release opening 260 to be in the water even when the water in the basin 121 is relatively low. Optionally, the deflector 330 further comprises a magnet to bias the vacuum release door 261 in the closed position. Optionally, in addition to the vacuum release door 261 and the vacuum release opening 260 , the deflector 330 further comprises a bypass opening 720 and a bypass door 719 to removably close the bypass opening 720 , the bypass door 719 configured to move between a closed position wherein the bypass door 719 closes (e.g., at least partially closes) the bypass opening 720 and an open position wherein the bypass door 719 allows water located in the basin 121 to enter through the bypass opening 720 and enter the first opening 706 . Optionally, the bypass door 719 is configured to rotate relative to the bypass opening 720 . Optionally, the bypass door 719 is generally circular in shape and is configured to rotate about a pivot point 721 located in a center of the circle. In other embodiments (not shown), the bypass door 719 is configured to slide/move vertically relative to the bypass opening 720 . The purpose of the bypass opening 719 and bypass door 720 is that the bypass door 720 preferably has a number of settings, the settings differing in the amount in which the bypass door 719 covers the bypass opening 720 , so that the user can adjust the bypass door 719 and let varying amounts of water through the bypass opening 720 depending on the force of the pump 190 ). Adjusting the bypass door 719 changes the pressure level at which the vacuum release door 261 (which is normally closed) is triggered open. More particularly, it has been observed that without the bypass door 719 and bypass opening 720 , stronger pumps 190 (as well as pumps that are not drawing water from the main drain 101 ) are more apt to trigger the vacuum release door 261 to open than weaker pumps 190 . This can be problematic as the vacuum release door 261 is designed as an emergency measure, like an electric breaker, to protect the pump 190 from drawing air when the additional weir 230 is too high, and the vacuum release door 261 is designed to be normally closed. However, by uncovering the bypass opening 720 in these stronger pumps 190 , water is able to enter through the bypass opening 720 and a greater amount of water pressure is required to cause the vacuum release door 261 to open. Like the vacuum release door 261 , the bypass opening 720 is normally in the bottom half 650 of the deflector 330 to ensure that the bypass opening 720 is under water. Unlike the vacuum release door 261 , which is normally closed and is triggered open by high pressure, the bypass door 719 is a dial door that is adjusted by a user depending on his/her pump 190 and is always kept in the same position.
[0129] The deflector 330 can be attached, directly or indirectly, to the pool sidewall 120 by any acceptable method. For example, a nut 729 may be screwed onto the pipe/tube 722 extending from the deflector 330 and a frame 400 , with an aperture 728 receiving the pipe/tube 722 , may be located between the nut 729 and the skimmer opening 135 . In such a case, the frame 400 is prevented from moving rearwardly by the nut 729 and the frame 400 is prevented from moving forward due to the flanges 198 located in the skimmer interior 700 . For example, the Hayward model SP1070 skimmer (Hayward Industries, Elizabeth N.J.) has flanges 198 on the top and the bottom in the location where the skimmer weir 170 is normally located and in such skimmers, the skimmer weir 170 is removed and the top and bottom flanges 198 prevent the frame 400 from moving forward. In other embodiments, the deflector 330 and/or plate 709 may be screwed to the faceplate 135 in the case of a vinyl pool or an adjustable frame 400 located inside the throat 196 as described in the prior embodiments. Optionally, the deflector 330 further comprises a substantially water impermeable floor 340 such that, for example, approximately 95% of the surface area of the floor 340 is not permeable to water, it being understood that the bypass door 719 and opening 720 may be located on the floor 340 . Optionally, the top of the deflector comprises a top aperture 350 allowing water to also enter the deflector interior 705 through the top aperture 350 . Optionally, the pool skimmer 100 further comprises a skimmer weir 170 located inside the pool skimmer interior 700 and the skimmer weir 170 is immobilized. Optionally, the pool skimmer 100 does not have a skimmer weir 170 in the skimmer interior 700 . Optionally, the skimmer interior 700 further comprises a skimmer basket 160 . Optionally, the system further comprises a pump 190 in fluid communication with the basin 121 and the skimmer interior 700 . Optionally, the deflector 330 further comprises a removable large debris door 731 , which slides into the deflector 330 via tracks (not shown), and covers a large debris opening 732 . The function of the large debris door 731 and opening 732 is that the large debris door 731 normally covers the large debris opening 732 but the large debris door 731 can be removed for example in the fall months so that large leaves and other debris can enter into the deflector interior 705 given that the large debris door 731 has a width that is typically larger than the width 707 of the second opening 320 . Optionally, the median width of the large debris door 731 is from about 3 inches to about 8 inches and the large debris door has a height of approximately 3 inches to about 12 inches. In some embodiments, the deflector 330 described directly above is provided as a kit that attaches to the sidewall 120 and/or skimmer 100 and includes one or more features, including but not limited to the additional weir 230 , tracks 210 , wheels 627 / 628 , vacuum release door 261 , vacuum release opening 260 , bypass door 719 , bypass opening 720 , large debris door 731 , large debris opening 732 , and pipe 722 .
[0130] In some embodiments, the present disclosure provides a method of using a system to increase the range of a pool skimmer that includes
[0000] a) providing the system described above; and
b) flowing water from the basin 121 , through the second opening 320 , through the deflector interior 705 , through the first opening 706 , through the skimmer opening 135 , and into the skimmer interior 700 .
[0131] As described above, it has been found that wheels 627 / 628 are particularly useful for moving the additional weir 230 to reduce friction. Thus, in some embodiments, the present disclosure provides a pool skimmer system comprising:
[0000] a) a swimming pool 100 comprising a basin 121 configured to hold water and a plurality of sidewalls 120 defining a perimeter of the basin 121 ;
b) a pool skimmer 100 comprising a skimmer opening 135 located in one of the sidewalls 120 and a skimmer interior 700 ;
c) two tracks 210 located in the pool basin 121 ; and
d) an additional weir 230 located in the pool basin 121 , the additional weir 230 configured to move upwards and downwards and regulate water entering the skimmer opening 135 , the additional weir 230 having two opposite sides, each of the opposite sides having at least one wheel 627 / 628 attached thereto, each of the wheels 627 / 628 received in a track 210 .
[0132] Optionally, the tracks 210 are curved and the additional weir 230 is configured to move in an are upwards and downwards in response to changing water levels in the pool basin 121 .
[0133] In other embodiments, the additional weir 230 with attached wheels 627 / 628 is located inside the skimmer interior 700 . In such embodiments, the present disclosure provides a pool skimmer system comprising:
[0000] a) a swimming pool 100 comprising a basin 121 configured to hold water and a plurality of sidewalls 120 defining a perimeter of the basin 121 ;
b) a pool skimmer 100 comprising a skimmer opening 135 located in one of the sidewalls 120 and a skimmer interior 700 ;
c) two tracks 210 located in the skimmer interior 700 ; and
d) a weir 170 located the skimmer interior 700 , the weir 170 configured to move upwards and downwards in response to changing water levels in the basin 121 , the weir 170 having two opposite sides, each of the opposite sides having at least one wheel 627 / 628 attached thereto, each of the wheels 627 / 628 received in a track 210 .
[0134] Optionally, in either of these embodiments described directly above, the skimmer interior 700 further comprises a skimmer basket 160 . Optionally, the system further comprises a pump 190 in fluid communication with the basin 121 and the skimmer interior 700 . In addition to these features, the system may have any of the features described above with respect to FIGS. 25-32 , including without limitation, the vacuum release door 261 and opening 260 , the bypass opening 720 and door 719 , the attachment mechanisms described above, the float 714 , the tab 713 , etc. In addition, the tracks 210 may be vertical or in the shape of an arc as described above.
[0135] The Embodiment of FIGS. 33-35 .
[0136] As shown in FIGS. 33-35 , in some embodiments, the present disclosure provides a new design of a pool skimmer 100 that allows the skimmer opening 135 to be very close to the top of the sidewall 120 and the top of the concrete surrounding the pool 120 . This allows the pool owner to skim effectively when the pool 110 is filled with water to the top of the sidewall 120 . In some embodiments, the new skimmer 100 has
[0000] a) a front end 600 comprising a top 601 , a bottom 602 , and a skimmer opening 135 leading to the skimmer interior 700 and comprising a top 605 , a bottom 606 , a left side 604 , a right side 603 , a width 608 extending from the skimmer opening left side 604 to the skimmer opening right side 603 of at least about 2 inches and a height 607 extending from the skimmer opening top 605 to the skimmer opening bottom 606 of from about 2 inches to about 16 inches;
b) a rear end 610 comprising a top 611 comprising a top opening 612 , a lid 613 configured to removably close the top opening 612 , a bottom 614 comprising a bottom opening 199 in fluid communication with the skimmer opening 135 , a well 616 located directly below the top opening 612 , the bottom opening 199 extending into the well 616 , a skimmer basket 160 located in the well 616 and comprising a floor 617 , a sidewall 618 extending from the floor 617 , at least one of the floor 617 and the basket sidewall 618 comprising a plurality of apertures configured to allow water to flow from the basket 160 to the bottom opening 199 and ultimately the pump 190 ; and
c) a middle portion 620 located between the front end 600 and the rear end 610 and comprising a top 621 , a bottom 622 , a height extending from the top 621 to the bottom 622 and a throat 196 in fluid communication with the skimmer opening and the rear end 610 , wherein the top 601 of the front end 600 , the top 611 of the rear end 610 , and the top 621 of the middle portion 620 are within about 1 inch of each other when the top 601 of the front end 600 , the top 611 of the rear end 610 , and the top 621 of the middle portion 620 are positioned parallel to the ground. Optionally, the top 601 of the front end 600 , the top 611 of the rear end 610 , and the top 621 of the middle portion 620 are within about 0.5 inches of each other (i.e., 0 to about 0.5 inches) when the top 601 of the front end 600 , the top 611 of the rear end 610 , and the top 621 of the middle portion 620 are positioned parallel to the ground. In other words, preferably, the top 601 of the front end 600 , the top 611 of the rear end 610 , and the top 621 of the middle portion 620 are co-planar. More particularly, the top 611 of the rear end 610 (more particularly the top of the lid 613 ), the top 621 of the middle portion 620 and the top 601 of the front end 600 are substantially level so that no concrete is placed on top of the rear end 610 , on top of the middle portion 620 and on top of the front end 600 after positioning the skimmer 100 in the sidewall 120 . Rather, users are able to walk on the top 611 of the rear end 610 , the top 621 of the middle portion 620 and the top 601 of the front end 600 , just as users now walk on the top of the lid 613 . (It will be appreciated that concrete is typically poured over the middle portion 620 and front portions 600 of typical prior art skimmers, as shown in FIG. 2 )
[0137] In some embodiments, the throat 196 extends substantially to the top 621 of the middle portion 620 . Optionally, the top 611 of the rear end 610 , the top 621 of the middle portion 620 and the top 601 of the front end 600 , are comprised of plastic. Optionally, the lid 613 is generally circular.
[0138] Optionally, the height 607 of the skimmer opening 135 is from about 8 inches to about 14 inches. Optionally, the width 608 of the skimmer opening 135 is between about 3 and about 6 inches. Optionally, the pool skimmer 100 further includes a weir configured to move upwards and downwards in response to changing water levels in the basin 121 . In some embodiments, similar to FIGS. 4-10 , the weir is an external weir 230 and located exterior to the skimmer interior 700 and skimmer opening 135 . In other embodiments, the weir is an internal weir 170 located in the skimmer interior 700 and configured to move upwards and downwards in response to changing water levels in the skimmer interior 700 . Optionally, the weir 230 / 170 is located adjacent to the skimmer opening 135 (e.g., about 0 to about 6 inches from the opening 135 ). Optionally, similar to the above embodiments, the skimmer 100 comprises a left track and a right track (not shown in FIGS. 33-35 ) and the weir 230 / 170 is configured is configured to move along the left and right tracks. Optionally, similar to the embodiment of FIGS. 25-32 , the weir 230 / 170 further comprises at least one left wheel located in the left track and at least one right wheel located in the right track (not shown in FIGS. 33-35 ). Optionally, the weir 230 / 170 further comprises a float 714 . Optionally, the float 714 comprises foam. Optionally, the weir 230 / 170 is attached to the skimmer 100 via a hinge 155 and is configured to pivot between a horizontal position in which the weir 230 / 170 is parallel to the lid 613 and a vertical position in which the weir 230 / 170 is perpendicular to the lid 613 . Optionally, similar to the above embodiments, the weir 230 / 170 further comprises a vacuum release door and a vacuum release opening (not shown in FIGS. 33-35 ), the vacuum release door configured to move between a closed position wherein the vacuum release door closes the vacuum release opening and an open position wherein the vacuum release door allows water to enter through the vacuum release opening. Optionally, similar to the above embodiments, the weir 230 / 170 further comprises a hinge attaching the vacuum release door to the weir 230 / 170 and further wherein the vacuum release door is moveable along the hinge. Optionally, similar to the above embodiments, the weir 230 / 170 comprises a tab located exterior to the vacuum release door, the tab configured to prevent the vacuum release door from rotating beyond the tab. Optionally, similar to the above embodiments, the weir 230 / 170 comprises a top half and a bottom half and the vacuum release opening is located in the bottom half of the weir 230 / 170 . Optionally, the throat 196 has a length of from about 3 inches to about 12 inches. Optionally, the throat 196 is generally rectangular in shape. Optionally, as shown in FIGS. 34 and 35 , the skimmer 100 is generally in the shape of an upside down “L” with the top 611 of the rear end 610 , the top 621 of the middle portion 620 , and the top 601 of the front end 600 forming the horizontal portion of the “L” and the rear end 610 forming the vertical portion of the “L” it being understood that the rear end 610 may taper in width, as shown in FIGS. 34 and 35 .
[0139] Terms of degree such as “substantially”, “about” and “approximately” as used herein mean a reasonable amount of deviation of the modified term such that the end result is not significantly changed. For example, these terms can be construed as including a deviation of at least ±5% of the modified term if this deviation would not negate the meaning of the word it modifies. In addition, use of the singular form of a term embraces the plural.
[0140] Having now described the invention in accordance with the requirements of the patent statutes, those skilled in the art will understand how to make changes and modifications to the disclosed embodiments to meet their specific requirements or conditions. Changes and modifications may be made without departing from the scope and spirit of the invention, as defined and limited solely by the following claims.
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The present invention relates to systems for improving the range of pool skimmers. In some embodiments, the present invention provides a weir that is located in the basin of a swimming pool, moves in response to changing water levels in the pool and feeds water from the basin to a skimmer located in a sidewall of the swimming pool. In other embodiments, the present invention provides a deflector that is adjacent to a pool sidewall and extends above the skimmer opening, and includes an opening for feeding water to the skimmer opening. The present disclosure also provides for systems having combinations of such features. Without being bound to any particular theory, it is believed that the apparatuses are relatively cheap to manufacture, safe, conserve water and chemical use, and allow for an aesthetically pleasing full pool.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present patent application claims the benefits of priority of U.S. Patent Application No. 62/141,457, entitled “Self-detaching support frame system for an implement and method for using the same”, and filed at the US Patent Office on Apr. 1, 2015, the content of which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention generally relates to frames and frame assemblies for supporting implements on vehicles and more particularly relates to frames and frame assemblies for supporting implements on small vehicles such as, but not limited to, all-terrain vehicles (“ATV” or “ATVs”) and utility-terrain vehicle (“UTV” or “UTVs”).
BACKGROUND OF THE INVENTION
[0003] Since a couple of years, the All-terrain vehicles (“ATV” or “ATVs”), utility-terrain vehicle (“UTV” or “UTVs”) or other recreational off highway vehicles (“ROV”) (hereinafter, ATV should be understood to refer as comprising ATV, UTV, ROV and other similar vehicles) market has been growing steadily. Moreover, ATV users have been using their vehicles for new tasks such as snow removal, load transport, etc. To help ATV users make the fullest use of their vehicles, numerous accessories have been put on the market. ATV and other similar vehicles are often equipped with implements such as plows to allow the vehicles to displace snow, dirt, soil, gravel, etc. Such implements are typically removably mounted to the vehicles via appropriate supporting frames or supporting frame assemblies.
[0004] However, in order for the ATV user to use an accessory to its full capacity, the accessory must be easy to use and more importantly, easy to install. In the field of support frame assemblies for snow plows and other front-mounted implements, this is even more important since these assemblies are generally relatively heavy and thus difficult to manipulate and install.
[0005] Support frame assemblies currently on the market are not easy and/or are time consuming to install. In the vast majority of cases, when the user is alone, he or she (hereinafter, for the sake of simplicity, only the masculine form will be used) must use brute force to install the frame assembly on his ATV. This comes from the fact that all the weight of the plow assembly rests on the ground. Thus, the user must overcome the friction force between the ground and the plow. Moreover, since snow plows are generally made of metal, they can be relatively heavy and the friction force between the ground and the plow can be relatively large.
[0006] Thus, in general, most frame assemblies currently on the market are more easily installed when two or more individuals are present.
[0007] As a result, in current frame assemblies, the majority of the systems on the market offer the possibility of a quick attach, which allows the user minimal handling to mount the plow system on the ATV. Unfortunately, these systems require the user to get out of the vehicle to detach the plow system from the ATV. Some plow systems comprise quick release mechanisms which allow removing the plow system from the vehicle without undue labor. However, even these quick release mechanisms require the user to get out of the vehicle. There are even some plow systems that are not equipped with quick release mechanisms and imply that the users should lie down under the vehicle to install or detach the plow push frame from the ATV.
[0008] In view of the foregoing, there is indeed a need for a new and improved support frame assembly for a plow or other implement which mitigates at least some of the shortcoming of prior art support frame assemblies.
SUMMARY OF THE INVENTION
[0009] The shortcomings of the prior art are generally mitigated by providing a self-detaching support frame system for an assembly.
[0010] Since the self-detaching support frame system for an implement in accordance with the present invention can be used with implements and accessories other than plows, hereinafter, the term “plow” shall be construed broadly and shall therefore relate to any front-mounted accessories such as plow, blade and other similarly mounted implements.
[0011] The self-detaching support frame system for an implement is designed to fill a need on the market for mechanical self-detach system that can at least partially, preferably totally disconnect the push frame from the vehicle by pulling on a release handle while remaining seated on the vehicle.
[0012] Hence, the self-detaching support frame system for an implement allows the user to at least partially, preferably entirely, disengage the support frame assembly by activating a control, preferably a single control such as a handle located near the vehicle steering. Understandably, the handle could be located at various locations on the vehicle as long as the user may access the handle without requiring him to go off the vehicle.
[0013] According to one aspect of the present invention, once disengaged, the vehicle is preferably ready to drive without the plow system and without the user having to get off the vehicle. This system has a pull cable with a handle located near the ATV steering, which is connected to the mount plate latching system.
[0014] According to one aspect of the present invention, the self-detaching support frame system for an assembly does not require the user to get off the vehicle or lay down on the floor to disengage the plow system.
[0015] According to one aspect of the invention, the self-detaching support frame system for an assembly may additionally release the winch hook automatically without further user manipulation.
[0016] According to one aspect of the present invention, the self-detaching support frame system for an assembly preferably requires no engine or electric system, only mechanical components to detach the plow system. The absence of an engine or electric actuated system generally implies a low-cost mechanism.
[0017] According to one aspect of the present invention, a method for removing a support frame system for an assembly is disclosed. The method comprises the step of:
a. pulling a handle on the vehicle to activate the mechanism.
[0019] According to one aspect of the present invention, the trigger handle is preferably connected to the activation cable. This cable is then connected to a mount plate that is fastened under the vehicle. Pulling on the trigger handle rotates the lock system and releases the hook of the latching system. The latching mechanism is held to the mount plate by the hook and by two brackets (parts are attached on the ATV). By releasing the hook, the latching system falls on the ground by gravity, then releasing the front brackets in the same movement. The system is now completely disengaged. Once disengaged, the tube or lever arm retained under the vehicle moves. As such, upon falling of the latch system on the ground, a lever arm is released thus disengaging a rod operatively connected to a rotated lock plate previously engaging a winch hook. By this movement, the rod pulls the pivot link and ejects the winch hook. As a result, the winch hook is now completely disengaged. The system is totally free to be moved and the vehicle ready to ride without the plow system.
[0020] Hence, a self-detaching support frame system for an assembly, in accordance with the principles of the present invention, generally extends longitudinally and generally comprises, at its rear end, a rear attachment mechanism for removably mounting the rear end of the support frame to the underside of the vehicle, and at its front end, an implement attachment assembly for supporting the implement.
[0021] The rear attachment mechanism typically allows the support frame to pivot with respect to the vehicle, thereby allowing the support frame to be raised and lowered as needed, typically by the winch of the vehicle. In typical though non-limitative embodiments of the support frame, the rear attachment mechanism is a latching mechanism that comprises one or more latches.
[0022] In typical though non-limitative embodiments of a support frame, the support frame is configured to support a plow.
[0023] The support frame assembly in accordance with the principles of the present invention also generally simplifies the installation and removal of the support frame assembly to and from a vehicle.
[0024] According to one aspect of the present invention, a self-detaching support frame for an implement for a vehicle is disclosed. The support frame comprises a first portion, a second portion and a lever arm. The first portion comprises a first end adapted to receive an implement and a second end adapted to receive a lifting system. The second portion being pivotally mounted to the first portion and comprises a first end comprising a first securing member adapted to engage with a retaining member mounted to the vehicle and a second end comprising a second securing member adapted to engage with a receiving member mounted to the vehicle. The lever arm is pivotally mounted to the second portion, the lever arm being adapted to engage the lifting system. The disengagement of the retaining member from the first securing member allows the second portion to move downwardly, the downward movement allowing the lever arm to move and to release the lifting system.
[0025] According to one aspect of the present invention, the second portion has a D-shape made from tubular members and comprises side arms mounted to the tubular members adapted to be pivotally mounted to the first portion.
[0026] According to one aspect of the present invention the axis of rotation of the lever arm with regards to the second portion and the axis of rotation of the second portion with regards to the first portion are substantially parallel.
[0027] According to one aspect of the present invention the axis of rotation of the second portion with regards to the first portion is substantially perpendicular to the length of the support frame. The lever arm may be mounted between the end of the second portion and the opposite end of the first portion.
[0028] According to one aspect of the present invention the first end is a latch hook adapted to be engaged by the retaining member. The receiving member may be a rod substantially perpendicular to the length of the support frame. The lever arm may be mechanically connected to the attachment system.
[0029] According to one aspect of the present invention the mechanical connection is a rod.
[0030] According to one aspect of the present invention, the attachment system comprises a hook mounted to the first portion, a supporting member mounted to the hook, and a lock plate pivotally mounted to the supporting member and connected to the rod. The rotation of the lock plates closes the hook in an engaged position or opens the hook in a disengaged position.
[0031] According to one aspect of the present invention, the retaining member is pivotally mounted to the vehicle and mechanically connected to a mechanical connection adapted to move the retaining member to release the first end.
[0032] According to one aspect of the present invention, the mechanical connection is engaged by a release controller. The release controller is located within arm's reach of the vehicle user when located in the driving position.
[0033] According to one aspect of the present invention a vehicle mounting assembly for mounting a support frame to a vehicle is disclosed. The mounting assembly comprises a mounting plate being configured to be mounted to an underside of the vehicle; a retaining element supported by the mounting plate, the retaining element being adapted to retain the support frame to the vehicle in a first position and to release the support frame in a second position; and an actuator operatively connected to retaining element to move the retaining element between the first and second position, the actuator being located on the vehicle in a location allowing a user to reach the actuator while the user is in the driving position. The actuator may be mechanically connected to the retaining element and the retaining element may either be a latch or a hook.
[0034] According to one aspect of the present invention, the self-detach support frame comprises a rear end configured to be removably mounted to the mounting plate and engaged by the retaining element, and a front end operatively mounted to an implement, the support frame comprising a rear section and a front section pivotally connected thereto.
[0035] Other and further aspects and advantages of the present invention will be obvious upon an understanding of the illustrative embodiments about to be described or will be indicated in the appended claims, and various advantages not referred to herein will occur to one skilled in the art upon employment of the invention in practice.
BRIEF DESCRIPTION OF THE DRAWINGS
[0036] The above and other aspects, features and advantages of the invention will become more readily apparent from the following description, reference being made to the accompanying drawings in which:
[0037] FIG. 1 is a user view of an ATV exposing a control for the self-detaching support frame system for an assembly
[0038] FIG. 2 is a close up view of the control of FIG. 1 .
[0039] FIG. 3 is a side view of an ATV exposing the self-detaching mechanism of the self-detaching support frame system for an assembly mounted thereto.
[0040] FIG. 4 is a close up view of the self-detaching mechanism of FIG. 3 .
[0041] FIG. 5 is a close up view of the self-detaching mechanism of FIG. 3 upon actuation of the self-release control.
[0042] FIG. 6 is a perspective view of an ATV exposing the self-detaching mechanism of the self-detaching support frame system for an assembly partially mounted thereto.
[0043] FIG. 7 is a close up view of the self-detaching mechanism of FIG. 6 .
[0044] FIG. 8 is a side elevation view of a self-detaching support frame system for an assembly mounted to an ATV.
[0045] FIG. 9 is a side elevation view of a self-detaching support frame system for an assembly partially mounted to an ATV.
[0046] FIG. 10 is a side perspective view of a self-detaching support frame system for an assembly.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0047] A novel self-detaching support frame system for an implement and method for using the same will be described hereinafter. Although the invention is described in terms of specific illustrative embodiments, it is to be understood that the embodiments described herein are by way of example only and that the scope of the invention is not intended to be limited thereby.
[0048] Referring first to FIGS. 1-6 , an embodiment of a self-detaching support frame system for an implement 220 , in accordance with the principles of the present invention, is depicted mounted to a vehicle 100 . In FIG. 1 , the vehicle 100 is an ATV. However, the vehicle 100 could be a UTV, ROV or any other similar small vehicles.
[0049] Now referring to FIGS. 1-6 , in the present embodiment, the self-detaching support frame system for an implement 220 comprises a vehicle plate 120 mounted on the underside of the vehicle 100 , a release control 130 in distance reach of the vehicle user, a mechanical connection 240 between the release control 130 and the vehicle plate 120 and a support frame structure for implement 300 . The in distance reach release control 130 , once disengaged, preferably renders the vehicle 100 ready to drive without the plow system and without the user having to get off the vehicle 100 .
[0050] In the present embodiment, the self-detaching support frame system for an implement 220 comprises a support frame structure for implement 300 releasably mounted to a mounting rod 116 located on the front side 118 of the frame of the vehicle 100 and a releasable attachment mechanism 320 located on a vehicle plate mounted to the underside of the vehicle. The mounting rod 116 can be either mounted to the underside of the frame 112 or integral therewith.
[0051] The system preferably has a pull cable with a handle located near the vehicle 100 steering, which is connected to the vehicle plate latching system 170 . As it will be best understood below, the connection between the support frame 300 and the frame 112 allows the implement 220 mounted to the support frame 300 to self-detach upon the actuation of a release control 130 by the user (see FIG. 2 ).
[0052] In other embodiments, the support frame 300 could be mounted to the underside of the vehicle 100 via different attachment mechanisms. However, these other attachment mechanisms must still allow the support frame 300 to pivot with respect to the frame 112 of the vehicle 100 . One of such other attachment mechanism is the use of a clevis pin. The clevis pin in another embodiment preferably acts as the pivot from which the frame may pivot with regard to the frame of the vehicle. In such an embodiment where the self-detach mechanism is combined with a clevis pin, the mechanical connection between the release control and the release mechanism could be via the clevis pin. As such, upon actuation of the release control, the clevis pin or pins would be removed, thus releasing the support frame.
Support Frame
[0053] As seen generally in the figures and more particularly in FIGS. 6-10 , the support frame 300 comprises the frame 340 and attachment means 315 for supporting the implement. The frame 340 generally extends longitudinally and comprises a front or forward end portion 342 and a rear or rearward end portion 344 . In the present embodiment, the front portion 342 is substantially H-shaped and comprises two longitudinal members 350 and 352 reinforced by a middle support member 354 . The front portion 342 comprises a first end 336 for mounting the implement 220 and a second end 338 pivotally connected to the rear portion 344 . The front portion 342 further comprises a winch hook attachment system 370 .
[0054] Referring to FIGS. 6-10 and particularly to FIG. 6 , the forward end portion 342 of the support frame 300 , and of the members 350 and 352 , are hingedly connected to the rear end portion 344 as to permit the implement 220 to pivot with respect to the vehicle 100 . The rear portion comprises front brackets 362 for mounting the support frame 300 to the vehicle 100 , a D-shape body 382 comprising right and left side arms 368 for pivotally connecting the rear portion 344 to the front portion 342 and a rear latch hook 388 for securing the support frame 300 to the vehicle 100 . The rear portion 344 further comprises a reinforcing arm 390 abutting on the right and left side arms 368 . The reinforcing arm 390 , also referred to as the middle arm 390 comprises a lever arm 364 mounted thereto. The lever arm 364 is used to pull the rod 394 actuating winch hook attachment system 370 in a closed position, securing the winch hook 160 to the support frame 300 upon mounting of the support frame 300 to the vehicle 100 . The movement of the lever arm 364 is initiated when the lever arm 364 is pressed against the skid plate (not shown) of the vehicle 100 when mounting the support frame 300 to the vehicle 100 . The middle arm 390 also comprises a finger 366 connected to an elongated member 394 operatively mounted to the winch hook attachment system 370 release mechanism.
[0055] Referring back to FIGS. 6-10 , winch hook attachment system 370 comprises a winch cable supporting member 374 connected to and extending between the members 350 and 352 . In the present embodiment, the winch cable supporting member 374 has a generally inverted ‘U’ shape and a rotated lock plate 372 adjacent thereto for retaining the winch hook 160 . The winch cable (not shown) and winch hook 160 referred to herein are the winch and winch hook 160 of the vehicle 100 . The rotated lock plate 372 is preferably operatively mounted to the winch cable supporting member 374 via a pair of supporting members 376 . Although preferred, any other suitable means of releasably securing the winch hook to the winch hook attachment system 370 would be suitable provided the winch hook 160 is easily releasable. The rotated lock plate 372 is also operatively connected to a spring loaded end 393 of the elongated member 394 for interlinking the rear portion 344 and winch hook attachment system 370 . Accordingly, though not shown, the position of the winch cable supporting member 374 could be adjustable in order to accommodate different configurations of winch positions and mounting plate positions.
[0056] As it will also be best understood below, having the rotated lock plate 372 adjacent to the winch cable supporting member 374 allows the retention of the winch hook 160 during use of the self-detaching support frame system for an implement 200 . The rotated lock plate 372 also allows the release of the winch hook 160 upon actuation of the release control 130 which provides significant benefits such as making the self-detaching mechanism complete and not requiring the user to get off the vehicle 100 even after detaching off the support frame 300 from the vehicle plate 120 .
[0057] According to one embodiment of the present invention, now referring to FIGS. 6-10 the right and left side arms 368 comprise indentations 367 for receiving the side walls of stoppers 365 installed on the front portion 342 of the support frame 300 . The stoppers 365 may be installed at various positions to allow adjustment of the height of the front brackets 362 when the support frame 300 rests on the ground. The adjustment of the stoppers 365 thus modulates the height of the support frame 300 as a function of the height of the vehicle 100 . As such, the stoppers 365 are positioned to ensure that the brackets 362 are at least as high as the front mounting rod 116 to ensure proper mounting of the support frame 300 to the vehicle 100 .
Locking System
[0058] As seen generally in the figures and more particularly in FIGS. 5 and 6 , the locking system comprises front and rear vehicle attachment 396 , 398 and a locking mechanism 170 . The rearward end portion 344 of the frame 300 comprises the rear vehicle attachment 396 configured to be releasably engaged to a mounting plate (also referred to as vehicle plate) 120 (see FIG. 5 ) secured to the underside of the vehicle 100 .
[0059] In the present embodiment, the rear vehicle attachment 396 comprises a latch hook 388 operatively connected to the rearward end portion 344 . The front vehicle attachment 398 comprises a pair of front hooks 362 which are respectively mounted to a matching rod 116 installed on the vehicle 100 or integrated in the frame of the vehicle 100 . The locking mechanism 170 , generally located on the mounting plate 120 comprises a spring-loaded retaining member 146 actively locking the latch hook 388 . The spring loaded locking mechanism 170 comprises a retaining member 146 operatively biased in an operative position, a position in which the retaining member 146 would retain the latch hook 388 to secure the front and rear vehicle attachments 396 , 398 of support frame 300 to the vehicle 100 . In the present embodiment, the operational bias is applied to the retaining member 146 by a resilient member 148 operatively connected to the retaining member 146 and to the vehicle plate 120 via a plate support member 150 .
[0060] The main use of the latch hook 388 , in cooperation with the front hooks 362 , is to securely attach the rear portion 344 of the support frame 300 to the mounting plate 120 connected to the vehicle 100 , and more particularly to the front mounting rod 116 and spring loaded locking mechanism 170 also referred to as a latch mechanism 170 (see FIG. 5 ).
Vehicle Plate Latching System
[0061] Referring now to FIGS. 3-5 , in the present embodiment, the vehicle plate 120 comprises attachment means, typically apertures (not shown), for mounting the vehicle plate 120 to the vehicle 100 . According to one embodiment, the vehicle plate could be fastened to the underside of the vehicle using fasteners 154 . According to another embodiment, the vehicle plate could be integrated to the vehicle frame 112 . The vehicle plate 120 generally comprises a latch mechanism 170 for receiving the latch hook 388 of the rear portion 344 of the support frame 300 . The latch mechanism 170 comprises a retaining member 146 configured to insert in the latch hook 388 thus releasably securing the support frame 300 to the vehicle 100 . The retaining member or rod 146 is controlled by a retention control 130 . From the retaining member 146 , a spring 148 extends which is preferably configured to maintain the retaining member 146 in a locked position. The retaining member 146 is preferably mounted on side support arms 142 , 152 pivotally connected to attachment plates 140 , 144 mounted to the vehicle plate 120 . As such, the vehicle plate 120 comprises a plate opening 174 for receiving the latch hook 388 . Understandably, the opening 174 is properly sized to receive the latch hook 388 . The plate opening 174 is preferably larger than the latch hook 388 to allow for ease of securing the latch hook 388 to the retaining member 146 . At least one of the side support arms 142 , 152 is biased in the operative position by a resilient member, preferably a spring, 148 operatively mounted to the support plate, preferably via a plate support member 150 . Understandably, any suitable biasing mechanism for biasing the retaining member 146 in its operative position, the position where the latch hook 388 is retained and where the support frame is mounted to the vehicle, would allow the latch mechanism 170 to retain the latch hook 388 .
[0062] As best shown in FIGS. 3 and 4 , the recess 198 cooperates with the similarly curved surface of the retaining member 146 of the vehicle plate 120 to form a secure attachment when in the locked position.
[0063] In accordance with the principles of the present invention, now referring to FIGS. 3-6 , the rear vehicle attachment 396 work in cooperation with the balancing effect of the hooks 362 and front supporting rod 116 . More particularly upon advancing of the vehicle 100 , the vehicle skid plate (not shown) interacts with the lever arm 364 to actuate the winch hook attachment system 370 securing the winch hook 160 to the support frame 300 . The vehicle front supporting rod 116 is then received in the support frame front hooks 362 , which upon further advancement of the vehicle 100 directs the latch hook 388 in the opening 174 to engage the retaining member 146 and secure the support frame 300 to the vehicle 100 .
Release Mechanism
[0064] In embodiment shown in FIGS. 4 and 5 , the self-detaching support frame system for an implement 300 comprises a release control 130 for releasing the latch hook 388 from the vehicle plate 120 . The release mechanism also referred as latch mechanism 170 releases the latch hook 388 by actuation of the release control 130 mechanically connected to the vehicle plate through a mechanical connection 240 . The mechanical connection 240 pulls the retaining member 146 in its inoperative position, the position where the latch hook 388 is released or unrestrained by the retaining member 146 . As such, the actuation of the release control rotates the lock system (the latch 170 ) and releases the hook 388 of the latching system 170 . The latching mechanism holds to the mount plate by the hook 388 and by two brackets 362 (parts are attached on the ATV). By releasing the hook 388 , the support frame 300 falls on the ground by gravity, then releasing the front brackets 362 in the same movement. The system is now completely disengaged. Once disengaged, the tube or lever arm 364 retained under the vehicle moves. As such, upon falling of the latch system on the ground, a lever arm 364 is released thus disengaging a rod 394 operatively connected to a rotated lock plate 372 previously engaging a winch hook 160 . As such, movement of the rod 394 pull the rotated plate or pivot link 372 and eject the winch hook 160 . As a result, the winch hook 160 is now completely disengaged. The system is totally free to be move and the vehicle ready to ride without the plow system 300 .
Description of the Method
[0065] In the present embodiment, the method of mounting the plow system comprises the steps of: moving the vehicle forward while substantially aligned with the support frame 300 , to engage the front brackets 362 with the mounting rod 116 located on the front side 118 of the frame of the vehicle 100 , the vehicle moving forward until the latch hook 388 is securely mounted to the retaining member 146 . The winch hook 160 is then manually attached to the hook receiving portion of the support frame 300 .
[0066] Conversely, the method for self-detaching the self-detach support frame system for an implement comprises the step of:
a. pulling a handle on the vehicle to activate the release mechanism.
[0068] Understandably, prior to disengaging the support frame 300 from the vehicle 100 , the implement 220 should be lowered and in contact with the ground thus releasing any tension in the winch cable (not shown).
[0069] While illustrative and presently preferred embodiments of the invention have been described in detail hereinabove, it is to be understood that the inventive concepts may be otherwise variously embodied and employed and that the appended claims are intended to be construed to include such variations except insofar as limited by the prior art.
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A self-detaching support frame system for an implement designed to self-detach from a vehicle by actuation of a release handle located within arm reach of the driver is disclosed. The self-detaching support frame system for an implement allow the user to at least partially, preferably entirely, disengages the support frame assembly by activating a control, preferably a single control such as a handle located near the vehicle steering.
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[0001] This application is a continuing application of U.S. patent application Ser. No. 13/743,832, filed Jan. 17, 2013, which claims benefit of U.S. Provisional Application No. 61/610,643, filed Mar. 14, 2012. The applications listed above are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to oilfield production equipment and, more particulary, to a coiled tubing injector apparatus for inserting and removing coiled tubing from a well.
[0004] 2. Description of the Prior Related Art
[0005] Coiled tubing has seen a marked increase in use through the oil and gas industry since its inception. Coiled tubing operations have grown from the limited applications thought feasible in the early 1950's and are now considered a viable solution in multiple operations, including subsea wells, snubbing, fracturing, and even coiled tubing applications. Coiled tubing operations have grown more popular as a result of their rapid mobilization times and generally smaller footprint with respect to traditional well operations. Furthermore, they require less site crew and personnel, in addition to significant cost savings. As applications for coiled tubing have become more numerous, the strength and size of the coiled tubing has increased in options as well. Coiled tubing was generally less than 1 in. in diameter in the beginning, while it can be found now in sizes up to 4 in. in diameter.
[0006] Coiled tubing rigs primarily consist of an injector head for inserting and removing the coiled tubing from the wellhead, a spool reel for storing and transporting the coiled tubing, a power pack to power the injector head, and a control room to operate the machinery. The injector head is responsible for gripping the coiled tubing, usually through a series of grippers powered by a chain design, which provide enough force to move the tubing when necessary, without impeding the structural stability of the tubing. Although the other components are required to functionally operate the system, the injector head is the integral part of a coiled tubing rig.
[0007] The injector head comprises components that are subject to considerable wear and therefore require frequent maintenance.
[0008] The following patents discuss background art related to the above discussed subject matter:
[0009] U.S. Pat. No. 8,191,620, issued Jun. 5, 2012, to Maschek, Jr. et al. discloses a gripper assembly for use within a coiled tubing injector unit. The gripper assembly comprises a carrier for securing the gripper to the chain drive mechanism of the coiled tubing injector unit and a gripping shoe carried by the carrier. The configuration of the gripper assembly permits removal and replacement of the gripping shoe.
[0010] U.S. Pat. No. 6,910,530, issued Jun. 28, 2005, to Austbo et al. discloses a coiled tubing injector apparatus for use in inserting coiled tubing into a well, temporarily suspending the coiled tubing, and removing the coiled tubing from the well is described. The apparatus includes a base with a pair of spaced-apart carriages extending upwardly therefrom. The base is part of a frame positioned above a wellhead. The carriages each have a gripper chain drive system rotatably mounted thereon and movable therewith. An actuation and linkage system allows the carriages to move toward and away from one another in a lateral or transverse direction with respect to the superstructure and the base. Thus, the gripper chain systems comprise gripper chains that can be engaged or disengaged from the coiled tubing extending through the apparatus. A wetting fluid basin is positioned below the gripper chains, and support guides engage the coiled tubing below the gripper chains to prevent buckling of the coiled tubing. The gripper chain drive system includes idler sprockets mounted on an idler sprocket shaft. The position of first and second ends of the idler sprocket shaft are monitored, and may be adjusted to maintain a parallel relationship with a drive sprocket shaft on which are mounted drive sprockets supporting the gripper chain.
[0011] U.S. Pat. No. 6,347,664, issued Feb. 19, 2002, to Perio, Jr. discloses a coiled tubing injector head comprised of a plurality of endless chains, each of which are at least three links wide, that are positioned around a plurality of sprockets and/or idler rollers within the injector head. A plurality of gripper assemblies are positioned around the middle links of the endless chains. A bearing skate is positioned within the injector head, the bearing skate being comprised of a plurality of bearings in a staggered configuration, the bearings being adapted for rolling engagement with a portion of the gripper assemblies. An injector head is comprised of a plurality of halves, each of the halves being coupled to a positioning bar, the positioning bar having a plurality of openings formed therein, the openings adapted for use in varying the distance between the first and second halves.
[0012] U.S. Pat. No. 6,173,769, issued Jan. 16, 2001, to Goode discloses a gripping element of a coiled tubing injector has a carrier and a removable gripping shoe mounted to the carrier. The removable shoe slides onto slots formed on the carrier and is floated on the carrier by inserting an elastomeric pad sandwiched between the carrier and shoe. A manually depressible spring along ones side of the carrier prevents the shoe from sliding out of the slots during operation of the injector.
[0013] U.S. Pat. No. 5,918,671, issued Jul. 6, 1999, to Bridges, et al. discloses an injector for flexible tubing has endless drive conveyors on opposite sides of a pathway for the tubing. The drive conveyors include gripper blocks that work in opposing pairs along the tubing pathway. The pairs of gripper blocks are clamped to the tubing and moved along the tubing pathway to either inject the tubing into a well or withdraw the tubing from a well. The gripper blocks are clamped to the tubing by way of skates, which work in opposing pairs. The skates have rollers, with rollers contacting the gripper blocks. Each roller has two ends, which ends are received by bearings inside of mounts on the respective skate.
[0014] The above discussed prior art does not address solutions provided by the present invention, which teaches a system that is useful for increasing reliability and reducing the frequency and time required for repairing and/or maintaining injection heads. Consequently, those skilled in the art will appreciate the present invention that addresses the above described and other problems.
SUMMARY OF THE INVENTION
[0015] A first possible object of the present invention is to provide a more reliable coiled tubing injector system for deep wells and high snubbing forces.
[0016] One possible object of the present invention is to provide an improved injector head assembly for a coiled tubing system.
[0017] Another possible object of the present invention is to provide a coiled tubing injector requiring reduced maintenance costs and down time during operation.
[0018] Yet another possible object of the present invention is to provide an improved chain on chain skate design for use with coiled tubing operations, including snubbing and workover operations.
[0019] These objects, as well as other objects, advantages, and features of the present invention will become clear from the description and figures to be discussed hereinafter. It is understood that the objects listed above are not all inclusive and are intended to aid in understanding the present invention, not to limit the scope of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] A more complete understanding of the invention and many of the advantages thereto will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in conjunction with the accompanying drawings, wherein:
[0021] FIG. 1 is an exploded perspective view of a portion of a coiled tubing injector apparatus showing a skate plate in accord with one possible embodiment of the present invention.
[0022] FIG. 2 is a top elevational view of a part of a coiled tubing injector apparatus showing a chain drive and skate plate in accord with one possible embodiment of the present invention.
[0023] FIG. 3 is an elevational view, in section, of a coiled tubing injector apparatus in accord with one possible embodiment of the present invention.
[0024] FIG. 4 is a side elevational view of a coiled tubing injector, partially in section, of section 10 of FIG. 3 , in accord with one possible embodiment of the invention;
[0025] FIG. 5 is a perspective view of a coiled tubing injector apparatus in accord with one possible embodiment of the present invention
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0026] Referring now to the drawings, and more particularly to FIG. 1 , there is shown an exploded view of internal assembly 1 , which is a portion of coiled tubing injector apparatus 100 , shown assembled in FIG. 5 , in accord with one possible embodiment of the present invention. In one embodiment, existing coiled tubing injector units may be modified or retrofitted in accord with the present invention for longer and more reliable operation. In one embodiment, coiled tubing injector 100 utilizes a chain on chain skate design in which manufactured rollers may be connected to chain links, and is designed for various pulling and snubbing applications. Coiled tubing injector 100 can be used for conveying various sizes of coiled tubing into and out of wells for a variety of other oil and gas operations.
[0027] Internal assembly 1 utilizes center plate 10 , which comprises a plurality of circular orifices in which cylinder retaining rings 35 retain hydraulic cylinders 40 , in the process of compressing grippers that are used to grip the pipe. Skate plate 20 is located on a first side of center plate 10 and may be mounted to center plate 10 by support posts 55 . Skate plate 20 may, in one embodiment, be rectangular shaped with elongated sides containing cutout portions that correspond with cylinder retaining rings 35 of center plate 10 so as not to interfere with the operation of hydraulic cylinders 40 . Skate plate 20 further comprises channel 90 sized to receive elongate wear plate 15 . In this embodiment, it is not necessary that the entire skate plate be comprised of hardened material designed for longer wear in response to friction. Moreover, wear to skate plate is limited for less expensive repairs. Wear plate 15 is clamped to skate plate 20 by a plurality of clamp plates 30 , which fit within recesses 95 formed along channel 90 of skate plate 20 . Wear plate 15 may be thicker than channel 90 and, if desired, extend outwardly from skate plate 20 . Recesses 95 and clamp plates 30 may be shaped differently than shown and could be elongate. Clamp plates 30 further each comprise at least one tongue 32 which fit within corresponding slots 22 of wear plate 15 . Tongue 32 may be rectangular, round, or the like. In another embodiment, clamp plates 30 may be machined onto wear plate 15 with tongue 32 for insertion into corresponding recess 95 on skate plate 20 .
[0028] Cap screws 75 further secure clamp plates 30 to skate plate 20 , but do not bear any of the lateral forces created through operation of coiled tubing injector 100 . The lateral forces on clamp plates 30 are supported by the walls of recesses 95 and the walls of slots 22 , therefore cap screws 75 need only fasten clamp plates 30 to skate plate 20 , a force which is not resisted during operation.
[0029] Tensioner assembly 60 is located on an opposite side of center plate 10 with respect to skate plate 20 and secured to center plate 10 by bolts 80 and socket head screw 65 . Other types of fasteners may be utilized for this operation. Tensioner assembly 60 supports a plurality of injector springs 85 corresponding with hydraulic cylinders 40 respectively. Injector springs 85 expand and compress in response to the force exerted by hydraulic cylinders 40 during operation. Cylinder spacers 45 are placed between hydraulic cylinders 40 and center plate 10 for alignment purposes and to provide extended operation to account for size differences in coiled tubing. Tensioner assembly 60 comprises at least two prong sets which are for connecting with at least two of side plates 25 for securing tensioner assembly 60 with skate plate 20 . Side plates 25 interlock with tensioner assembly 60 and then are secured to skate plate 20 by small cap screws 70 . In other embodiments, alternative means of attaching side plates 25 with skate plate 20 may be used including pins, clamps, and the like. Side plates 25 mate with wear plate 15 and guide chain assembly 50 around skate plate 20 and wear plate 15 . In one embodiment, wear plate 15 comprises track 17 upon which chain assembly 50 revolves along during operation of coiled tubing injector apparatus 100 , to be discussed in more detail hereinafter.
[0030] Turning now to FIG. 2 , a top view of internal assembly 1 , with respect to the view of FIG. 1 , is depicted in accord with one possible embodiment of the present invention. Chain assembly 50 comprises a plurality of rollers interconnected by a series of chain links rotating along track 17 of wear plate 15 (See FIG. 1 ). However, the present invention is not limited to the current depiction of chain assembly 50 and may include alternative configurations in accord with the present invention. In another embodiment, chain assembly 50 may further comprise a skate cylinder traction beam and an alternative drive chain tension system, i.e. chain sprockets, planetary gears, hydraulic motors and/or controls, and the like may be used to drive chain assembly 50 . Skate plate 20 is fashioned to fasten with center plate 10 so that it does not interfere with hydraulic cylinders 40 or cylinder retaining rings 35 during normal operation of coiled tubing injector apparatus 100 .
[0031] In FIG. 3 , a front sectional view of coiled tubing injector 100 is depicted in accord with a preferred embodiment of the present invention. Coiled tubing injector 100 comprises first injector component 170 and second injector component 175 housed within frame 110 . First injector component 170 and second injector component 175 may be identical or substantially identical in structure with regards to internal assembly 1 as described in conjunction with FIG. 1 and oppose each other with respect to central pathway 145 . In operation, first injector component 170 and second injector component 175 are used in conjunction to insert and/or remove coiled tubing 140 from central pathway 145 using grippers 120 , 122 . Grippers 120 , 122 interconnect with gripper bands 115 , 117 respectively, with gripper band 115 revolving around gears or sprocket pair 130 , 132 , and gripper band 117 revolving around gears or sprocket pair 125 , 127 respectively. In an alternative embodiment, gripper bands 155 , 177 may be fashioned with grippers 120 , 122 as a single, unified component.
[0032] Grippers 120 , 122 apply pressure to coiled tubing 145 after being energized by hydraulic cylinders 40 being operated either manually or automatically, typically at a control room or at controls on frame 110 . Hydraulic cylinders 40 are operable to expand and contract, thereby changing the pressure grippers 120 , 122 apply onto coiled tubing 145 , as well as converging first injector component 170 and second injector component 175 towards each other. Grippers 120 , 122 may comprise a semicircular channel which provides a better contact area with coiled tubing 140 , although various shapes of grippers 120 , 122 may be employed consistent with the teachings of the present invention. In some embodiments, grippers 120 , 122 may, if desired, comprise a substantially resilient material to depress for engaging with smaller diameter tubing or expand to handle larger diameter tubing.
[0033] In FIG. 4 , an enlarged front view of Section 11 of coiled tubing injector 100 as shown in FIG. 3 is depicted in accord with one possible embodiment of the present invention. Center plate 10 , skate plate 20 , and wear plate 15 are arranged as described in detail when discussing FIG. 1 . Chain assembly 50 makes contact with gripper assembly 120 providing a drive force to move gripper assembly during operation of coiled tubing injector apparatus 100 . In this embodiment, gripper assembly 120 further comprises carriers 115 for direct contact with chain assembly 50 . This arrangement prevents any undue wear upon skate plate 20 and provides for quicker and easy replacement of wear plate 15 instead of the more expensive skate plate 20 , which is also harder to replace.
[0034] Referring now to FIG. 5 , coiled tubing injector apparatus 100 is shown with adjustable base 165 for adjusting to various size wellheads. Adjustable base 165 is supported by posts 150 , 155 , 160 while the components of coiled tubing injector apparatus 100 as described hereinbefore are contained within frame 110 .
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A coiled tubing injector apparatus for inserting and/or removing coiled tubing from a well head comprising a first injector column and a second injector column forming a central pathway within a frame. The first and second injector columns each comprise an inner and outer band, the outer band containing a plurality of rolling elements for engaging the coiled tubing and the inner band creating drive force to energize the outer band. The inner band further comprises a wear plate designed to sustain the majority of wear for less costly maintenance and repair of injection heads.
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FIELD
[0001] The present invention relates to building products and more particularly, to windows and window frames.
BACKGROUND
[0002] Some windows utilize vent surrounds and frames made from metal, e.g., aluminum alloy. Metal windows are in use in residential and commercial buildings, e.g., in storefronts and in curtain walls used on the façade of high-rise buildings. The energy transfer characteristics of windows are an important factor in the overall energy efficiency of a building and there is a continual search for building features and methods of construction that improve energy efficiency. Improved and/or alternative structures and methods for controlling the heat transfer characteristics of windows remain desirable.
SUMMARY
[0003] The disclosed subject matter relates to an access structure for an opening through a building envelope, including a frame structure coupled to the building, framing the opening and a spanning element spanning the frame structure, at least partially covering the opening. The spanning element has at least one panel and a surround embracing the periphery of the panel, the frame structure having a parallel portion extending parallel to the spanning element in a spanning direction and a perpendicular portion extending perpendicular to the spanning element relative to a spanning direction. At least one of the perpendicular portion of the frame structure and the surround being a composite of a metal portion and a non-metal portion, the non-metal portion having a lower thermal conductivity than the metal portion, the non-metal portion being exposed to a first environment on a first side of the building envelope and the metal portion being proximate a second environment on a second side of the building envelope.
[0004] In one approach, the access structure is a window providing access to light and the at least one panel is a glazing panel.
[0005] In one approach, the window has an opened and a closed position.
[0006] In one approach, the surround includes a box portion made from metal and the perpendicular portion includes a non-metallic ledge that attaches to the box portion.
[0007] In one approach, the box portion has an elongated channel and the non-metallic ledge has an L-shaped cross-sectional shape, the ledge having an insertion leg capable of being received in the elongated channel and forming a portion of the L-shape.
[0008] In one approach, the ledge has at least one finger extending therefrom in a direction opposite to the insertion leg for reducing airflow proximate the ledge.
[0009] In one approach, the insertion leg has a plurality of burrs having a directionality that promotes insertion of the insertion leg into the channel and opposes withdrawal therefrom.
[0010] In one approach, the ledge has a front-to-back slope capable of promoting water runoff.
[0011] In one approach, the ledge has a plateau at the base of the insertion leg that mates with a mating recess communicating with the channel to establish a given relative orientation.
[0012] In one approach, the perpendicular portion of the frame has a connection bead that is capable of snap-fitting to an adaptor, the adaptor being non-metallic.
[0013] In one approach, the adaptor, when in place on the connection bead is proximate at least one seal extending from the surround when the spanning element at least partially covers the opening.
[0014] In one approach, the connection bead has a bifurcated arrowhead cross-sectional shape having a pair of opposed lead-in surfaces that interact with corresponding sloped surfaces on opposed arms of the adaptor, which define a hollow there between having a shape complementary to the connection bead, the arms resiliently displacing when pushed against the lead-in surfaces and snapping to a closed position when pushed beyond the lead-in surfaces.
[0015] In one approach, the arrowhead cross-sectional shape has a recess at the tip to receive sealant.
[0016] In one approach, the window is fixed.
[0017] In one approach, the access structure is a door.
[0018] In one approach, the at least one of the composite frame structure and surround are composite via an interlocking interface, such that a plurality of interchangeable parts may be attached at the interface giving rise to modularity supporting use of the access structure for a plurality of different applications.
[0019] In one approach, both the frame structure and the surround are composite.
[0020] In one approach, the metal portion is formed from an aluminum alloy and the non-metallic portion is formed from a polymer.
[0021] In one approach, the first environment is the out-of-doors and the second environment is interior to the building envelope.
[0022] In one approach, both the frame structure and the surround are formed from a plurality of elongated elements attached together at the ends thereof.
[0023] In one approach, the adaptor has a raceway distal to the opposed arms for receiving a trim cover.
[0024] In one approach, a method for assembling a window for an opening through a building envelope, includes obtaining a plurality of elongated frame elements made from aluminum alloy extrusions and attaching them together at the ends thereof to form a frame structure; obtaining a plurality of elongated box sections made from aluminum alloy extrusions and having an outward facing channel; attaching the plurality of elongated box sections together at the ends thereof to form a first portion of a window surround; obtaining a glazing panel; obtaining a plurality of L-shaped ledge portions made from polymer and having insertion legs; inserting the insertion legs of the ledge portions into corresponding channels of the box sections to form a surround capable of embracing the periphery of the glazing panel and inserting the glazing panel into the surround to form a vent assembly; attaching the frame structure to the building, framing the opening; and attaching the vent assembly to the frame structure.
[0025] In one approach, a method for assembling a window for an opening through a building envelope, includes obtaining a plurality of elongated frame elements made from aluminum alloy extrusions and having an attachment bead disposed on a surface thereof; attaching the elongated frame elements together at the ends thereof to form a frame structure; obtaining a plurality of polymer adaptors having a coupling head; attaching the adaptors to corresponding ones of the frame elements by snap-fitting the coupling head over the attachment bead to form a frame assembly; obtaining a plurality of elongated vent surround sections made from aluminum alloy extrusions; attaching the plurality of elongated vent surround sections together at the ends thereof to form a vent surround; obtaining a glazing panel; inserting the glazing panel into the vent surround to form a vent assembly; attaching the frame structure to the building, framing the opening; and attaching the vent assembly to the frame structure.
[0026] In one approach, a vent surround, includes a box portion made from a plurality of metal sub-sections connected at the ends thereof and a non-metallic ledge with a plurality of sub-sections that attach to the sub-sections of the box portion, the sub-sections of the box portion each having an elongated channel and each of the sub-sections of the non-metallic ledge having an L-shaped cross-sectional shape with an insertion leg capable of being received in the elongated channel, the non-metallic ledge having a lower thermal conductivity than the metal box portion, the non-metallic ledge being proximate a first environment on a first side of the building envelope and the metal box portion being proximate a second environment on a second side of the building envelope.
[0027] In one approach, a frame structure couplable to a building to frame an opening through the building envelope includes a metallic base portion that couples to the building; a metallic extension portion extending perpendicular to the building envelope proximate the opening; a non-metallic adaptor capable of being coupled to the extension portion, the non-metallic adaptor having a lower thermal conductivity and position proximate a first environment on an exterior of the building envelope and the metallic base and extension portions having a higher thermal conductivity and positioned proximate a second environment on the interior of the building envelope.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] For a more complete understanding of the present disclosure, reference is made to the following detailed description of exemplary embodiments considered in conjunction with the accompanying drawings.
[0029] FIG. 1 is elevational view of a fragment of a window system.
[0030] FIG. 2 is a cross-sectional view of a sill of the window system of FIG. 1 taken along section line 2 - 2 and looking in the direction of the arrows.
[0031] FIG. 3 is a cross-section like FIG. 2 , but of a window system in accordance with an embodiment of the present disclosure.
[0032] FIG. 4 is a perspective view of a ledge portion of a vent surround.
[0033] FIG. 5 is a side view of the ledge portion of FIG. 4 and alternative ledge portions.
[0034] FIG. 6 is a cross-section like FIG. 2 , but of a window system in accordance with another embodiment of the present disclosure.
[0035] FIG. 7 is an enlarged portion of FIG. 3 .
[0036] FIG. 8 is a perspective view of a frame adaptor in accordance with another embodiment of the present disclosure.
[0037] FIG. 9 is a series of cross-sectional views of frame adaptors in accordance with embodiments of the present disclosure.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0038] FIG. 1 shows a window system 10 , e.g., for a façade of a commercial building, such as a multi-story high rise building. Using conventional terminology, each window unit 12 of the window system 10 has a head 14 , a sill 16 and jambs 18 . The jambs 18 between adjacent window units 12 may be designated mullions. Some or all of the window units 12 may be hinged to be opened and closed for ventilation. For applications where there is no protective roof or awning overhang, the window unit would typically open at the sill 16 . In other applications, the window units 12 may open at the head 14 or at the jambs 18 .
[0039] FIG. 2 is a cross-sectional view of a window unit 12 of FIG. 1 at the sill 16 in accordance with the prior art. A compound structural beam 20 having an interior portion 20 I and an exterior portion 20 E separated by a thermal break 22 and bridged by a plate 24 is a component of the building structure, e.g., a storefront. The beam 20 is attached to the superstructure of the building and serves as the mounting surface for a window frame element 26 , which may be fastened to the beam 20 by screws 28 or other fasteners extending through a peripheral portion 26 P. A plurality of attached frame elements 26 , e.g., four (at the head, sill and jambs) may be used to define a rectangular frame for the window unit 12 . The frame elements 26 may be L shape in cross section, a limiting portion 26 L limiting the motion of a vent 30 in the direction of the interior I. The vent 30 is the portion of the window unit 12 that typically contains an optically transparent/translucent glazing unit 32 , e.g., one or more (e.g., double or triple glazed windows) glass or plastic panels 32 A, 32 B separated by an intermediate spacer 34 , defining a space 36 , which may contain air, an inert gas or radiation/convection barrier films. A peripheral setting block 38 is attached to the edge of the panels 32 A, 32 B to protect glazing unit 32 from being damaged by direct contact with vent surround ledge portion 40 L. The vent surround 40 may be made from a plurality of extrusions that are coupled together to embrace the glazing unit 32 at all sides thereof, e.g., four sides for rectangular glazing panels 32 A, 32 B. For example, the vent surround 40 may be formed from four aluminum alloy extrusions that are miter cut at the ends thereof and then assembled, by welding, staking and/or with brackets and/or fasteners. The vent surround 40 may have a boxed portion 40 B to impart structural rigidity and an integrally formed ledge portion 40 L that surrounds the glazing unit 32 . The glazing unit 32 may be secured to the vent surround 40 by the use of a silicone sealant 42 A, 42 B.
[0040] A first seal 44 , which may be formed from an elastomer is attached to the vent surround 40 and reduces weather infiltration between the window frame elements 26 and the vent surround 40 . A second seal 45 attached either to the frame elements 26 or the vent surround 40 (but not both) may aid in preventing weather intrusion into the interior I. The seals 44 and 45 allow the vent surround 40 to be moved relative to the frame elements 26 , such that the window unit 12 may be opened and closed, while decreasing weather (air and water) infiltration.
[0041] An aspect of the present disclosure is the recognition that the vent surround 40 is a conduit for heat transfer from the environment E exterior to the window unit 12 to an environment I interior to the window unit 12 (inside a building).
[0042] FIG. 3 is a cross-section of a window unit 112 in the sill 116 area like the window unit 12 of FIG.2 , but in accordance with an embodiment of the present disclosure. The window unit 112 features a composite vent surround 140 featuring a boxed portion 146 made, e.g., from aluminum alloy to impart structural rigidity, and an independently formed ledge portion 148 made, e.g., from a polymer, such as rigid PVC or glass reinforced nylon, having a lower heat conductivity than aluminum. Ledge portion 148 has an insertion leg 150 which may have a plurality of engagement ribs/barbs 152 (See FIGS. 4 and 5 ) that are disposed at an angle B relative to the insertion leg 150 , the angle facilitating insertion into and resisting removal from a channel 146 C in the box section 146 . The insertion leg 150 may be retained in the slot 146 C by friction fit, the action of the ribs/barbs 152 and/or an adhesive. As in the window unit 12 described above, a plurality, e.g., four, vent surrounds 140 with associated box portions 146 and ledge portion 148 may be assembled together to surround and retain the glazing unit 130 . The aluminum alloy boxed portions 146 may be connected by welding, brackets and fasteners, etc., thereby forming a rigid framework for mounting the ledge portions 148 , which may also be attached together, e.g., by screws or rivets. The glazing unit 130 may be adhered to the box section 146 by a sealant 142 A and the window unit may also feature a a peripheral setting block 142 B (shown in dashed lines tofor eas of illustration).
[0043] FIGS. 3 , 4 and 5 shows that the ledge portion 148 may be provided with a self-centering plateau 154 that matingly engages corresponding surfaces of the channel 146 C to automatically establish a pre-selected relative orientation between the ledge portion 148 and the box portion 146 . A hinge hardware locating nub 155 provides a reference surface for uniform and precise hinge hardware positioning when hinges are used and acts in conjunction with insertion stop 157 to limit insertion and stabilize the ledge portion 148 relative to the box portion 146 . The ledge portion 148 has a plurality of thermal barrier fingers 159 made, e.g., from high durometer, soft PVC or other flexible materials, that may bear against or pass close to an opposing surface to reduce the passage of air and consequent transfer of energy. As explained more fully below, the window unit 112 embodiment shown in FIG. 3 features a composite frame element 126 with a bifurcated coupling bead or barb 168 upon which a frame extension/adaptor 170 may be received and retained. The adaptor 170 abuts against (and displaces) the first finger 159 F to effect a weather seal. The fingers 159 may be spaced to minimize thermal conduction, as explained further below.
[0044] The ledge portion 148 , which may be considered a first ledge portion 148 , has an integrated screw port 156 for receiving screws S (one screw head shown diagrammatically in dotted lines) extending through an adjacent second ledge portion 148 to hold the adjacent second ledge portion to a first ledge portion 148 via a screw screwed through the second ledge portion and extending into the screw port 156 . For example, if a first ledge portion 148 (as depicted in FIG. 3 ) is disposed along the sill then a second ledge portion 148 disposed along the adjacent jamb may be tightly attached to the sill ledge portion 148 via a screw that extends through the jamb ledge portion 148 and into the screwport 156 of the sill ledge portion 148 . A flat offset area 158 allows the first and second ledge portions 148 to seat flush to one another and defines a ledge that prevents relative translational movement when the screw S is tightened.
[0045] An integral raceway 160 accommodates a variety of trim covers 162 or other modular parts in snap-fit relationship. The trim cover 162 covers the adjacent edge of the glazing unit 130 and also extends down to reduce weather infiltration. The box section 140 also features a raceway 164 for receiving a bead seal 166 that seals against limiting portion 126 L of window frame element 126 . The frame element 126 has a bifurcated coupling bead 168 at an end thereof for coupling to a selected adaptor 170 , as described more fully below. The adapter 170 may be selected to interact advantageously with a given window unit installation environment (to reduce heat transfer/weather infiltration) and also to accommodate different types of glazing units 130 , e.g., double and triple glazed. FIG. 4 shows that the ledge 148 may have a surface 148 S from which the fingers 159 extend with a front-to-back taper angle alpha of e.g., 1 degree. The taper angle may be used to shed water away from the window unit 112 when the ledge portion is used at the head 14 , i.e., with the fingers 159 pointed up. Alternatively, the extending portion 148 E may be molded at an angle less than 90 degrees relative to the insertion leg 150 .
[0046] FIG. 5 shows that different ledge portions 148 , 148 A, 148 B, 148 C with different dimensions and number of fingers 159 , 159 A, 159 B, 159 C may utilize the same features, e.g., insertion leg 150 , plateau 154 , hinge nub 155 and insertion stop 157 , that allow coupling the ledge portions 148 , 148 A, etc. to the same type of box portion 146 . In a similar manner, the box portion 146 may be varied in dimensions but have a consistently shaped and dimensioned channel 146 C that may couple in a consistent manner to one or more different ledge portions 148 . The consistent coupling features lead to modularity, i.e., multiple parts with variations optionally coupling to multiple parts with variations, in the same manner. Ledge portion 148 with fingers 159 (all in solid lines) is an example of a ledge portion 148 that may be suitable for use with a double glazed glazing unit 130 used in a storefront application. The dimensions of ledge portion 148 may be varied, e.g., to be suitable for use in a curtain wall application by extending the length of fingers 159 A, yielding a variant ledge portion 148 A. Ledge portion 148 B with fingers 159 B (in dashed lines) may be suitable for a triple glazed storefront window. For a curtain wall application, the fingers 159 B can be lengthened, as shown by 159 C to yield a variant ledge portion 148 C. Notwithstanding the variations in dimensions of the ledge portions 148 , 148 A, 148 B, the tooling used to process an elongated extrusion, e.g., eighteen feet in length, into assemblable portions of a given length for surrounding a given glazing unit 130 , may remain consistent. For example, a cutter (not shown) used to remove a length, e.g., 4.25 to 5.0 inches of the insertion leg 150 at either end of the horizontal lengths of the ledge portion 148 to permit mating with the vertical lengths, may be the same for each variant of the ledge portions 148 A, 148 B and 148 C. Similarly, tools for miter cutting, punching or drilling the holes for passing screws S, etc. may be standardized for a variety of ledge portions with different dimensions.
[0047] FIG. 6 is a cross-section of a window unit 112 in the sill 116 area like the window unit 12 of FIG. 3 , but with a different type of adaptor 270 . As before, the window unit 112 features a composite vent surround 140 featuring a boxed portion 146 made, e.g., from aluminum alloy to impart structural rigidity, and an independently formed ledge portion 148 made, e.g., from a polymer, such as rigid PVC or glass reinforced nylon, having a lower heat conductivity than aluminum. The composite frame element 126 has a bifurcated coupling bead or barb 168 upon which a frame extension/adaptor 270 may be received and retained. The adaptor 270 is made from a polymer, such as rigid PVC or glass reinforced nylon, having a lower heat conductivity than aluminum and abuts against (and displaces) the first finger 159 F to create a weather seal. An extension portion 270 E extends below and proximate to the ends of fingers 159 A, 159 B and trim cover 162 to further improve weather resistance. Optionally, the fingers 159 A, 159 B may contact the extension 270 E.
[0048] FIG. 7 shows the coupling bead/barb 168 with dual lead-in surfaces 168 A, 168 B that meet negatively cambered surfaces 168 C, 168 D at a cusp or point. The adaptor 170 has a coupling portion 171 having a pair of opposed arms 170 A 1 and 170 A 2 with complementary, mating surfaces, viz., sloped lead-in surfaces 170 B 1 , 170 B 2 that meet positively cambered surfaces 170 C, 170 D at a rounded point. The lead-in surfaces 168 A, 168 B and 170 B 1 , 170 B 2 facilitate inserting the barb 168 into the cavity 170 E of the coupling portion 171 , the adaptor 170 resiliently bending and then snapping back into a rest configuration when the barb 168 is fully inserted into the cavity 170 E in the engaged position. When in the engaged position, the surfaces 168 C, 168 D and mating surfaces 170 C, 170 D hinder dis-engagement and ensure a positive locking interaction with minimal rotation. Central recesses 168 F and 170 F accommodate a bead sealant (not shown) that is applied prior to assembly to aid in preventing water infiltration. Surfaces 170 B 1 , 170 B 2 closely parallel surfaces 168 G, 168 H when the adaptor 170 is coupled to the coupling bead 168 to aid in sealing the coupled adaptor 170 and coupling bead 168 .
[0049] FIG. 8 shows the adaptor 270 of FIG. 6 prior to connection to a coupling bead 168 of window frame element 126 . An extension portion 270 E extends from coupling portion 271 .
[0050] FIGS. 9A-9F show a series of frame adaptors 370 , 470 , 570 , 670 , 770 , 870 , e.g., that may be used in the context of a curtain wall window system. FIG. 9F shows a perspective view of the frame adaptor 870 . The adaptors 370 , 470 , 570 , 670 , 770 , 870 are varied in dimensions and have various extensions, e.g., 370 E, 470 E, 570 E, 670 E, 770 E, 870 E with different dimensions and features, e.g., the positioning of the screw ports 356 - 856 and wings 380 , 480 , 680 , 780 , but have a common configuration with respect to coupling portion 371 , 471 , 571 , etc., which have coupling arms, e.g., 370 A 1 , 370 A 2 , 470 A 1 , 470 A 2 , allowing the different adaptors to be attached to the same types of coupling bead 168 ( FIG. 7 ).
[0051] While the foregoing describes composite vent surrounds 140 and composite window frames 126 with metal and plastic components explained relative to use in a sill 116 , the head 14 , and jambs 18 may be similarly formed from composite elements to reduce heat transfer and weather infiltration.
[0052] It will be understood that the embodiments described herein are merely exemplary and that a person skilled in the art may make many variations and modifications without departing from the spirit and scope of the claimed subject matter. For example, while the present disclosure has been expressed relative to windows, the disclosed concepts could be applied to doors, non-window vents and other building structures. All such variations and modifications are intended to be included within the scope of the appended claims.
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A manufacture for reducing thermal transfer through windows has a composite metal/nonmetallic frame and/or a composite vent surround. The metallic and non-metallic components are modular and selectively coupled, such that a range of variations to accommodate different applications may be inter-coupled via common interfaces.
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RELATED PATENT, AND APPLICATION
[0001] The present invention is related to U.S. Pat. No. 7,207,141, entitled “Sliding Door Insert for Portable Pet Portal,” issued on Apr. 24, 2007. The present invention also takes priority from co-pending Provisional Application No. 61/204,872, filed on Jan. 12, 2009. The teachings of the related Patent, and co-pending Provisional Application, are incorporated herein by reference to the extent that they do not conflict herewith.
FIELD OF THE INVENTION
[0002] The present invention relates generally to building access, and more particularly to a storm window and window screen for a window module.
BACKGROUND OF THE INVENTION
[0003] When a pet door panel is inserted in a sliding patio door the ability to utilize the screen door feature of the sliding patio door to ventilate the room to outside air is restricted since doing so would make the pet portal unusable as the screen door would block ingress and egress from and to the outside of the room. For example, the pet door panel, as described in U.S. Pat. No. 7,207,141, consists of three modules that are assembled to form the pet door panel for a sliding patio door. The bottom module contains the pet portal while the center and top modules are essentially solid filler pieces.
[0004] The current state of the art pet door panels for sliding patio doors do not have any ventilation feature and must be removed from the sliding patio door in order to close the screen to ventilate the room while keeping insects out or sliding the screen door closed over the pet door panel preventing ingress and egress of a pet through the pet portal. An aftermarket filler strip is available that may permit the screen door to be closed to the edge of the pet door panel leaving the portal free for pet use. However, in this configuration the screen door cannot be locked to prevent passage of a person.
[0005] Accordingly, there is a need for a pet door panel adapted to permit ventilation to the outside air directly through the sliding door insert for portable pet portal while providing a double pane clear polymer storm window for protection in foul weather and/or insulation in cold weather. There is a further need for a pet door panel wherein the center and top modules have openings housing a ventilation screen and storm window. In this manner, the storm window can be removed allowing outside air to infiltrate into the interior of the room containing the patio door and pet door panel without the need to remove the pet door panel and close the sliding patio door screen. There is a further need for a pet door panel whereby the screens are an integral part of the pet door and as such permit ventilation with the pet door panel installed and the sliding patio door locked preventing the unwanted passage of a person.
SUMMARY OF THE INVENTION
[0006] The present invention relates generally to a pet door panel adapted to permit ventilation to the outside air directly through the sliding door insert for portable pet portal while providing a double pane clear polymer storm window for protection in foul weather and/or insulation in cold weather. The pet door panel includes center and top modules having openings housing a ventilation screen and storm window. In this manner, the storm window can be removed allowing outside air to infiltrate into the interior of the room containing the patio door and pet door panel without the need to remove the pet door panel and close the sliding patio door screen. The pet door panel includes screens, which permit ventilation while the pet door panel is installed and the sliding patio door is locked, thereby preventing the unwanted passage of a person.
[0007] The present invention is operatively associated with a modular component pet access door designed for use in sliding glass patio doors. The modular construction permits the apparatus to be packaged and stored in a portable compact container when in a disassembled state. The compact size of the disassembled unit minimizes storage space requirements while facilitating transportation opportunities by the retailer and consumer. Modular construction and the design of components permit the invention to be changed in the field to accommodate a variety of styles and sizes of sliding glass patio doors. The universal nature of the modular construction and component system enhances the portability of the apparatus and permits the pet access door to be adjusted in the field to accommodate a growing pet or a new pet.
[0008] The present invention requires no tools to install nor does it require modification to any component of an existing sliding glass patio door. When assembled the modules and components create a sliding glass patio door pet access door panel.
[0009] The present invention is designed for simple assembly in the field by the consumer. Once assembled the panel may be installed and removed as one piece. The leading edge of the panel is designed to fit into the moveable sliding door side of the patio doorframe to create a secure fit and effective weather seal.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The following drawings are illustrative of embodiments of the present invention and are not intended to limit the invention as encompassed by the claims forming part of the application, wherein like items are identified by the same reference designations:
[0011] FIG. 1 is a front or interior elevational view of the pet access door installed in a sliding glass patio door with the moveable sliding door in a closed position, providing partial access through the sliding glass door when the moveable sliding door is moved to an open position, for various embodiments of the invention absent a storm window.
[0012] FIG. 2 is a back or exterior elevational view of the pet access door of FIG. 1 installed in a sliding glass patio door with the moveable sliding door in a closed position, providing partial access through the sliding glass door when the moveable sliding door is moved to an open position.
[0013] FIGS. 3A-3C show front elevational assembly views of the five primary modules and components comprising the pet access door panel of FIG. 1 , and illustrate how the modules and components slide together to assemble the pet access door.
[0014] FIG. 3D is a perspective view illustrating the initiation of installation of the pet access door of FIG. 1 into a sliding glass patio door.
[0015] FIG. 3E is a partial perspective and elevational view illustrating a step in the installation of the pet access door of FIG. 1 into a sliding glass patio door.
[0016] FIG. 3F is an elevational view illustrating a step in the installation of the pet access door of FIG. 1 into a sliding glass patio door.
[0017] FIG. 4A is a front elevational view of a center module of the pet access door panel of FIG. 1 further including an opening, a ventilation screen, and a storm window in position for one embodiment of the present invention;
[0018] FIG. 4B is a top cross sectional view of the center module taken along 4 B- 4 B of FIG. 4A in accordance with the present invention;
[0019] FIG. 4C is a trailing edge view of the center module of FIG. 4A in accordance with the present invention;
[0020] FIG. 5A is an interior side elevational view of a center module half in one embodiment of the present invention;
[0021] FIG. 5B is a top cross sectional view of the center module half taken along 5 B- 5 B of FIG. 5A in accordance with the present invention;
[0022] FIG. 5C is a bottom view of the center module half of FIG. 5A in accordance with the present invention;
[0023] FIG. 6A is an interior side elevational view of a left side center module half in one embodiment of the present invention;
[0024] FIG. 6B is an interior side elevational view of a right side center module half in one embodiment of the present invention;
[0025] FIG. 6C is a cross sectional view of the right side and left side center module halves of FIGS. 6D and 6E joined along the interior sides to form the center module in accordance with the present invention;
[0026] FIG. 6D is a cross sectional view of the left side center half taken along 6 D- 6 D of FIG. 6A in accordance with the present invention;
[0027] FIG. 6E is a cross sectional view of the right side center module half taken along 6 E- 6 E of FIG. 6B in accordance with the present invention;
[0028] FIG. 7A is a front elevational view of a ventilation screen of the center module for one embodiment of the present invention;
[0029] FIG. 7B is a right side elevational view of the ventilation screen of FIG. 7A with the left side elevational view being substantially the same in accordance with the present invention;
[0030] FIG. 7C is a cross sectional view of the ventilation screen along 7 C- 7 C of FIG. 7A in accordance with the present invention;
[0031] FIG. 7D is a top plan view of the ventilation screen of FIG. 7A with the bottom plan view being substantially the same in accordance with the present invention;
[0032] FIG. 8A is a front elevational view of a storm window of the center module for one embodiment of the present invention;
[0033] FIG. 8B is a right side elevational view of the storm window of FIG. 8A in accordance with the present invention;
[0034] FIG. 8C is a left side elevational view of the storm window of FIG. 8A in accordance with the present invention;
[0035] FIG. 8D is a top plan view of the storm window of FIG. 8A , the bottom plan view being substantially the same in accordance with the present invention;
[0036] FIGS. 9A , 9 B and 9 C, in combination, show an exploded assembly view of the center module in one embodiment of the present invention;
[0037] FIG. 9D is a cross sectional view of the storm window taken along 9 D- 9 D of FIG. 9A in accordance with the present invention;
[0038] FIG. 9E is a cross sectional view of the ventilation screen taken along 9 E- 9 E of FIG. 9B in accordance with the present invention;
[0039] FIG. 9F is a cross sectional view of the joined module halves taken along lines 9 F- 9 F of FIG. 9C in accordance with the present invention;
[0040] FIG. 10A is a partially assembled view of the center module having the storm window partially inserted over the ventilation screen with the storm window and ventilation screen assembly partially mounted into the module in one embodiment of the present invention; and
[0041] FIG. 10B is a cross sectional view of the center module taken along 10 B- 10 B of FIG. 10A in accordance with the present invention.
[0042] FIG. 11 is a front or interior elevational view of the pet door panel shown in FIG. 1 , but with the addition of a storm window and screen in each of the upper two modules.
DETAILED DESCRIPTION OF THE INVENTION
[0043] As shown in FIGS. 1-3A to 3 F, the preferred embodiment of the invention, pet door panel 25 , is installed between the sliding door frame 11 , and the leading side of frame 15 on movable sliding door 21 , to provide a means of ingress and egress for a pet. Drop lock security lock 6 is installed on the interior side of stationary sliding door 21 , between sliding door frame 11 , and the trailing side of frame 15 on movable sliding door 21 , to secure pet door panel 25 between sliding door frame 11 and the leading side of frame 15 on movable siding door 21 , to prevent movable sliding door 21 from being opened with pet door panel 25 installed. Sliding door frame 11 is typically secured to a building structure 23 , such as a home or office. For illustrative purposes all elevational views, except as noted, depict the sliding glass patio door in a right opening configuration. Therefore, when describing various elements of the invention reference made to right and left side views pertains to installation of the invention in a right opening sliding glass door configuration. However, since the invention may be installed in either a right or left opening sliding glass patio door configuration the term left or right is relative, therefore, the terms leading, trailing, interior and exterior are used in combination or in place of the terms right and left side and front and back views where referenced.
[0044] The sliding door frame 11 has a lower track portion 29 and an upper track portion 27 . The lower track portion 29 slideably receives at least one sliding door member 21 therein. A complementary upper track portion 27 is typically positioned on the upper side of the siding glass door frame 11 , in alignment with the lower track portion 29 , enabling the sliding door member 21 to be slideably moved between open and closed positions within the sliding door frame 11 .
[0045] The preferred embodiment of the invention consists of a pet door panel 25 with pet portal 146 , drop lock security lock 6 with locking bracket 202 , and storage bracket 208 . As shown in FIG. 3A , pet door panel 25 is an assembly consisting of five primary components; top module weather seal 1 , top module 2 , center module 3 , bottom module 4 with pet portal 146 and bottom module weather seal 5 . In this embodiment, the modules 2 and 3 are shown as being solid, without storm windows or screens, for the preferred embodiment to be described in detail below. Top module weather seal 1 , top module 2 , center module 3 , bottom module 4 with pet portal 146 , and bottom module weather seal 5 are slideably attached to one another for assembly, disassembly, or replacement, as shown in FIG. 3B , via an interlocking tongue and groove system integral to each component. More particularly, interlocking groove 85 , located in the lowermost portion of top module weather seal 1 , is slideably attached to interlocking tongue 9 located on the uppermost portion of top module 2 , as indicated by directional arrow(s) 35 and/or 350 . Interlocking tongue 9 , located on the lowermost portion of top module 2 , is slideably attached to interlocking groove 22 located on the uppermost portion of center module 3 , as indicated by directional arrows 35 and/or 350 . Interlocking groove 22 located in the lowermost portion of center module 3 is slideably attached to interlocking tongue 19 located in the uppermost portion of bottom module 4 as indicated by directional arrows 35 and/or 350 . Interlocking tongue 19 located in the lowermost portion of bottom module 4 is slideably attached to interlocking groove 96 located in the uppermost portion of bottom module weather seal 5 as indicated by directional arrows 35 and/or 350 .
[0046] FIG. 3C shows assembled pet door panel 25 with pet portal 146 . Top module weather seal 1 is attached to top module 2 at seam 37 , top module 2 is attached to center module 3 at seam 39 , center module 3 with pet portal 146 is attached to bottom module 4 at seam 41 , and bottom module 4 with pet portal 146 is attached to bottom module weather seal 5 at seam 43 .
[0047] FIGS. 3D-3F show installation of the assembled pet door panel 25 with pet portal 146 into an existing sliding glass door assembly. Although assembled pet door panel 25 may be assembled in place within sliding door frame 11 , the preferred method of assembly is accomplished on a flat surface such as a floor or table top. When assembled outside of sliding door frame 11 , the inventive assembled pet door panel 25 is brought to sliding door frame 11 as shown in FIG. 3D . FIG. 3E shows movable sliding glass door 21 being pulled away from sliding door frame 11 to open movable sliding glass door 21 as indicated by directional arrow 45 , to permit pet door panel 25 to be installed. The top module weather seal 1 component located on the uppermost portion of assembled pet door panel 25 is lifted up into a recess of upper track portion 27 of sliding door frame 11 , as shown in by directional arrow 47 , and then rotated into alignment with the upper track portion 27 and a recess of lower track portion 29 of sliding door frame 11 . The top module weather seal 1 is constructed to allow a spring loaded flexible sleeve to compress in order to fit pet door panel 25 between upper track portion 27 and lower track portion 29 of sliding door frame 11 . When in alignment with upper track portion 27 and lower track portion 29 of sliding door frame 11 , the bottom module weather seal 5 component located on the lowermost portion of assembled pet door panel 25 is lowered into the recessed lower track portion 29 of sliding door frame 11 . As shown in FIG. 3F , after assembled pet door panel 25 is in place in upper track portion 27 and lower track portion 29 of sliding door frame 11 , between the leading side of frame 15 on movable sliding glass door 21 and sliding door frame 11 , movable sliding glass door 21 is pulled closed against assembled pet door panel 25 as indicated by directional arrow 49 . In turn, assembled pet door panel 25 is pulled against sliding door frame 11 as indicated by directional arrow 51 restricting access through movable sliding glass door 21 , while providing egress and ingress for pets through pet portal 146 . Frame 15 of movable sliding glass door 21 abuts the trailing side of assembled door panel 25 within a channel formed by trailing side weather seal shims (not shown) in top module 2 and bottom module 4 , and weather seal shims (not shown) in center module 3 , that comprise assembled pet door panel 25 , with assembled pet door panel 25 installed and movable sliding glass door 21 in a closed position. When installed, the leading side of assembled pet door panel 25 abuts sliding door frame 11 .
[0048] After installation of assembled pet door panel 25 as described above, drop lock security lock 6 is installed between the trailing side of frame 15 on movable sliding glass door 21 by drop lock security lock 6 handlebar 180 and sliding door frame 11 , as shown in FIG. 1 . Drop lock security lock 6 consists of an adjustable lower housing assembly that sits in lower track portion 29 of sliding door frame 11 between the trailing side of frame 15 on movable sliding door 21 and sliding door frame 11 with assembled pet door panel 25 installed. Drop lock security lock 6 is attached to the trailing side of frame 15 on movable sliding door 21 by handlebar 180 , and locking bracket 202 which is mounted on the trailing side of frame 15 of movable sliding door 21 . Drop lock security lock 6 can be installed in any sliding glass door between the trailing side of frame 15 on movable sliding glass door 21 and sliding door frame 11 , with or without assembled pet door panel 25 installed to prevent forced entry from the exterior or unintentional opening from the interior of the structure.
[0049] In another embodiment of the invention, drop lock security lock 6 is the primary means of locking movable sliding glass door 21 with assembled pet door panel 25 installed. In order to open movable sliding glass door 21 , the handlebar 180 is rotated out of a locked position in locking bracket 202 and lifted to storage bracket 208 also located on the trailing side of frame 15 on movable sliding glass door 21 . In so doing, security lock 6 is lifted out of lower track portion 29 of sliding door frame 11 allowing movable sliding glass door 21 to be pulled opened for passage or installation or removal of assembled pet door panel 25 .
[0050] Top module 2 , center module 3 , and bottom module 4 are designed to be of an injection molded or injection blow molded polymer construction with a rigid insulation core. This type of construction provides privacy while providing insulation quality superior to prior art. All three modules are designed to fit a variety of sliding glass patio door heights and door thicknesses through an adjustable top module weather seal 1 and left or trailing side and right or leading side weather seal shims 12 or 13 , and 8 , respectively.
[0051] FIGS. 4A , 4 B and 4 C show details of front elevational, top cross sectional trailing edge, and trailing edge views, respectively, of the center module 3 with a window opening 78 having a circumferential channel 80 in which a ventilation screen 102 and storm window 104 are installed. The top module 2 ventilation screen storm window configuration is identical, other than possible dimensional differences, and the use of a top module weather seal 1 , as described above.
[0052] In one embodiment of the invention all three modules 2 , 3 , and 4 comprising the pet door panel 25 are of a two-piece construction consisting of two halves that are joined together to form a single module. This type of construction permits the formation of recesses 90 , 92 , 94 , and 96 on the interior sides of module halves 100 and 101 , respectively, for the top module 2 and center module 3 . These recesses 90 , 92 , 94 , and 96 form the ventilation screen 102 and storm window 104 channels within the module 3 , when the halves 100 and 101 are joined. FIGS. 5A , 5 B, and 5 C show a center module half 100 in three views, interior side elevational, top cross sectional, and bottom, respectively, the window opening 78 , ventilation screen recess 92 , and storm window recess 90 . FIGS. 6A , 6 B, 6 C, 6 D, and 6 E depict both center module 3 halves 100 , 101 each shown in interior views ( FIGS. 6A , 6 B), respectively, trailing edge cross sectional views ( FIGS. 6D , 6 E), respectively, and as joined ( FIG. 6C ) showing ventilation screen and storm window channels formed by the recesses 92 , 96 , and 90 , 94 , respectively, with the halves 100 , 101 being joined to complete the module 3 , in this example.
[0053] The ventilation screen 102 is shown in FIGS. 7A through 7D in front elevational, left side, cross sectional side view taken along 7 C- 7 C, and a top plan view. Note that the screen 102 is encased in a polymer frame 108 with molded in or added soft rubber gaskets 109 on the outside and inside perimeters of the frame that are designed to seal the ventilation screen against the channel within the module formed by the recesses 92 , 96 in the joined halves of the module 3 , and to seal against the interior of the double pane storm window 104 when inserted over the ventilation screen frame 108 . The rubber gasket 109 around the perimeter of the ventilation screen seals against the module halves 100 , 101 to prevent air infiltration, while the inside perimeter gasket seals 110 against the inside of the double pane storm window to enhance the insulation quality of the storm window.
[0054] In FIGS. 8A through 8D , the storm window 104 is a “U” shaped clear tempered glass or clear polymer panel formed to create two panes 112 , 113 with a closed end 114 , permitting storm window 104 to be inserted over the ventilation screen 102 and into the storm window channel in the module 3 formed by the recesses 92 , 96 with the halves 100 , 101 joined. FIGS. 9A through 9C , in combination, show an exploded assembly view of the module 3 components, including storm window 104 , and ventilation screen 102 . FIGS. 9D through 9F show top cross sectional views of the module 3 components 102 , 104 of FIGS. 9A through 9C , respectively. The ventilation screen 102 is inserted into the module 3 by sliding the screen 102 into the channel created by recesses 92 , 96 for that purpose in the trailing edge of the module 3 . The storm window 104 is then inserted by sliding it over the ventilation screen 102 and inside the channel created by recesses 90 , 94 for that purpose in the module. FIGS. 10A and 10B further illustrate the process of inserting the ventilation screen 102 into the module 3 , followed by inserting the storm window 104 over the ventilation screen 102 and into the module 3 .
[0055] In inclement or cold weather the double pane storm window 104 when installed, permits light to pass through but prevents outside cold air from infiltrating. When exposure to outside air is desired, the sliding patio door 21 is moved back away from the trailing edge of the pet door panel 25 . Next, the storm windows 104 in the top and center modules 2 , 3 , respectively, of the pet door panel 25 are removed by pulling them back and sliding them out of the associated channels. The sliding patio door 21 is then closed against the trailing edge of the pet door panel 25 , and secured to prevent unwanted passage of people, animals, insects, etc. FIG. 11 shows the pet door panel 25 of FIG. 1 , but having screens 102 and storm windows 104 installed in each of the top and center modules 2 , 3 , respectively.
[0056] The foregoing discussion discloses and describes merely exemplary embodiments of the present invention. One skilled in the art will readily recognize from such discussion, and from the accompanying claims, that various changes, modifications, and variations can be made therein without departing from the spirit and scope of the invention as defined in the following claims.
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A pet door panel or module is configured to include a pocket window opening having an open side portion to permit a ventilation screen to be slid into the pocket on centrally located tracks to provide ventilation means, and to further permit dual panel storm window means to be slid into the pocket via tracks on either side of the centrally located track to enclose the screen between the window panes to prevent air from flowing through the window opening to protect from foul weather and insulate from cold outside temperatures.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
TECHNICAL FIELD
[0001] The present disclosure relates generally to hand tools, and, more particularly, to a multi-function tool suitable for various demolition tasks.
BACKGROUND OF THE INVENTION
[0002] Many construction or building projects, including demolition tasks, require a plurality of functions for proper completion. Accordingly, numerous specialized tools are frequently needed to perform specific respective functions. For large or complex jobs, the acquisition, storage, and/or maintenance of a large number of specialized tools required may become burdensome and/or expensive.
[0003] In order to alleviate such burden and to reduce such cost, multi-function tools have been designed to allow a single tool to perform two or more tasks. The specific functionality selected for a multi-function tool is typically selected to allow performance of tasks or functions that are commonly necessary to complete a single project. For example, the common roofing project of shingling frequently requires both a striking function to drive nails, as well as a cutting function to adjust shingle size. Accordingly, hammers having a striking surface and cutting means have been developed and employed to make performance of both functions more convenient. Unfortunately, the number of such multi-function tools is limited, typically to jobs or projects that require relatively few functions, such as two or three. For many projects, however, many more functions are necessary, even if infrequently, and thus require numerous specialized tools, including one or more of multi-function tool(s).
[0004] Thus, it is clear that there is an unmet need for a multi-function tool that conveniently enables performance of a greater number of functions, whereby the number of specialized tools required to complete a large or complex job may be reduced, preferably to a single tool, and whereby the need for storage and carriage of a large number of tools may be reduced or eliminated.
BRIEF SUMMARY OF THE INVENTION
[0005] Briefly described, in an exemplary embodiment, the multi-function tool of the present disclosure overcomes the above-mentioned disadvantages and meets the recognized need for such a tool by providing a multi-function tool providing a hammer function, a first-class lever function, a second-class lever function, a chisel function, an axe function, a wrench function, and a scoring function, among others.
[0006] More specifically, the exemplary multi-function tool includes a generally extended handle portion, such as in the form of a bar or shaft, and a plurality of structures associated therewith, each structure configured and arranged to enable performance of at least one function or task. The handle portion preferably includes a grip for comfortable secure grasping and manipulation. The handle portion further preferably terminates at a first end in a chisel point or blade, whereby the handle portion may be used to drive the chisel point or blade, such as for chiseling, chipping, gouging, or puncturing, or to manipulate the point or blade, such as for scoring or cutting. A wrench structure may additionally be included proximate the first end, whereby nuts, bolts, or other threaded fasteners, or the like, may be adjusted. Furthermore, a nail or other fastener removing structure may be included proximate the first end, such as a second-class lever nail puller.
[0007] A hammer head is preferably included on a second end of the handle portion having a striking face radially spaced from a longitudinal axis of the handle portion in a first direction. The striking face may be smooth or textured, such as having a waffle pattern. A claw is preferably also included on the second end of the handle portion extending generally radially from the longitudinal axis of the handle portion in a second direction. The claw portion may be configured for use in prying a first-class lever, including for pulling nails, or the like, and may additionally include chisel blades, or the like, for chipping or chiseling. An axe blade is preferably further included proximate the second end of the handle, such as formed over a lateral edge of the side handle, preferably at a transition between the handle portion or grip proximate the hammer head and/or the claw. The axe blade may enable a cutting and/or chopping function.
[0008] The second end of the handle portion may optionally further be provided with a slot adapted to receive a member, such as a piece of dimensional lumber, or the like, whereby the handle portion may be used to wrench or lever the member. The slot may include a varying dimension or a plurality of slots having different dimensions may be provided in order to accommodate members having different dimensions. Additionally, teeth or other textured gripping structures or surfaces may be included to ensure secure gripping of the member in the slot.
[0009] Generally, the exemplary multi-function tool is configured such that any enabled function may be performed without interference from structures of the tool that enable different functionality without reconfiguration or other manipulation. Accordingly, the tool need not be adjusted in order to accomplish any function, whereby transition between performance of various functions may be accomplished quickly and conveniently. Furthermore, the configuration of the tool is preferably selected to at least partially imitate the general configuration of known tools, such as the overall configuration of a hammer, whereby the tool may be used with conventional accessories, such as a toolbox or case, a tool belt, or the like.
[0010] Accordingly, one feature and advantage of the tool of the present disclosure is its ability to provide a tool useful for the performance of a plurality of different tasks whereby acquisition, storage, and/or maintenance of a plurality of task-specific tools may be avoided.
[0011] Another feature and advantage of the present tool is its ability to enable quick and convenient transition between the performance of different one of a plurality of various functions.
[0012] These and other features and advantages of the tool of the present disclosure will become more apparent to those ordinarily skilled in the art after reading the following Detailed Description of the Invention and Claims in light of the accompanying drawing Figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] Accordingly, the present disclosure will be understood best through consideration of, and with reference to, the following drawings, viewed in conjunction with the Detailed Description of the Invention referring thereto, in which like reference numbers throughout the various drawings designate like structure, and in which:
[0014] FIG. 1 is a perspective view of a multi-function tool;
[0015] FIG. 2 is a side view of the tool of FIG. 1 ; and
[0016] FIG. 3 is a side view of a multi-function tool according to an alternative configuration.
[0017] It is to be noted that the drawings presented are intended solely for the purpose of illustration and that they are, therefore, neither desired nor intended to limit the scope of the disclosure to any or all of the exact details of construction shown, except insofar as they may be deemed essential to the claimed invention.
DETAILED DESCRIPTION OF THE INVENTION
[0018] In describing exemplary embodiments of the tool of the present disclosure illustrated in the drawings, specific terminology is employed for the sake of clarity. The invention, however, is not intended to be limited to the specific terminology so selected, and it is to be understood that each specific element includes all technical equivalents that operate in a similar manner to accomplish a similar purpose.
[0019] In that form of the tool of the present disclosure chosen for purposes of illustration, FIGS. 1 and 2 show tool 100 including body 101 and grip 103 . Body 101 is preferably formed as a monolithic or unitary member from a suitable metal, composite, or synthetic material, or the like and includes grip 103 formed or installed thereon. Grip 103 may be formed from natural or synthetic rubber, plastic, composite, or the like, and may be resilient and/or sculptured or contoured to provide a comfortable and secure grasping surface. Grip 103 is preferably disposed proximate a medial portion of body 101 along longitudinal axis 102 . Body 101 preferably includes first end 101 a and second end 101 b each extending beyond grip 103 , and each preferably carrying or including at least one structure adapted to enable at least one associated function.
[0020] For example, and as illustrated best in FIG. 2 , first end 101 a preferably includes chisel 111 and/or blade 113 . Additionally, first end 101 a may include first and second wrench apertures 115 and 117 , respectively, adapted to engage nuts, bolts, or the like, of different sizes. Slot 119 may further be included for prying nails or the like. As will be understood by those ordinarily skilled in the art, the sizes, shapes, or other configuration parameters selected for each of chisel 111 , blade 113 , wrench apertures 115 and 117 , and/or slot 119 may be selected as desired, such as for use with commonly found fasteners, materials, or tasks. For example, chisel 111 may be formed as a pointed member, as illustrated in FIG. 2 or as a flat member, as illustrated in FIG. 3 , depending on a material with which tool 100 is intended to be used. Similarly, the sizes and configurations of wrench apertures 115 and 117 , e.g. half inch hex pattern, may be selected as desired. As will further be understood by those ordinarily skilled in the art, first end 101 a may include additional and/or alternative structures to enable additional and/or alternative functions, such as a Phillips or flat head screwdriver bit, a saw blade, a rasp surface, wire stripping slots, an awl, or the like.
[0021] Second end 101 b preferably includes a generally V-shape having first projection 105 and second projection 107 . First projection 105 preferably includes hammer head 121 disposed or formed generally at a distal end thereof and spaced radially from longitudinal axis 102 . Hammer head 121 may include a smooth or textured face and is preferably configured and arranged for at least one of driving fasteners, breaking objects, or moving objects. Accordingly, first projection 105 is preferably configured to withstand repeated substantial impact forces without failure. Hammer head 121 and/or first projection 105 may additionally include one or more structures, such as a magnetic nail holder, bottle opener 123 , or the like. Second projection 107 is preferably arranged opposite first projection 105 and includes claw 125 extending away from longitudinal axis 102 . Claw 125 may include slot 127 for pulling nails, or the like, and/or at least one blade 129 for use in chipping, chiseling, or prying. Second projection 107 preferably further includes blade 131 formed over a length of an edge portion thereof. Blade 131 may be used for cutting, splitting, chopping, or the like, and may optionally include notch 132 for use in pulling nails, cutting or stripping wire, or the like. Accordingly, and similar to first projection 105 , second projection 107 is preferably adapted to withstand repeated impact forces without failure.
[0022] Additionally, second end 101 b preferably further includes at least one open-ended slot 133 between first and second projections 105 and 107 . As illustrated in FIG. 2 , slot 133 includes a first wider portion 135 and a second narrower portion 137 . Teeth 139 or other texture or friction surface is preferably provided on portions of second end 101 b proximate slot 133 , or at least one or more portion thereof, for enabling secure gripping engagement of tool 100 with a board or other member disposed within slot 133 . As will be understood by those skilled in the art, the sizes of wider portion 135 and narrower portion 137 may be selected to accommodate different sizes of dimensional lumber, metal studs, plywood, engineered lumber, composite members, or the like typically found or used in construction or demolition projects. As will further be understood by those ordinarily skilled in the art, wider portion 135 and narrower portion 137 of slot 133 may be replaced by separate slots 135 a and 137 a , as illustrated in FIG. 3 , wherein one or more of slots 135 a and 137 a may include varying or different dimension portions.
[0023] In use, tool 100 may be used to perform many different functions necessary for a selected job or task. For example, with regard to a demolition task, tool 100 may be used as a hammer wherein a user may hold tool 100 by grip 103 and swing second end 101 b to strike a desired object with hammer head 121 . Such striking may be useful in demolishing tile, masonry, metal, and/or wood structures, among others. When removing tile, hammer head 121 may be used to break a tile to remove it. Once the tile is removed, adjacent tiles may easily be removed by driving chisel 111 or blade 129 beneath the tile, whereby the tile may be pried loose either by a leverage action or by an increasing dimension of chisel 111 or blade 129 . Specifically, chisel 111 may be used as a second-class lever wherein the tip of chisel 111 acts as the fulcrum and wherein force is applied to grip 113 and/or second end 101 b. Claw 125 , however, may be used as a first-class lever wherein force is applied to grip 103 and/or first end 101 a and wherein a curved surface of claw 125 acts as a fulcrum to move blade 129 .
[0024] When desired tiles have been removed, tool 100 may further be employed to open a wall or floor to which the tiles were previously attached by striking with hammer head 121 blade 129 , blade 131 , and/or chisel 111 . Enclosed wires, pipes, or other conduits may likewise be demolished or removed by chopping with blade 131 or by striking with hammer head 121 . Structural members such as studs, beams, joists, or the like, may be removed by striking with hammer head 121 and/or by wrenching or torquing such members via grip 103 and/or first end 101 a and slot 133 . Nails or other fasteners projecting from removed members or remaining structures may be removed via slot 127 of claw 125 , via slot 119 , via notch 132 , or may be driven flush or bent flat via striking with hammer head 121 . Furthermore, any structures secured via bolts may be removed by disposing a bolt head or nut within a corresponding one of apertures 115 and 117 and by torquing via application of force to second end 101 b and/or grip 113 .
[0025] Thus, many different functions may be performed by tool 110 in order to accomplish a task without the need for additional tools. Accordingly, in many instances, tool 100 may be the only tool necessary to complete a selected task or job. As a result, such task or job may be finished more quickly due to the ability of a user to transition between different functions without having to stop, find a different tool, and resume work.
[0026] Having thus described exemplary embodiments of the present invention, it should be noted by those skilled in the art that the within disclosures are exemplary only and that various other alternatives, adaptations, and modifications may be made within the scope and spirit of the present invention. Accordingly, the present invention is not limited to the specific embodiments as illustrated herein, but is only limited by the following claims.
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A multi-function tool having a handle portion and a plurality of structures operable therewith for the performance of a plurality of functions. The multi-function tool allows fast and convenient transition between any of the plurality of functions in order to enable completion of jobs or tasks requiring such functions without acquisition, storage, and/or maintenance of a plurality of specialized tools.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates to floor systems, and specifically, to an edge trim for access floor systems incorporating access floor panels.
[0003] 2. Background Art
[0004] Access floor systems, also referred to as “raised floors,” “computer floors,” or “elevated floors,” have been utilized in a variety of applications in which a plenum, void or cavity beneath a floor surface is required by the user. Traditionally, access floor systems have been heavily utilized in computer room environments, in which a significant amount of interstitial space beneath the floor structure is required to accommodate and manage cables, components and other electrical services. Increasingly, however, demand for access floor systems has grown as usage of access floor systems has become more common in other building environments such as cleanrooms, equipment rooms, and general purpose office space. Such applications benefit from other uses of the space beneath the floor surface, such as housing HVAC componentry or other mechanical services.
[0005] An access floor system is made up of a plurality of individual, modular access floor panels supported on a series of pedestals which may be of a fixed height or are adjustable in height. When assembled, the access floor panels form a deck upon which the contents of the room rest. Each access floor panel is a modular unit, which is removable, replaceable, and interchangeable with other panels and is constructed to meet the performance requirements of the entire floor system, including, for example, load bearing requirements, combustibility resistance, and corrosion resistance.
[0006] Access floor panels are commonly constructed of a formed steel bottom pan fixedly attached to a load surface which supports a floor covering that forms the actual flooring surface. Due to standard requirements for static electricity dissipation and the desire for an aesthetically pleasing appearance and a smooth rolling surface, access floor panels for use in computer and equipment room applications commonly utilize a floor covering of high pressure laminate or other floor tile materials having a hard, resilient surface. It is these types of applications to which the present invention is particularly directed.
[0007] Frequently, unavoidable slight misalignments between neighboring panels create a narrow void between panel edges, which appears as an aesthetically undesirable dark line. Additionally, floor covering materials are frequently brittle and susceptible to cracking under rough wear conditions at the panel edges. Chipping or cracking is problematic in all access floor systems, because it often results in exposure to view of the unsightly interior of the floor covering and degradation of panel stability at the edges. Accordingly, an “edge trim” is frequently applied to or formed within the floor covering or the panel around its perimeter. The edge trim should be capable of withstanding rough handling during installation and removal and severe use conditions, and should maintain at all times the structural properties required by the panel system.
[0008] Current art has attempted to satisfy these requirements in several ways. Edge trim strips and corner pieces have been utilized which are formed to engage an edge flange of the access floor bottom pan or load surface. Such systems suffer the disadvantage of frequent breakage or separation from the panel assembly. Other systems have been utilized wherein the edge portion of a non-standard high pressure laminate material is removed to expose specially formulated uniformly colored laminate core layers, forming an “integral” trim. Such systems suffer from increased material cost and increased process control costs, as well as the presence of a relatively deep “groove” between adjacent panels that tends to collect dust, water or other contaminants between panels.
SUMMARY OF THE INVENTION
[0009] The disadvantages of the prior art are overcome by the present invention, which in one aspect, is an improved access floor panel having a printed edge trim. The invention includes an access floor panel including a panel base capable of being suspended above a subfloor surface and having a load surface for supporting loads. A floor covering, affixed to the load surface, is formed from a material having a top layer and a backing layer underlying the top layer. The top layer has a thickness, and in some coverings, one or more distinct materials may make up the top layer, such as in coverings where a decorative layer is provided below a transparent or translucent wear layer. The topmost surface, or wear surface, of the covering includes a central portion and perimeter edges therearound. The wear surface along the perimeter edges of the covering is etched to a depth that is less than the thickness of the top layer, such that no portion of the underlying backing layer is exposed. An edge trim element is then applied to the etched portion of the covering.
BRIEF DESCRIPTION OF THE FIGURES OF THE DRAWINGS
[0010] [0010]FIG. 1 is a perspective view of an access floor panel according to the present invention.
[0011] [0011]FIG. 2 is a cross-sectional side view of a portion of an access floor panel according to the present invention, taken along line 2 - 2 in FIG. 1.
[0012] [0012]FIG. 3 is a top plan view of an access floor panel according to the present invention.
[0013] [0013]FIG. 4 is an enlarged cross-sectional side view of a portion of the covering of the access floor panel shown in FIG. 2.
[0014] [0014]FIG. 5 is an enlarged top plan view of a portion of the access floor panel shown in FIG. 3.
DETAILED DESCRIPTION OF THE INVENTION
[0015] The present invention is more particularly described in the following examples that are intended as illustrative only since numerous modifications and variations therein will be apparent to those skilled in the art. As used in the specification and in the claims, “a,” “an,” or “the” can mean one or more, depending upon the context in which it is used. The preferred embodiment is now described with reference to the figures, in which like numbers indicate like parts throughout the figures.
[0016] The present invention provides a neat, accurate, functional, cost-effective and aesthetically pleasing edge trim along the perimeter of an access floor panel. In addition, the edge trim should be durable.
[0017] Referring to FIGS. 1 and 2, in one embodiment, the invention is an improved access floor panel 10 having a printed edge trim element 20 . An access floor panel 10 is provided including a panel base 12 capable of being suspended above a subfloor. The panel base 12 may be constructed of a variety of rigid materials, including aluminum and stamped sheet metal. In the illustrated embodiment, the panel base 12 has a bottom pan 14 fixedly attached to a load surface 16 for supporting loads. A covering 18 , which forms the visible surface of the access floor panel 10 , is fixedly attached to the load surface 16 by conventional means, such as an adhesive.
[0018] Access floor panel coverings may be selected from a variety of materials, including carpet, vinyl, vinyl composite tile, PVC and high pressure laminate (“HPL”) materials, such as those commonly used in countertop or conventional flooring applications. Though this invention may be utilized in access floor panels having any covering, the invention is utilized mainly in applications where an HPL laminate floor covering, commercially available under trade names including Formica, Nevamar or Wilsonart, forms the covering of the access floor panel.
[0019] In the embodiment shown in FIG. 4, the covering 18 is formed from an HPL floor tile having a top layer 22 and an underlying backing layer 24 . The top layer 22 of an HPL tile includes one or more thin, durable, water-resistant and transparent wear sheets (not shown) bonded to one or more sheets of decorative paper that form the visible surface of the floor covering 18 . The topmost surface, or wear surface 23 , of the covering includes a central portion 25 and perimeter edges 26 therearound. Preferably, the wear surface 23 of the covering 18 is hard and resilient to resist damage and wear resulting from extended use.
[0020] The backing layer 24 in such an embodiment is composed of a plurality of laminated kraft paper backing sheets, horizontally extending beneath the top layer 22 . The sheets which make up the top layer 22 and the backing layer 24 are collectively laminated together to make up the full laminate thickness, as is well known in the art of HPL floor coverings.
[0021] Coverings constructed of materials other than HPL may also be utilized. In some embodiments, the top layer of such floor coverings includes one or more wear sheets which provide durability and water resistance to the covering. The backing layer, which is bonded to the top layer, may be constructed of any material capable of maintaining the required structural properties of the covering.
[0022] To form the edge trim element 20 , the wear surface 23 along the perimeter edges 26 of the covering 18 is etched to a depth D that is less than the thickness of the top layer 22 (i.e., to a depth that does not result in any portion of the underlying backing layer 24 of the covering 18 being exposed to view). As discussed in this specification, the terms “etch,” “etched” and “etching” should be understood to refer to a procedure whereby at least a portion of the covering 18 is removed or disturbed such that a portion of only the top layer 22 is penetrated or removed, in preparation for the addition of the edge trim element 20 . According to the invention, a portion of the top layer 22 is etched in preparation for the application of the edge trim element 20 , but the covering 18 is never etched to a depth whereby the top layer 22 is completely removed such that any portion of the underlying backing layer 24 would be exposed.
[0023] The covering 18 should be etched to a width W that enables the application of an edge trim element 20 of a suitable width to achieve the aesthetic and functional requirements of the system. Any width W is therefore acceptable, according to the preference of the user. In the presently preferred embodiment, widths W in the range of 0.105 inches to 0.135 inches have been found to be acceptable, and a width of 0.115 inches has been found to be most suitable.
[0024] The covering 18 should be etched to a depth D in preparation for the application of the edge trim element 20 . Etching the covering 18 to any depth D that is less than the thickness of the top layer 22 has been found to be acceptable. For example, if the thickness of the top layer 22 is 0.004 inches, etching to any depth less than 0.004 inches has been found to produce an acceptable result. In the presently preferred embodiment, in which the top layer 22 has a thickness of 0.004 inches, a depth D of as little as 0.0005 inches has been found to produce an acceptable result, and depths D of between 0.0015 inches and 0.0030 inches have been found to be preferable.
[0025] Those skilled in the art will appreciate that further variations in the dimensions of the etched area are possible, except that the depth D of the etched area should not exceed the thickness of the top layer 22 . Additionally, though the etched area is illustrated as a rectangular cross-sectional recess in FIG. 4, one skilled in the art will appreciate that other configurations of the etched recess may be provided, such as U-shaped or V-shaped, provided that aesthetic requirements are met, and provided that the depth D does not exceed the thickness of the top layer 22 .
[0026] To etch the covering 18 , a heat generating laser (not shown) with appropriate optics may be utilized to burn a recess into the edge of the covering 18 . The depth of the laser etching may be controlled by a variety of parameters, including the power capacity of the laser system, the distance of the wear surface 23 from the focal point of the laser beam, and the speed at which the laser beam traverses the covering 18 . It has been found to be beneficial to minimize the “step” or recess cut into the edge of the covering 18 . Such a recess results in a groove between adjoining access floor panels 10 which results in increased noise and vibration when loads are rolled across the access floor system. The groove also reduces the structural rigidity of the system by decreasing the thickness of the covering 18 at the panel perimeter edges 26 , and makes the perimeter edges 26 more susceptible to cracking and splitting. To reduce the detrimental effect of such a groove, it is beneficial to etch the covering 18 only to a depth which makes application and retention of the edge trim element 20 possible.
[0027] Thus, the top layer 22 of the covering 18 is etched such that any protective wear- or water-resistant covering provided on the top surface is removed or abraded and such that the remaining exposed surface of the top layer 22 is receptive to the application of the edge trim element 20 . At no time is the top layer 22 completely removed such that the laser penetrates into the underlying backing layer 24 . By removing or abrading any non-porous surface treatment from the covering 18 , that portion of the top layer 22 which has been removed may be penetrated by fluid ink or other selected materials applied to the etched area to form an edge trim element 20 .
[0028] A two-axis DNC 150 watt sealed CO 2 laser system provides sufficient power and precision to provide sufficient etching to the top surface of the covering. Such systems are manufactured by several companies, including Beam Dynamics, Inc. in San Carlos, Calif. In the preferred embodiment, an elongated oval laser beam positioned at an axial rotation of approximately 30 degrees has been found to produce satisfactory results when focused at an after-focus width of approximately 0.140 inches to 0.180 inches and moved at a feed rate of 450 to 480 inches per minute. Satisfactory results have been achieved with a cylindrical laser cutting lens. Such laser cutting lenses are available from manufacturers including Preco Industries Inc., based in Lenexa, Kans.
[0029] Alternatively, the etching may be performed by other conventional means, such as by routing, grinding, sanding, sandblasting or the application of acid or other chemicals. Other etching methods not specifically described herein may also be utilized to etch the covering 18 , and are considered to fall within the scope of the invention.
[0030] According to the mechanical etching processes described above, a router bit, grinding wheel or other rotating tool (not shown) may be brought into contact with the perimeter edge of the floor tile. By controlling the operation of the tool relative to the floor tile, both the depth and width of the resulting cut may be maintained. It is desirable to limit the depth of the etching to remove only a portion of the top layer of the covering of the floor panel. Similarly, etching may be performed by sandblasting or application of chemical solutions to the covering. When the etching step is completed, the edge of the floor tile is prepared to receive an edge trim element to provide the finished edge of the access floor panel.
[0031] The methods and devices disclosed in this application may also be used to provide a decorative appearance to areas of the covering other than the perimeter edges. For example, interior portions of the top layer of the covering may be etched as disclosed above in the shape of decorative patterns, corporate logos or trademarks selected by the user. After etching the top layer in the shape of the selected pattern, an edge trim element may be applied to this etched top layer as described below to provide a visually satisfying and structurally sound finished floor covering.
[0032] The edge trim element 20 , which in one embodiment is a liquid permanent ink or paint, may be applied to the etched portion of the floor tile by a variety of processes. Ink may be applied by manual or automated use of an ink marker containing an appropriately colored ink. Alternatively, a paintbrush may be manually or automatically used to apply ink to the etched portion of the covering. In other embodiments, automated ink applying devices such as ink jet, laser jet, bubble jet or other printer technology may be utilized to apply ink. Such devices may be utilized as long as they satisfy the volumetric demands and accuracy requirements of the manufacturing process.
[0033] Ink may be applied to the etched portion of the covering by other automated devices, including ink applying devices or screen printing machines. Printing speed and accuracy needs are sufficiently met by the use of a flat bed screen printing machine having a 1400×1000 mm print area, such as that manufactured by Maschinenbau Bochonow of Besigheim, Germany. The screen printing system enables the covering to be fastened to a printing table by a strong, adjustable vacuum during printing. A polyester screen is then placed over the covering, which is provided with a blocked area corresponding to a “negative” of the desired printing pattern. Thus, to create the embodiment of the edge trim element described in this specification, the screen is constructed such that ink passes through the screen only at the perimeter edges of the covering, corresponding to the etched area of the top layer. Ink is then applied to the covering through the screen, creating a highly accurate and precisely controlled application of ink to form the edge trim element 20 .
[0034] The edge trim element 20 should be resistant to chemicals commonly used to clean the floor surface during subsequent manufacturing operations, as well as by the end user of the access floor system. Additionally, the edge trim element 20 should be resistant to the abrasion of daily foot traffic and other office traffic such as casters of rolling office equipment.
[0035] Ink utilized in the above-described embodiment of the edge trim element 20 should have suitable viscosity, coverage ability and pot life, along with sufficient durability and aesthetics after the ink dries to a suitable set. A currently preferred ink formulation is Ruco 985-UV series printing ink, in black or brown, which can be purchased from Diversified Printing Techniques, Inc. in Charlotte, N.C. The currently preferred ink includes 7.5% hardener and 2% varnish.
[0036] Other formulations of the edge trim element 20 may be provided according to the invention, as long as the trim material utilized is sufficiently bonded to the etched perimeter edge of the floor tile to avoid detachment of the trim edge element 20 . For example, solid (such as powder) ink formulations may be utilized as an alternative to liquid ink. Additionally, solid trim elements fixed to the etched edge of the covering may be utilized to form the edge trim element. The slightly recessed edge of the floor tile advantageously provides protection of such adhesively applied trim elements from scuffing and damage from lateral or sliding loads applied in the installation environment.
[0037] When installed, the edge trim element 20 is preferably contained within the groove formed in the covering 18 by the etching process. In such an embodiment, the edge trim member 20 is below or even with the central portion of the top surface 22 , such that the resulting wear surface of the covering 18 is substantially a planar surface. The tendency of the groove to collect moisture, dirt and other contaminants is minimized, and less noise is created when rolling loads are moved across neighboring access floor panels 10 .
[0038] Additionally, ink may be selected that exhibits resistance to moisture penetrating and chemical resistance, thereby lengthening the life of the covering 18 .
[0039] To provide an aesthetically pleasing appearance, materials which contrast with the top layer 22 in color may be used to form the edge trim element 20 . Dark inks or other edge trim materials, such as black or brown, may be used. A dark color may also be most effective in masking imperfect alignment between neighboring access floor panels, such as a void between imperfectly fit panels which often gives the appearance of a dark or black line. Other colors of ink may be utilized, however, according to the preference of the user.
[0040] In another aspect, the covering 18 of the invention may be utilized as a traditional floor covering, independent of any panel base or other components of an access floor system. For example, the covering 18 may be directly applied to the subfloor surface in household, commercial or industrial environments.
[0041] In another aspect, the invention is a method of forming an access floor covering. The method of the invention includes the steps of selecting a floor covering 18 with a top layer 22 having a thickness and an underlying backing layer 24 , the covering 18 having wear surface 23 with a central portion 25 and perimeter edges 26 therearound;
[0042] etching at least a portion of the wear surface 23 along the perimeter edges 26 of the covering 18 to a depth D that is less than the thickness of the top layer 22 ; and applying an edge trim element 20 to the etched portion of the covering 18 .
[0043] In one embodiment, the etching step is performed by feeding a pre-sized and pre-cut piece of HPL floor covering onto the carriage of a computer controlled table (such as a CNC, DNC or CAM controlled machine). The table may provide for automated control of the position of the covering with respect to a laser cutting beam, as described above. It is anticipated that the covering may be held steady while the laser beam is manipulated, or that the laser beam may be stationary with controlled movement of the covering, or some combination of those options. The intensity and focus of the laser beam may be controlled by the user, as well as the speed at which the laser beam traverses the floor covering, such that the top surface of the covering is etched to a depth that does not exceed the thickness of the top layer.
[0044] In one embodiment, the etching step is performed in two “passes.” A square covering is received into and secured within a laser machining unit. The covering is held stationary within the machining unit, while a pair of moveable laser beams traverse the longitudinal edges of the square covering. Thus, the longitudinal edges of the covering are simultaneously etched by the laser beams as the beams traverse the longitudinal edges, each of the longitudinal edges being contacted by a separate stationary laser beam within the machining unit. After the first pass is completed, the covering is removed from the machining unit, rotated 90 degrees and returned to the machining unit for the second pass, such that the latitudinal edges may be similarly etched, forming a completely etched covering. Machining units capable of performing the etching step in a single “pass” are also possible according to the invention.
[0045] Alternately, of course, a machining unit with stationary laser beams may be utilized according to the invention. In such an embodiment, the covering may be received within the machining unit and transported through the machining unit along a longitudinal axis that is parallel to the two longitudinal edges of the covering. The longitudinal edges are etched as they are contacted by the stationary laser beams within the machining unit.
[0046] In the presently preferred embodiment, the covering 18 is placed onto the carriage of a DNC laser system machine and is automatically carried into the working area of the laser. An elongated oval shaped laser beam, adjusted to an “after-focus” height and rotated off-parallel to achieve the preferred beam width described above, travels around the perimeter of the covering 18 at the above-referenced speed and power output to etch the covering 18 .
[0047] The etching step of the method of the present invention may also include an optional cleaning step, in which any debris, soot or ash are removed from the covering 18 . In the presently preferred embodiment, the covering 18 is sprayed with a high-pressure, low-volume water mist to wet the covering 18 . It is then scrubbed with high-speed rotating bristle brushes to remove any debris. Any residue is then removed with a vacuum. Alternatively, other methods may be utilized to remove debris from the covering 18 , as those skilled in the art will appreciate.
[0048] In the presently preferred embodiment, once the covering 18 has been etched, the covering 18 is transferred to a screen printing station, where a layer of ink is applied to the previously etched area of the top surface. The covering may then be moved to a drying station, such as a convection, ultraviolet or radiant heat oven. In embodiments of the invention in which an ultraviolet curing ink formulation is utilized, one suitable drying station that utilizes ultraviolet light to cure the edge trim element is manufactured by Satos and distributed by Diversified Printing Techniques in Charlotte, N.C. A conveyorized ultraviolet drying tunnel with a 9600 watt ultraviolet lamp has been found to produce acceptable results.
[0049] Alternately, the covering may be left to dry without assistance from a drying unit. After drying is completed, the covering may be attached to other access floor panel components as needed and is ready for use.
[0050] Although the present invention has been described with reference to specific details of certain embodiments thereof, it is not intended that such details should be regarded as limitations upon the scope of the invention except as and to the extent that they are included in the accompanying claims.
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An access floor panel having an improved applied edge trim element comprising a panel base capable of being suspended above a subfloor surface, having a load surface for supporting loads, and a method for forming such an edge trim element. Affixed to the load surface is a covering comprising a top layer having a thickness and an underlying backing layer. The covering further comprises a wear surface with a central portion and perimeter edges therearound, the wear surface along the perimeter edges of the covering being etched to a depth that is less than the thickness of the top layer. An edge trim element, such as ink, is applied to the etched portion of the covering, providing an aesthetically pleasing appearance to the access floor panel. It is noted that this abstract is provided to comply with the rules requiring an abstract that will allow a searcher or other reader to ascertain quickly the subject matter of the technical disclosure. The abstract is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims pursuant to 37 C.F.R. §1.72(b).
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OBJECT OF THE INVENTION
[0001] The present invention, tooth and adaptor for dredging machines, relates to a tooth or wear member which, attached to an adaptor or adaptor member, creates an assembly the purpose of which is to deepen and clean the beds of ports, rivers, channels, etc., removing therefrom sludge, stones, sand, etc., the adaptors being attached to the blades of the propellers and thus forming the cutter head of the dredging machine.
[0002] The dredging machine, or dredger, allows excavating, transporting and depositing material that is located under the water, and they can be mechanical or hydraulic machines, the mechanical machines being used with cutting members, teeth or blades for their use on compact terrain.
[0003] The tooth and adaptor object of the present invention are preferably intended to be used in dredging machines having a suctioning cutter head of the type which while at the same time it excavates the terrain under the water, the loosened material is suctioned by a pump and transported through a pipe to somewhere else.
STATE OF THE ART
[0004] Systems of tooth and adaptor or adaptors are known in the state of the art for their application in dredging operations. The main objective of said operations is to remove material from marine or river beds, and to do this it is common to use dredge boats including a dredge or dredging machine on which the various teeth are arranged and in turn connected to tooth bars or adaptors.
[0005] The U.S. Pat. No. 3,349,548-B describes a tooth and adaptor system attached to one another by means of an elastic strap such that if such strap is poorly arranged, the entire system is altered as to its correct assembly. It also only has one contact area between the tooth and the adaptor, which negatively affects the distribution of stresses.
[0006] Another, also US, U.S. Pat. No. 4,642,920-B describes a tooth and adaptor system attached to one another by means of a retaining system formed by a pin, the area where the pin is housed being easily accessed by dirt, making the subsequent removal thereof difficult. This system presents difficulty in absorbing the torsional and bending stresses and loads, generating a strong lever reaction in the system. As with the preceding patent document, there are few contact surfaces between the tooth and the adaptor.
[0007] Spanish patent document number ES-2077412-A describes a tooth and adaptor assembly made up of three parts requiring the use of two fastening systems. The fact that it has three parts complicates the entire system because it requires a larger number of spare parts and three fastening systems, one of which requires the use of a hammer whereas the other two fastening systems are formed by welding, making the tasks for replacing them long and complex.
[0008] The solutions existing in the state of the art for dredging machines have, among others, the following drawbacks:
The teeth are solid members such that the material of said members is not optimized for the functions for which it has been designed. Another drawback of using the solid teeth known in the state of the art is that they are more difficult to handle due to their weight. The teeth used in the state of the art for the same application are larger, requiring more space for storage thereof. The interlockings between tooth and adaptor known in the state of the art have a retaining member or vertical pin assuring the attachment between said tooth and the adaptor during operation thereof. When the tooth becomes worn it is necessary to replace it and to that end the cutter head is taken out of the water and usually has material from the aquatic bed where it is working adhered to the lower part of the teeth and adaptors. Said pin is usually removed by striking said pin at the upper part and re moving it through the lower part of the tooth-adaptor assembly, which often causes the pin to fall into the water (since the tooth is changed above the water) preventing recovery thereof. Likewise, the fact that there is material adhered to the lower part of the tooth-adaptor assembly makes it difficult to remove the mentioned pin because it prevents the pin from coming out of its housing. Furthermore it is common for the pin to be lost when it is inserted in the mass of material adhered to the assembly and subsequently falling into the water. Due to the configuration of the interlockings existing in the state of the art, the teeth are excessively large, generating long interlockings, with less strength in the tooth, a larger occupied volume and an increase of the distance from the cutter head to the blade, which reduces the performance of the tooth and the assembly. The adaptor likewise has no additional protection other than the protection provided by the tooth and is affected by the materials loosened due to the action of the tooth and striking against the adaptor, causing damage and wear thereof.
DESCRIPTION OF THE INVENTION
[0014] The invention describes a tooth with a front wear part and a rear projecting part or nose intended for being housed within a hollowing arranged in the body of an adaptor and an assembly formed by both for dredging machines, both members being attached to one another by means of a preferably hammerless, preferably vertical-type, retaining system, i.e. without needing to use hammers or without having to strike the pin attaching both members to one another. The adaptor is attached to the blade of the cutter head of the dredging machine at the end opposite to the hollowing by means of a coupling adapted for such purpose.
[0015] The object of the present invention is a tooth, an adaptor and the assembly formed by both, preferably applied to dredging machinery, allowing optimal wear of the material of the tip of the tooth and coupling between the tooth and the adaptor. These objects of the invention are achieved due to a particular construction of the contact surfaces between both members, allowing the self-tightening force to be produced close to the force (load), such that the horizontal component of the rearward reaction is larger and therefore the self-tightening force is also larger since the tooth pushes against the adaptor.
[0016] In dredging operations the tooth must be replaced on the actual dredge boat, i.e. at the worksite or the operations area, usually on the water and working directly on the cutter head carrying the adaptors, or tooth bar, and the teeth. Said operations are carried out by the employees on said boat, i.e. at the work site, far from maintenance shops with the suitable conveniences and tools for optimally performing these types of operations. For this reason all the mentioned components can be coupled with fastening members and pins so that the replacement operations are simple, without an excessive number of tools and preventing the use of complex equipment.
[0017] Another object of the present invention is to present in addition to the tooth-adaptor assembly, a tooth as well as an adaptor which, due to their configuration, allow a distribution of stresses that favors retaining the tooth in the adaptor and reducing the stresses to which the retaining system, and specifically the pin thereof, is subjected. The configuration of the tooth and of the adaptor can also be used outside of dredging operations, such that the adaptor or tooth bar can be connected to the bucket of an excavating machine or the like for on-shore works.
[0018] The tooth and adaptor object of the present invention have contact surfaces and constructive features allowing the coupling between both members to increase the performance of the coupling, particularly the efficiency of each tooth, thus improving the efficiency of the dredging machine.
[0019] The tooth is made up of two different parts, a first wear part, which is the part acting on the terrain and is subject to erosion due to the terrain, and a second part or nose, which is the part that is inserted in a housing arranged for such purpose in the adaptor, forming the interlocking of the system, and subjected to the reactions and stresses generated by the work of the tooth on the terrain. Said nose is formed by a lower base body and an appendage integrated in the upper surface of said lower base body, one of its ends being free and at the opposite end said nose is attached to the wear part. The gap between the wear part and the nose is determined by the upper surfaces of the appendage and by the lower surface of the lower base body which, after reaching a maximum height from the free end of the nose, converge towards the tip of the tooth, such that the union line of both surfaces is located on the side of the wear part of the tooth and in front of the line of maximum height of the nose.
[0020] The longitudinal vertical section of the nose varies along the length thereof, and has at the free end thereof a cross-section with rounded vertices. The area of the cross-section of the nose gradually increases as the nose approaches the end for being attached to the wear part of the tooth, specifically until a maximum height is reached between the lower side of the base body and the upper side of the appendage of the base body. After this point the area of the cross-section of the nose begins to decrease until the upper surface of the appendage intersects with the lower surface of the base body.
[0021] Said section can have different shapes, such as elliptical, trapezoidal or rectangular shapes, but having at least four sides.
[0022] The appendage located in the upper part of the nose, and the trapezoidal cross-section of which is narrower than the section of the base of the nose, is centered with respect to the latter. The height of said appendage is preferably nil in an area close to the free end of the nose (although it is possible for the appendage to have a certain height at said free end) and such height gradually increases until reaching said point of maximum height before decreasing again. The lateral sides of the successive cross-sections of the appendage and the upper side of the successive cross-sections of the base body of the nose of the tooth form an angle varying, due to manufacturing issues, between 45° and an angle of less than 180°, preferably between 45° and 135°. Even more preferably the angle is greater than 90°, such that the lower base of the appendage is larger than the upper base, although the opposite is also possible, i.e. the angle is less than 90°
[0023] The nose likewise has at least one first contact area with the inner surface of the housing of the adaptor, such contact area being formed by the two upper surfaces of the base of the nose that are located on both sides of the appendage of the nose of the tooth. The main feature of this first contact area is that it achieves the self-tightening of the tooth in the adaptor.
[0024] Due to the proximity of these surfaces with the tip of the tooth, i.e. the point of application of the force produced during the work of the tooth on the terrain, causes the reactions on said surfaces to be greater and therefore the self-tightening forces (components of said reactions} are also greater.
[0025] The nose has a second contact area with the adaptor, this contact area being located on the lower surface of the base of the nose, in the area close to the free end thereof.
[0026] The adaptor is also made up of two parts: at one end it has a configuration that can vary depending on the type of machinery to which it is connected, i.e. either a cutter head of a dredging machine, or to the bucket of an excavating machine, whereas at the opposite end it has a hollowing, housing or cavity intended to receive the nose of the tooth. The inner configuration of the surfaces of the hollowing or housing of the adaptor for receiving the tooth are complementary to that of the nose of the tooth, thus assuring a perfect coupling between both members.
[0027] For the coupling between the tooth and the adaptor, both parts preferably have a hole or through borehole from the upper part of the adaptor, traversing the nose of the tooth, and to the lower part of the adaptor. A pin preferably with surfaces of revolution and with a preferably hammerless retaining system (which does not require striking with a hammer or mallet for being inserted or removed) aiding in changing teeth in the adaptor will be inserted in said housing.
[0028] The coupling of the rear part or nose of the tooth in the hollowing or housing of the adaptor is due to the conjunction of the planes defining the described locking surfaces. A tightening or crushing effect between the tooth and the adaptor is furthermore achieved by means of said planes when a stress is applied perpendicular to the wear tip of the tooth and upwardly, this being the normal working situation of the teeth in a cutter head of a dredging machine.
[0029] Due to this interlocking system, the pin is subjected to fewer stresses than in conventional interlocking systems since the to oth-adaptor system tightens itself when it is subjected to upward vertical loads in the tip of the tooth, releasing stresses into the retaining system and its pin, and therefore allowing designing pins of the retaining system with a smaller size and section since they are subjected to fewer stresses, thus reducing deterioration or mattage of the pin and allowing it to be reused.
[0030] With the described configuration of the coupling the contact surfaces between the tooth and the adaptor are closer to the working tip of the tooth than in known couplings. This reduces the lever effect created between the tooth and the adaptor, and therefore the stresses to which the assembly is subjected, including the fastening or retaining system, are also reduced, thus reducing deterioration or mattage. Reducing lever stresses in the tooth allows reducing the dimensions of the nose of said tooth. And furthermore, due to its geometry, the resistant section of the rear projection or nose decreases towards the free end thereof, such that the bending moments in said area, caused by the load at the tip of the tooth, decrease and therefore the larger moments are located at the point where the resistant section is larger. Reducing the total dimensions of the system also allows therefore reducing the height of the interlocking, thus achieving a more deeply penetrating system.
[0031] The tooth object of the invention together with the adaptor allows optimizing the wear material, i.e. the use of the material arranged in the front wear part of the tooth, which is the part that directly acts on the terrain, is optimized. Said optimization is achieved by reducing the material of the tip of the tooth that is not going to be used to a minimum. The material forming part of the tip of the tooth, or wear tip, and which is then not worn, is material that has been paid for but then not used for its purpose. The material of the tip of the tooth is optimized because the tip has been designed according to the inclination of the upper surface of the appendage of the nose, which is parallel to the line of wear of the tooth, thus making use of the largest possible amount of material at the tip of the tooth before being replaced with a new tooth.
[0032] Due to this configuration of the tooth-adaptor coupling, and taking into account that dredging operations are done “blindly” for the user, the tip of the tooth must be completely worn, the unused wear material being minimal, before the tooth bar begins to become worn, since if this occurs it causes a serious drawback both in terms of time and financial resources, since not only the tooth but also the adaptor has to be replaced. It is necessary to take into account that the wear time of the teeth further depends on the revolutions at which the cutter head works, of the material it is working on, it being difficult to predict the life of the teeth. It also so happens that once the tooth is worn, and before the tooth bar begins to be worn due to the direction action on the terrain, the user perceives increased vibrations, notifying him or her that the tip of the tooth has already been consumed. Said vibration is due to the fact that as the tooth gradually wears, the section thereof gradually increases, the section of attack of the tooth on the terrain therefore being increasingly larger, causing the mentioned vibration since the optimal section for penetration has been consumed, such that when the entire section of the tip of attack has been consumed and the tooth bar is reached, said vibration is very large notifying the operators that it is necessary to replace the tooth.
[0033] Another object of the invention consist of the tooth being able to have between the front wear part and the nose for coupling to the adaptor, according to the previously defined inclined planes, a perimetral projection or flange or collar, the main purpose of which is to protect the contact area between the tooth and the adaptor from the material loosened during its dredging operation. Said collar also carries out three functions in the coupling:
Protecting the adaptor from wear through the deflectors in the upper and lower areas and which have been designed to redirect the flow of loosened material, preventing such material from rubbing or striking against the adaptor and therefore preventing the wear thereof, Preventing the loosened material from entering into the interlocking, acting as a plug and also reducing the entrance of material in the fastening or retaining system, and Making contact with the adaptor after prolonged wear through stoppers located in the upper and lower areas, said stoppers being thicker to resist the larger stresses to which it is subjected when contact with the adaptor is made, determining a third contact area between the tooth and the adaptor.
[0037] Said collar can have variable thicknesses along its length depending on the stresses to which it is subjected during the work of the coupling. Specifically, said collar has the thickest areas in its upper and lower area such that when contact is made, the reactions of the tooth bar on the collar exert a component directly opposing the applied force (Fc). In addition the middle area of the collar has a curve towards the tip of the tooth that adapts to the shape of the interlocking, according to the parallelism to planes S and I and allowing the contact areas to be closer to the tip of the tooth, this area being where the main contact areas, located close to said tip to also reduce the lever effect, are located. Said central areas have less thickness than in the upper and lower areas.
[0038] Another object of the invention is a tooth the nose of which is hollow, such that the amount of material that is worn out is reduced.
DETAILED DESCRIPTION OF THE DRAWINGS
[0039] To complement the description being made and for the purpose of aiding to better understand the features of the invention, according to a preferred practical embodiment thereof, a set of drawings is attached as an integral part of said description which show the following with an illustrative and non-limiting character:
[0040] FIG. 1 depicts a perspective view of a collarless tooth and an adaptor prior to their coupling.
[0041] FIG. 2 depicts a side elevational view of a collarless tooth and an adaptor prior to their coupling.
[0042] FIG. 3 depicts a perspective view of a collarless tooth.
[0043] FIG. 4 depicts the rear elevational view of a collarless tooth.
[0044] FIG. 5 depicts a side elevational view of a collarless tooth.
[0045] FIG. 6 depicts a plan view of a collarless tooth.
[0046] FIG. 7 depicts a side elevational view of a collarless tooth showing the inclined planes S and I.
[0047] FIG. 8 depicts a side elevational view of a tooth with a collar.
[0048] FIG. 9 depicts a front elevational view of a tooth with a collar.
[0049] FIG. 10 depicts a plan view of a tooth with a collar.
[0050] FIG. 11 depicts a cross-section of a solid tooth with a collar.
[0051] FIG. 12 depicts a cross-sectional view of a hollow collarless tooth.
[0052] FIG. 13 depicts a side elevational view of a collarless tooth.
[0053] FIG. 14 depicts a section, according to Y-Y, of the hollow collarless tooth of FIG. 13 .
[0054] FIG. 15 depicts a section, according to Z-Z, of the hollow collarless tooth of FIG. 13 .
[0055] FIG. 16 depicts a section, according to AC-AC, of the hollow collarless tooth of FIG. 13 .
[0056] FIG. 17 depicts a section, according to AA-AA, of the hollow collarless tooth of FIG. 13 .
[0057] FIG. 18 depicts a section, according to AB-AB, of the hollow collarless tooth of FIG. 13 .
[0058] FIG. 19 depicts a section, according to AE-AE, of the hollow collarless tooth of FIG. 13 .
[0059] FIG. 20 depicts a perspective view of an adaptor.
[0060] FIG. 21 depicts a view of an adaptor.
[0061] FIG. 22 depicts a rear view of an adaptor.
[0062] FIG. 23 depicts a section, according to AB-AB, of the adaptor of FIG. 22 , showing the inclined planes SA and IA.
[0063] FIG. 24 depicts a view of a collarless tooth and an adaptor coupled together.
[0064] FIG. 25 depicts a section, according to AE-AE, of the coupling between a collarless solid tooth and an adaptor shown in the FIG. 24 .
[0065] FIG. 26 depicts a collarless tooth and an adaptor coupled together showing the forces to which the assembly may be subjected and its reactions.
[0066] FIG. 27 depicts a collarless tooth in which the appendage of the nose of said tooth has a certain height along its entire length.
DESCRIPTION OF A PREFERRED EMBODIMENT
[0067] As observed in FIG. 1 , the invention object of the present application, tooth and adaptor for dredging, is formed by an interchangeable tooth 10 , an adaptor 20 coupled to a blade of a cutter head of a dredging machine, and a retaining member 30 responsible for assuring the connection between the tooth and the adaptor.
[0068] As can be observed in FIG. 3 and FIG. 20 , the tooth 10 consists of a front wear part 11 or tip of the tooth responsible for the task of eroding the terrain, in contact with the ground and stones, and in its rear part it has a projection or nose 12 intended for being housed in a housing or hollowing 24 arranged in the adaptor 20 .
[0069] FIG. 4 shows how the nose 12 of the tooth is formed by a lower base body 16 and an appendage 15 integrated in its upper surface, with a free end 14 attached at the end opposite to the front wear part, said nose 12 being separated from the wear part by the intersection of the upper surfaces of the appendage and the lower surface of the base body. More specifically, the gap between the wear part 11 and the nose 12 is determined by the two inclined planes S, I determined by said upper surfaces of the appendage and lower surface of the base body, such that the imaginary horizontal intersection line of both planes 1 1 is located in front of the vertical line (h max1 -h max2 ) determining the maximum height of the tooth 10 , located in the side opposite to that of the free end of the nose 14 . Said maximum height of the tooth H 3 is formed by the maximum height of the base body H 1 combined with the maximum height of the appendage H 2 .
[0070] According to a first vertical plane XY varying along the horizontal axis x, the base body of the nose, FIG. 13 to FIG. 19 , has a cross-section at the free end x 0 , according to a second vertical plane YZ, with a rectangular shape with rounded vertices such that the area of the cross-section, along the horizontal axis x, of the nose 12 gradually increases as the nose approaches the end for being attached to the wear part of the tooth, inclined planes S,I, specifically until the lower surface of the nose intersects the lower inclined plane I, after the point where the area of the cross-section along the horizontal axis x of the nose begins to decrease again until the intersection x 1 of the inclined upper S and lower I planes.
[0071] In addition, the section of the appendage 15 of the nose 12 of the tooth 10 has a trapezoidal cross-section, its lower base being narrower than the upper surface of the base body of the nose 16 and centered with respect to said base body 16 , such that the height of said appendage is nil in an area close to the free end 14 of the nose x 0 , and its height gradually increases until reaching a maximum height H 2 , at which point the upper surface of said appendage 15 and therefore of the nose 12 intersects the upper inclined plane S of separation with the wear part of the tooth 11 , the height of the appendage decreasing after this point until reaching the intersection x 1 of the upper S and lower I inclined planes. Said appendage 15 could also not have nil height at the free end of the nose 14 (see FIG. 27 ), or not be centered with respect to the base of the nose 16 .
[0072] The lateral sides 151 , 152 of the successive cross-sections of the appendage 15 and the upper side 121 , 122 of the successive cross-sections of the base of the nose 16 of the tooth 10 form an angle varying between 45° and 180°, preferably between 45° and 135°, and even more preferably greater than 90°.
[0073] According to the foregoing, the description provides that the nose of the tooth 10 has a lower base body 16 , with a section of at least four sides with rounded vertices and with an upper surface 120 and a lower surface 123 . On said lower base body 16 there is an upper appendage 15 with an upper surface 153 and a lower surface 154 , and with a trapezoidal section the lower base 154 of which is larger than the upper base 153 and the lower base 154 is in turn narrower than the upper surface 120 of the lower base body 16 and is centered with respect to the upper surface 120 of the lower base body 16 . The nose also has a free end 14 , opposite to the front wear part or tip 11 , and an end opposite to the mentioned free end and attached to the tip 11 of the tooth 10 .
[0074] The nose of the tooth and its section, as well as that of the area of attachment with the front part of the tooth or tip of the tooth, is determined by the progressive gap of the upper 120 and lower 123 surfaces of the lower base body 16 starting from a point close to the free end 14 of the nose 12 and therefore increasing the section of said base body 16 in the direction of the tip of the tooth 11 , until defining a maximum gap H 1 corresponding with the maximum height H 1 ) of the lower base body 16 . The upper 153 and lower 154 surfaces of the appendage 15 also progressively separate from one another from a point close to the free end 14 of the nose 12 , thus increasing the section of said appendage 15 in the direction of the tip of the tooth 11 , until determining a maximum gap H 2 defining the maximum height H 2 of the appendage 15 . The union of the maximum heights H 1 , H 2 of the lower base body 16 and of the appendage 15 , determine a line of maximum height H 3 of the nose of the tooth 12 , such that after said line of maximum height H 3 the upper surface 153 of the appendage 15 and the lower surface 123 of the lower base body 16 begin to converge towards the tip 11 of the tooth 10 until the union of both surfaces 153 , 123 , the union line of both surfaces 11 being located on the side of the wear part of the tooth 11 and in front of the line of maximum height H 3 . Said maximum height is located at a balance point between good penetration of the system, which as mentioned depends on the total height of the nose, and of the resistance of the system, which depends on the stresses to which it is subjected.
[0075] The adaptor, FIG. 20 , is formed by a body having a coupling 21 at one end to be attached to a blade of the cutter head of a dredging machine and at the opposite end it has a hollowing or housing 24 for receiving the rear projecting part or nose 12 of a tooth 10 , which is inserted in said housing 24 . The inner surfaces, FIG. 22 , of said housing 24 of the adaptor 20 are complementary to the surfaces of the nose 12 of the tooth 10 . In other words, said housing 24 is formed by a lower base hollow 22 and an inverted T-shaped appendage in its upper surface 25 in the opening 28 of the housing 24 coinciding with the free end thereof. The shape of said free end or opening 28 is defined by two inclined planes, an upper plane SA and another lower plane IA, which correspond with the upper surface of the hollow appendage and with the lower surface of the base hollow of the nose, intersecting at their intersection line (or point) 12 formed by the infinite points x 3 of the intersection of the planes, such that the intersection line 1 2 of both planes is in front of the line (h max1 -h max2 ) determining the maximum height A 3 of the hollowing 24 , as shown in FIG. 23 .
[0076] As previously described, the inner surfaces are complementary to that of the nose of the tooth, therefore the infinite sections of said housing are complementary to the infinite sections of the nose of the tooth such that according to a first vertical plane XY, which varies along the horizontal axis x, the hollowing has at the bottom 26 of the hollowing 24 , opposite to the opening 28 , a cross-section, according to a second vertical plane YZ, with rectangular shape with rounded vertices, such that the area of the cross-section of the hollowing 24 gradually increases as it approaches the opening 28 of the hollowing 24 (planes SA, IA), specifically until the lower side of the hollowing 24 intersects with the lower inclined plane IA, such that after this point the area of the cross-section of the hollowing 24 begins to decrease again until the intersection x 3 of the inclined upper SA and lower IA planes.
[0077] Likewise the section of the upper appendage 25 of the hollowing 24 has a trapezoidal cross-section, narrower than the base of the hollowing 22 , and centered with respect to same 22 , such that the height of said appendage is nil in an area close to the bottom of the hollowing 26 , and its height gradually increases until the upper surface of said appendage 25 intersects with the upper inclined plane SA of separation, the height of the appendage 25 decreasing after this point until reaching the intersection X 3 of the inclined upper SA and lower IA planes. Likewise, the upper appendage 25 may not end in its area close to the bottom of the hollowing 26 with nil height, but rather with certain height, and it could also not be centered with respect to the base of the hollowing 22 .
[0078] Obviously as in the nose 12 of the tooth 10 , the lateral sides 251 , 252 of the successive cross-sections of the appendage 25 and the upper side 221 , 222 of the successive cross-sections of the base of the hollowing 22 forms an angle with one another varying between 45° and 180°, preferably between 45° and 135°. Even more preferably said angle is greater than 90°.
[0079] In other words, the adaptor 20 has at the end opposite to that of the coupling 21 a hollowing or housing 24 for receiving the rear projecting part or nose 12 of a tooth 10 , which is completely inserted in said housing 24 . Said housing 24 is formed by a lower base hollow or hollowing 22 having a section of at least four sides with rounded vertices, an upper surface 220 and a lower surface 223 , arranging on said upper surface a hollow upper appendage 25 forming the housing 24 of the nose 12 of the tooth 10 . Said hollow appendage 25 is formed by un upper surface 253 and a lower surface 254 , and it also has a trapezoidal section the lower base 254 of which is larger than the upper base 253 and such lower base 254 is in turn narrower than the upper surface 220 of the lower base hollow 22 , said hollow appendage 25 being centered with respect to the upper surface 220 of the lower base body 22 . The housing 24 has an opening 28 at the end opposite to the end for coupling the adaptor to the, and an end opposite to that of the opening 28 forming the bottom 26 of the housing 24 , and therefore located close to the coupling to the blade. The housing 24 of the adaptor 20 is also determined by the upper 220 and lower 223 surfaces of the lower base hollowing 22 which progressively separate from one another from a point close to the bottom of the hollowing 26 of the adaptor 20 , such that the section of said base hollowing 22 gradually increases in the direction of the opening 28 of the adaptor 20 until a maximum gap A 1 is defined, corresponding with the maximum height A 1 of the lower base hollowing 22 . The upper 253 and lower 254 surfaces of the hollow upper appendage 25 progressively separate from one another from a point close to the bottom of the hollowing 26 of the adaptor 20 , the section of said hollow appendage 25 thus increasing in the direction of the opening 28 of the adaptor 20 , until determining a maximum gap A 2 defining the maximum height A 2 of the hollow appendage 25 . The union of both heights A 1 , A 2 of the lower base hollowing 22 and of the hollow appendage 25 determine a line of maximum height A 3 of the opening 24 of the housing 24 of the adaptor 20 . After said line of maximum height A 3 the upper surface 253 of the hollow appendage 25 and the lower surface 223 of the lower base hollowing 22 begin to converge in the direction opposite to that of the bottom of the hollowing 26 until the union of both surfaces 253 , 223 , the union line of both surfaces 12 being located on the opposite side of the bottom of the hollowing 26 and in front of the line of maximum height A 3 of the opening 28 of the hollowing 24 of the adaptor 20 .
[0080] As shown in FIG. 24 and FIG. 25 , both members are coupled together by inserting the nose 12 of the tooth 10 into the housing 24 of the adaptor 20 , the different complementary surfaces of the nose 12 and of the housing 24 coming into contact with one another.
[0081] At the same time the adaptor 20 has been installed through its coupling 21 in the blade or propeller of the cutter head of the dredging machine, the tooth 10 is installed, using for that purpose a preferably hammerless retaining member 30 , i.e. a member that does not require the action of a mallet or hammer for removing it from or inserting it in the housings intended for such purpose in the tooth and in the adaptor. The retaining system is vertical, being inserted and removed through the upper part of the tooth and of the adaptor, traversing the nose 12 of the tooth 10 and the body of the adaptor 20 through respective through holes 13 , 23 .
[0082] Once the assembly is put together and during the working operations, the tooth 10 is subjected at its tip 11 to an upward perpendicular force (Fc) in the lower side of the tip of the tooth 11 , less commonly being able to be subjected to a force normal Fs to the tip of the tooth due to the swell of the boat, causing a series of stresses and reactions in the coupling between the tooth 10 and the adaptor, specifically in the contact surfaces between both.
[0083] The first contact area between both is formed by the two surfaces, both in the tooth and the adaptor, coming into contact with one another, specifically those which are located on both sides of the appendage 15 of the nose 12 of the tooth 10 or of the appendage 25 of the hollowing 24 of the adaptor 20 , i.e. surfaces 121 , 122 in the tooth 10 and surfaces 221 , 222 in the adaptor 20 . This first contact area, which is very close to the tip of the tooth 11 , generates self-tightening reaction Rx 2 preventing the tooth 10 from being ejected from the adaptor 20 due to the stresses to which it is subjected. It is also possible that there is only one first contact surface between the tooth 10 and the adaptor 20 , for example in the case in which the appendage 15 of the nose 12 of the tooth 10 is not centered with respect to the base of the nose 16 of the tooth 10 .
[0084] A constructive alternative in the tooth 10 consists of arranging a collar or flange 40 therein (see FIG. 8 to FIG. 11 ), located on the perimeter of the tooth and coinciding with the gap previously defined between the front part of the tooth or tip 11 thereof and the beginning of the nose 12 of the tooth 10 . The thickness or width of said collar 40 varies depending on the area of the tooth it surrounds depending on the stresses to which said area is subjected.
[0085] Another feature of the tooth 10 object of the present invention is that the nose 12 of the tooth 10 has a hollowing or cavity 50 to reduce the weight of the tooth without affecting its mechanical features (see FIG. 12 ).
[0086] It should be mentioned that the adaptor has at least one groove 27 in its contact area with the tooth for inserting a tool and aiding in removing the tooth once the retaining member arranged between both has been removed.
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The tooth and adaptor for dredging machines object of the present invention relates to a tooth or wear member which, attached to an adaptor or adaptor member, creates an assembly the purpose of which is to deepen and clean the beds of ports, rivers, channels, etc., removing therefrom sludge, stones, sand, etc., the adaptors being attached to the blades of the propellers and thus forming the cutter head of the dredging machine. The constructive features of the coupling between the tooth and the tooth bar or adaptor allow making better use of the cutting material of the tooth and a simple and quick replacement thereof in the adaptor, between other advantages.
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COPYRIGHT NOTICE
A portion of the disclosure of this patent contains material that is subject to copyright protection. The copyright owner has no objection to the reproduction by anyone of the patent document or the patent disclosure as it appears in the Patent and Trademark Office patent files or records, but otherwise reserves all copyright rights whatsoever.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to plumbing vent stacks that extend above the roof on a building for venting of sewer gases. In particular, the present invention relates to a vent pipe protective cover for protecting the vent pipe when installed over the vent stack.
2. Description of Related Art
A vent stack protrudes from the roof deck of a building with toilet facilities to vent and remove the sewer gases from the sewer trap. The vent stack is normally installed at the time the building is built, integrated into the roof as it is installed and sealed with a flashing that creates a gasket seal against the vent pipe. The installed vent stack system is normally weatherproofed at that time. Studies have shown that in as little as 6 or 7 years, the flashing can deteriorate where it contacts the pipe and begin to leak due to the exposure to the elements. In addition, animals such as mammals, birds, reptiles, and the like may damage the flashing integrity while nesting, feeding, or the like.
In states where there is a raised crown surrounding the base used for the flashing around the vent stack pipe, it is quite common that the flashing leaks begin at the intersection where the vent pipe enters the crown.
When the flashing begins to leak, the building owner is faced with either replacing the entire vent which is an expensive and probably prohibitive procedure, or use one of a number of covers. A number of covers have been available for covering the leaking roof vent stack, however, the current ones all suffer from problems such as the need to have multiple sizes, ones to accommodate different roof pitches and attachment means which are readily susceptible to leaking. Because vent stacks are not cut to exact standard sizes, they vary in height by a large amount and covers of a specific height are difficult to install, if not impossible in some cases to use. In the case where there is a raised crown surrounding the base, many of the solutions will not work at all since they are designed to be used with a flat base, and will not work with a raised base.
U.S. Pat. No. 3,797,181 issued Mar. 19, 1974 to Nievelt, teaches a cylindrical cover of a fixed size, which requires a different height device for each vent pipe. In U.S. Pat. No. 5,245,804 issued Sep. 21, 1993 to Schieddegger et al., a roof vent pipe shield comprises an outer plastic cylinder and an inner plastic cylinder connected at one end by a fusion creating space between the cylinders. Once again, the device requires that it be custom made to a height that matches each vent pipe.
U.S. Pat. No. 5,694,724 issued Dec. 9, 1997 to Santiago discloses a stack vent cover used for flashing. This cover acts as flashing and requires attachment to the roof. In U.S. Pat. No. 6,244,006 issued Jun. 12, 2001 to Shue et al., there is taught a vent pipe cover with a flat flashing porting and an end cap. The end cap does not appear to be secured and is sufficiently small that it can be blown off the device in high winds.
BRIEF SUMMARY OF THE INVENTION
The Invention relates to the discovery that a two piece weatherproof cover overcomes many of the problems associated with the previous methods of weatherproofing a vent stack pipe, either in new construction or after a flashing failure. In particular, by having a piece that covers a portion of the vent pipe and rests on the boot of the vent stack pipe and then a second portion which fits inside and outside the vent stack pipe and covers the top of the first portion, a weather tight fitting can be accomplished along with a single device being adapted for various sizes of vent stack pipes for either new construction flashing or repairing flashing leaks.
Accordingly, one embodiment of the present invention relates to a plumbing vent pipe cover for use with a raised boot vent flashing on a roof having a selected roof pitch comprising:
a) a first portion comprising:
i. a cylindrical sheath having an open bottom and top, an inner diameter larger than an outer diameter of the vent pipe, optionally one or more friction rings on the inner diameter for grabbing an outer diameter of the vent pipe and a friction gripping surface on at least a portion of the outer diameter of the sheath for grabbing an inner diameter of a second portion of the cover; ii. a flaring boot portion in fluid connection with the open bottom for positioning on the raised boot portion of the vent flashing; and iii. an alignment device sufficient to align the sheath on the vent pipe and the flaring boot portion on the raised portion based on the selected roof pitch;
b) a second portion comprising:
i. an inner and outer cylinder concentrically positioned in spaced relationship by a weatherproof connection at the top end of each cylinder; and ii. the spaced relationship for positioning the second portion on the open top of the cylindrical sheath such that the inner cylinder is positioned on the inner part of the sheath and the outer cylinders inner surface is in contact with the friction gripping surface on the outer diameter of the sheath for holding the second portion in place.
Accordingly, in yet another embodiment of the present invention there is a method of weatherproofing a plumbing vent pipe with a raised boot vent flashing on a roof having a selected roof pitch comprising:
a) selecting a cover comprising:
i. a first portion comprising
a. a cylindrical sheath having an open bottom and top, an inner diameter larger than an outer diameter of the vent pipe, optionally one or more friction rings on the inner diameter for grabbing an outer diameter of the vent pipe and a friction gripping surface on at least a portion of the outer diameter of the sheath for grabbing an inner diameter of a second portion of the cover; b. a flaring boot portion in fluid connection with the open bottom for positioning on the raised boot portion of the vent flashing; and c. an alignment device sufficient to align the sheath on the vent pipe and the flaring boot portion on the raised portion based on the selected roof pitch;
ii. a second portion comprising:
a. an inner and outer cylinder concentrically positioned in spaced relationship by a connection at the top end of each cylinder; b. the spaced relationship for positioning the second portion on the open top of the cylindrical sheath such that the inner cylinder is positioned on the inner part of the sheath and the outer cylinders inner surface is in contact with the friction gripping surface on the outer diameter of the sheath for holding the second portion in place;
b) slidingly engaging the first portion over the vent pipe until the flaring boot portion covers at least a portion of the raised boot portion of the vent flashing; and c) slidingly engaging the second portion over the vent pipe and first portion such that the inner cylinder is positioned inside the vent pipe and the outer cylinder is positioned outside the vent pipe and covers the top of the first portion.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side perspective of the first portion over a vent pipe.
FIG. 2 is a top view of the first portion over a vent pipe showing the friction rings.
FIG. 3 is a side perspective of the second portion positioned over the first portion on a vent pipe.
FIG. 4 depicts an embodiment wherein the alignment device is a flaring boot portion acceptor device.
FIG. 5 is an exploded view of the cover of FIG. 4 showing more detail of acceptor 30 .
DETAILED DESCRIPTION OF THE INVENTION
While this invention is susceptible to embodiment in many different forms, there is shown in the drawings and will herein be described in detail specific embodiments, with the understanding that the present disclosure of such embodiments is to be considered as an example of the principles and not intended to limit the invention to the specific embodiments shown and described. In the description below, like reference numerals are used to describe the same, similar or corresponding parts in the several views of the drawings. This detailed description defines the meaning of the terms used herein and specifically describes embodiments in order for those skilled in the art to practice the invention.
The terms “a” or “an”, as used herein, are defined as one or as more than one. The term “plurality”, as used herein, is defined as two or as more than two. The term “another”, as used herein, is defined as at least a second or more. The terms “including” and/or “having”, as used herein, are defined as comprising (i.e., open language). The term “coupled”, as used herein, is defined as connected, although not necessarily directly, and not necessarily mechanically.
Reference throughout this document to “one embodiment”, “certain embodiments”, and “an embodiment” or similar terms means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, the appearances of such phrases or in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments without limitation.
The term “or” as used herein is to be interpreted as an inclusive or meaning any one or any combination. Therefore, “A, B or C” means any of the following: “A; B; C; A and B; A and C; B and C; A, B and C”. An exception to this definition will occur only when a combination of elements, functions, steps or acts are in some way inherently mutually exclusive.
The drawings featured in the figures are for the purpose of illustrating certain convenient embodiments of the present invention, and are not to be considered as limitation thereto. Term “means” preceding a present participle of an operation indicates a desired function for which there is one or more embodiments, i.e., one or more methods, devices, or apparatuses for achieving the desired function and that one skilled in the art could select from these or their equivalent in view of the disclosure herein and use of the term “means” is not intended to be limiting.
As used herein a “plumbing vent pipe” refers to those vent pipes having a raised boot vent flashing in new or repair construction. A side view of the style of vent pipe flashing can be seen in FIG. 1 as an example. While all boots of such will be raised, there will of course be differences in the style and exact shape based on the individual manufacturer of the flashing. Other examples of such flashing are in U.S. Pat. Nos. 5,588,267 and 4,864,782. As can be seen, the flashing attaches to the roof and then the vent pipe passes through an opening in the flashing creating a gasket seal between the pipe and the flashing. This seal works initially, but frequently leaks, by some reports on average after 7 years, no matter which company's flashing is used. The flashing can be replaced but must include taking up and replacing a small portion of roofing as well.
The present invention comprises a two piece weatherproof covering for placing over the vent pipe and flashing for the purposes of weather proofing. It can repair damaged flashing or used in new construction with flashing that seals or doesn't seal against the vent pipe. This cover can be used after the assembly leaks or at any time prior to leaking occurrences. The first portion of the vent pipe cover comprises a device that covers the lower portion of the exposed vent pipe and covers at least a portion of the raised boot portion of the flashing. A “flaring boot portion” of the first portion covers (circumferentially) the boot where the vent pipe passes through it and comes to rest (circumferentially) on the sides of the raised boot, thus, covering the top of the raised boot completely as well. This can be seen clearly in FIG. 1 . In general the first portion is made from a polymeric or rubberized weatherproof material. Such materials for manufacturing roof devices are well known. In one embodiment, such materials are a polypropylene/rubber blend but essentially any weatherproof material could be selected.
Attached to the flaring boot portion is a “cylindrical sheath” having an open bottom and top. The bottom is in fluid communication with the flaring boot portion such that the first portion can be placed over the vent pipe and at least a portion of the raised boot. The inner diameter of the cylindrical sheath is larger than the vent pipe. The inner diameter of the cylindrical sheath is optionally lined with one or more friction rings which hold onto the vent pipe by friction against the vent pipe. The friction rings can be polymeric, rubberized, or the like, or any kind of inner ring which creates friction against the vent pipe for holding the first portion in place. Other means include high friction surfaces and the like. The exact material and the manufacture of a friction ring is based on the material of the vent pipe the diameter and the like, and is within the skill in the art in view of this disclosure. While gravity will initially hold the first portion in place by the use of friction rings or friction, one can be assured the device will remain in place during high winds and storms. Also, if the flaring boot portion is tight against the raised boot, then there is less chance for wind or rain to blow underneath the device's first portion.
The outer diameter of the cylindrical sheath has on at least a portion of the surface a friction gripping surface. The friction surface can be a roughed surface, a coating, or the like that increases friction between the outer diameter and the second portion placed on the first portion as described below. The friction portion can cover the entire cylindrical sheath but only needs to be where it will come in contact with the first portion. One skilled in the art can decide where and how much friction surface is necessary to place the first portion over the second portion and hold it in place during normal weather conditions. The rough surface can be made by abrasion, attaching a rough material to the surface of the sheath and selecting a material with sufficient friction coefficient. The rough surface can also be molded into the sheath or by any manner that leaves a portion of the surface rough. The exact material selected is within the skill in the art in view of the present teaching.
The lower portion of the cylindrical sheath has an alignment which is sufficient to angle and align the sheath on the vent pipe and at the same time align the flaring boot portion on the raised boot of the flashing. Because the roof will have a selected pitch to it, the flaring boot portion will need to be at an angle to properly cover the raised boot of the flashing. The alignment device allows for the flashing to be angled as desired and held in place by friction and gravity. For example, a series of 1 or more accordion pleats could be in the lower portion of the cylindrical sheath. Another alignment device would be use of a flaring boot portion which allows the flaring portion to rotate on an acceptor device to the desired angle.
The second portion comprises an inner and an outer cylinder which are concentrically positioned and joined together at their respective top diameters forming a complete seal between the two and forming a spaced relationship between the two cylinders. One way of achieving this is to mold a single piece that is a cylinder turned into itself, though any means of manufacture is contemplated. Since when the first portion is placed on the vent pipe and flashing allowing water to leak between the top diameter of the sheath and the vent pipe, the second portion prevents such leakage and creates the weatherproof seal between the two cover portions. The second portion is held in place by the friction between the inner diameter of the outer cylinder and the high friction surface on a portion of the outer diameter of the sheath.
The two portions are thus held in place with just gravity and friction and as such can be installed in seconds without the need for other attachment means. The height of the cylindrical sheath would normally be higher than the average vent pipe and the inner diameter of the second portion long enough to reach the inner diameter of the vent pipe. Thus, the device could be used on various size vent pipes without the need for any kind of adjustment or use of a tightening ring that exposes the ring connection to the elements. In addition, it can be used to repair or used in new construction.
The device can usually be made by any methods used to manufacture polymeric or rubberized materials, such as injection or blow molding, but could also be fabricated by hand or any other convenient method, such as by sculpting or the like. The function and use of the present cover can be clearly seen from the examples in the drawings which follow.
Now referring to the drawings, FIG. 1 depicts a side view of a first portion 1 of the present cover. Shown is roof 5 having selected pitch angle 6 . The raised boot 7 of a vent flashing is shown while a hidden part, 7 a , is hidden under roof 5 . A flaring boot portion 10 is shown covering raised boot 7 while from the side it may not be clear the flared boot 7 is oval shaped and the flaring boot portion 10 is oval to match it.
A cylindrical sheath 11 encircles the vent pipe 4 and friction rings 15 grab the vent 4 except for the highest ring 15 a . Highest ring 15 a is positioned for a taller vent pipe than vent pipe 4 . An accordion pleat 12 is used as an alignment device positioned in between the sheath 11 and flaring boot portion 10 to allow for angling the flaring boot portion 10 as needed to compensate for roof pitch angle 6 . As can be seen in this view the outer diameter 18 of cylindrical sheath 11 has a roughed up surface as will be described below for creating friction and holding the second portion.
FIG. 2 depicts a top view of the cylindrical sheath 11 encircling the vent pipe 4 . A top view of an optional friction ring 15 can also be seen.
FIG. 3 depicts the second portion in cut through view placed on the first portion 1 and the vent pipe 4 . The second portion 20 is actually one piece with its top 23 completely encircling the top 21 of the sheath 11 . The inner cylinder 25 is positioned with the bottom end 26 inside vent pipe 4 . The outer cylinder 28 is positioned on the outer surface 18 of the sheath 11 in a manner that the inner surface of the outer cylinder comes in contact with the outer diameter 18 rough surfaces and holds it in place. In this position rain cannot come between the vent pipe and the first portion 11 . And the device is held in place by the friction of the first portion against the raised boot and vent pipe and the second portion held in place by gravity and the friction against the first portion creating a weatherproof seal with minimal work effort.
In FIG. 4 depicts an embodiment wherein the alignment device is a flaring boot portion acceptor device. A flaring boot portion 10 is covering raised boot 7 . In this embodiment the boot portion 10 also covers acceptor 30 . The shape of boot portion 10 matches the acceptor and allows it to rotate to match the roof pitch and still cover an upright vent pipe.
FIG. 5 is an exploded view of the cover of FIG. 4 showing more detail of acceptor 30 . The acceptor 30 consists of sides 31 , front 32 and back 34 . The current top 33 allows the first portion 10 to rotate on the curve 33 to obtain the proper angle to match the roof pitch of a selected roof. The acceptor rests on the raised boot 7 and has pass through 35 to allow a vent pipe to pass through to the first boot portion 10 with enough room to accommodate various roof pitches.
It is clear that the drawings are not intended to be limiting unless otherwise indicated. The claims are to be read in view of the particular description and the drawings intended for the further understanding of the invention and not necessarily as a limiting function thereof.
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The present invention relates to a vent pipe protection cover for repairing damaged flashing or for any new construction for waterproofing the vent pipe. A two piece construction which allows one device to accommodate roof pitches and various size vent pipes without the need to custom make the device is disclosed.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a marker having a flexible element which allows the marker to bend.
2. Description of the Prior Art
Markers are often used along roadsides or areas where there is a potential that the marker will be hit by passing objects, such as automobiles. When the markers are hit, the markers are often damaged and must eventually be replaced. To help minimize the damage to these markers, these markers are often constructed to be flexible so that when the marker is struck, the marker bends or flexes and thereby sustains little if any damage. This also helps prevent damage to the automobile or object which strikes the marker. Flexible markers may have a flexible element, such as a spring or elastomeric sleeve, which allows the marker to bend. The flexible element also restores the marker to its original position.
SUMMARY OF THE INVENTION
The bendable marker of the invention has a base with an upward protruding mandrel and a marker post. A flexible, elastomeric sleeve having a longitudinal axis extending from the upper end of the flexible sleeve joins the base and marker post. The lower end of the sleeve is mounted over and secured to the mandrel of the base, and the upper end is secured to the marker post. Located about the midsection of the flexible sleeve are a plurality of longitudinally extending ribs formed in the flexible sleeve. The ribs are located on both the inner and outer surface of the sleeve and enhance the resiliency of the flexible sleeve.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of a bendable marker constructed in accordance with the invention.
FIG. 2 is a side view of a flexible element of the bendable marker of FIG. 1 which is constructed in accordance with the invention.
FIG. 3 is a cross-sectional side view of the bendable marker constructed in accordance with the invention.
FIG. 4 is a cross sectional view of the bendable marker of FIG. 2 taken along the lines IV--IV.
FIG. 5 is another embodiment of the bendable marker constructed in accordance with the invention.
FIG. 6 is a cross-sectional view of the flexible element of the bendable marker of FIG. 5 taken along the lines VI--VI.
DETAILED DESCRIPTION OF THE INVENTION
Referring to the figures, FIG. 1 shows a bendable marker 10 having a base 12 and a marker post 14 which is joined to the base 12 by means of an elastomeric, flexible sleeve 16. The base 12 is formed with an upwardly protruding mandrel 20, as shown in FIGS. 2 and 3. The mandrel 20 is provided with holes 22 which extend through the mandrel 20.
The marker post 14 is a substantially rigid member having a lower end which serves as a mounting portion 26. The mounting portion 26 is inserted into the upper end of the flexible sleeve 16. The lower end 26 of the mounting post 14 is provided with holes 28 which extend through the thickness of the marker post 14 through the mounting portion 26. The upper end of the flexible sleeve 16 surrounds the mounting portion 26 of the marker post 14, while the lower end of the flexible sleeve 16 mounts over and surrounds the protruding mandrel 20 of the base 12.
As can be seen in FIG. 3, the lower end of the marker post 14 and the upper end of the mandrel 20 are spaced apart to form a gap or clearance 32. This allows the marker post 14 to bend relative to the base 12.
The flexible sleeve 16 is substantially rectangular in cross section, in the embodiment of FIG. 4, and is formed from a single piece of resilient, molded polyurethane or other elastomeric material. Two sides of the rectangular sleeve 16 are about twice the dimension of the other two sides. The flexible sleeve 16 is formed as a continuous wall with inner and outer ribs 36A, 36B protruding from the interior and exterior surfaces, respectively, of the sleeve 16. The ribs 36A, 36B extend longitudinally from the upper end of the sleeve 16 to the lower end of the sleeve 16. Each of the ribs 36A, 36B has longitudinally extending, converging sidewalls 38, 40 which converge from a base of the ribs 36A, 36B toward a peak 42 formed on the outermost extremity of each rib 36A, 36B.
Each of the inner ribs 36A on the inner surface of the sleeve 16 is evenly spaced apart from adjacent inner ribs 36A to form a longitudinally extending inner groove 44A between each inner rib 36A which is defined by the sidewalls 38, 40 of adjacent inner ribs 36A. The inner ribs 36A and grooves 44A are evenly spaced apart and extend circumferentially around the inner surface of the sleeve 16. Likewise, the outer ribs 36B on the outer surface of the sleeve 16 are evenly spaced apart from adjacent outer ribs 36B to form longitudinally extending outer grooves 44B between each outer rib 36B. The outer ribs 36B and outer grooves 44B are also evenly spaced apart and extend circumferentially around the outer surface of the sleeve 16.
The inner and outer ribs 36A, 36B and grooves 44A, 44B each have substantially triangular cross sections with the width of the ribs 36A, 36B and the grooves 44A, 44B being the same. As shown in FIG. 4, the outer ribs 36B are circumferentially staggered from the inner ribs 36A approximately a distance equal to one half the width of the ribs 36A, 36B with the outer grooves 44B corresponding with the inner ribs 36A. Likewise, the inner grooves 44A correspond with the outer ribs 36B. The ribs 36A, 36B and grooves 44A, 44B create a corrugated cross section of the continuous wall which forms the flexible sleeve 16.
Located on the exterior of the flexible sleeve 16 at the upper and lower ends are flat portions 46 cut into the ribs 36B formed on the exterior of the sleeve 16. Holes 48 located in the flat portions 46 and extending through the thickness of the sleeve 16 are oriented to align with the holes 22, 28 of the upward protruding mandrel 20 and mounting portion 26, respectively. Fasteners 50, preferably rivets, extend through the holes 48 of the sleeve 16 and the holes 22, 28 of the mandrel 20 and mounting portion 26, thereby joining the flexible sleeve 16 to the marker post 14 and base 12.
As shown in FIG. 4, when the flexible sleeve 16 is mounted to the base 12 and marker post 14, the ribs 36A formed on the interior of the sleeve 16 contact the mounting portion 26 of the marker post 14, as well as the mandrel 20 of the base 12. The mounting portion 26 and the mandrel 20 are smooth rectangular members and do not have corrugations or grooves.
The flexible sleeve 16 allows the marker post 14, which is stiff or rigid, to bend relative to the base 12 from a first position to a second position, as shown by the broken lines in FIG. 1, when subjected to an outside force as indicated by the arrow of FIG. 1. The longitudinally extending ribs 36A, 36B improve the resiliency of the flexible element 16 and minimize the amount of polyurethane or elastomeric material necessary to form the sleeve 16. It should be noted that the flexible sleeve 16 does not have to be rectangular as shown in FIG. 4, but could be formed in a variety of shapes.
FIGS. 5 and 6 show another embodiment of the invention. As shown in FIG. 5, a flexible sleeve 54 is disposed between an upward protruding mandrel 56 of a base 58 and a marker post 60. The mandrel 56 and lower portion of the marker post 60 each have a circular cross section. The flexible sleeve 54 is similar to the flexible sleeve 16 of FIGS. 14, however, the sleeve 56 has an upper and lower end 62, 64 which are free of ribs. The upper and lower ends 62, 64 are joined to the mandrel 56 and the lower end or mounting portion of the marker post 60 by rivets 66 or fasteners.
Inner and outer ribs 70A, 70B are formed only on the midsection of the sleeve 54 and are similar to the ribs of the sleeve 16 of FIGS. 14. Each of the ribs 70A, 70B has inclined sidewalls 72, 74, which are inclined from the base of the ribs 70A, 70B toward a peak 76 located on the outer extremity of the ribs 70A, 70B. Each of the inner ribs 70A on the inner surface of the sleeve 54 is evenly spaced apart from adjacent inner ribs 70A to form a longitudinally extending inner gap or groove 78A between each inner rib 70A. Each inner groove 78A is defined by the sidewalls 72, 74 of adjacent inner ribs 70A. The inner ribs 70A and grooves 78A are evenly spaced apart and extend circumferentially around the inner surface of the sleeve 54. The outer ribs 70B on the outer surface of the sleeve 54 are also evenly spaced apart from adjacent outer ribs 70B to form longitudinally extending outer grooves 78B between each outer rib 70B. The outer ribs 70B and outer grooves 78B are also evenly spaced apart and extend circumferentially around the outer surface of the sleeve 54.
The grooves 78A, 78B and ribs 70A, 70B each have a triangular cross section perpendicular to the longitudinal axis of the sleeve 54 causing the wall of the sleeve 54 to have a corrugated cross section. As shown in FIG. 6, the sleeve 54 itself has a substantially circular cross section which corresponds to the circular cross section of the mandrel 56 and lower end of the marker post 60.
The bendable marker of the invention has several advantages. Because the flexible sleeve is ribbed and provided with grooves, the marker post of the invention is more resilient when subjected to deformation. The longitudinally extending ribs allow the flexible sleeve to have thinner walls while still providing substantial structural rigidity. The ribbed sleeve requires less polyurethane or elastomeric material to be used to provide the same resiliency and strength as a flexible sleeve which has no ribs.
While the invention has been shown in only one of its forms, it should be apparent to those skilled in the art that it is not so limited, but is susceptible to changes in variations without departing from the scope of the invention.
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A bendable marker for use in areas where the marker is required to be flexible is provided with a base and a marker post which are joined together by a flexible sleeve. The flexible sleeve has a plurality of evenly spaced ribs which extend longitudinally along the sleeve from an upper end to a lower end. The ribs are evenly spaced apart with a groove being formed between each of the ribs. The ribs protrude from both the inner and outer surfaces of the flexible sleeve. If the marker post is struck, the flexible sleeve allows the marker post to bend relative to the base. The ribs strengthen and enhance the resiliency of the sleeve.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
FIELD OF THE INVENTION
The present invention relates to a device for articulating a cover or lid to a frame in particular of a manhole.
BACKGROUND
A device of this type is known, which enables the cover to adopt a position for sealing or closing the frame, or an open position in which the cover is upright so as to allow an operator to access the manhole.
This articulation device includes a male component connected to the cover and mounted with limited pivoting in a housing made in the frame.
The cover can be locked to the frame by a latch placed on the opposite side from the articulation.
However, this device presents a major drawback in that when in the upright position for opening the cover, it can be extracted from the frame by malicious persons.
In order to solve this problem, locking means of the lock type have been associated with the articulation in order to connect the cover to the frame permanently.
However, these means have a complex structure and increase the manufacturing costs of the articulation device.
SUMMARY OF THE INVENTION
The present invention aims to eliminate the aforementioned drawbacks by proposing a device for articulating a cover or lid to a frame in particular of a manhole, which enables the cover to adopt a position for sealing the frame, or an open position in which it is upright so as to allow access to the opening of the frame and including a male component connected with the cover and mounted with limited pivoting in a housing made in the frame, characterized by the fact that the male component of the articulation can be, as desired, either mounted in a removable manner in its housing of the frame in order to allow the cover to be pulled off the frame when in its upright position, or connected in its housing of the frame so that the cover cannot be removed from its frame.
Preferably, the male articulation component includes a cylindrical barrel set in the housing of the frame configured in the form of a clevis, making it possible to support a hinge pin which passes through the cylindrical barrel and can be attached in a tamper-proof manner to the clevis in order to make it so that the cover cannot be removed from its frame.
The diameter of the hinge pin is smaller than the diameter of the bore of the cylindrical barrel through which this pin passes, where the ends of the pin are attached, for example by welding, respectively to the two parallel walls of the clevis.
The cylindrical barrel has means for holding the cover in its upright position.
The holding means advantageously includes two stubs connected to the ends of the cylindrical barrel perpendicularly to it and which can engage by gravity, when the cover is in the upright position, respectively in two recesses in the bottom of the housing of the frame.
When the cover and the frame are circular, the cylindrical barrel is attached to the cover by a radial projecting piece in such a way that the barrel and the projecting piece have a T-shaped configuration.
The cover occupies an upright open position of approximately 90° relative to the frame.
BRIEF DESCRIPTION OF DRAWING FIGURES
The invention will be better understood and its other objectives, characteristics, details and advantages will appear more clearly in the following explanatory description in reference to the drawings given only by way of example illustrating an embodiment of the invention and in which:
FIG. 1 is a perspective view of a manhole cover and frame assembly with the cover articulated to the frame according to the invention;
FIG. 2 is an enlarged perspective view of the articulation of the invention which allows attachment of the cover to the frame;
FIG. 3 is an enlarged perspective view similar to that of FIG. 2 and representing only the housing of the frame which makes it possible to receive the articulation of the invention;
FIG. 4 is an enlarged perspective view similar to that of FIG. 3 and showing also a hinge pin which passes through the housing of the frame; and
FIG. 5 is an enlarged perspective view of a part of the cover with the male articulation component.
DETAILED DESCRIPTION
In reference to the figures, reference 1 designates a frame which has a generally circular shape and on which cover or lid 2 , also circular, is articulated, where it is understood that frame 1 and cover 2 may be of different shapes, for example, rectangular or square.
Frame 1 is intended to be sealed in the pavement so as to constitute, with cover 2 , a manhole.
Articulation 3 allows cover 2 to adopt a position for sealing or closing of frame 1 represented in FIG. 1 or an open position, not represented, in which cover 2 is upright in a determined angular position relative to the frame in order to allow an operator to access the manhole through the opening of frame 1 .
As is known in itself, articulation 3 includes male component 4 connected to cover 2 and mounted with limited pivoting or rotation in housing 5 arranged in frame 1 .
FIG. 1 also shows that cover 2 is provided with latch 6 , known in itself, diametrically opposite from articulation 3 and allowing one to lock cover 2 to frame 1 in its closed position.
According to the invention, male articulation component 4 may as chosen be either mounted in a removable manner in its housing 5 of frame 1 to allow cover 2 , if desired, to be pulled off frame 1 in its upright position, or to be connected in its housing 5 so that cover 2 cannot be disassembled from frame 1 .
Thus, articulation 3 of the invention, with the same cast elements, can as chosen be made part of the frame so that cover 2 cannot be disassembled, or attached in a removable manner in its housing 5 of frame 1 to allow cover 2 to he pulled off the frame.
To this end, male articulation component 4 includes cylindrical barrel 7 set in housing 5 of frame 1 , housing which is configured in the form of a clevis for support of hinge pin 8 which goes freely through longitudinal bore 9 of barrel 7 and is attached in a tamper-proof manner to the clevis of housing 5 .
More precisely, the clevis of housing 5 is defined by two essentially parallel walls 10 externally connected to circular peripheral rim 1 a of frame 1 in which cover 2 is set. Each wall 10 is thus situated in the extension of a chord of frame 1 . Hinge pin 8 goes through holes 10 a in each of walls 10 , which are perpendicular to the hinge pin 8 , and ends of the hinge pin 8 are connected to the respective walls 10 . For example, each end of hinge pin 8 is connected by welding to the external side of wall 10 as indicated at 11 in FIGS. 2 and 4 . Male component 4 of articulation 3 also has projecting piece 12 connected radially to cover 2 and which can engage, in the closed position of cover 2 , in opening 13 , which is delimited between two circumferentially spaced walls 14 in extension of rim 1 a of frame 1 and delimiting, with walls 10 and their connecting external wall 15 , housing 5 for male articulation element 4 . Thus, the latter has a T-shaped general configuration.
The diameter of bore 9 of barrel 7 is larger than the diameter of hinge pin 8 .
Cylindrical barrel 7 has two stubs 16 respectively connected to both ends of barrel 7 perpendicularly to its longitudinal direction, protruding on the same side and situated approximately in the same longitudinal median plane as projecting piece 12 and barrel 7 . The two stubs 16 make it possible to maintain cover 2 in its upright open position by respectively engaging in two recesses 17 in the bottom of housing 5 . Preferably, cover 2 is maintained in its upright position at approximately 90° relative to the plane passing through the upper edge of rim 1 a of frame 1 .
Setting of the two stubs 16 by gravity in their respective recesses 17 , when cover 2 has its male component 4 articulated in such a manner that it cannot be disassembled, in its housing 5 by hinge pin 8 , is allowed by the fact that the diameter of bore 9 of cylindrical barrel 7 is larger than the diameter of hinge pin 8 .
Of course, when one wishes to make articulation 3 removable relative to frame 1 in order to allow cover 2 to be extracted from the frame, hinge pin 8 is not present at all, and the two stubs 16 can also engage by gravity in their respective recesses when cover 2 is in its upright position in order to prevent it from tipping over in its frame.
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A device for articulating a stopper or lid to a frame, in particular of a man hole. The male articulating member may optionally be mounted either removably in its housing of the frame to enable the stopper to be extracted from the frame in its upright position or secured in its housing such that the stopper is not detachable from the frame.
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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 a self adjusting toilet bolt assembly for connecting a toilet bowl to a closet flange and, more particularly to such an assembly wherein a tightening stud or bolt assembly component can adjust downwardly in length when the assembly is tightened. Beneficially, the proposed invention allows unencumbered placement of a covering cap over the connecting hardware extending above the top surface of the toilet bowl base and eliminates the need to cut a bolt member.
2. Description of the Related Art
In the past, the most commonly used closet bolt employed for connecting a toilet bowl to a closet flange was a fixed length component having a diameter of either ¼″ or 5/16″. The closet bolt was conveniently made longer than necessary to accommodate floor, flange and toilet height variation during installation. For that reason and following connection, it was necessary to cut off an excess top length portion of the threaded stud or bolt or rod member extending above the tightened hold down nut so that the connection hardware could be hidden with an attractive covering cap. If the excess top length portion was not removed, the cap piece could not be seated properly in hardware concealment position. Additionally, it was also recognized that an uncovered hardware assembly provided a debris gathering area in the bathroom and that the covering cap enabled easy cleaning for a beneficial health benefit.
U.S. Pat. No. 6,254,141 to Piper, the entire contents of which are herein incorporated herein by reference, discloses an adjustable length closet fastener in which a length adjustment bolt can be adjusted downwardly by rotating it in a length adjustment sleeve, which length adjustment sleeve passes through an arcuate flange slot in a mounting ring part of the closet flange. The width of the arcuate flange slot is essentially of a standard diameter being fractionally or slightly wider than 5/16″. A shortcoming of the patented Piper fastener is that it cannot be used with a 5/16″ bolt since an internally threaded sleeve receptive of a 5/16″ bolt must include an outer member mandating an outer dimension in excess of 5/16″, such excess providing that the internally threaded sleeve cannot fit into the standard arcuate flange slot. Accordingly, the patented fastener is useable only with a ¼″ bolt.
It is therefore desirable that a self adjusting toilet bolt assembly useable with both ¼″ and 5/16″ diameter threaded studs or bolts be provided.
It is additionally recognized, that conventional use of steel assembly members promotes rust development in the moist bathroom environment and that brass and stainless steal bolts have been used as substitutes to overcome this corrosion detriment. Unfortunately, this use of stainless steal contrasts with the need to adjust the bolt length by cutting to fit each installation. Thus, since stainless steal bolts are much harder and are impossible or highly difficult to cut with a conventional hand-held metal saw brass bolts may be readily cut with a conventional hand-held metal saw and have become the standard material in use. Ultimately, while the strength and corrosion resistance of stainless steal makes it a more desirable metal, the use of brass has been widely adopted because of the need to cut bolts to length after installation due to the non-adjustability of the standard assembly configuration.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a self adjusting toilet bolt assembly which overcomes at least one of the drawbacks of the related art.
Another object is to provide a self adjusting toilet bolt assembly that can be used with both ¼″ and 5/16″ diameter studs and bolts, and which enables the use of full 5/16″ studs and bolts without compromising attachment or positioning strength.
Another object is to provide a self adjusting toilet bolt assembly which makes it unnecessary to cut off any length portion of the bolt once tightening with the hold down nut has been completed.
Another object of the present invention is to provide a self adjusting toilet bolt assembly that enables self driving of a 5/16″ stud with a separable head nut that also adjusts the ultimate assembly length to the minimum necessary to affix the toilet to a closet mounting flange.
The present invention provides a self adjusting toilet bolt assembly provides an anchor member for connecting a toilet bowl to a closet flange which allows use of downward 5/16″ stainless steal or brass stud travel through a standard width dimension slotted opening in the closet flange incident making connection of a toilet bowl to the closet flange. This result is made possible by use of apertures in an anchor member body lower body portion extending between two lower body portion wall parts providing clearance for the stud to pass unobstructedly in the flange slotted opening and connected with a bottom web member.
In accordance with the invention, the bolt assembly includes a threaded stud and an anchor member in which the stud is received. The anchor member includes an upper body portion and a lower body portion, the upper body portion having an internally threaded bore, the lower body portion comprising two spaced apart wall parts which extend down from the upper body portion. A retainer web is carried fixedly at a lower terminus of the wall parts. The closet flange has arcuate course slotted openings to which the anchor member lower body portion is slidably mounted, the mounting being one wherein the retainer web locates at an underside of the closet flange and disposes laterally of the slotted opening to capture the anchor member on the closet flange. The wall parts locate in the flange slotted opening and a first washer encircling the spaced wall parts and retain-ably positioned proximate the point where the wall parts have juncture with the upper body part is set on a top surface of the closet flange. The threaded stud is threaded into the upper body portion and an opening in a toilet bowl base is received over the threaded stud where the stud extends up from the closet flange. Optionally, a second washer encircling the stud is set on top of the toilet bowl opening. A hold down nut threaded onto an upper end of the stud is rotated down on the stud until the nut encounters an interference on the stud that produces unitary rotation of the stud and hold down nut along the threads into the anchor member. The stud thus is moved down to thereby reduce the length of the stud extending above the top surface of the toilet bowl base and eliminating any interference the upstanding stud and hold down nut would present to securement of a decorative concealment cover over the connection hardware
The interference producing unitary rotation of the stud with the hold down nut can be effected by engagement of the hold down nut with any suitable system known to those of skill in the assembly arts, including the use of an unthreaded or narrowed-thread segment on the stud, or with a deposit of a self hardening material such as LOCTITE® applied on the a segment of the threads.
The spacing of the wall parts of the anchor member lower body part portion provides apertures in the lower body portion. With the wall parts disposed in the closet flange slotted opening, the apertures provide a clearance space presence allowing the stud to move down between these wall parts. It is this arrangement that allows presence of a 5/16″ stud in the closet flange slotted opening which opening is only slightly larger than 5/16″. Prior art closet bolt types employing an internal threaded sleeve in which a stud is received and which sleeve extends down through the closet flange slotted opening, is limited in use to a maximum stud diameter of ¼″. A prior art sleeve companion to a 5/16″ stud has an external sleeve diameter too large to pass through the slotted opening. Thus, a 5/16″ stud cannot be used with the prior referenced Piper patent.
The above, and other objects, features and advantages of the present invention will become apparent from the following description read in conduction with the accompanying drawings, in which like reference numerals designate the same elements.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a bottom front perspective depicting the toilet bolt assembly disposition when it is anchored in place to a closet flange extension ring, the flange extension ring being a metal type, a portion of a toilet bowl base part which has been connected to the closet flange being shown in phantom depiction.
FIG. 2 is top perspective view of the bolt assembly shown in FIG. 1 except the assembly tightening bolt is disposed in bolt assembly untightened disposition without the top washer.
FIG. 3 is a top perspective view similar to FIG. 1 except the closet flange extension ring is a plastic type.
FIG. 4 is a view similar to FIG. 3 except the assembly tightening bolt is disposed in bolt assembly untightened disposition.
FIG. 5 is an exploded perspective view of the bolt assembly.
FIG. 6 is a partly exploded perspective view of the bolt assembly illustrating the tightening direction in which the bolt will be rotated on insertion thereof into the anchor member component of the assembly to initiate tightening as well as moving the stud downwardly in the anchor member.
FIG. 7 is a partial cutaway perspective section view of the anchor member component illustrating the upper internal threaded bore passage of the anchor member upper body portion, the threaded stud of the assembly not being shown, the anchor member integral lower body portion wall parts optionally being devoid of threads.
FIG. 8 is a view of the anchor member but with the stud being threaded in the receiver body portion, the stud extending downwardly in the boss portion in disposition thereof when bolt assembly is tightened.
FIG. 9 is a perspective view of the anchor member with a first assembly washer positioned above the anchor member preliminary to the forced passage of the first washer over the skirted structure at the juncture of the upper and lower body portions to capture said first washer encircling the wall parts.
FIG. 10 is a perspective view depiction the arrangement after the washer has been pressed down past the skirted structure with the first washer now being captively slidably mounted but slidably moveable of the wall parts between the underface of the skirted structure and the top face of anchor member base.
FIG. 11 is a plan view of the assembly first washer depicting in dashed lines the stress distortion of the washer imposed in consequence of forcing it past the skirted structure.
FIG. 12 is a fragmentary plan view partly in section showing how a 5/16″ diameter stud large size stud is slidably accommodated in a clearance area defined by apertures in the oppositely facing wall parts in an anchor member as a result of cutting opposite side aperture openings in the anchor member lower body boss portion for sliding access.
FIG. 13 is a perspective showing of an assembled toilet bolt provided in ready-to-use condition in a kit form package, the package including a receptacle receiving a pair of bolt assemblies and a transparent wrapper enclosing the receptacle.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference will now be made in detail to several embodiments of the invention that are illustrated in the accompanying drawings. Wherever possible, same or similar reference numerals are used in the drawings and the description to refer to the same or like parts or steps. The drawings are in simplified form and are not to precise scale. For purposes of convenience and clarity only, directional terms, such as top, bottom, up, down, over, above, and below may be used with respect to the drawings. These and similar directional terms should not be construed to limit the scope of the invention in any manner. The words “connect,” “couple,” and similar terms with their inflectional morphemes do not necessarily denote direct and immediate connections, but also include connections through mediate elements or devices.
Referring to FIGS. 1 through 4 , the self adjusting toilet bolt assembly 100 comprises as components, a hold down nut 200 , a threaded stud 300 , an anchor member 400 , a first washer 500 made of nylon, and a second metal washer 550 . Assembly 100 is interfitted with optional plastic closet flanges 600 A or metal closet flanges 600 B having assembly entry openings 800 with opposing side walls 802 , 802 for sliding access along a sliding direction B.
Referring additionally to FIGS. 5-8 , anchor member 400 includes an upper body portion 415 and a lower body portion 420 . Upper body portion 415 comprises a cylindrical part 416 and a lower frusto-conical part 408 includes defining a skirted structure. Upper body portion 415 includes a bore passage extending there through, the bore passage being internally threaded as at 401 . Lower body portion 420 comprises a pair of spaced apart wall parts 405 A and 405 B, these extending downwardly from the skirted structure part 408 , the wall parts 405 A, 405 B being arranged at reciprocal locations on the anchor member and having opposing cut-away wall faces 406 A, 406 B respectively. A retainer web part 403 includes a bottom opening 402 and is carried at the bottom of the wall parts 405 A and 405 B, this web structure being provided to be received under a lower face 601 B of flange 600 B ( FIG. 2 ). Spaces on the anchor member intermediate the wall parts 405 A, 405 B, define apertures 417 , 417 in the lower body portion 420 , these apertures being disposed at oppositely located sides of the lower body portion on cut away wall faces 406 A, 406 B respectively. The inner surfaces of the depicted wall parts are devoid of any threaded formation, although threads on these surfaces can be optionally provided for additional strength, the threads being identical with threads 401 .
Stud 300 receives on a top end thereof, the hold down nut 200 , while at an opposite or bottom stud end 418 ( FIG. 5 ) is the end inserted into the top of the threaded bore of the upper body portion 415 . The stud 300 can be threaded into the bore passage threads 401 and down below that passage such as to locate a lower tip end segment of the stud slightly below the retainer web parts 402 , 403 , the wall part lengths immediately above the retainer web parts 402 , 403 when the stud lower tip end segment is so situated, are disposed between oppositely facing slot walls 802 , 802 which define arcuate course slotted openings 810 in the closet flange, the said slotted openings 810 each having an enlarged entry opening as at 800 ( FIG. 3 ).
When hold down nut 200 is mounted at a top end segment of stud 300 , the hold down nut can be freely rotated on the stud in up or down directions without rotating the stud, the extent of free downward hold down nut independent of any rotation of the stud being limited. An optional and advantageous limitation is effected by presence of a resistance means on the stud provided to produce a unitary rotation of the hold down nut and the stud. This means can comprise a deformed or narrowed thread segment 305 formed on the stud ( FIG. 4 ). When the hold down nut 200 is being freely rotated on the stud 300 in the rotation direction R show by arrow in FIG. 6 and moving downwardly on the stud reaches the deformed thread segment 305 , the hold down nut threads bind with the stud threads produce unitary rotary movement of the hold down nut and the stud. The result is the stud concurrent with rotation thereof moves downwardly into the anchor member in the direction of the vertical arrow in FIG. 6 . The means to bind the hold down nut to the stud could be any means known to those of skill in the art and in a preferable embodiment may be an application of a self-hardening agent polymeric material such as a deposit 700 of LOCTITE® applied to a thread segment on the stud ( FIG. 5 ).
Referring now to FIGS. 9-11 , when nylon washer 500 is subjected to forced passage over the skirted structure 408 having an outer diameter X and slid down to an encircling of the wall parts 405 A and 405 B, the washer becomes elastically deformed with the result that it cannot be again forced over the skirted structure 407 A, 407 B to remove it from the anchor member. FIG. 11 depicts the elastic deformation impart to the washer 500 . The force passage of the washer over the skirted structure 408 results in a deformation of the normal circular inner diameter Y of the washer in a first outer direction X′ to accommodate the outer diameter X of skirted structure 408 a certain distance, the diameter differences being on the order of a few thousandths to several millimeter (mm). Also following such forced passage of the washer, the inner diameter of washer 500 elastically deforms in a direction D, a second inwardly distance X-Y′ to accommodate the opposing stretch in outer direction X′ and balance the elastic energies related thereto. Consequently, washer 500 shortens its inner dimension to a dimension Z from its original inner dimension Y, or an amount Z 2 on each side proximate each side wall region 406 A, 406 B, as shown. It will be recognized that this Z 2 deformation of washer 500 on the wall parts impedes removal relative to cut in lips 407 A, 407 B but does not completely stop sliding or rotation of the washer up and down of the wall parts 405 A, 405 B.
As noted earlier herein, and as can be seen from FIG. 12 , a particular advantage of the invention is that the presence of apertures 417 between the wall parts 405 A, 405 B in the anchor member 400 provides an enabling clearance area accommodating presence of the anchor member lower body portion in the closet flange arcuate course anchoring slotted openings 801 . In contrast to the present invention, where a 5/16″ diameter threaded bolt is received in a fully cylindrical length adjustment sleeve as in the Piper patent, such sleeve outside surface cannot enter slotted openings 801 being too wide for entering in between the walls 802 , 802 of the slotted openings 801 . As FIG. 12 depicts, the threads of the stud 300 of the present invention just fits between walls 802 , 802 and side walls 406 A, 406 B prevent relative rotation to the slot side walls enabling an easy installation and operating as rotational resistant surfaces contacting respective side walls 802 during installation.
The invention also provides as shown in FIG. 13 , a kit of components parts for connecting a toilet to a connecting closet flange. The kit includes at least one components parts assembly 100 , the assembly including an anchor member 400 having an upper body portion and a lower body portion. The upper body portion has a threaded through bore passing from an upper body portion top end to a location where the upper and lower body portions have a joinder juncture.
The lower body portion 420 comprises two spaced apart wall parts extending downwardly of the upper body portion, there a retainer web 403 is carried fixedly to a lower terminus of each wall part. A threaded stud 300 , a hold down nut 200 and a first washer 500 are included in the assembly as is a second washer 550 . The components are arranged in an assembly with a lower length portion of the stud threaded into an upper body bore passage with the first washer encircling the lower body wall parts, as shown although each member may be provided separately in wrapper 88 without departing from the spirit and scope of the present invention.
The hold down nut is threaded to an upper length part of the stud and the second washer is mounted on the stud intermediate the anchor member upper body portion intermediate a top end the anchor member upper body portion and a lower face of the hold down nut. The component parts assembly in wrapper 88 may be optionally received in a flexible side-walled container such as a open top box 77 , there being a transparent wrapper 88 encasing said container. It is advantageous that two assemblies be packaged in a container for sale since a bowl installation will require use of two assemblies.
In addition to the description above, it is noted that FIG. 1 depicts (in phantom outline) how a toilet bowl base 150 is positionally connected to the closet flange 600 B when the assembly has been tightened with hold down nut. It is seen that the bottom face of the bowl base sits on top of the upper face of closet flange 600 B, and the base upper face is engaged under a the lower face of a washer received on stud 300 next below the bottom of the hold down nut 200 .
Referring again to FIG. 12 , it is seen that the retainer webs carried on wall parts 405 A and 405 B mount the anchor member to the flange 600 B, this mounting being effected by inserting the retainer web parts 403 into enlarged entry end 800 of the arcuate course slotted openings 802 in the closet flange and at the underface of the flange. The web parts 403 are widened and extend under the structure of the closet flange, and need not be a continuous structure despite preference for same for strength reasons.
Referring again to the description of the FIGS. 1 and 2 , the structure and function is replicated with respect to FIGS. 3 and 4 , the these embodiments being identical except for the material from which the closet flange extension rings are made. One is made of metal while the other is plastic.
In the claims, means- or step-plus-function clauses are intended to cover the structures described or suggested herein as performing the recited function and not only structural equivalents but also equivalent structures. Thus, for example, although a nail, a screw, and a bolt may not be structural equivalents in that a nail relies on friction between a wooden part and a cylindrical surface, a screw's helical surface positively engages the wooden part, and a bolt's head and nut compress opposite sides of a wooden part, in the environment of fastening wooden parts, a nail, a screw, and a bolt may be readily understood by those skilled in the art as equivalent structures.
Having described at least one of the preferred embodiments of the present invention with reference to the accompanying drawings, it is to be understood that the invention is not limited to those precise embodiments, and that various changes, modifications, and adaptations may be effected therein by one skilled in the art without departing from the scope or spirit of the invention as defined in the appended claims.
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A self adjusting toilet bolt assembly provides an anchor member for connecting a toilet bowl to a closet flange which allows use of downward 5/16″ stud travel through a standard width dimension slotted opening in the closet flange incident making connection of a toilet bowl to the closet flange. This result is made possible by use of apertures in an anchor member body lower body portion extending between two lower body portion wall parts providing clearance for the stud to pass unobstructedly in the flange slotted opening.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
CROSS REFERENCE TO RELATED APPLICATION
This application makes reference to and claims priority to U.S. Provisional Patent Application No. 61/943,142, entitled “Air-Liftable, Modular, Rapidly Deployable Shelter,” filed Feb. 21, 2014, the contents and disclosure of which is hereby incorporated by reference in its entirety.
GOVERNMENT LICENSE RIGHTS
This invention was made with government support under W911QY-12-C-0128 awarded by the US Army Natick Soldier Research, Development and Engineering Center (NSRDEC). The government has certain rights in the invention.
FIELD OF THE DISCLOSURE
The present disclosure relates generally to a rigid wall shelter having both a packaged configuration and a deployed configuration, and more particularly to a rapidly deployable portable shelter.
BACKGROUND OF RELATED ART
A deployable shelter transforms from a smaller packaged state to a larger deployed state. Deployable shelters can be divided into two main groups: soft wall shelters and rigid wall shelters.
Soft wall shelters utilize a frame or skeletal structure to create the general supporting form of the shelter and a flexible cover stretched over the support structure to form a barrier. Examples of existing frame materials include wood, steel, aluminum, and fiberglass in the form of support poles, posts, or rails. Examples of existing flexible cover materials include fabric, vinyl, and animal skin. More generally, examples of existing soft wall shelters include tents and canopies.
As described in U.S. Pat. No. 8,602,044, tents of conventional, soft-sided construction are typically time-consuming to erect. For instance, U.S. Pat. No. 8,602,044 describes that tents with conventional internal frames require substantial effort by more than one person to place all the poles in position and then build a tent body around the pole structures.
As described in U.S. Pat. No. 3,368,575, some shelters require additional assembly and disassembly of the framework components (with the possibility of losing parts) and may require ropes, stakes, or other auxiliary devices to maintain them in an erected condition. Additionally, International Patent Application No. WO/2013/033819A1 describes large-scale collapsible fabric-covered structures, and typically the frames for such structures consist of multiple separate pieces which can become misplaced and are complicated to assemble, disassemble, and pack for shipment.
As described in U.S. Pat. No. 8,156,952, due to their temporary and portable nature, tent structures are often made of lightweight materials, which can lead to only marginally sturdy enclosures. U.S. Pat. No. 8,156,952 further describes that the fabrics of the tents can expand and shrink due to weather conditions or storage conditions.
Rigid wall shelters form a barrier from the outside environment through the use of rigid walls or panels. Examples of rigid-wall materials include wood, composites (e.g., carbon fiber or glass fiber reinforced polymer), brick, concrete, or layers of materials (e.g., sandwich panels). More generally, examples of existing rigid-walled shelters include buildings, houses, or containerized housing units (CHUs) such as mobile homes.
As described in U.S. Pat. No. 6,202,364, prefabricated structures are heavy to manipulate and often require large cranes which are expensive. U.S. Pat. No. 6,202,364, further describes that many of the prefabricated or other type home or building structures are constructed for permanent installation and cannot be easily dismantled and reassembled on another site.
As described in U.S. Pat. No. 8,622,066, due to their design and construction at least some of these portable shelters may require a significant amount of time and labor in order to properly set the shelter up for use, and to reconfigure the portable shelter for transportation when the shelter is no longer needed.
Finally, U.S. Patent Publication No. 2009/0014044 describes a folding shed including a first sidewall and a second sidewall. A first roof section is pivotally coupled with the first sidewall. A second roof section is pivotally coupled with the second sidewall. A foldable first end wall is pivotally coupled with the first sidewall, and the first end wall is pivotally coupled with the second sidewall. A foldable second end wall is pivotally coupled with the first sidewall, and the second end wall is pivotally coupled with the second sidewall. The first and second sidewalls, the first and second roof sections, and the first and second foldable end walls are configurable into a first position to define an interior of a shed. The first roof section is pivotally movable outwardly from the interior of the shed when the first and second sidewalls, the first and second roof sections, and the first and second foldable end walls are configured in the first position.
Deployable shelters are often used in situations where a temporary or seasonal shelter is required. Examples include emergency and disaster relief situations, athletic events, entertainment venues, and livestock transportation. Military soldiers are one of the largest user groups of deployable shelters, utilizing shelters in theater environments for soldiers, aircraft, vehicles, equipment, or any other suitable device. Such shelters range from tents carried by mobile foot soldiers to entire camps built of prefabricated, re-locatable buildings.
Accordingly, there is a need for a single deployable shelter solution that generally provides a sturdy enclosure that is relatively easy to erect, manipulate, and reconfigure as needed.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of an example shelter constructed in accordance with the teachings of the present invention in an open, non-deployed configuration.
FIG. 2 is a plan view showing the example shelter in a packaged configuration.
FIG. 3 is an elevation view showing the example shelter in a packaged configuration.
FIG. 4 is a perspective view showing the example shelter in a deployed configuration.
FIG. 5 is a plan view showing the example shelter in the deployed configuration.
FIGS. 6A and 6B are opposite side elevation views showing the example shelter in the deployed configuration.
FIG. 7 is a plan view showing the example shelter in the open, non-deployed configuration including insulation material between the panels.
FIGS. 8A-8F together illustrate one example of a general method of deploying the example shelter.
FIG. 9 is a perspective view showing two of the example shelters mated to form an example shelter compound.
FIG. 10 is a perspective view of a plurality of shelters interfacing with a container to create an example of a larger shelter compound.
DETAILED DESCRIPTION
The following disclosure of example methods and apparatus is not intended to limit the scope of the description to the precise form or forms detailed herein. Instead the following description is intended to be illustrative so that others may follow its teachings.
The shortcomings of previous efforts by others in the field of this technology may be overcome and additional advantages may be provided through a shelter having a packaged configuration and a deployed configuration. Additional features and advantages may be realized through the techniques utilized in the present shelter. Other embodiments and aspects of the shelter are described in detail herein and are considered a part of the claimed shelter. For a better understanding of the shelter with advantages and features, refer to the description and to the drawings.
Referring to the figures, wherein like numerals indicate like or corresponding parts throughout the several views, FIG. 1 illustrates a plan view of an example shelter 100 in a generally open, non-deployed configuration having a back wall, such as a first panel 101 having a first edge 102 , a second edge (Z 3 ) 103 , a third edge 104 , a fourth edge (Z 2 ) 105 , a first face 106 , and a second face 107 , a first wing wall such as a second panel 108 having a first edge (X 2 ) 109 , a second edge 110 , a third edge (W 2 ) 111 , a fourth edge 112 , a first face 113 , and a second face 114 , a second wing wall such as a third panel 115 having a first edge (X 3 ) 116 , a second edge 117 , a third edge (W 3 ) 118 , a fourth edge 119 , a first face 120 , and a second face 121 , and a roof such as a fourth panel 122 having a first edge 123 , a second edge (Y 3 ) 124 , a third edge 125 , a fourth edge (Y 2 ) 126 , a first face 127 , and a second face 128 .
As best illustrated in FIGS. 6A and 6B , an angle alpha (α) 600 is formed between the second edge 110 and third edge (W 2 ) 111 of the second panel 108 and the third edge (W 3 ) 118 and fourth edge 119 of the third panel 115 . Similarly, an angle beta (β) 601 is formed between the first edge (X 2 ) 109 and second edge 110 of the second panel 108 and first edge (X 3 ) 116 and fourth edge 119 of the third panel 115 .
In the present disclosure, the angle alpha (a) is generally greater than zero degrees and generally less than or equal to 90 degrees, as provided in Equation (1). Similarly, the angle beta (β) is generally greater than 180 degrees minus alpha (180°−α) and generally less than 180 degrees, as provided in Equation (2). It will be appreciated by one of ordinary skill in the art that other sizes of the shelter 100 will satisfy the conditions for the angles alpha (a) and beta (β). In one example, the first edge (X 2 ) 109 of the second panel 108 has a length generally greater than zero and generally less than or equal to a length of the fourth edge (Y 2 ) 126 of the fourth panel 122 , as provided in Equation (3). Further in one example, the first edge (X 3 ) 116 of the third panel 115 has a length generally greater than zero and generally less than or equal to a length of the second edge (Y 3 ) 124 of the fourth panel 122 , as provided in Equation (4). In one example, the third edge (W 2 ) 111 of the second panel 108 has a length generally greater than zero and generally less than or equal to a length given by the equation (Z 2 ) cos (α)+(Y 2 ) cos (α+β−180°), as provided in Equation (5). Further in one example, the third edge (W 3 ) 118 of the third panel 115 has a length generally greater than zero and generally less than or equal to a length given by the equation (Z 3 ) cos (α)+(Y 3 ) cos (α+β−180°), as provided in Equation (6).
0<α≦90° (1)
180°−α<β<180° (2)
0< X 2≦ Y 2 (3)
0< X 3≦ Y 3 (4)
0< W 2≦( Z 2)cos(α)+( Y 2)cos(α+β−180°) (5)
0< W 3≦( Z 3)cos(α)+( Y 3)cos(α+β−180°) (6)
The shape of the panels can include any quadrilateral such as, for example, square, rectangular, trapezoidal, rhombus, or other suitable shape. Panel materials can include, for example, metal, composite (such as carbon fiber or glass fiber reinforced polymer), wood, or other suitable material. Panels can be of a solid construction of a single material or a sandwich construction of multiple layers of material. In the disclosed example, the first and fourth panels have a rectangular shape and the second and third panels have a quadrangle shape. A hinge, such as a pivot connection 129 connects the second panel 108 to the first panel 101 , the third panel 115 to the first panel 101 , and the fourth panel 122 to the first panel 101 . Such a pivot connections can include, for example, a single hinge or a plurality of hinges.
Referring to FIG. 2 there is illustrated a plan view of one example of the shelter 100 in a generally closed packaged configuration having the second face 114 of the second panel 108 generally parallel and adjacent to the second face 107 of the first panel 101 , and the second face 121 of the third panel 115 generally parallel and adjacent to the second face 107 of the first panel 101 . Other variations of packaged configurations are possible by rotating the panels about their respective pivot connections in any desired order. In one example, the packaged configuration of the shelter has a periphery within surface area dimensions of a standard military pallet. For instance, one example packaged configuration of the shelter has a periphery within surface area dimensions of a 463 L pallet, which extends approximately 88 inches by approximately 108 inches.
Referring to FIG. 3 there is illustrated a elevation view of one example of the shelter 100 in a generally closed packaged configuration having the second face 114 of the second panel 108 generally parallel and adjacent to the second face 107 of the first panel 101 , the second face 121 of the third panel 115 generally parallel and adjacent to the second face 107 of the first panel 101 , and the first face 127 of the fourth panel 122 generally parallel and adjacent to the first face 106 of the first panel 101 . In the illustrated example, the fourth panel 122 is generally wider than the first panel 101 .
Referring to FIG. 4 there is illustrated a perspective view of one example of the shelter 100 in a generally deployed configuration of the first panel 101 , second panel 108 , third panel 115 , and fourth panel 122 .
Turning now to FIG. 5 there is illustrated a plan view of one example of the shelter 100 in a generally deployed configuration having the second face 114 of the second panel 108 generally perpendicular to the second face 107 of the first panel 101 , the second face 121 of the third panel 115 generally perpendicular to the second face 107 of the first panel 101 , and the second face 128 of the fourth panel 122 generally perpendicular to the second face 114 of the second panel 108 and generally perpendicular to the second face 121 of the third panel 115 . Other variations of deployed configurations are possible by rotating the panels about their respective pivot connections in any desired order. Additionally, the panels may engage with one another at any suitable angle.
Referring to FIG. 6A-B there are illustrated opposite side elevation views of the example shelter 100 in a generally deployed configuration having the angle alpha (a) 600 formed between the second edge 110 and third edge (W 2 ) 111 of the second panel 108 and the third edge (W 3 ) 118 and fourth edge 119 of the third panel 115 . The angle beta (β) 601 is formed between the first edge (X 2 ) 109 and second edge 110 of the second panel 108 and first edge (X 3 ) 116 and fourth edge 119 of the third panel 115 .
Referring to FIG. 7 there is illustrated a plan view of the example shelter 100 in a generally open packaged configuration having a strip of insulation material 700 adjacent to the second edge 110 of the second panel 108 and the fourth edge (Z 2 ) 105 of the first panel 101 , a strip of insulation material 700 adjacent to the fourth edge 119 of the third panel 115 and the second edge (Z 3 ) 103 of the first panel 101 , and a strip of insulation material 700 adjacent to the third edge 125 of the fourth panel 122 and first edge 102 of the first panel 101 . Such insulation material can include, for example, spray foam, duct tape, weather-stripping, foam, putty, a gasket, or any other suitable material. Insulation material can be applied on site after deployment of the shelter 100 . In one example, insulation material can be applied to close any gap formed between panel edges. Other insulation methods can include, for example, covering the shelter 100 with canvas, tarpaulin fabric, or any other suitable material.
Referring to FIG. 8A-8F there is illustrated one example of a general method of deploying the shelter 100 from a packaged configuration to a deployed configuration by providing the shelter 100 ( FIG. 8A ), rotating the shelter 100 about an axis of rotation defined by the third edge 104 of the first panel 101 in contact with a supporting surface ( FIG. 9B, 9C ), rotating the second panel 108 about an axis of rotation defined by the second edge 110 of the second panel 108 and the fourth edge (Z 2 ) 105 of the first panel 101 to extend from the first panel 101 ( FIG. 9D ), rotating the third panel 115 about an axis of rotation defined by the fourth edge 119 of the third panel 115 and the second edge (Z 3 ) 103 of the first panel 101 to extend from the first panel 101 ( FIG. 9D ), and rotating the fourth panel 122 about an axis of rotation defined by the third edge 125 of the fourth panel 122 and the first edge 102 of the first panel 101 to rest upon the wing walls ( FIG. 9E, 9F ). Other variations of deployed configurations are possible by rotating the panels about their respective pivot connections in any desired order. Additionally, the panels may engage with one another at any suitable angle.
In the present example, the step of rotating the shelter 100 about an axis of rotation is further defined as operatively connecting a lever arm 900 in a generally perpendicular position to the first face 106 of the first panel 101 and adjacent to the third edge 104 of the first panel 101 and providing a force to the lever to overcome the self-weight of the shelter. In one example, the lever arm 900 may include a counterweight, or other suitable attachment for assisting in the erection of the shelter. Rotating the shelter 100 during deployment can be accomplished by any suitable method, including for example, via a cable(s) or by hand. The lever arm 900 materials can include, for example, metal, wood, composite, or any other suitable material.
Referring to FIG. 9 there is illustrated one example of two shelters 100 in a configuration to create a generally larger shelter compound. It will be appreciated by one of ordinary skill in the art that other panels and/or configurations may be utilized. For example, in one configuration, there may be enclosure panels utilized to construct a shelter having an enclosed space.
Referring to FIG. 10 there is illustrated one example of a plurality of shelters 100 interfacing with a container 1100 to create a generally larger shelter compound. In one example, the container 1100 can be a shipping container, building, home, shelter, or other suitable container. For instance, in one example, the container 1100 may be a Tricon modular container available from Charleston Marine Containers, Inc., Charleston, S.C.
Obviously, many modifications and variations of the present technology are possible in light of the above teachings and may be practiced otherwise than as specifically described while within the scope of the claims. For instance, although certain example methods and apparatus have been described herein, the scope of coverage of this patent is not limited thereto. On the contrary, this patent covers all methods, apparatus, and articles of manufacture fairly falling within the scope of the appended claims either literally or under the doctrine of equivalents.
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A shelter has a packaged configuration and a deployed configuration. The shelter has four panels, each with four edges and two faces. The first and fourth panels have a rectangular shape, and the second and third panels have a quadrangle shape. The relationship of panel edge lengths and angles of the quadrangle shelter panels create a sturdy enclosure that is easy to erect, manipulate, and reconfigure. Furthermore, the shelter may be erected by rotating the panels into place via pivotal connections between the panels and optionally through the use of a lever arm.
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BACKGROUND OF INVENTION
1. Field of Invention
This invention relates to a confidential financial security banking system for banking consumers. Specifically, to an improved banking security system to protect the communication of customers requesting financial transactions of services from or with bank-tellers in the lobby of banks and from drive-in/drive-through banking lanes.
2. Related Art
Originally; and currently, persons entering the lobby of any banking institutions, must go directly to the bank-teller's window to communicate their transactions, while doing this financial transaction, other persons are constantly entering the bank lobby. Each person stands directly behind each other; thus forming a “waiting-line” to perform similar financial transactions of business from the bank-teller. The second or third person in the “waiting-line” has a clear opportunity to “listen” to and observe the customers financial transactions. The current banking security system does not provide any secured communications of the customers financial transactions to keep other banking customers from listening to conservations the customers are discussing with the bank tellers. The current system allows for open and unprotected communications and for banking customers to be easily identified as potential victims of financial exploitation's or become extorted.
It is well known throughout the world; that the banking consumers-population is consistently increasing, that financial exploitations, extortations and bank robbers are also increasing. There is not a general method of prior art addressing these problems with solutions within the entire banking industries. Nor, is there a general method of an anti-theft invention of this nature to protect banking personnel and banking consumers.
3. Summary of Invention
This invention provides an anchored steel framed structural chamber of Paltech paneled construction, mirrored on the outside, 15′5″ L, 6′5″ W, with electronic sliding doors of 3′ wide. This structural chamber is easily anchored within the lobby of bank directly in front of each bank teller's transaction area. Bank teller controls electronic opening and closure of sliding doors, permitting only one customer to enter and exit at a time to perform financial transactions.
The advantages of this invention provides a protected financial transaction between customer and bank teller, prevents other “customers waiting in line” within the bank lobby from listening to previous customer's financial transaction, and lip reading of customer's financial transaction is also eliminated. An additional advantage of this invention ensures banking customers performing financial transaction with teller from being identified as targeted victims for financial exploitation's or extortion by observant perpetrators waiting in the bank lobby.
It is also well known throughout the world that as the population continues to ages, most consumers will become “hearing impaired” and consequently they will talk louder. The U.S. Census Population Graph below, indicates projected growth of age 65+ in millions to year 2050.″ 1 The U.S. Census provides opportunities of marking progress of the consumer-population and identifies growth of every interest in this society. Therefore, a clear potential for financial exploitation's and extortion's will increase proportionally with this growth.
1 Data Base News in Aging. U.S. Census Bureau. The Official Statistics. August, 17. htt//blue census gov/search/cigi/s
A further advantage of this invention eliminates accessibility for perpetrators to rob banking institutions, and provides immediate apprehension of any person attempting to rob a bank from within lobby of bank after entering structural chamber to request any type of financial transaction.
This invention for banking-lobby financial transaction is TDDY equipped at Bank teller's transaction counter for deaf-consumer population and is wheelchair accessible.
An additional advantage of this invention provides for customer from drive-in, drive-through banking lanes to initiate and or communicate with bank teller from their car without conversations being heard by other customers waiting in their cars or by persons walking around the parameters of drive-through banking lane areas. A telephone receiver is interconnected with money depository module and has a retractable flexible conduit card attached to phone receiver with an extension capacity for customer to hold phone receiver, while in a comfortable sitting position in a car to perform conversation of financial transaction. Bank teller at drive-in window transaction has a wireless system communication headset which provides a complete private conversation channel between drive-in, drive-through banking customer with bank teller.
This total invention and its object provides protection for banking personnel, prevents endangerment to banking consumers and increases levels of security as their conversations with bank tellers are not being heard by other customers.
Further advantages of this invention will become better understood by reference to the detailed description and viewed drawings.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1A is a parallel view of exterior entryway security chamber;
FIG. 1B is a parallel view of inside illustration of security chamber and teller window;
FIG. 1C is a longitude outside schematic view of drive-in/drive-through teller window;
FIG. 2 is a diagrammatic view of layout perimeter of security chamber;
FIG. 2A is a perspective view of anchor choices illustrating the mounting of assembly;
FIG. 2B is a sectional view of gauge steel hold-downs to stabilize structure;
FIG. 3 is a diagrammatic inside view of teller transaction window;
FIG. 4 is a partial sectional view of double stud beam assembly;
FIG. 4A is a sectional view of window casing;
FIG. 5 is a diagrammatic view of entrance wall configuration;
FIG. 5A is a partial view of entrance way door headers;
FIG. 5B is a diagrammatic view of entrance door sliding tracks;
FIG. 6 is a perspective diagrammatic view of containment room assembly;
FIG. 6A is a plan view of hydraulic scissors type supporting component parts for steel drop doors;
FIG. 6B is a sectional view of gauge steel bottom plate track for containment room;
FIG. 7 is schematic view of conventional electrical wiring system;
FIG. 8 is a schematic view of conventional filtration unit for building;
FIG. 9 is a side perspective view of the bank teller window;
FIG. 9A is a clear perspective view of drive-through communication module;
FIG. 10 is a illustrative overview of the lobby banking financial security transaction and interconnected privacy telecommunication drive-in, drive-through channels.
DETAILED DESCRIPTION OF INVENTION
In describing preferred elements of this invention, it is to be understood that each specific element includes all technical equivalents which operates in a similar manner to accomplish a similar purpose.
FIG. 1A, FIG. 1 B and FIG. 1C provides overview of elements of security systems structure 5 in accordance 6 comprises a steel drop door to a secured containment room for apprehension of bank robber from within lobby. While 3 comprises controlled teller/customer verbal and financial transaction areas for maximum protection, and FIG. 1C shows side exterior similar arrangements.
FIG. 2 Detailed elements provides the layout perimeter of 12 “Lobby Banking Financial Security Chamber,” as 7′×16′ OD and establish 14 anchor location line of 1¾″ inside first line all the way around. Establish 16 anchor locations from intersecting corner lines for teller end wall. Now, measure on a horizontal plane, inward from both ends 5¾″ and 24″ on center for a total of 4 anchor locations. For entrance sliding doors to Lobby Banking Financial Security Transaction Chambers; measure on a horizontal plane, inward from both ends 5¾″ and 14¼″ on center for total of 4 anchor locations. Now, for wall construction, measure on a vertical plane, inward from both ends 6¾″ and 25″ on center for a total of 7 anchor locations. Both walls are with identical measurement and locations.
FIG. 2 a Using 18 , 1″ conventional drill bit; drill 19 hole depth of 7½″ deep, clear all debris from holes with 20 manual or conventional air compressor.
Now we are going to use 21 ET-22 Epoxy-tie resin, and place in each hole, one at a time, fill half full from bottom up and to avoid air bubbles, slowly withdraw 22 mixing nozzle as hole is being filled. 24 insert ⅞″ 11 UNC 2A×8½″ anchor threaded stud flat, and turning slowly until seated. 24 anchor threaded stud flat will have a 26 1″ above grade check for plumb. Set time is 6 hours and cure time is 24 hours. It is noted here that Epoxies offer stronger bonding, shorter cure time, and less hydrolization that other types of resin anchors. ET-22 Epoxy-tie is a two-component amine-based system for high strength bonding.
Locate on all 28 bottom plate track, corresponding 16 anchor locations and pre-drill with 18 1″ conventional drill bit. Apply polyurethane sill sealer to all edges of bottom track webs and install over 24 anchor threaded stud flat, ⅞″ UNC 2A×8½.″ It is noted here that the anchor stud and installations used in this design is for an existing floor. A powder driven anchor provides another option, such as, ½″ ×10″ A.B. 6′-0″ O/C (TYP. UN.0.) 9″ from ends. Minimum 2 per track section. There are several anchor choices available for new single or double pour floors; for single pour S/PAHD42, S/MPAHD, S/HPAHD22, HPAHD22-2 holddowns, and for double pour, typical HPAHD22-2P or typical S/HPAHD.
Teller wall has a horizontal length of 7′ with 4 anchor locations, entrance wall will be a 2′ 28 bottom track length on each side of the wall and with two anchor locations on each side. Vertical bottom track wall length is 15′5″, I.D. (inside diameter). Vertical 28 bottom plate track has 7 anchor locations, and with other side being identical. Both vertical 28 bottom plate tracks will butt both horizontal 28 bottom plate tracks.
FIG. 2 b Install 30 S/HD 8-10 gauge steel holddowns, ¼″ plate at all corners to stabilize structure. Secure to corners with 24 #10 screws. To anchor, secure all anchors with 32 heavy locking washer {fraction (15/16)}″ steel and 33 hex nut ⅞″ UNC 2 B steel. Total number of 16 anchor locations is 22 .
FIG. 3 Provides detailed elements of teller transaction window wall within the Lobby Banking Financial Security Chamber. To make double studs interconnect 34 two (2) single studs of 3½″ ×8′ 20 gauge steel fastened together through flanges with 37 ¾ #8 teks low profile pan head screws pan head screws through flanges on both sides of studs.
Now, install vertical 36 double stud assembly to 28 bottom plate track 3½ 20 gauge steel to each end, and secure with 31 ¾″ #10 teks low profile pan head screw through each flange. There are four (4) flanges here. From top of inside face of 36 double studs, measure down 3½″ of each assembly of each side. Fasten to 36 double studs 38 bent plate angle steel 3″×3″×3″×¼″ (each side is 3″ tall and 3″ long by ¼″ thick), using 31 ¾″ #10 teks low profile pan head screws, and each side of angle will require three (3) of these pan head screws. Take 39 horizontal beam double stud which is 6′5″ and place on 38 bent plate angle 20 gauge steel 3″×3″×3″×¼″. Fasten angle to beam from bottom side with 31 . There are three (3) screws required for each side.
Install 6′5″ length of 48 1¼″ window casing steel to underside and outside edge of 39 horizontal beam, fasten with 66 1¾″ #10 teks low profile pan head screws. Measure inward from each end 2½″. Now, measure and place screws every 24″ apart. There are four (4) screws required for these. From 39 horizontal beam 36 double stud intersection, install vertical length of 48 1¼″ window casing steel on each side of 18½″ in length, use 66 1¾″ #10 teks low profile pan head screws. Measure 7″ apart and fasten to studs on both side, three (3) on each side. To 36 install 38 bent plate angle 3″×3″×3″×¼″ 20 gauge steel with one on each side. Fasten this with 31 ¾″ #10 teks low profile pan head screws, and put three (3) screws to each side of angle. Fasten 42 3″×¼″ plain plate 20 gauge steel with horizontal measurement of 6′5″ and fasten with 41 ½″ #8 teks low profile pan head screws. To bottom of 42 , install 43 a 2″ double window track 20 gauge steel to bottom of 42 3″×¼″ plain plate 20 gauge steel, and fasten with 41 ½″ #8 teks low profile pan head screws. Measure every 24″ and secure pan head screws. Now, continue with 43 2″ double window track 20 gauge steel, install in a downward, vertical length with a measurement of 2′8″ for both sides, and fasten with 41 ½″ #8 teks low profile pan head screws, measure every 24″ and secure screws.
Install 38 bent plate angle 3″×3″×3″×¼″ steel 20 gauge to 36 double studs with 31 ¾″ #10 teks low profile pan head screws and continue in horizontal measurement of 6″5 40 to 43 2″ double window track 20 gauge steel; leave a 2″ space for 49 2″ granite counter top and at 2′10″, install 50 3″ clip to 36 double studs, on each side with 31 ¾″ #10 teks low profile pan head screws and fasten 44 top plate track; 3½″×6′5″ 20 gauge steel and 28 bottom plate track 3½″×7′ 20 gauge steel, fasten with 31 ¾″ #10 teks low profile pan head screws, using one pan head screw on each flange.
Now, returning to top of wall, install into the 6′56″×21″ opening from the back side 45 1″ Bullet and Bomb Resistant Paltech Advanced Polymers Plastic; mirrored on outer side, 6′5″×1″×21″ and attach 46 ¼″ vinyl wedge gasket using a caulking gun with 47 silicon sealer (conventional), spread on both sides and entire length of 46 ¼″ vinyl wedge gasket, then secure to the 6′5″×1″×21″ Paltech panel. Install 48 1¼″ window casing 6′5″ to underside of outside edge of 39 horizontal beam with 66 1¾″ #10 teks low profile pan head screws. Measure 2½″ inward from each end. Remaining screws are 24″ apart on bottom window casing as this is identical. Vertical side pieces are 18½″ long. Measure 1¼″ inward from each end and remaining screws are 8″ apart.
Now, element 51 install sliding window panels 2′8″×1″×1′ with 45 1″ Bullet and Bomb Resistant Paltech Advanced Polymers Plastic; mirrored on outside, install in back track of 43 2′ double window track 20 gauge steel. These panels are pre-framed from manufacture. This creates 2′8″×1″×1′ teller transaction window in front track of 43 2″ double window track 20 gauge steel. Install 2′8′×1″×6′5″ 45 Paltech panel with 46 ¼″ vinyl wedge gasket all around. Using caulking gun with spreading 47 silicon sealer (conventional) all around. Install 48 1¼″ window casing all around and attach to 36 double studs with 31 1¾″ #10 teks low profile pan head screws, and measure horizontal 6′5″ and 12″ on center, then measure vertical 2′8″ and 8″ on center. Back of wall is identical. 45 Paltech panel has a 4″ circumference cut for teller communication.
Element 53 , measure 43″ from teller counter top to floor, install 6′5″×2″×1″×43″ sheet of synthetic marble covering front and back of teller wall. 60 measure directly centered in front of teller window located on floor is 2″×4″×5′ steel drop door. Additional embodiments are shown in FIG. 5 b , FIG. 6 and FIG. 6 a.
54 Electrical Master Control Console 20″×3″×5″ is located behind teller wall underneath teller transaction counter top and is floor mounted at a 45 degree angle. The 54 Electrical Master Control Console is also within an extended distance where the bank teller will be able to extend leg to reach 54 push button switches with foot, while standing or in a sitting position. Additional embodiments are shown in FIGS. 4, 5 , 5 a , 5 b , 6 , and 7 ; as each push button controls 68 Leaner Track Lighting System, 70 Fire Sprinkler, 58 Security Camera Lens Track System, 74 Entrance Doors with Locks, 51 Teller Sliding Windows with Locks, 56 Pepper Gas Spray Heads, 60 Steel Drop Doors with Locks, and 55 Alarm System. These systems can be activated independently of each or together simultaneously. Element 111 is also shown in FIG. 5 b and FIG. 9 .
FIG. 4 Describes detailed elements of Interlocking 36 Double Stud 39 Horizontal Beam Assembly of Lobby Banking Financial Security Chamber walls which measured 15′5″ in length. Fasten this to 28 bottom plate track through flange using 41 ½#8 screws and put 2 screws on each side of 36 double studs. Now, fasten previously installed 30 S/HD holddown with 31 ¾″ #10 screws, with already pre-drilled holes and 24 screws are required. 109 TDDY System is counter mounted for hearing impaired.
Fasten together two (2) 24 single stud, using ½″ #8 screws, and measure every 24″ apart through flanges for each screw, 8 screws are required to make a 36 double stud assembly. Measure 3½″ from end of stud, prior to fastening together. Cope flange and bend outward. Cut and discard web; this is done to each single stud, one end and one side. Fasten studs together with 41 ½″ #8 screws, place one screw every measured 24″ through flanges on both side. 39 horizontal beam, when erected will be threaded into 36 double studs and fastened; creating an interlocking 36 double stud 39 horizontal beam connection and providing maximum strength for the stud and beam structure.
To previously installed 28 bottom plate track, a length of 15′5″, measure and mark all 36 double stud location of 37″ apart for a total number of 5 sets of 36 double studs. Erect each set and center 36 double studs in track on location marks. Fasten these to 28 bottom plate track using 31 ¾″ #10 screws, and put one screw through each flange on each side. Both walls are identical. Install all 36 double studs at this time.
Raise and install 39 horizontal beams 6′11″ in length as follows: raise 39 horizontal beam, thread into coped 36 double stud, fasten through bend out flanges to 39 horizontal beam
Use 31 ¾″ #10 screws, measuring 1½″ apart vertically and horizontally. Put 6 screws on each side of 36 double studs for connection. To underside of 39 horizontal beam and 36 double stud intersection, fasten 38 bent plate angle, using 31 ¾″ #10 screws and 4 screws to each side of angle; eight (8)screws are required on the already pre-drilled bent plate. Now to bottom of 39 horizontal beam, raise 62 head track of 6′8½″ in length flange turned up and secure to bottom of 39 horizontal beam through 62 head track web and flanges on both sides. Now, measure inward 2½″ from edge of 62 head track web end, and 1″ inward from outside web edge for first row of screws. There are 2 rows and remaining screw locations are 35″ apart for each row. Flange screws correspond to horizontal web screw locations. With vertical spacing of ½″ from top edge of flange. Use 31 ¾″ #10 screws and ten (10) screws are required.
Element installation of 44 top plate track. The 44 top plate track is 15′5″ in length, with a manufactured coped-straight out flange on one side. Now, erect and set in place over tops of 36 double studs and connect from end to end. Turn coped flange to inside and fasten outside track flange to outside face of 36 double studs, with one on each side. Use ¾″ #10 screws, putting two screws of equal distance apart on each stud. A total of 10 screws are required.
FIG. 4 a To inside web of 44 top plate tract, install 40 1″×2″ window casing 34″ long, butt to flange. Secure casing by fastening through 44 tops plate track down through casing, using 41 ½″ #8 screws, measuring 10{fraction (5/16)}″ apart; three ( 3) screws are required for this. To 28 bottom plate track install 40 1″×2″ window casing 34″ long butt to flange, secure down through casing to track with 64 1¾″ #8 screws, measured 10{fraction (5/16)}″ apart. Three (3) screws are required. Butt to bottom and top 40 1″×2″ window casing, of 7′11⅞″ on side section. Fasten through casing to 36 double studs and using 64 1¾″ #8 screws, measure 2½″ inward from each end. Installation of remaining screws are 18″ apart and 7 screws are required on each side.
We are now going to backside of 40 1″×2″ window casing and apply 63 conventional Epoxy sealer. Insert manufactured cut-to-fit panel of 45 1″ Paltech plastic panel 34″ wide×1″ thick×7′11¾″ long with 46 ¼″ vinyl wedge gasket. To 28 bottom plate track, install 40 1″×2″ window casing 34″ long. Butt to flange and secure down through casing to track with 64 1¾″ #8 screws, measuring 10{fraction (5/16)}″ apart. Three (3) screws are required. Butt to bottom 40 1″×2″ window casing, 7′11⅞″ for inside section. Now, fasten through casing to 36 double studs with 64 1¾″ #8 screws, measured 2½″ from end edge distance of each end. Remaining screws are 18″ apart, and 7 screws are required on each side. Lets install 46 1¼″ vinyl wedge gasket with 47 silicon sealer. There are five (5) panels per wall length.
Elements of ceiling installations are as follows: measure down from top edge of previously installed 39 horizontal beam 1″ on both ends, mark and strike a line end to end. Install 6′8½″ length of 40 1″×2″ window casing. Use 66 1¾″ #10 screws. Measure 2½″ inward from end edge remaining screws are 16″ apart and 5 screws are required. Now, fasten through 48 1¼″ window casing to 39 horizontal beam and fasten through casing to both beam. Apply 63 epoxy sealer to top side of 40 1″×2″ window casing, and each end of manufactured pre-cut 45 1″ Paltech Panel of 34″ wide×1″ thick×6′8½″ long. 45 1″ Paltech Panel will be maneuvered up through span between 39 horizontal beams and threaded into position, end edges of 45 1″ Paltech Panel butt to side window panel and rest on horizontal 40 1″×2″ window casing length. Weight of ceiling panel and 63 epoxy sealer provides an air tight seal, fully supported ceiling and wall Paltech connection. Both walls of structure are identical with this installation. All ceiling installation are also identical.
Elements of 68 track lighting, halogen system, will be installed inside chamber, 7′8½″ top parameter of chamber structure, 6′5″ wide, 15′5″ length. A conventional 70 fire sprinkler head is located on 39 horizontal beam, measuring 3′2½″ on center. This sprinkler system is interconnected with already existing banking sprinkler system.
FIG. 5 Provides-detailed elements of Entrance Wall Configuration. This entrance is 7′ in width, center is 3′6″, to each side of center, measure 18.″ This measurement combined equals 36″, which is the width of the 74 entrance doors and the 73 doorjamb location begins on these measurements. We are going to erect and install 36 double studs 6′9″ in length. To previously installed 28 bottom plate track, using 37 ¾″ #8 screws, fasten through track flange 2 screws are on each side. Four (4) screws are required. Identical installation is for other side.
Now, we going to install a second set of 36 double studs 8′ in length. To 28 bottom plate track using 37 ¾″ #8 screws and fasten through track flange, two (2) screws on each side. Four (4) screws are required. These studs are erected and standing side by side. The other side is identical. This installation will provide maximum load bearing support for 74 entrance doors and 71 door header.
Lets measure a distance of 14″ and install corner 36 double stud assembly 8′ in height and both ends of entrance are the same. We are going to erect 36 double studs and fasten to 28 bottom plate track through flanges. Using 37 ¾ #8 screws, two (2) screws on each side, equal distance apart, for a total of 8 screws. Secure previously install 30 S/HD holddown to 36 double studs with 31 ¾″ #10 screws, 24 screws are needed for each installation for each end of wall.
Now, we must connect to both previously erected 36 double stud assemblies 6′9″, a horizontal length of 62 head track a length of 3′7″. Cope web on both ends of 3½″ of 62 head track flange pointing them up, bend web in an upward direction. Secure coped web to 36 double studs, and both ends. Use 41 ½″ #8 screws, two (2) on each side and each end; measured 1″ apart. Secure coped cut flanges to 36 double studs, use 41 ½″ #8 screws, two screws (2) for each flange, measured 1″ apart. There are eight (8) screws required.
To 62 head track install in a vertical direction, two (2) 72 cripple studs 10″ in length, with flanges turned facing each other, secure to 36 double studs on each side and fasten flange through flange with 41 ½″ #8 screws, 1 screw each top and bottom flange on each side. Four screws are required.
To vertical 72 cripple studs install 44 top plate track, 3′7″ in length. Again, cope both ends 3½″ inward on each end and bend downward on both ends. Erect and install over cripple studs, flange turned down. Secure coped web to sides of 36 double studs using two (2) 64 1¾″ #8 screws, measured 1½″ apart, using 2 screws for each web and each end. There are four (4) screws are required.
We are now going to secure coped flanges to sides of 36 double studs and both sides using 64 1¾″ #8 screws, measured 1″ apart; two (2) screws for each flange and for each side. Fasten to 72 cripple studs, with 31 ¾″ #10 screws, flange through flange, put screws in center where the flanges connect. There are two (2) screws to each side. A total of four (4) screws are required for top and bottom on both sides. Now, install 112 over face of door header, secure with ½″ #8 pan head screws, 3½″ inward from each end, space screws every 18″. Three screws are required at top and bottom sides. Both sides are identical.
FIG. 5 a Provides described elements for installation of 71 Door Header, as follows: cut two lengths of 34 stud, 3′7″ in length. Cope each end of each 34 stud, 3′½″, cut off and discard flange pieces from each end. There will be a 3′½″ web extension on each end, with each length being turned on its flange side and aligned with 44 top plate track edge. Flanges are facing inward. Each side is identical. Thiscreates the 71 Door Header. Secure this in place to 44 top plate track with 64 1¾″ #8 screws. Now, screw these through 44 top plate track web, and up through flanges of 71 Door Header, measuring on each side is 12″ apart to put screws. Other side is identical. To top of this entire wall assembly, raise and install over tops of all 36 double studs, 44 top plate track. This track is manufactured coped on one side. Install this coped flange toward inside of chamber, flange will overlap at wall 44 top plate track intersection. Fasten, 44 top plate track to 36 double studs and down through overlapping, 44 top plate track, with 37¾″ #8 screws. Measure 1″ apart, put screws through flange and web to studs, and measure 1″ apart on over lapped track, put screws through track connection. A total of twelve (12) screws are required.
Now, standing inside of Lobby Banking Financial Security Chamber, look out through 14″ opening and install 48 1¼″ window casing; with a measurement of 14″ in length, butt to outer flange 44 top plate track. Secure 48 1¼″ window casing by screwing down through web of 44 top plate track into 48 1¼″ window casing. Use 37 ¾″ #8 screws, measure 6″ each way from center on window casing; with a measurement of 14″ in length, butt to outer flange 44 top plate track. Secure 38 1¼″ window casing by screwing down through web of 44 top plate track into 48 1¼″ window casing. Use 37 ¾″ #8 screws, measure 6″ each way from center on window casing, two (2) screws are required; to 28 bottom plate track. Butt 48 1¼″ window casing to outer flange and secure through casing to 28 bottom plate track using 64 1¾″ #8 screws, measure 6″ each way on center of casing, put two (2) screws on each side. Total of two (2) screws are required. Install side pieces of 48 1¼″ window casing 6′5½″ in length. Butt between top and bottom casing, apply 63 epoxy sealer to front side and secure to 36 double studs on each side. Fasten 64 1¾″ #8 screws, measure 16″ both ways from center. Four (4) screws are required to fasten. Install 14″×1″×6′ 8½″ 45 Paltech panel. Insert 46 ¼″ vinyl wedge gasket, and install to 44 top plate track and 28 bottom plate track 14″ in length of 48 window casing. Fasten down through 44 top plate track with 37 ¾″ #8 screws, measure from center 6″ each way, and two (2) screws are required. Coat side that touches panel with 63 epoxy sealer and install 46 ¼ vinyl wedge gasket between panel and 48 1¼″ window casing edge. To 28 bottom plate track install 14″ length 48 1¼″ window casing and coat side that touches panel with 63 epoxy sealer. Fasten using 66 1¾″ #10 screws, and measure 6″ both ways from center. Two (2) screws are required.
Insert 46 ¼″ vinyl wedge gasket between panel and 48 1¼″ window casing edge. Between top and bottom horizontal 48 1¼″ window casing install a measured 6′5½″ vertical 48 1¼″ window casing, after coating sides that touch 45 1″ Paltech panel with 63 epoxy sealer, fasten to 36 double studs with 66 1¾″ #10 screws, and measure 16″ from both ways from the center. Fasten with a total of 4 screws. Insert 46 ¼″ vinyl gasket. Other side is identical.
Having addressed the structural elements/components and inter-connections of FIG. 5 and FIG. 5 a . I now focus on FIG. 5B, 74 entrance doors.
FIG. 5B Describes elements of 74 entrance doors. These doors are installed in a set back sliding track, top and bottom. This horizontal track is set flush to inside edges of 73 door jamb. 74 entrance doors consist of two equals panels which are measured 18″×1″×6′9″ when closed they are 36″×6′9″. These panels are manufactured pre-framed and adaptable to conventional sliding track. These doors are constructed polymers of 45 1″ Paltech high-impact resistant advanced polymers, which is a combined strength of polycarbonate and security film, laminated in layers. This provides a level-4 bullet and bomb resistance; is mirrored on outside, providing complete confidentiality and security for all transactions.
Having completed 12 , 111 Height Measurement Strip is adhesively secured on inside frame of entrance doors of Lobby Banking Security Chambers and the frames closest to lobby banking transaction teller. These 111 Height Measurement Strips are complimentary blended colors to total interior decor.
FIG. 6 Provides detailed elements of Containment Room. For this configuration, we must start from teller wall base of inside Lobby Banking Financial Security Chamber Teller Wall. Locate, by measuring for center of teller chamber wall. Teller wall base is 38 ½″ from top counter to floor, measure 2′ on each side of center line (mark these locations). Now, measure in a vertical direction, toward inside of chamber for 1′ and mark this on both previously location 2′ measurement lines. We are going to continue on these lines, and measure 5′. Connect these lines in a horizontal direction. The end result is a 4′×5′ rectangle. Measuring 1′ from bottom of teller wall, this rectangle configuration will be cut out all the way through to the basement. Clean all debris.
FIG. 6 a Having completed all of the above, we are now going to install 60 Steel Drop Door. Desired carpet, complimenting bank decor, will be measured and cut to fit steel drop door panels. This pre-cut measured carpet panels will then be adhesively secured to steel drop door panels prior to steel drop door installation. This steel drop door is manufactured pre-framed and consist of (2) 2′×5′ with removable pre-hinged panels, hinges are to the underneath sides. Frame is pre-drilled for required concrete fasteners, which are necessary to secure frame in place. For 5′ side, measure 1″ indention on both ends, with remaining holes measured 14½″ apart, and both sides are identical, 75 powder driven fasteners; eight (8) are required for each side. For 4′ frame sides, there will be a 1″ indention on both ends. Remaining holes are measured to be 11½″ apart, and both sides are identical, eight (8) 75 powder driven fasteners are required. Understanding variables of floor thickness; it is best to use two (2) rows of fasteners on all sections of frame for this application. The floor is 6″ thick, rows will be measured 2″ inward from top and bottom of outside edge for all sides. Now, apply 63 epoxy sealer and 61 ½″ rubber gasket to all sides of frame, prior to installation of fasteners. These doors are electronically operated with electronic controlled instant self locking, 65 hydraulic scissors type hinges are installed from underneath and two (2) sets are on each side; located 1′6″ to the inside of 5′ panels. Remaining desired carpet shall be adhesivley secured to entire floor of Lobby Banking Financial Security Chamber after completion of chamber.
We are now in the basement; and standing looking up at the opening for 60 steel drop door of 4′×5′, measure 6″ to both sides of 4′ dimension strike line, creating a 5′ square on ceiling. Now, transfer this exact measurement to floor directly below for FIG. 6 containment room dimensions which are 5′×5′×6′ in this application. We have now constructed the perimeter top and bottom of FIG. 6 containment room. It is noted, basement height may vary according to an existing banking facility structure.
Install to ceiling, on both horizontal lines, one (1) section of 44 top plate track 5′ in length, pre-cope flange on each end, and on one side only, measure 3½″ bend flange where it is level with 44 top plate track web. Pre-drill track to accept fasteners. Locate center of web at 1¾″ strike a line, end to end and-along this line, measure inward 2″ from each end mark. Remaining hole locations are 14½″ apart. Install 44 top plate track flange side painting toward floor and coped end turned toward floor and coped end turned toward center of FIG. 6 containment room. Fasten with 75 powder driver fasteners. Four (4) fasteners are required for this.
Now, install two (2) vertical lengths of 44 top plate track 5′7″ to already installed 5″ lengths. Pre-cope flange on each end and one side only, 3½″ bend flange where it is level with 44 top plate track web. Pre-drill track to accept fasteners. Locate center of web, measure 1¾″, strike a line end to end. Along this line, measure inward 3″ from each end and mark. Remaining holes locations are 14½″ apart. Install these 44 top plate tracks with flange side pointing to floor and coped end turned toward center of FIG. 6 containment room. Insert coped ends of vertical 44 top plate track into previously installed horizontal 44 top plate track coped ends. These coped ends will lay inside and on 44 top of one another. Secure and fasten with powder driven fasteners.
Element 28 bottom plate track installation for FIG. 6 containment room is mirror image of 44 top plate track installation; with one exception being, on in one vertical 5′7″ wall length, this 28 bottom plate track will be in two (2) sections, and each being 17½″. 3½″ is to be inserted into horizontal 28 bottom plate track coped end, leaving a wall length of 14″ and both ends of wall are the same. Measure 3″ inward from coped intersections; secure with fasteners and measure 1″ inward from opposite end of 14″ section. This provides a 32″ opening for 82 steel door installation. It should be noted to face all coped flanges toward inside of room.
Elements to all corners, where 44 top plate track and 28 bottom plate track mate. Install 36 double studs measured 6′ in length. Fasten through flange into 36 double studs with 37 ¾″ #8 screws, two (2) screws are required and measurement are equal distance apart. Install these fasteners on all locations where 36 double studs connects with flanges. Thirty-two (32) fasteners are required. Now, install 36 double studs to ends of 14″ vertical wall lengths. Fasten using 37 ¾″ #8 screws, measuring equal distance apart, eight (8) screws per double stud installation for top and bottom.
Once again, we are standing inside FIG. 6 containment room, looking out through wall opening. We will now install to all 36 double studs and between 44 top plate track and 28 bottom plate track 79 L 2 ″×2″×¼″×5′11½″ angles, secure to 44 top plate track and 28 bottom plate track, through flanges with 41 ½″ #8 screws and two (2) screws are required. Fasten to 36 double studs 79 L 2 ″×2″×2″×¼″ with 4′×11½″ 41 ½″ #8 screws. Measure inward from each end 1¾″ and remaining screws are 17″ apart. There are five (5) screws are required for this.
Now, apply 78 industrial adhesive to 44 top plate track and 38 bottom plate track flanges and to 79 L 2 ″ angles. Place 45 1″ Paltech Panels of 4′11½″×1×5′11½″ inside wall openings. Press in place to flanges and 79 L 2 ″ angles. Secure in place with 80 L 1 ″ angle to flanges. Measure inward from each end 1¾″. Then measure 28″ each way toward center. Use three (3) 79 L 2 ″×2″×¼″×2″ and three (3) are required. Fit 80 L 1 ″ angles tight against panels and fasten to 44 top plate track and 28 bottom plate track webs with 41 ½″ #8 screws. There are two (2) screws to one leg of each angle. Twelve (12) screws are required for top and bottom. Two (2) sides, which are 5′11½″ long, fasten to 36 double stud with 80 L 1 ″×2″×¼″×2″. Measure 2½″ inward from each side and remaining locations are 22″ apart. Again, fit four (4) 80 L 1 ″ 0 tight against panels. Use 31 ¾″ #10 screws and put two (2) screws to one leg of each angle. A total of eight (8) screws are required to both sides.
The 14″×1″×15′×11½″ panel installation is identical with exception of 80 L 1 ″ locations. Exceptions are as followings: Measure 2″ inward from each end. Two (2) 80 L 1 ″ top and bottom. Side locations are measured 2 ½″ inward from each end. Remaining locations are 22″ apart.
Elements for installing 82 steel door is as following: to inside web of 32″ length of 44 top plate track; install a 32″ length of 34 stud 3½″ and fasten with 41 ½″ #8 screws through flanges on each side. Now, measure 2″ inward from each end and 14″ apart. Three (3) screws are required for each side. Install pre-hung 82 steel door, measuring 2′8″×2″×5′11″ and secure frame to 44 top plate track with 37 ¾″ #8 screws, measure 2″ inward from each end and 14″ apart. Three (3) screws are required. Fasten sides to 36 double stud. Measure 2½″ inward from each end. Remaining screws are 22″ apart. A total of four (4) screws are required. Other side is identical. 82 steel door has an 83 observation window of 45 1″ Paltech is centered in door, from top of door, measure a distance of 1′ down and center for 2×1″×2′, 83 observation window has 1′ square access section; which can only be opened from outside, and to the outside. This access window has electronic magnetic locking system.
FIG. 6 b Now, returning to inside containment room. The ceiling, entire wall, entire floor, and entire side of door, facing room is secured with industrial adhesive 77 8″ of urethane padding with fire retardent cover; affixed to inside, to inside top of wall next to 83 steel door on both side is an 67 institutional steel case enclosed light fixture 88 double pole switch.
FIG. 7 To existing 84 breaker panel, install 5 85 20 amp breakers. Connect to each breaker 86 #12-20, Romax cable. Run cables from 84 breaker panel and install 87 . Step down transformers to each, 2′ from breaker panel. Continue cable run to 54 electrical master control console, located behind “Lobby Banking Financial Security Chamber” teller wall as illustrated in FIG. 5 . 3 , 7 .
Standing behind FIG. 3, teller wall in front of teller window, facing chamber to the right hand side, install 88 single pole switch with receptacle to 36 double stud. Connect 86 No. 12-26, Romax cable to 88 single pole switch continue to run to top of 36 double stud and install to 90 junction box with cover, on top of 44 top plate track. Connect with 68 leaner track lighting system and 58 security chamber lens tracking system. Continue to run 86 NO. 12-26 Romax cable to 90 junction box located at the intersection of the center 39 horizontal interlocking beam and 44 top plate track. Run 89 branch circuit an connect to previously installed 70 fire sprinkler with water supplied from existing system.
Returning to teller window illustrated in FIG. 3, secure height adjustable, side leg brackets of 54 electrical master console to floor directly in front of teller window, using 75 powder driven fasteners 2 to each leg bracket, 54 electrical master control console mounts between brackets and can be rotated stopped and secure in place from a horizontal position to 45°. The 45° angle requires a minimum amount of foot motion necessary to activate this maximum security, invention.
Remove cover of 54 electrical master control console, exposing four 92 oxtogonal elect box's secured together with 41 ½″ #8 low profile pan head screws to each box, eight (8) are required. The knockouts on 54 electrical master control console and 92 octagonal electrical boxes are aligned. Starting at the right hand end of 54 electrical master control console, run 86 cable 1 -A- 1 , to 92 electrical box and connect to 93 SM/C with relay. This push bottom black switch No. 1 . Next, run 86 cable 1 -A- 3 to 93 SM/C momentary contact switch No. 3 Red, moving to your left, to the next 92 electrical box, run 86 cable 2 - 3 - 1 , connect to 93 SM/C with relay; this is a push bottom green switch No. 2. Run 86 cable 2 -b- 2 to 66 steel drop doors and lock actuators. Run 89 branch circuit 2 -B- 3 to basement and install 67 institutional steel cased includes light fixture mounted to inside wall of FIG. 6, containment room. Run 2 -B- 3 to outside wall and install 88 single pole switch. Continue to run 86 cable 2 -B- 4 out of 92 electrical box and connect into 86 cable 1 -A- 3 .
Moving to the next 92 electrical box, run 86 cable 3 -C- 1 and connect to 93 SM/C with relay; this is push bottom red alarm switch no. 3 . Connect 86 cable 1 -A- 3 and 86 cable 4 -D- 4 to 86 cable 3 -C- 3 and connect 86 cable 3 -C- 2 to alarm system.
Moving to the 92 electrical box, run 86 cable 4 -D- 1 and connect to 93 SM/C with relay, this push button white switch no. 4 . Now, run 86 cable 4 -D- 1 and connect to 86 cable 4 -D- 2 . Run this cable up and along 44 top plate track to 74 entrance doors and lock actuators. Run 86 cable 4 -D- 3 to 56 pepper gas spray head's. Connect 86 cable 4 -D- 4 to 86 cable 4 -D- 3 components are conventional, and are interconnected to the bank's emergency standby electrical power source.
FIG. 8 A loop air distribution system will be used to heat and cool both overview of Lobby Banking Financial Security Transaction chamber's and FIG. 6 containment room.
The 96 supply duct loop, will be secured to basement ceilings and will run the perimeter of the overview. Pre-cut 4 openings in chamber floor to accept 94 register. Now, measure in from inside walls 5′. Measure in vertical direction 4′ and 9′ along one wall, mark these locations. On opposite wall, measure 2′6″ and 7′2″, mark locations. Measure 6″ on either side of these marks. From this line measure 4″ horizontal and strike another vertical line. This will create opening for 94 register. These offset 94 registers will provide a more even air distribution. The are four (4) 94 registers.
In basement install 96 supply duct loop to ceiling using 95 Aluminum Brackets every 1′6″ from each corner and one at 8′ on both sides. This duct work is conventional square and insulated from manufacture, with 97 riser's to 94 registers installed. Fasten with 75 powder driven fasteners, as required. On the back wall of FIG. 6, cut openings for 94 register and install. This 94 register is located 1′ down from top of FIG. 6 and 1′6″ inward from of left side. Cut openings and install register seal with 21 epoxy resin. Continue to the bottom of this wall, measure up 1′ from bottom and 2′ in from left corner edge. Cut openings and install 94 registers, seal with 21 epoxy resin. Continue with this 96 duct loop to 98 air filtration unit and connect 98 air filtration unit is conventional and is installed to the left side of FIG. 6 containment room and is connected to existing unit. Air from existing unit comes in through 98 air filtration unit circulates through overview of chamber and FIG. 6 containment room returns to 98 air filtration unit is cleaned and recirculated Electrical Power is connected to existing power source. All components are conventional.
FIG. 9 Teller drive through window is based on existing bank teller drive through window, which is part of main bank building. Teller window being housed within main building.
Remove all existing glass and frame work. Install 44 top plate track flange turned up and bottom plate track flange turned down. Each begin 8′8″ in length, fasten through web to window header and sill using 37 ¾″ #8 LPPH, screws. Measure inward from each end 4″ and mark. Then measure and mark every 25″. There will be six (6) screws needed for each track. Cut and install to the sides of window frame 2 lengths of 34 stud 2′7½″. Butt between 44 and 28 bottom plate track secure through web to wall sides. Using 37 ¾″ #8 LPPH, measure 2″ inward from each end of each length, then measure and mark every 9″ and six (6) screws are needed for each side.
Standing on the inside of FIG. 9, looking out through window, install to the outside edge of 44 top plate track 79 L 2 ″×2″×¼″×8′7½″. Turn inside of angle facing to the inside of window, fasten with 41 ½″ #8 LPPH screws. This 8′7½″ length will be cut and install in three (3) sections, two (2) sections will be 2′8″ and one (1) section will be 24″ in length. Screw spacing on 2′8″ length is: 2¼″ inward from each end; then measure 17″, there are three (3) screws required for each length. For the 24″ length, measure 2″ in from each end, then measure 10″; three (3) screws are required. Installation to 28 bottom plate track is identical.
We will now install to sides install 79 L 2 ″×2″×¼″×2′7″ one length for each side 2′7″ long, turn angle to inside of window. On each 2″ leg, on both lengths, cut and remove a 2″ length. This is to allow side sections to mate with top and bottom 79 angles. Fasten to sides with 31 ¾″ #10 LPPH screws. Measure in from each end 2″ then measure 9″ apart; four (4) screws are required, for each side.
Now, install factory fabricated and framed sheet of 45 1″ Peltech. This sheet is 8′7″×2′7″; 3′2½″ inward from each end of this panel, we will find 2 vertical panels pre-framed 45 1″ Peltech panels 16″×1″×2′7″. These have been sandwiched between the horizontal panel. These panels are hinged which allows them to be closed and secured. They will rest on 108 which is the outside window counter. Apply 63 epoxy sealer to all edges of panel and lift in place, sliding 45 1″ panels through 1¼″ openings that were left open when 79 L 2 ″×2″×¼×8′7½″ was installed to 44 top plate track and 28 bottom plate track. Press and secure this panel to 79 with 100 1¼″ #10 LPPH head screws. Top and bottom of panel screw spacing are 2″ inward from each end toward center. Remaining screws are 11″ apart. Eleven (11) screws are required. Side screw spacing is 2½″ inward from each end toward center, remaining screws are 13″ apart; four (4) screws required. Install factory framed sliding 45 1″ Peltech panels. Butt frame to previously installed 45 1′ Peltech panel. Fasten frame top and bottom with 41 ½″ #8 LPPH, screw 2″ inward from each end toward center. Remaining screws are 11″ apart. Eleven (11) screws each are required top and bottom. Install to each side measure, 2″ inward from each end toward center remaining screws are 9″ apart. Five (5) screws are required on each side.
58 Pepper gas spray heads are mounted inside 108 Hollan Stainless Steel window counter and are set at 45 angles toward customer's face. Also mounted inside the counter will be a 102 customer phone which raises for use when button is pressed and retracts when not in use. 110 teller drawer phone and 56 pepper gas spray heads have sliding automatic steel covers which secures them when bank is closed. To the top of the inside window, will be a 58 security camera lens security track system installed facing the walk up window, and teller drive through module with the FIG. 9 drive through banking system.
Inside FIG. 9 Teller drive through banking window, to the underneath edge of the teller counter, there are two (2) 93 momentary contact switches black push button open or close window, the red one closes window, activates alarm and pepper spray. This enable the teller to protect themselves and the bank, sound the alarm and 56 pepper spray and a would be assailant. These are wired into the existing electrical system.
The 103 communication console is located in the FIG. 9 teller driver through window area, directly beneath the customer service window. The 103 communication console, base is equipped with pa-lamps that correspond to each alpha-numeric coded drive through lane.
When customer activates 104 receiver 103 lights indicating, drive throughout lane. All teller's will wear 101 when communications are completed and 104 is replaced privacy communication channel automatically closes. The 104 receiver and 101 head set communication create a privacy system, that cannot be overhear by the public. All drive through will be connected to 105 with 105 CATV-V cable to prevent cross talk.
FIG. 9 A and FIG. 10 Teller drive-through module built in the existing communication will be removed and replaced 104 by touch tone phone, receiver will be mounted next to each depository in each 9 A teller drive-through module. Each 104 touch tone receiver is connected to 103 communication console, located in the FIG. 9 area and has it's own alpha numeric code. Customer picks up 104 touch tone phone receiver, hears dial tone, dials in proper alpha numeric numbers, console lights up, teller communicates, customer communicates, customer hangs up breaking connection. Teller can contact customer by activating a ringing tone to that 104 touch tone phone receiver, 105 communication console is used to prevent cross talk and is wired to existing electrical system, 104 each teller drive-through module is identical.
As shown in FIG. 10 particular references are enhanced showing security for bank teller. Closed circuit control of all verbal conversation between customer and bank teller with financial transactions.
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A primary communication channel for drive-in customers performing financial transactions with bank teller while customers are in their cars from the drive-through lanes. This telecommunication system is a conduit secured line telephone receiver for each separate lane and is interconnected with corresponding headsets. The total design prevents cross-talk, amplified overhead conversations to other customers in their cars or to persons walking perimeter of drive-through banking areas. Each customer is provided with a complete primary communication channel for financial transactions Preventions of customers being identified as potential victims of financial exploitations through car tag associations with amplified conversations. Improved apprehension of person attempting to rob bank from bank teller's transaction window of drive-in area.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] (Not Applicable)
STATEMENT RE: FEDERALLY SPONSORED RESEARCH/DEVELOPMENT
[0002] (Not Applicable)
BACKGROUND OF THE INVENTION
[0003] The present invention relates in general to exposed particulate concrete, and in particular to an improved method for surface-seeding the particulates into the upper surface of the concrete.
[0004] U.S. Pat. No. 4,748,788 entitled SURFACE SEEDED EXPOSED AGGREGATE CONCRETE AND METHOD OF PRODUCING SAME, hereby incorporated by reference in its entirety, discloses a surface seeded exposed aggregate concrete characterized by the use of small, rounded aggregate, such as sand, being broadcast over the upper surface of concrete. The method disclosed results in a reduction in the size of the aggregate exposed on the surface of concrete compared to other prior art methods. The resultant surface seeded exposed aggregate concrete exhibits an extremely flat exposed aggregate surface suitable for extremely high traffic flooring applications. Additionally, the surface texture and color are able to approximate the surface color and texture of more conventional flooring surfaces, such as stone, granite and marble.
[0005] U.S. Pat. No. 6,033,146 entitled GLASS CHIP LITHOCRETE AND METHOD OF USE OF SAME, hereby incorporated by reference in its entirety, discloses a surface seeded exposed particulate concrete and method for producing same. U.S. Pat. No. 6,033,146 improves upon the surface seeded aggregate concrete and method of making same disclosed in U.S. Pat. No. 4,748,788 by disclosing a method that produces surface seeded particulate concrete that expands the colors and surface texture appearances of concrete surfaces beyond those disclosed in U.S. Pat. No. 4,748,788.
[0006] The patents described above produce surface seeded exposed particulate concrete with desirable characteristics, as evidenced by the use and extensive licensing of such products throughout the United States. However, the application of the surface seeded particulate is a timely process. Furthermore, uniformity of application is difficult to achieve for large surface areas. Typically, it is difficult to achieve a uniform application for surface areas which require broadcasting of particulate beyond a distance of ten feet from the broadcaster.
[0007] Accordingly, there is a need for an improved process for surface-seeding of the particulate into the upper surface of a very large concrete slab.
BRIEF SUMMARY OF THE INVENTION
[0008] The present invention specifically addresses and alleviates the problems described above in treating large areas of poured concrete with exposed particulates.
[0009] Aspects of the present invention may be regarded as a surface seeded exposed particulate concrete product and a method of forming the surface seeded exposed particulate concrete product. The surface seeded exposed particulate concrete has a generally flat exposed particulate surface suitable for flooring applications. The particulate may be reactable with a hydrolyzed alkali silica to form an insoluble silicate structure. For example, such a particulate may comprise glass or organic materials, such as sea shells. The alternate may also be a non-reactive particulate. For example, a non-reactive particulate may comprise coarse sand, such as Monterey Aquarium coarse sand.
[0010] The method begins by preparing a subgrade to a desired grade. A concrete mixture is poured over the subgrade. The concrete mixture is screeded to a desired grade which forms a top surface thereof. The top surface of the concrete mixture is finished with a float to seal the top surface and dispose a quantity of cement/fines derived from the concrete mixture at the top surface of the concrete mixture to form an upper surface of cement/fines concrete paste. A quantity of particulate is sprayed upon the upper surface of cement/fines concrete paste. A quantity of particulate is mixed into the cement/fines concrete paste with a float to form an exposed surface of a depth of a mixture of surface-concentrated particulate and cement/fines concrete paste. A surface retarder is applied uniformly over the exposed surface of the surface-concentrated particulate and cement/fines concrete paste. Surface films are washed from the exposed surface. The concrete mixture and paste are cured to form a cured mixture and a cured paste. The exposed surface is then washed to remove surface residue therefrom.
[0011] If the particulate is reactable with a hydrolyzed alkali silica, after the exposed surface is washed, a chemical treatment of hydrolyzed alkali silica solution is applied uniformly over the exposed surface in a quantity sufficient to penetrate only the depth of the surface-concentrated particulate and cement/fines concrete paste. The hydrolyzed alkali silica used with particulates may be a hydrolyzed lithium quartz solution. Applying of chemical treatment may cause penetration of the hydrolyzed alkali metal and silica compound into the upper surface of the concrete mixture through a distance greater than the mean diameter of the particulate.
[0012] Preferably, the particulate has a mean diameter of less than three-eighths of one inch.
[0013] The spraying the quantity of particulate is accomplished using a material gun. The spraying uniformly sprays the quantity of particulate. The spraying includes spraying some of the quantity of particulate a distance of at least twenty feet.
[0014] Applying of the surface retarder may cause penetration of the surface retarder into the upper surface of the concrete mixture through a distance greater than the mean diameter of the particulate.
[0015] The particulate may be sprayed over the upper surface of the concrete mixture at an approximate rate of one pound per square foot of concrete mixture.
[0016] Mixing may comprise using a float in a circular motion to cover the particulate with the cement/fines concrete paste.
[0017] The method may include sponging in a circular motion any areas of the upper surface of the concrete mixture after the mixing and before the applying of the surface retarder.
[0018] The washing of surface film may include applying water to the upper surface of the concrete mixture and lightly brushing the upper surface of the concrete mixture. Preferably, the lightly brushing removes no more than five percent of the particulate from the upper surface of the concrete mixture.
[0019] The washing of the upper surface of the concrete mixture to remove surface residue therefrom may comprise washing the upper surface of the concrete with a mixture of water and muriatic acid.
[0020] The method may include covering the upper surface of the concrete mixture with a vapor barrier after applying of the surface retarder and before washing surface film. The covering the upper surface of the concrete mixture with a vapor barrier may extend for a period of two to twenty-four hours.
[0021] The curing may comprise curing the concrete mixture by use of a logger or curing the concrete mixture by use of a soaker hose.
[0022] Reinforcement means may be placed upon the prepared subgrade to be disposed within the poured concrete mixture.
[0023] The pouring may comprise mixing the concrete mixture with a color additive.
[0024] After the curing, the method may include altering the surface roughness of the upper surface of the concrete mixture.
[0025] Prior to spraying particulates, the method may include washing with potable water and air drying the particulates.
[0026] The subgrade may be prepared by compacting the subgrade to approximately ninety percent compaction. Preparing the subgrade may include placing a layer of sand between the subgrade and the poured concrete mixture.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] These as well as other features of the present invention will become more apparent upon reference to the drawings wherein:
[0028] FIG. 1 is a partial cross-sectional view of the surface seeded exposed particulate concrete of the present invention;
[0029] FIG. 2 is an enlarged partial perspective view of the concrete mixture having the exposed particulate thereon; and
[0030] FIG. 3 is a schematic flow diagram of the manipulative steps utilized in producing the surface seeded exposed particulate concrete of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0031] Referring now to the drawings wherein the showings are for purposes of illustrating preferred embodiments of the present invention only, and not for purposes of limiting the same, the surface seeded exposed particulate concrete and method of producing the same is pictorially and schematically illustrated. The particulate may be potentially reactive with the concrete mixture 16 . For example, the particulate 18 may comprise glass, such as silica glass, organic materials, such as sea shells of marine animals and mollusk, and other various metals and composite materials. Alternatively, the particulate 18 may be an aggregate that does not react with the concrete mixture. For example, the particulate may comprise coarse sand, such as Monterey Aquarium (Grade) coarse sand. Preferably, the particulate is characterized by having a mean average diameter size of approximately one-eighth inch diameter. The particulate may possess a rounded external surface configuration. Alternatively, the individual particulates may have an angled external surface configuration.
[0032] As is conventional, the initial step in the method of the present invention comprises the preparing of the subgrade to the desired elevation and grade and the compacting of the same to preferably 90% compaction. Subsequently, the subgrade 10 is covered with a one inch minimum thick layer of clean, moist fill sand 12 . The fill sand 12 is not absolutely necessary, but it is highly desirable to control the hydration process of the concrete. Further, in order to increase the resultant strength of the concrete and inhibit subsequent cracking, reinforcement wire mesh or rebar 14 is positioned upon the bed of fill sand 12 .
[0033] With the rebar 14 in place, a concrete mix or mixture 16 is poured over the fill sand 12 and rebar 14 respectively, and as is conventional is poured to approximately a three and one half to four inch thickness. Although variations in the concrete mix 16 are fully contemplated, preferably the mixture 16 comprises 70% sand and 30% three-eighth inch mean diameter particulate combined with a minimum of five sacks of cement, such as Portland cement per cubic yard. Dependent upon individual preferences, various conventional color mixtures may be added to the concrete mix.
[0034] The concrete surface is preferably struck off or screeded to the desired level plane of the concrete surface. However, the mix is preferably not tamped as is conventional, as Applicants have found tamping brings up too many sand fines in most concrete mixes, which would interfere with the subsequent surface seeding of the exposed particulate thereupon. Rather, subsequent to screeding the concrete surface, the surface is floated using a conventional bull float, which may be manufactured of fiberglass, wood, magnesium, or the like. Such floats are characterized by possessing an extremely smooth surface which tends to seal the top surface of the concrete mix 16 and bring out appropriate amounts of cement paste for the subsequent steps of the present invention.
[0035] When the upper surface of the concrete mix 16 is still plastic, small size exposed particulate 18 is sprayed over the top surface of the concrete mix 16 . An industrial sprayer, such as a Goldblat material sprayer or a sand blaster may be used to spray the exposed particulate. Use of such a spraying device allows for the uniform placement of the particulate over large surface areas. For example, the particulate can be uniformly sprayed for distances of about twenty to twenty-four feet from the sprayer as compared to traditional methods of broadcasting the particulate (e.g., manually) which can only achieve uniformity for a distance of about eight to ten feet away from the person broadcasting the particulate.
[0036] Depending on the particulate used, it may be desirable to wash the particulate with potable water and air dry it prior to spraying the particulate on the plastic concrete surface. The particulate 18 should not initially depress below the top surface of the concrete mix 16 but rather, should be sprayed solely to cover the same.
[0037] After the spraying of the particulates 18 , the particulates are then floated into the plastic upper surface of the concrete mix 16 using floats, for example, a fiberglass, wood or magnesium float. The mixing of the particulates 18 with the sand cement paste is critical as it ensures that the particulates 18 are thoroughly adhered or bonded to the top surface of the concrete mix 16 upon resultant curing. Hand sponges may then be used in a rotary fashion to further coat the surface seeded particulates 18 with the sand cement paste of the concrete mix 16 . The entire surface is then finished with steel trowels.
[0038] When the resultant particulate 18 and concrete surface 16 has sufficiently set such that a finger impression not in excess of three-eighths of an inch deep is made upon manually pressing with the fingertips thereupon, a conventional surface retarder, preferably a citric acid based surface retarding agent, is spread to uniformly cover the top surface of the concrete mix 16 . The surface retarder slows down the hydration process of the concrete by penetrating the top surface of the concrete mix to a depth of approximately one-eighth inch.
[0039] After the uniform coverage of the surface retarder thereon, the top surface of the concrete mix 16 is covered with either a plastic sheathing membrane or a liquid evaporation barrier, maintained thereupon for a period of approximately two to twenty-four hours. After about four hours, the surface can usually support a workman without leaving an impression, and the sheathing is removed and the top surface may be loosened with clean wet sponges working in a circular fashion, revealing the top surface of the embedded particulate 18 . The surface is then washed with clean water at low pressure and the heavy latents removed with a soft broom. The washing procedure and light bristle brushing preferably removes no more than five percent of the particulate 18 from the top surface of the concrete mix 16 . Subsequent to the washing, the concrete mix 16 is cured for a minimum of seven days with water only by use of a conventional fogger or soaker hose. Craft paper or liquid membrane cures may be used in place of water as job conditions dictate. Preferably after curing for a minimum of seven days, the surface is subject to conventional power washing using 3,000 PSI water pressure at a temperature of approximately 220° F. A mixture of 10-50% muriatic acid is preferably introduced into the hot water wash. The entire surface is then flushed with clean hot water. Preferably 28 days after the initial concrete placement, the surface is again washed with the high pressure/hot water wash to remove any efflorescence or discoloration from the surface. Sandblasting, acid etching or grinding and polishing may also be used to create texture variations on the surface.
[0040] If the particulate is reactable with a hydrolyzed alkali silica to form an insoluble silicate structure, after the final washing of the concrete, the top surface is treated with a hydrolyzed alkali silica solution, preferably lithium quartz sealer (approximately 12.5% lithium compound by volume). Other members of the alkali family of metals which may be suitable include sodium, potassium, rubidium, sesium, and francium. Other abundant silicone containing materials which may be suitable include feldspars, amphiboles or pyroxenes, and mica. The SINAK HLQ sealer is applied in light even coats using a sprayer or brush to a surface having a temperature between 50°-100° F. The hydrolyzed lithium quartz sealer penetrates the top surface of the concrete mix 16 , again to a depth of approximately one-eighth of an inch. The chemical treatment reacts with the mineral compounds or silicious materials within the concrete mix. The reaction causes formation of an insoluble silicate structure, which acts as a protective barrier, reducing the permeability of the surface to water. Applicant believes that minimizing the addition of moisture over time minimizes the undesired expansion and cracking, even given some chemical reaction in the concrete involving the potentially reactive particulates. Applicant also believes that minimizing the addition of moisture minimizes the scope of the chemical reaction involving the non-inert particulates. Of course, this chemical treatment may be omitted when non-reactive particulates are used.
[0041] The resultant surface seeded exposed particulate concrete besides exhibiting an extremely flat exposed particulate surface suitable for pedestrian and vehicular paving applications, is also not subject to deterioration from the chemical reaction from the non-inert particulates and minerals and silicates found in the concrete mix 16 . The surface texture and color approximates conventional flooring surfaces such as terrazzo, or ceramic tile, and this resemblance may be further accentuated by cutting the concrete surface into rectangular or irregular grids. The present invention comprises a significant improvement in the art by providing surface seeded exposed particulate concrete, wherein a large variety of exposed particulates not necessarily chemically inert may be introduced into the upper cement surface of the concrete mixture.
[0042] Although the invention has been described with reference to a specific embodiment, this description is not meant to be construed in a limiting sense. Various modifications of the disclosed embodiment as well as alternative embodiments of the invention will become apparent to one skilled in the art upon reference to the description to the invention. It is therefore contemplated that the appended claims will cover any modifications of the embodiments that fall within the true scope of the invention.
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An improved surface seeded exposed particulate concrete and method of making the improved surface seeded exposed particulate concrete is disclosed. Small particulate is sprayed over the upper surface of the concrete. The particulate may be sprayed using a material sprayer. The particulate may be uniformly sprayed to distances exceeding twenty feet. The particulate is mixed into a cement paste derived from the concrete mixture using floats. A surface retarder is then applied to cover the concrete surface. Subsequently, any surface film is washed from the surface of the concrete and the concrete is cured. The result is a surface seeded particulate with an exposed surface that is flat and is suitable for high traffic areas. The resultant surface may resemble stone, granite or marble.
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CROSS-REFERENCE TO RELATED U.S. APPLICATIONS
[0001] Not applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
NAMES OF PARTIES TO A JOINT RESEARCH AGREEMENT
[0003] Not applicable.
REFERENCE TO AN APPENDIX SUBMITTED ON COMPACT DISC
[0004] Not applicable.
BACKGROUND OF THE INVENTION
[0005] 1. Field of the Invention
[0006] This invention concerns a separator element or road stud intended to form a barrier. The barrier is produced by juxtaposing such separator elements by an articulated connection. This barrier is intended for delimiting roadways or race tracks, parking areas, piers, airstrips, etc., as well as for protection of users, in other words, drivers, pedestrians, pilots, or spectators, especially by restraining vehicles in case they leave the track.
[0007] The invention also concerns a manufacturing method of such a barrier and of the separator elements claimed that form the barrier.
[0008] 2. Description of Related Art Including Information Disclosed Under 37 CFR 1.97 and 37 CFR 1.98.
[0009] It has been proposed, in Publication Document WO 99/53145, a barrier intended for the same applications, which consists of several separator elements juxtaposed one after the other, and connected with supple cross straps. These separator elements have an oblong longitudinal section and comprise one convex cylindrical end and one concave cylindrical end intended to form an articulated interlocking with the concave cylindrical end and the convex cylindrical end, respectively, of neighboring, identical or similar separator elements. One characteristic of these separator elements resides in the fact that they are equipped with a hollow body containing a volume of air designed to act as a shock absorber.
[0010] The dampening provided by a barrier consisting of these separator elements is, however, only of mediocre effectiveness, given that such separator elements lack mechanical strength. In fact, these elements are poorly suited to effectively withstand violent shocks caused, for example, by a Formula 1 race car leaving the track. The cover of the separator element exploding is, in this case, unavoidable, which reduces its shock dampening capacity to zero.
[0011] Thus, if the separator elements and the articulated barrier proposed in Publication Document WO 99/53145 are useful for setting boundaries of roadways and protecting pilots and spectators in certain sport competitions, such as go-kart races where vehicles are lightweight, they are not very effective in auto sporting events involving powerful and heavier cars, such as, for example, automobiles, motorcycles, trucks and more particularly, Formula 1 race cars.
BRIEF SUMMARY OF THE INVENTION
[0012] The invention proposes solving this problem by making a separator element whose mechanical properties and, more particularly, its damping and shock-resistant functions, are greatly improved.
[0013] The objective is achieved, according to the invention, with a separator element that has an oblong horizontal section comprising a cover, preferably made from plastic, supple and flexible, containing a central reinforcement or hollow core in its middle section, preferably metallic, made as a flattened sheath extending from one end to the other of the element. Between such cover and such tubular central reinforcement, there are spaces that are filled or intended to be filled with a damping material.
[0014] The mechanical strength and damping capabilities of the separator element are thus highly increased. A barrier equipped with separator elements according to the invention allows for absorbing and damping violent shocks, such as those that can occur, for example, when cars leave the track in Formula 1 car races.
[0015] According to a preferred execution method, the cover and also, preferably, the flattened hollow core of the claimed separator element are filled with a damping material, preferably consisting of plastic foam, for example, polyethylene foam.
[0016] The presence of this supple material in the separator element further improves shock damping and consequently reduces risk of damage that can occur in a violent collision resulting, for example, from a vehicle leaving the road or the race track.
[0017] According to an advantageous form of execution, the separator element, in accordance with the invention, contains at least two stacked passages or orifices, made in each of its ends. Such passages allowing the crossing of said element by at least two stacked links, preferably consisting of supple straps or flexible metal bands allowing to connect it to a set of identical or similar separator elements successively arranged one after the other to create a hinged barrier.
[0018] According to another form of execution, the ends of the flattened hollow core are laid out so as to allow the securing of at least two, and preferably three, stacked flexible metal ties, preferably constructed as flat bands, allowing the separator elements to be connected to one another.
[0019] According to an interesting form of execution, each of the separator elements, according to the invention, includes one convex cylindrical end and one concave cylindrical end, so that they may abut and be fitted successively to one another by said ends that form an articulated interlocking or cylindrical articulation with the concave cylindrical end and with the convex cylindrical end, respectively, of neighboring separator elements.
[0020] Shipping and handling of the separator elements on the installation site can, however, be difficult, when they are filled with a damping material, as is the case for the separator elements proposed by the invention. Their weight is, in fact, significantly higher than that, for example, of separator elements comprising only a hollow body.
[0021] The manufacturing method of separator elements according to the invention intends to remove this difficulty in order to facilitate handling and shipping of such elements.
[0022] This goal is achieved through a remarkable manufacturing process in that it consists of producing an element comprising the cover and the central hollow core in a plant, for instance by rotary molding. The introduction of the supple material into the free internal space of said separator element is done, for example, by injection on the sites where barriers are assembled and positioned after the supple or flexible links ensuring the linkage of the elements have been installed.
[0023] This method is particularly advantageous in the sense that it facilitates handling and shipping of the separator elements to the location where the barrier is supposed to be placed. Likewise, the manual positioning work of the separator elements, one after another, before their assembly by insertion of supple or flexible links to form the barrier, will be less onerous.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0024] The aforementioned goals, characteristics and advantages and additional ones, will become more apparent from the description below and attached drawings illustrating an interesting, although by no means limiting example, of the implementation of the separator element and its manufacturing method according to the invention.
[0025] FIG. 1 is the elevation view of a separator element crossed by three supple or flexible links.
[0026] FIG. 2 is the top view of this separator element.
[0027] FIG. 3 is the front view of the separator element.
[0028] FIG. 4 is the left-side view of the separator element.
[0029] FIG. 5 is the right-side view of the separator element.
[0030] FIG. 6 is the cross sectional view according to Line 6 - 6 of FIG. 3 .
[0031] FIG. 7 is the longitudinal cross-sectional view according to Line 7 - 7 of FIG. 3 .
[0032] FIG. 8 is a top view showing an articulated barrier resulting from the assembly of several separator elements.
DETAILED DESCRIPTION OF THE INVENTION
[0033] These drawings describe an advantageous example, although being by no means limiting, of construction of a damping separator element and a protective or demarcation barrier produced according to the invention.
[0034] This damping separator element 1 comprises a supple cover 3 with an oblong horizontal section and a core or central hollow reinforcing piece constructed as a flattened sheath in a middle portion of the element. The element has a rectangular section, extending practically from one end to the other of the element 1 , with the supple cover 3 and the flattened central tubular reinforcing piece 2 defining filled spaces or spaces meant to be filled by damping material 11 .
[0035] Cover 3 may be constructed of a supple and flexible material, preferably shatterproof, for example, low-density polyethylene that, besides its aforementioned qualities, has the property of appropriately tearing if it breaks, preventing its fragmentation or shattering. The thickness of the cover may vary depending on the intended use of the separator elements. It may be between 5 and 8 mm, for example.
[0036] The reinforcing piece 2 is advantageously made of metal, preferably of steel, to provide good mechanical resistance to impacts. It may have a thickness and width that can vary depending on the intended use of separator elements. Solely by way of example, it may have a thickness on the order of 2 mm to 5 mm and a width on the order of 1 cm to 10 cm. It extends approximately over the entire height of the element.
[0037] The central reinforcing piece 2 is integrated into cover 3 , when the latter is constructed, for example, by a known rotary moulding process.
[0038] Separator element 1 thus obtained, has, for example, a height on the order of 1200 mm, a length of 1500 mm and a width of 600 mm.
[0039] Cover 3 consists of lower and upper bases comprising, for example, a wide oblong rib 4 . These ribs 4 are designed, on the one hand, to reinforce the rigidity of said cover 3 and, on the other hand, to incorporate, for example, a logo or other distinctive sign.
[0040] Cover 3 , in other words, separator element 1 , comprises a convex cylindrical end 5 and a concave cylindrical end 6 , with an identical radius, connected by two large flat lateral and parallel faces 7 .
[0041] Thus, it is possible to abut and interlock multiple identical or similar separator elements 1 A, 1 B, 1 C, . . . , 1 N, one after another to make up a demarcation or protective barrier, with the convex cylindrical ends 5 and concave cylindrical ends 6 of each intermediary separator element thus forming an articulated interlocking or cylindrical articulation with the concave cylindrical end and with the convex cylindrical end, respectively, of two identical or similar separator elements between which it is situated.
[0042] According to the advantageous execution method retained, by way of example, for the presentation and illustration of the invention, each of the two ends 5 and 6 of the damping separator element has at least two and, preferably, three passages or orifices, respectively 8 and 9, preferably stacked and spaced at regular intervals, formed in a vertical rectangular shape, and arranged in the median vertical plane P-P of separator element 1 . These passages or orifices 8 and 9 allow the crossing of cover 3 and reinforcing piece 2 by three supple or flexible links, advantageously and preferably consisting of straps or flat bands 10 . These bands or straps may advantageously have a width on the order of 50 mm and are arranged so that their width is placed in a vertical or substantially vertical plane, as notably shown by FIG. 1 .
[0043] The supple straps may be made from synthetic fabrics or fibers, such as polyamides, polyesters or others, and they have, in this case, a certain stretching capability, playing a role in shock damping.
[0044] Flexible bands 10 may also consist of metal bands, for example, steel or other metal types of strips.
[0045] Orifices 8 or 9 are arranged one near the upper edge of the element, another near the base of the latter, and the third one at mid height of said element. Thus, when they are in place, the straps or flat bands 10 cover the entire height of the barrier and any tendency of the elements to rotate or of the barrier to twist in case of impact is thereby eliminated.
[0046] Flat bands or straps 10 allow connecting multiple identical or similar separator elements 1 A, 1 B, 1 C, . . . , 1 N, interlocked one after the other to make an articulated demarcation or protection barrier ( FIG. 8 ) in which the configuration can be quickly and easily adapted to the needs.
[0047] Following a variant of execution (not illustrated), the ends of the flattened hollow core or central reinforcing piece 2 are laid out to allow the attachment, for example, in a detachable manner, of flexible metal ties, preferably made as flat bands, to connect the elements to one another. The ends are matched in a complementary way to allow for this attachment. The attachment of these flexible metal ties on two successive elements may, for example, be done by bolts or some other form of assembly.
[0048] Separator element 1 finally comprises a supple damping material 11 , preferably made of plastic foam, for example, polyethylene foam, filling the empty space between cover 3 and reinforcing piece 2 , as shown by FIGS. 6 and 7 . The internal space of reinforcing piece 2 may also be filled with this supple dampening material 11 , notably in the case where said reinforcing piece 2 has a width of more than 5 cm.
[0049] It was previously indicated that, according to an example of implementation of the process of the invention, an element is proposed to be built, in an initial phase, comprising cover 3 and flattened central tubular reinforcing piece 2 in a plant, for example, by a rotary molding process. The second phase consists of filling cover 3 and hollow core 2 with damping material 11 , being performed, for example by injection, on site, i.e. where the barriers are assembled and positioned, after installation of supple or flexible connecting links 10 .
[0050] To carry out this second phase, the separator elements are, first of all, arranged adjacent to one another, then straps 10 are inserted across each of them, in other words, through passages or orifices 8 and 9 , so that they cross the reinforcing piece 2 and cover 3 of each separator element 1 lengthwise. The ends of said reinforcing piece provide a common opening or individual openings for this purpose, allowing the passage of straps between the large vertical faces of the latter.
[0051] Finally the supple damping material 11 is inserted in separator element 1 by injection through one or several orifices (not shown) made in cover 3 , preferably in its upper wall. When desired, one or several orifices (not shown) are made in one of the walls of said reinforcing piece 2 , preferably in its upper wall, to allow penetration of said supple damping material 11 into the internal space of said reinforcing piece 2 . This injection is preferably performed under pressure so that the damping provided by the supple damping material 11 will be optimal in case of impact.
[0052] It is possible to assemble, easily and quickly, barriers or portions of barriers consisting of multiple elements, for example, of thirty elements assembled one after another, with the barrier portions thus obtained being themselves able to be assembled through truss rods known as such.
[0053] Because of the junction of separator elements through a ball and joint or cylindrical articulation, these elements can have various inclinations in relation to the other ones so that it is possible to quickly install straight or curved protective barriers with radii that are more or less short, depending for example on the layout of tracks or circuits.
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The invention concerns a damping separator element for producing delimiting or protective barriers, for example for road traffic lanes or motor sports tracks. The element includes an elongated horizontal section and a cover, preferably made of flexible plastic material. The central reinforcement or hollow core, preferably made of metal, produced in the form of a flattened sheath and extended from one end to the other of the element, is housed inside the cover. The reinforcement provides a space between the cover and the central flattened hollow reinforcement, the space being filled or to be filled with a plastic foam such as, for example, a polyethylene foam.
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RELATED APPLICATIONS
[0001] This Application is a Nonprovisional Patent Application related to U.S. Provisional Patent Application Ser. No. 61/407,805 filed Oct. 28, 2010 entitled “MULTI-USER PORTABLE TOILET”, which is incorporated herein by reference in its entirety, and claims any and all benefits to which it is entitled therefrom.
FIELD OF THE INVENTION
[0002] The present invention relates to an improved multi-user portable toilet, and more particularly, to an outdoor portable toilet with external urinal, and arrangements thereof, to meet public needs more efficiently.
BACKGROUND OF THE INVENTION
[0003] Portable toilets are simple enclosures containing a chemical or holding tank-type toilet. They are typically used at construction sites, outdoor sporting events, fairs, markets, and other temporary or infrequent gatherings and events. Most portable toilets have the typical open-front-U-shaped toilet seat with cover with or without an optional internal urinal system. They are often constructed out of light weight molded plastic.
[0004] The present invention is part of the next generation of portable restrooms, designed to counter the problems that arise due to massive attendance at popular outdoor events such as concerts, fairs, and festivals. Large music festivals which generate traffic of up to 80,000 people per half day should provide up to 1,190 portable restroom units. This alone amounts to more than 26,000 square feet that the venue is required to set aside for the restroom area or areas. Often, events are unable to meet these quotas due to rental cost or space restraints, which result in long lines and rapidly degenerating hygienic conditions. Moreover, with long lines, impatience often leads to inappropriate behavior, such as users urinating on the nearby structure or landscaping.
[0005] Portable urinal units are brought in sometimes to meet overwhelming public demands at outdoor events. However, often these systems compromise the user's privacy. Also, almost all portable urinal units need their own waste tank, which increases difficulty in cleaning.
[0006] U.S. Publication No. 20090235445, published Sep. 24, 2009 to Goldstein teaches an addition of an external urinal to a conventional portable toilet. It however fails to address the issue of privacy. Additional portable screens may be introduced to alleviate the associated problems, but add to installation and break down time and costs.
ADVANTAGES AND SUMMARY OF INVENTION
[0007] Through innovative use and placement of an external urinal, the present invention allows two people to use a single unit simultaneously, while maintaining privacy of both users. The present invention is a portable toilet assembly with an internal chamber, an external urinal and a shared waste container located beneath the internal chamber.
[0008] The simultaneous use of the present invention by 2 users drastically reduces wait times by redirecting urinal users to the back side areas of the units, an area which is generally un-used on the standard portable toilet. The present invention also has the ability to accommodate more users with fewer units which not only reduces the amount of space needed for restrooms at outdoor events or other events in which sufficient indoor restroom facilities are lacking, but also reduces costs, thus allowing extra budget allowance to be spent elsewhere. With less units required per event, less are manufactured and transported, greatly reducing the carbon footprint of portable restrooms. The present invention's external curvature design, integrated into both its overall form and into its structural support are reminiscent of water and gentle waves when multiple units are place side by side.
[0009] The portable toilets of the present invention can be arranged in rows, circular and other configurations to best suit the spatial and/or aesthetic requirements and considerations of the venue. Due to the unique design of the present invention, a singular unit in itself can provide acceptable privacy to users of the external urinal. When multiple units are arranged strategically, they create not only a natural private space for the external urinal users, but each adjacent unit provides additional privacy for all users.
[0010] Further details, objects and advantages of the present invention will become apparent through the following descriptions, and will be included and incorporated herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIGS. 1A through 1D are representative isometric views of an embodiment of the multi-user portable toilet 100 of the present invention.
[0012] FIGS. 2A through 2D are representative side views of an embodiment of the multi-user portable toilet 100 of the present invention. FIG. 2E is a representative top view of an embodiment of the multi-user portable toilet 100 of the present invention.
[0013] FIG. 3A is a representative cross-sectional view of an embodiment of the multi-user portable toilet 100 of the present invention showing the privacy compartment 150 .
[0014] FIG. 3B is a representative isometric view of an embodiment of the multi-user portable toilet 100 of the present invention showing assembly of external urinal panel 108 .
[0015] FIG. 3C is a representative top isometric view of an embodiment of the multi-user portable toilet 100 of the present invention showing the contour design of top panel 136 .
[0016] FIG. 4 is a representative lateral, cut-away schematic view showing an embodiment of the portable toilet 100 of the present invention showing the internal commode, waste containment chamber, external urinal, drainage means connecting the external urinal to said waste containment chamber and acoustic insulation/sound-proofing disposed along the compartment shell to provide additional privacy for multiple simultaneous users.
[0017] FIG. 5 is a representative isometric view of an alternative embodiment of multi-user portable toilet 600 .
[0018] FIG. 6A is a representative top side view of multiple multi-user portable toilets 100 of the present invention in a row arrangement 200 .
[0019] FIG. 6B is a representative back side view of multiple multi-user portable toilets 100 of the present invention in a row arrangement 200 .
[0020] FIG. 6C is a representative upper back side view of multiple multi-user portable toilets 100 of the present invention in a row arrangement 200 .
[0021] FIGS. 7A through 7C are representative side top isometric and top views, respectively, of multiple multi-user portable toilets 100 of the present invention in a stall arrangement 300 .
[0022] FIGS. 8A and 8B are the representative top and upper isometric views, respectively, of multiple multi-user portable toilets 100 of the present invention in a chamber arrangement 400 .
[0023] FIGS. 9A and 9B are the representative top and upper isometric views, respectively, of multiple multi-user portable toilets 100 of the present invention in a ring arrangement 500 .
[0024] For a better understanding of the invention reference is made to the following detailed description of the preferred embodiments thereof which should be taken in conjunction with the prior described drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0025] The description that follows is presented to enable one skilled in the art to make and use the present invention, and is provided in the context of a particular application and its requirements. Various modifications to the disclosed embodiments will be apparent to those skilled in the art, and the general principals discussed below may be applied to other embodiments and applications without departing from the scope and spirit of the invention. Therefore, the invention is not intended to be limited to the embodiments disclosed, but the invention is to be given the largest possible scope which is consistent with the principals and features described herein.
[0026] FIGS. 1A through 1D are representative isometric views of an embodiment of the multi-user portable toilet 100 of the present invention. In one embodiment, multi-user portable toilet 100 of the present invention is a simple portable enclosure consisting essentially of an internal toilet chamber 150 , as best shown in FIG. 3A , an external receptacle/urinal 106 and a shared waste container 102 disposed within the internal toilet chamber 150 . In one embodiment, essential portions of multi-user portable toilet 100 are often constructed out of light weight molded plastic, for easy transportation and cost effectiveness. As best shown in FIGS. 1A to 1D , instead of having four side panels to create a rectangular internal chamber, the multi-user portable toilet of the present invention 100 has five side panels, viz., door panel 130 at the front, right panel 132 and left panel 134 , both adjacent to door panel 130 , back panel 138 , and urinal panel 108 that connects right panel 132 , or left panel 134 , to back panel 138 . All five side panels leave a footprint, and connect to the top panel 136 , in the shape of a pentagon.
[0027] FIGS. 2A through 2D are representative side views of an embodiment of the multi-user portable toilet 100 of the present invention. FIG. 2E is a representative top view of an embodiment of the multi-user portable toilet 100 of the present invention. As best shown in FIGS. 1B and 2E , the top panel 136 is a pentagon resembling a rectangle with one of its corners cut away, that corner replaced with urinal panel 108 . As best shown in FIGS. 1C and 2A , a door 135 is installed on door panel 130 so users can enter and exit multi-user portable toilet 100 . In one embodiment, a lock or other mechanical closures [not shown] can be installed on door 135 to enhance privacy. A slanting or sloped roof line 202 assists in preventing water pooling on the upper panel 136 during rain, etc.
[0028] FIG. 3A is a representative vertical cross-sectional view of an embodiment of the multi-user portable toilet 100 of the present invention showing the privacy compartment 150 . In one embodiment, five side panels, viz.; door panel 130 at the front, right panel 132 and left panel 134 , back panel 138 , and urinal panel 108 ; and top panel 136 , and optionally floor panel 101 , create an enclosure i.e. privacy compartment 150 . As best shown in FIG. 3A , privacy compartment 150 is an enclosed space which further equipped therein a commode or toilet 104 emptying into a waste containment chamber 102 . In one alternative embodiment, water basin which also emptying into waste containment chamber 102 , a cold/hot water tap, a soap dispenser could be included within privacy compartment 150 . In another embodiment, commode with flushing and plumbing can be introduced to make the present invention 100 more pleasant. In yet another embodiment, lighting fixtures 140 can be installed within privacy compartment 150 for evening events. In yet another embodiment, electric fan, air-conditioning unit 133 and music loudspeakers [not shown] can be installed to further enhance the present invention 100 . In one embodiment, speakers [not shown] can also be useful for providing audio instructions for use of the toilet 100 , radio performance, emergency news broadcast, etc. optional equipment for the portable toilet 100 include auxiliary plumbing service hookups, hot water service, hot water heater, internal steam or chemical cleaning, holding tank for water, hot water and/or chemical cleaners.
[0029] FIG. 3B is a representative isometric view of an embodiment of the multi-user portable toilet 100 of the present invention showing assembly of external urinal panel 108 . In one embodiment, the external urinal panel 108 further has an urinal 106 installed. The urinal 106 is also equipped with drainage means 114 such that it empties into the shared waste container 102 within privacy compartment 150 through drainage hole 112 . In one embodiment, urinal panel 108 may be recessed, i.e., disposed within a cut-out or alcove in the external wall 109 surrounding the chamber to afford privacy to users. Further, the external wall 109 separating urinal panel 108 from privacy compartment 150 may include sound barrier or sound proofing layer 110 for further privacy between two simultaneous users of toilet 104 , i.e., one within privacy compartment 150 and one using external urinal 106 . it will be understood that sound proofing layers can also be installed, clad or lined on right panel 132 , left panel 134 and/or back panel 138 to provide further privacy to users. In one embodiment, sound proofing layers increase acoustic separation between the inside and outside of privacy compartment 150 . Examples of construction material of sound proofing layers or other sound reducing means 110 include “QUIET BARRIERS” Specialty Composite, which is an engineered acoustical composite of ½ inch decoupling foam, ⅛ inch high-mass sound-blocking barrier, and ¾ inch noise absorbing foam with 3 mm reinforced mylar facing, as well as other active and passive noise disturbance and cancelling technologies, designed to provide significant air and structure borne noise reduction in a low-profile configuration.
[0030] FIG. 3C is a representative top isometric view of an embodiment of the multi-user portable toilet 100 of the present invention showing the contour design of top panel 136 . In one embodiment, top panel 136 has vents 133 which are openings that improve air ventilation of privacy compartment 150 . In one alternative embodiment, an electric fan [not shown] can be installed around vents 133 to further enhance ventilation. Moreover, one function of top edge panel 120 is to divert falling rain away from door panel 130 and urinal panel 108 . External gutters can also be located to divert rain or other water fall to one side or another or to any intermediate, drainage point from the roof and top panel 136 as desired. Downspouts or scuppers can also be installed on the sides or corners of the portable toilet 100 of the present invention to collect and divert rain as desired. Directed drainage is also achieved by the contoured surface of top panel 136 which may have one or more ridges 122 to drain or divert moisture to right panel 132 , left panel 134 and/or back panel 138 . It is important to divert rain water away from the user. As for the urinal panel 108 , since it has urinal 106 that empties into waste containment chamber 102 , it is imperative to divert as much rain water away from urinal panel 108 as possible to avoid overflowing waste containment chamber 102 . In one embodiment, gutter or railing 120 can be installed at edge of top panel 136 at top of urinal panel 108 , acting as a dam to rain water.
[0031] FIG. 4 is a representative lateral, cut-away schematic view showing an embodiment of the portable toilet 100 of the present invention. In this embodiment, two users can multi-user portable toilet 100 simultaneously. The drainage means 114 connecting urinal 106 to waste containment chamber 102 within privacy compartment 150 and sound proofing layers 110 disposed along the side panels to provide additional privacy for simultaneous users.
[0032] FIG. 5 is a representative isometric view of an alternative embodiment of multi-user portable toilet 250 of the present invention where two external urinals 106 and 107 [not shown] are disposed upon the external shell, separated by a privacy protrusion 502 . In one alternative embodiments, urinals 106 are installed on both the urinal panel 108 and back panel 138 such that three users can use multi-user portable toilet 600 simultaneously.
[0033] FIG. 6A is a representative top side view of multiple multi-user portable toilets 100 of the present invention in a row arrangement 200 . FIG. 6B is a representative back side view of multiple multi-user portable toilets 100 of the present invention in a row arrangement 200 . FIG. 6C is a representative upper back side view of multiple multi-user portable toilets 100 of the present invention in a row arrangement 200 . FIG. 6D is a representative upper, isometric view showing a method of use of multiple multi-user portable toilets 100 of the present invention in a row arrangement 200 . In outdoor events, it is common to arrange multiple portable toilets together to create a temporary lavatory area. When a number of multi-user portable toilets 100 of the present invention are arranged in a row arrangement 200 as best shown in FIGS. 6A to 6D , left panel 134 of each multi-user portable toilet 100 acts as a screen, creating an external urinal area 210 within each multi-user portable toilet 100 . The external urinal area 210 provide even more privacy to urinal users.
[0034] FIGS. 7A through 7C are representative side, top isometric and top views, respectively, of multiple multi-user portable toilets 100 of the present invention in a stall arrangement 300 . In events held in places where outside walls 310 are available, multiple multi-user portable toilets 100 can be arranged in stall arrangement 300 as best shown in FIGS. 7A to 7C , creating a temporary stall 330 for the users of the external urinals 106 .
[0035] FIGS. 8A and 8B are representative top and upper isometric views, respectively, of multiple multi-user portable toilets 100 of the present invention in a chamber arrangement 400 . Multiple multi-user portable toilets 100 can be installed, as best shown in FIGS. 8A , to block on end of an event venue that has barricades 410 to create an instant outdoor lavatory 440 for urinal users.
[0036] FIGS. 9A and 9B are representative top and upper isometric views, respectively, of multiple multi-user portable toilets 100 of the present invention in a ring arrangement 500 . At event venues that no walls or barricades are available, multiple multi-user portable toilets 100 of the present invention can be installed in a ring arrangement 500 . Instantaneously creating a larger area for users to use urinals 106 .
[0037] For a better understanding of the invention reference is made to the following detailed description of the preferred embodiments thereof which should be taken in conjunction with the prior described drawings.
[0038] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the present invention belongs. Although any methods and materials similar or equivalent to those described can be used in the practice or testing of the present invention, the preferred methods and materials are now described. All publications and patent documents referenced in the present invention are incorporated herein by reference.
[0039] While the principles of the invention have been made clear in illustrative embodiments, there will be immediately obvious to those skilled in the art many modifications of structure, arrangement, proportions, the elements, materials, and components used in the practice of the invention, and otherwise, which are particularly adapted to specific environments and operative requirements without departing from those principles. The appended claims are intended to cover and embrace any and all such modifications, with the limits only of the true purview, spirit and scope of the invention.
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An improved portable toilet for simultaneous, private use by two persons, the portable toilet which contains an internal compartment having a commode, a waste containment chamber disposed below the commode for receiving waste, an external shell enclosing the compartment and the waste containment chamber, at least one urinal disposed externally upon the external shell and drainage system connecting the external urinal to the waste containment chamber. The portable toilet of the present invention has a cross-section and footprint in the shape of a pentagon.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
Introduction
The present invention relates to a fluid pressure powered actuator for imparting relative angular movement between two members connected together by a hinge.
Field of the Invention
The term "members connected together by a hinge" used in this specification includes not only a door or other closure member mounted in a frame or opening on a common form of hinge, that is to say a pair of rigid plates or the like pivotally connected by a hinge pin, but also includes any two hingedly connected members, that is to say any two members connected together by any jointing means, which allows relative angular motion about a pivot axis between the members similar to the relative angular motion that would be achieved if the members were connected by a more conventional construction of hinge.
It is known to provide a fluid pressure powered actuator for imparting relative angular movement between two members connected by a hinge in which the two members are arranged in a fixed angular relation to each other to form a substantially "V" shaped trough. At least one flexible sack or pouch of wedge shaped cross-section is disposed between the members and inflation of the pouch causes the members to be forced apart. For example U.S. Pat. No. 3,495,502 (D. E. Bousso) describes a device for converting fluid pressure to angular mechanical movement or vice versa, the device comprising at least one pouch of flexible material arranged to contain fluid under pressure and connected to hinge means arranged to restrain radial movement of the pouch relative to the axis of the hinge means.
U.S. Pat. No. 3,202,061 (L. B. Johnston) describes and claims a fluid actuator displacement and positioning system comprising; a pair of substantially rigid elongated members in juxtaposition; guide means to direct relative movement of the members; a closed chamber comprising a plurality of cells having flexible walls extending between and attached to one of the said members, and free of the other member, said flexible wall being so related to said members as to exert to force thereon when said chamber is subjected to fluid pressure; and the necessary means to introduce a fluid under pressure into the chamber.
These type of fluid pressure powered actuators may be described as "push" type fluid pressure powered actuators. There are, however, certain disadvantages in these known constructions of push type fluid pressure powered actuators in that they are relatively expensive to produce. Further they require a considerable amount of head room to install and indeed, are rather difficult to install in a confined space. Very often they require mechanical linkages to transmit the torque imparted or to magnify the displacement of the members. Further the flexible sack or pouch is often of rather large cross-sectional area. Additionally, these push type fluid pressure powered actuators impart substantially constant torque throughout their entire stroke and very often require a slave cylinder or buffer at the end of the stroke to provide adequate cushioning. Further with these push type fluid pressure powered actuators it has been noted that a considerable pressure is placed on the hinge between the two members, which thus necessitates the provision of fairly substantial and robust hinges.
OBJECTS
The present invention is directed towards providing an improved construction of fluid pressure powered actuator for imparting relative angular movement between two members connected together by a hinge.
Another object of the invention is to provide a fluid pressure powered actuator which will have a high initial starting torque and a low finishing torque thus giving a natural cushioning effect.
A further object of the invention is to provide a fluid pressure powered actuator that can be manufactured from relatively easily obtainable materials thus making it comparatively inexpensive to produce.
SUMMARY OF THE INVENTION
This invention provides a fluid pressure powered actuator for imparting angular movement comprising:
a first member;
a second member;
a hinge connected between the two members and defining a hinge pivot axis for the members;
an elongated inflatable conduit of substantially constant surface area, having its longitudinal axis substantially parallel to the hinge pivot axis;
a first connecting means, connecting the conduit to the first member;
a second connecting means, connecting the conduit to the second member, the second connecting means being spaced apart from the first connecting means around the conduit so that the first and second connecting means are substantially equispaced around the conduit; and
means for inflating the conduit to exert a pulling force between the members to impart relative angular movement therebetween.
In one embodiment of the invention the connecting means comprises:
a bar for location within the conduit;
a base plate for mounting on the member;
A hook-like member connected to the base plate and adapted for embracing from the exterior the bar and portion of the conduit, the edge of the hook-like member being spaced apart from the base plate to allow the conduit project therethrough;
means for rigidly mounting the base plate of the first connecting means on the first member; and
means for pivotally mounting the base plate of the second connecting means on the second member. A further embodiment of the invention provides a fluid pressure powered actuator for opening and closing a door mounted by a hinge on a door frame comprising:
an elongated and inflatable conduit of substantially constant surface area, having its longitudinal axis substantially parallel to the hinge pivot axis;
a connecting means connecting the conduit to the door frame;
a further connecting means connecting the conduit to the door, the two connecting means being arranged around the conduit so as to be substantially equispaced around the conduit;
means for inflating the conduit to exert a pulling force between the members to impart relative angular movement therebetween; and
means for returning the door to its original position on release of the fluid pressure.
The main advantages of the present invention are that readily obtainable materials are used thus reducing manufacturing costs. A further advantage of the invention is that the torque displacement characteristics of the fluid pressure powered actuator according to the invention are particularly suitable for closure members there being a high initial torque and a low finishing torque.
It has also been found that the present invention lends itself readily to installation on existing doors and that in view of the small cross-sectional area of the conduit that may be used it can be installed in very confined spaces along the length of the door post. A still further advantage of the fluid pressure powered actuator according to the present invention is that it has a very high torque to cross-sectional area ratio.
The above and other objects and advantages of this invention will become apparent from the following detailed description in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cut-away perspective view of portion of a door, door frame and fluid pressure powered actuator according to the invention, some sectional lines being omitted for clarity.
FIG. 2 is a view similar to FIG. 1 with the door in the open position.
FIG. 3 is a cross-sectional view in the directions of the arrows III -- III of FIG. 1.
FIG. 4 is a cross-sectional view in the direction of the arrows IV -- IV of FIG. 2.
FIG. 5 is a front view of portion of a door, a door frame and alternative construction of fluid pressure powered actuator according to the invention.
FIG. 6 is a cross-sectional view similar to FIG. 3 of the embodiment of FIG. 5, and
FIG. 7 is a cross-sectional view similar to FIG. 4 of the embodiment of FIG. 5. FIGS. 8(a), 8(b ) and 8(c) are diagramatical cross-sectional views showing the operation of the fluid pressure powered actuator according to the invention, and
FIG. 9 is a typical torque displacement characteristic curve of a fluid pressure powered actuator according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring to the drawings and initially to FIGS. 1 to 4 thereof there is illustrated a first member namely a door post 1 forming part of a door frame of substantially channel section mounted within an opening in wall 2. A second member in this embodiment, a door, indicated generally by the reference numeral 3 namely an aluminium glazed door is mounted on the door post 1 by means of a hinge 4 having a hinge pivot axis P. A conduit 5 is mounted partially within the door post 1. The conduit 5 is sealed at both ends 6, only one end 6 is illustrated in FIG. 1. The conduit 5 is an inflatable flexible conduit of substantially constant surface area that is to say, on inflation the surface area does not expand appreciably. The conduit 5 is reinforced circumferentially and longitudinally. If the conduit 5 is not reinforced the conduit 5 on inflation will expand circumferentially to a balloon shape and it will creep and deflect in its longitudinal direction. Thus the energy supplied will be absorbed in the deformation of the conduit 5 and accordingly, the conduit 5 would be unsuitable for use in the fluid pressure powered actuator.
A pipe 7 connects the conduit 5 to an air supply and also serves as an air exhaust. The conduit 5 is mounted by a first connecting means, indicated generally by the reference numeral 8 and a second connecting means 9 on the door post 1 and the door 3 respectively. The first connecting means 8 comprises a base plate 10 for mounting on the door post 1 and a hook-like member 11 connected by bolts 12 to the base plate 1. A bar 13 is located within the conduit 5. The hook-like member 11 embraces from the exterior the bar 13 and portion of the conduit 5, it will be noted that the edge 14 of the hook-like member 11 is spaced apart from the base plate 10 sufficiently to accomodate two thicknesses of the conduit 5 and thus allow the conduit 5 project therethrough. The spacing is so arranged that the portion of the conduit 5 in contact with the bar 13 cannot pull out of or away from the connecting means 8.
The second connecting means 9 is substantially similar to the first connecting means 8 and similar parts are identified by the same reference numerals. The second connecting means 9 is however, mounted on the door post 1 by means of a hinge 15.
It will be noted that the first and second connecting means 8 and 9 are displaced relatively around the conduit and are substantially equispaced circumferentially around the conduit 5. On inflation of the conduit 5, as will be described below, the two connecting means 8 and 9 are substantially diametrically opposed relative to the conduit 5.
In operation, air under pressure is introduced from an air pressure source through the pipe 7 into the conduit 5 to inflate it. This causes the conduit 5 to assume a more cylindrical shape and thus reduce the distance between the two connecting means 8 and 9. This causes the door 3 to be pivoted on its hinges 4 about its hinge pivot axis P. It will be noted that, on inflation, the longitudinal axis of the conduit 5 is substantially parallel to the hinge pivot axis P. Needless to say when deflated the longitudinal axis of the conduit 5 in so far as it can be said to have one, is still substantially parallel to the hinge pivot axis P. A conventional door closing device, for example, spring or hydraulically operated, is provided (not shown). On deflation of the conduit 5 the door closing device operates to close the door.
Referring to FIGS. 5 to 7 inclusive there is illustrated an alternative construction of fluid pressure powered actuator according to the invention. There is illustrated a first member namely a door post 20 mounted on a door saddle 21. A second member namely door 22 is mounted on the door post 20 by means of a hinge 23 having a pivot axis P. A conduit 24 sealed at both ends 25, only one end 25 of which is shown, lies adjacent the door post 20. A pipe 26 connects the conduit 24 to an air supply and also serves as an air exhaust. The conduit 24 is mounted on the door post 20 by a first connecting means indicated generally by the reference numeral 27 and on to the door 22 by a second connecting means indicated generally by the reference numeral 28.
The first connecting means 27 comprises of a base plate 29 and a clamping plate 30.
The base plate 29 is secured to the door post 20 by means of a number of nuts 31 and bolts 32 each bolt 32 engages an elongated slot 33 in the base plate 29. A spacer plate 34 is mounted on the bolts 32 between the base plate 29 and the door post 20. The slot 33 is used for adjustment of the fluid pressure powered actuator on installation. The clamping plate 30 is secured to the conduit 24 by bolts 35 having nuts 36. Preferably, the conduit 24 is sealed on itself where it is pierced by the bolts 35 to ensure an air tight joint.
The second connecting means 28 comprises of a base plate 37 having an elongated slot 38 whose longitudinal axis is at right angles to the pivot axis P of the hinge 23. A further clamping plate 30 and nuts 36 and bolts 35 are used to secure the conduit 24 to the base plate 37. The base plate 37 is secured to the door 22 by means of bolts 39 and nuts 40 and 41. It will be noted that there is a space between the head of the bolt 39 and the nut 40. Stiffening strips 42 are secured to the door 22 by the nuts 40 and 41. Thus the base plate 37 has provision not only for limited linear movement along the door 22 relative to the pivot axis P of the hinge 23 but also for limited linear movement along the bolt 39 towards and away from the door 22.
The operation of the embodiment described with reference to FIGS. 5, 6 and 7 is substantially similar to the operation of the embodiment described in reference to FIGS. 1 to 4 inclusive.
It will be noted that in both of the embodiments described above the conduit was not rigidly connected between the door post and the door. Referring to FIGS. 8(a) and 8(b) there is illustrated a first member 50 pivotally connected to a rigidly mounted second member 51 on which is mounted by first and second connecting means 53 and 52 a conduit indicated generally by the reference numeral 54, the outer portion of which is identified by the reference numeral 55 and the inner portion by the reference numeral 56. The "hinge" connection between the members 50 and 51 is not shown. The connecting means 52 and 53 are rigidly connected respectively to the members 51 and 50. When the conduit 54 is inflated the first member 50 pivots through approximately 60° away from the member 57. At this stage the first member 50 stops pivoting. It is believed that the reason why the first member 50 stops pivoting is firstly, that the inner portion 56 of the conduit exerts a pressure inwards on the members 50 and 51, and hence against further pivotal movement. It is also believed that the pull of the conduit 54 is mainly exerted through its outer portion 55 and that this is now not operating in the most efficient direction. It is believed that the pull exerted by the conduit 54 on inflation is exerted through its outer portion 55 and thus substantially tangentially at its connecting means 52 and 53, that is to say that the main pull on the first member 50 is in the direction of the arrow B (FIG. 8(b)).
Referring to FIG. 8(c) there is illustrated substantially the same fluid pressure powered actuator, the same parts being identified by the same number the only difference between the embodiment described in FIG. 8(c) and the embodiment described with reference to FIGS. 8(a ) and 8(b) is that the first connecting means 53 is now hingedly mounted at 57 on the first member 50. Because the first connecting means 53 is hinged on the first member 50 the first member 50 opens through 90°. This it is believed is because the pull of the conduit 54 on the first member 50 is now operating in the direction of the arrow C which is tangential to the outer portion 55 and it is now operating so as to pull the first member 50 wider relative to the second member 51.
Displacements of up to 120° have been achieved by a fluid pressure powered actuator mounted between two hingedly connected members.
Referring to FIG. 9 there is illustrated the torque displacement characteristics of a fluid pressure powered actuator according to the present invention. This fluid pressure powered actuator comprises a 6 foot length of conduit of 21/2 inch diameter which, when it was clamped in position had an effective diameter of 11/2 inches. The conduit was operated from an air supply at 30 p.s.i. There are illustrated three torque displacement curves:
Graph I illustrated the actual torque exerted by the fluid pressure powered actuator on the door, and
Graph II illustrates the torque of a conventional door closer mounted on the door, thus operating against the fluid pressure powered actuator and
Graph III represents the resultant torque of the fluid pressure powered actuator on the door.
It will be noted that the torque exerted by the fluid pressure powered actuator is initially rather high and that as the door opens the torque is reduced thus giving a natural cushioning effect.
While the embodiments described above relate to a door mounted on a door post it will be appreciated that the invention is equally applicable to any two members connected together by a hinge.
It will also be appreciated that fluids other than air for example, water may be used to operate the fluid pressure powered actuator. In view of the large diameter of conduit used there is no necessity to provide a clean fluid. It has been found that one of the advantages of the present invention is that it lends itself readily to installation on existing doors. A small cross-sectional area of conduit may be used and therefore, it can be installed in a very confined space along the length of the door post. It has also been found that the fluid pressure powered actuator has a very high torque to cross-sectional area ratio. Further it has been noted that the torque characteristics of this "pull" type fluid pressure powered actuator is more suitable for hinged door and closure member applications than push type fluid pressure powered actuators in that there is a high initial torque to overcome the initial high forces and a low finishing torque giving adequate cushioning at the end of a stroke. It has also been found with a fluid pressure powered actuator according to the invention, that longer life of the conduit due to limited flexing has been achieved, than with push types. The installation and manufacturing costs of the fluid pressure powered actuator according to the present invention are relatively low as it will be appreciated that relatively cheap "off the shelf" conduit may be used. In fact the invention has operated satisfactorily using conventional fire hose.
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The present invention relates to a fluid pressure powered actuator for imparting relative angular movement between two members, connected together by a hinge, comprising an elongated inflatable flexible conduit of substantial constant surface area, connected between the two members with its longitudinal axis substantially parallel to the hinge pivot axis and with the two members substantially equispaced around the conduit whereby on inflation, the conduit exerts a pulling force between the two members to impart relative angular movement therebetween.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
TECHNICAL FIELD
The present invention relates to supports for cantilever toilet bowls. More particularly, the present invention relates to apparatus and methods for selectively supporting cantilever mounted toilet bowls during high mass load usage.
BACKGROUND OF THE INVENTION
Recent years have seen increasing numbers of bariatric patients who suffer from obesity or weight significantly in excess of typical weights for individuals. For example, persons having a body mass index of 40 or greater (or often more than one hundred pounds over conventionally recommended body weight), may be considered morbidly obese. Special surgeries are available for such individuals, and hospitals handling this medical condition typically have facilities equipped for providing physical support and assistance to such individuals for accomplishing typical and ordinary physical functions. Additional supports are needed because the increased mass imposes higher than normal loadings on commonly used devices such as toilet bowls, chairs, beds, and the like.
Additional supports are particularly needed to assist the bariatric patient with using bathroom devices such as toilet bowls. Many facilities use cantilever mounted toilet bowls, whereby one end of the toilet bowl connects to a support in the wall. Cantilever toilets facilitate cleaning and mopping of the floor. The other support devices include rails mounted above the toilet bowl to facilitate grasping by the bariatric patient in order to assist use of the toilet bowl. However, such entrance and egress supports do not provide support to the cantilever toilet bowl, and the full weight of the bariatric patient on the toilet bowl can lead to failure and collapse of the toilet bowl.
While facilities especially designed for treating bariatric patients include floor-supported toilets, medical facilities are finding an increasing number of bariatric patients admitted for other reasons. Typical hospital rooms are configured for bathroom devices supporting patients of average weights, and particularly cantilever toilet bowls. Yet these fail to adequately provide reliable support to a heavily loaded toilet bowl, such as may be necessary for a bariatric patient.
Accordingly, there is a need in the art for a device for selectively and conveniently providing support to cantilever toilet bowls that are subject periodically to high mass loading. It is to such that the present invention is directed.
BRIEF SUMMARY OF THE INVENTION
The present invention meets the need in the industry by providing a support for being disposed between a floor surface and a lower surface of a distal end of a cantilever toilet attached at one end to a wall and extending therefrom, in which a base defines a surface oriented at an oblique angle relative to a horizontal plane and with a guide rail attached to an upper portion of the base member substantially parallel to the upper surface. A traveler operatively engaged to the guide member is movable on the upper surface for selective positioning to bear against a lower surface of a cantilever toilet for support thereof during use of the toilet.
Features, objects, and advantages of the present invention will be apparent upon reading the following detailed description in conjunction with the claims and the appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded pictorial view of a toilet support device according to the present invention.
FIG. 2 is a perspective view illustrating features of a bottom of a traveler used with the toilet support device illustrated in FIG. 1 .
FIG. 3 is a perspective broken-away view of the toilet support device illustrated in FIG. 1 in use for supporting a cantilever toilet bowl.
FIG. 4 is a side elevational view of the toilet bowl support installed under a distal edge of a cantilever toilet bowl in accordance with the present invention.
DETAILED DESCRIPTION
Referring now in more detail to the drawings, in which like numerals indicate like parts throughout the several views, FIG. 1 illustrates in exploded perspective view a toilet support device 10 according to the present invention. The support device 10 includes a base 12 having a bottom surface 14 that seats on a floor. An opposing traveler surface 16 is oriented at an oblique angle relative to a horizontal plane such as the floor on which the base rests. A pin 18 extends upwardly from the traveler surface 16 generally medial the opposing lateral sides and opposing distal ends, for a purpose discussed below. A pair of elongate slots 20 are defined in opposing sides of the base 12 . The slots 20 are parallel to the traveler surface 16 and spaced therefrom. A handle 22 attaches to a front face of the base 12 for convenience in carrying and positioning the support device 10 for use. The base 12 defines spaced-apart transverse through openings 23 between the slot 20 and the traveler surface 16 .
A traveler 24 seats on the traveler surface 16 for longitudinal movement of the traveler relative to the traveler surface 16 of the base 12 . The traveler 24 includes a traveler surface 26 oriented at an oblique angle to horizontal for conforming contact with the traveler surface 16 of the base 12 . The traveler surface 26 in an alternate embodiment can also have a slight oblique angle laterally. The traveler 24 defines opposing slots 27 spaced apart from the traveler surface 26 and parallel to the longitudinal angled orientation of the traveler surface 26 . A positioning hole 30 extends transverse through the traveler 24 between the slots 27 and the traveler surface 26 . In the illustrated embodiment, four positioning holes 30 are provided in spaced apart relation. While the positioning holes 30 may be equally spaced, in the illustrated embodiment, the spacing is non-uniform. Positioning holes 30 and 30 a are spaced 1.5 inches apart, positioning holes 30 a and 30 b are spaced 1.25 inches apart; and positioning holes 30 b and 30 c are spaced 0.75 inches apart. The non-uniform spacing facilitates selective positioning of the traveler 24 relative to the base 12 as discussed below. A resilient pad 31 attaches such as with adhesive to an opposing surface of the traveler 24 . The pad 31 provides a bearing surface to contact a lower surface of a cantilever toilet bowl.
A pair of opposing guiderails 32 interconnect the base 12 and the traveler 24 . The guiderails 32 define a U-shaped channel in cross-sectional view having a pair of opposing legs 34 and a transverse bridge 36 between the legs. The bridge 36 defines openings 37 that align with the openings 23 in the base 12 . The legs 34 are received in the respective slots 20 , 27 on opposing sides of the support device 10 . Fasteners 38 extend through the openings 23 in the base 12 and the aligned openings 37 in the guiderails 32 to secure the guiderails to the base. The traveler 24 seats for longitudinal movement on the traveler surface 16 of the base 12 . The guiderails 32 hold the base 12 and the traveler 24 together.
The guiderail 32 further defines a plurality of spaced apart openings 40 . The openings 40 are positioned to align selectively with one of the openings 30 . In the illustrated embodiment, the openings 40 are 9/32 inches in diameter and are spaced apart on one inch centers. Other spacings for the openings 40 and 30 are readily used. The position holes 30 selectively align with one of the openings 40 in the guiderail 32 as the traveler 24 is selectively moved relative to the base 12 . A pin 42 connects to a handle 44 and extends through one of the openings 40 and one of the aligned openings 30 in order to secure the traveler 24 in a selected position. A connector 46 extends between the handle 44 and the handle 22 .
With reference to FIG. 2 , the traveler surface 26 of the traveler 24 defines an elongate slot 48 having opposing distal ends 50 . The pin 18 extends from the traveler surface 16 into the slot 48 when the traveler 24 seats on the base 12 . The distal ends 50 act as stops when the traveler 24 moves longitudinally relative to the base 12 .
FIG. 3 illustrates in perspective broken-away view a cantilever toilet bowl 54 attached conventionally to supports in a wall with a distal end 56 supported by the toilet bowl support 10 . FIG. 4 is a side elevational view of the toilet bowl support 10 installed under an edge portion of the distal end 56 of the cantilever toilet bowl 54 in accordance with the present invention. The handle 22 facilitates carrying the support 10 to the room for installation as well as positioning the base 12 beneath the toilet bowl 54 .
The base 12 seats with the bottom surface 14 on the floor below an edge of the distal portion 56 of the toilet bowl 54 . The pin 42 is removed from the guiderail 32 releasing the traveler 24 for longitudinal movement relative to the base 12 . The traveler 24 is moved longitudinally to position the resilient pad 31 in contact with a lower surface of the toilet bowl 54 . The pin 18 (see FIG. 1 ) contacts the stop ends 50 (see FIG. 2 ) to prevent the traveler 24 from moving longitudinally off of the base 12 . With the upper surface of the pad 31 positioned in contact with the toilet bowl 54 , the pin 42 is then reinserted through one of the openings 40 and into one of the holes 30 aligned with the openings. The pin 42 secures the traveler 24 to the base 14 and restricts longitudinal movement of the traveler. The resilient pad 31 in bearing contact with the lower surface of the toilet bowl 54 communicates loading through the traveler 24 and the base 12 to the floor. In the embodiment in which the traveler 24 includes a transverse angled orientation, the pad 31 leans laterally towards the toilet bowl.
The spacings of the openings 30 , 30 a , 30 b , and 30 c facilitate positioning the traveler 24 such that one of the openings 40 aligns with one of the openings 30 , 30 a , 30 b , or 30 c , for selective receiving of the pin 42 to hold the traveler 24 fixed to the base 12 .
In an alternate embodiment, a jack screw attached to supports in the base and the traveler enable the traveler to move longitudinally relative to the base.
Accordingly, the present invention provides a support device 10 readily and conveniently used for providing additional loading support to toilet bowls, and particularly cantilever mounted toilet bowls, for use by bariatric patients. Thus, a hospital with toilets lacking suitable supports for a bariatric patient can readily and conveniently install the support 10 in a hospital room occupied by such patient on short notice and remove this support upon departure of the patient.
The present invention accordingly provides a device for supporting cantilever toilets conveniently and readily, without the need to remove and reinstall the cantilever toilet, to meet timely the need for supporting such device with significantly less labor, time, and coordination. The principles, preferred embodiments, and modes of operation of the present invention have been described in the foregoing specification. The invention is not to be construed as limited to the particular forms disclosed because these are regarded as illustrative rather than restrictive. Moreover, variations and changes may be made by those skilled in the art without departure from the spirit of the invention as described by the following claims.
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A support device selectively disposed between a floor surface and a lower surface of distal end of a cantilever toilet in which a base defines a surface oriented at an oblique angle relative to a horizontal plane and with a guide rail attached to an upper portion of the base substantially parallel to the upper surface. A traveler operatively engaged to the guide member moves on the upper surface for selective positioning to bear against a lower surface of a cantilever toilet. A method of supporting a cantilever toilet is disclosed.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
1. Field of Invention
The present invention relates generally to the field of hydrocarbon production, more particularly to methods for obtaining a wellbore schematic, and using same to monitor wellbore service operations.
2. Related Art
Due primarily to expense issues, the hydrocarbon production industry has come to accept taking surface measurements and making inferences of the downhole status. However, interpretation of real-time wellbore pressure data requires knowledge of the wellbore schematic, in particular the wellbore's variation of depth below the earth surface (“true vertical depth”, or TVD) versus its depth along the wellbore axis (measured depth, MD or just “depth”). In circumstances where the wellbore schematic is not known in advance by the interpreter, the wellbore schematic may be obtained directly by including a inclinometer in a downhole tool, but this option is not always available or economical.
In making wellbore pressure interpretations, the pressure read by a downhole meter inside a tubular such as coiled tubing will be the pressure in the tubing at the surface (the “circulating pressure”) less friction effects due to flow and plus the hydrostatic pressure, which is proportional to the TVD. For a uniform fluid, the hydrostatic pressure is given by the density of the fluid in ppg times 0.052 psi/ppg/ft. For a typical brine, this works out to approximately 0.5 psi/ft (11.3 kPa/m) of TVD. For a non-uniform fluid, integration along the length of the tubing is required. At zero flow, the TVD is thus given by subtracting the circulating pressure from the bottom-hole pressure and dividing by the constant of proportionality. It is uncommon (and sometimes inefficient) to run coiled tubing into the bottom of the wellbore without pumping fluid, however. When pumping fluid downhole through tubing, the bottom-hole pressure at the terminus of the tubing will be decreased by the friction of the fluid in the tubing. For laminar flow of Newtonian fluids, friction pressure equals a constant multiplied by the flow rate. For turbulent flow of Newtonian fluids, friction pressure equals a constant multiplied by the flow rate squared. In each case the constant of proportionality depends upon the tubing internal geometry as well as the local friction factor between the fluid and the inner tubing surface. For typical fluids pumped through coiled-tubing, there may be a different formula for computing friction loss for the component of the fluid flowing through the spooled coil at the surface, versus that fluid flowing in the tubing hanging in the wellbore. For non-Newtonian fluids, yet more complicated relationships exist between the circulating friction loss and the flow-rate.
In wellbore cleanout procedures and other procedures where liquids are pumped into the wellbore via tubing and out through the annulus, if hydrostatic head pressure may be removed, one has an accurate estimate of the wellbore pressure at the bottom of (entrance to) the annulus. However, the only way to remove the hydrostatic component from downhole data is to have a copy of the wellbore schematic in advance of the job. This schematic could have been obtained while drilling the well via measurement-while-drilling data, or after drilling by lowering a wireline inclinometer tool such as a gyroscope. However, no tool that is currently used for stimulating reservoirs is known to have an internal inclinometry platform, nor is there known any previously existing method to determine TVD strictly from pressure data and flow rate information.
In wellbore cleanout operations, various fill materials are carried by a fluid injected down the wellbore, typically through coiled tubing or other tubulars, and flowed out through the annulus. The cleanout fluid carrying solid particles along the annulus is a suspension whose density correlates with the concentration of solid particles. For an effective cleanout the suspended particles must be transported all the way out of the well. The hydrodynamic pressure in the annulus is directly proportional to the suspension density.
It would be an advance in the art if methods could be devised that provide information about the relationship between TVD vs. MD, in other words the wellbore schematic, while flowing fluids into the wellbore. It would further be an advance in the art to use the obtained wellbore schematic to monitor and/or control wellbore operations, such as wellbore cleanout procedures, via information about the annulus.
SUMMARY OF THE INVENTION
In accordance with the present invention, a wellbore schematic may be estimated from an interpretation of the pressure data itself. Despite the previously-mentioned complications, the designer of a wellbore treatment regime, such as a stimulation treatment, will usually be content to pump a fluid (for example brine) through the tubing for the initial pass into the wellbore. It is during this pass through the wellbore that information about the TVD versus depth may be obtained. Note that it is rather trivial to determine this relationship when not pumping, so one objective of the invention is to derive TVD versus MD relationship while pumping a fluid. Different fluid flow rates may be pumped when different lengths of coiled tubing have been entered into the wellbore. By combining surface measurements of pressure and flow of a known fluid with downhole measurements of pressure, the wellbore schematic may be obtained.
Thus, a first aspect of the invention is a method comprising:
(a) providing a coil of coiled tubing having a length able to reach a determined section of a wellbore; (b) running measured distances of the coiled tubing into a wellbore while pumping a fluid at varying flow rates through the coiled tubing; (c) measuring circulating pressure and pressure at bottom of the wellbore at various times during running and pumping; and (d) calculating wellbore parameters of the wellbore at the one or more measured distances using the pressure and flow rate data.
Methods within this aspect of the invention include methods wherein the wellbore parameters include true vertical depth of the wellbore along the length of the wellbore, and methods comprising cross-plotting the true vertical depth versus the measured distances as a function of time. As used herein “circulating pressure” means the pressure of the circulating fluid measured at the surface just before it enters the coiled tubing. One embodiment comprises pumping a sequence of fluid flow regimes into the wellbore at measured circulation pressures and flow rates, sending bottom-hole data to the surface, and fitting the data to find the wellbore geometry assuming a minimal radius of curvature for the wellbore. The true vertical depth may be cross-plotted versus measured distance as a function of time. Methods include those wherein the density of the pumped fluid is constant or varies, such as when a wellbore cleanout fluid picks up particles from the wellbore and transfers the particles with the fluid out through the annulus of the wellbore. When the density of the fluid changes, a second calculation using pressure measurements at the surface and in the wellbore may be used to calculate, and recalculate if necessary or desired, the fluid density. Alternatively, the density of the pumped fluid may simply be monitored for change of density.
Methods within this aspect of the invention include sending real-time pressure data to the surface during wellbore stimulation using one or more methods selected from wireless methods (such as mud-pulse electromagnetic telemetry), wire methods via a data-carrying wire (such as an eline cable), and fiber-optic lines. The wireless methods may be used particularly when running in joints of tubing. In other embodiments the tubing is brought to the well spooled onto a reel with a telemetry cable already inserted into the spool, but the invention is not so limited. The wireline may be inserted into the tubing at the well site. An advantage of fiber-optic telemetry is that the bottom-hole pressure may be measured without the need for downhole electronics. Indeed, if one has downhole electronics, then an inclinometer may be added to the electronics package for minimal additional cost, so one of the prime advantages of this invention is for bottom-hole assemblies without an electronics package. Fiber-optic techniques to measure pressure are well-known in the industry. One common device relies on interferometry to identify the size of a cavity, that cavity itself changing size based on the external pressure applied to the cavity. Such devices are made, for example, by FISO Technologies in Montreal, Canada and have been recently implemented in the bottom-hole assemblies. Certain methods of this aspect of the invention comprise repeating steps (b), (c), and (d) during repeated passes of the tubing through the wellbore. This may result in more certainty regarding the wellbore schematic.
Once the wellbore schematic is estimated then the same information on the wellbore and fluids may be used to analyze the annulus around the coil. Thus, another aspect of the invention is a method comprising:
(a) pumping a fluid at a wellhead down a wellbore through coiled tubing and measuring pressure and flow rate of the fluid at the wellhead and down the wellbore at a terminus of the coiled tubing, the fluid flowing out of the wellbore through an annulus; and (b) monitoring presence of particles in the fluid with or without detecting variations in their concentration.
One method according to this aspect of the invention comprises calculating the flowing fluid stream density in the annulus, or monitoring variations in fluid density in the annulus. Another method comprises quantifying the amount of fill material removed from the wellbore. In this respect, the methods are an alternative or complement to solids detection in annulus fluids at the wellhead.
Methods within this aspect of the invention include those wherein the wellbore is selected from substantially vertical wellbores, deviated wellbores, and combinations thereof. Other methods comprise determining the quantity f*k geo in the respective vertical and deviated instances, wherein f is the friction coefficient and k geo is a constant that depends on the geometry of the annulus. In certain methods if the quantity f*k geo is known, the density of the fluid in the annulus may be quantified, and therefore the concentration of particles in the fluid. This provides a method to monitor cleanout efficiency of a pumped cleanout fluid carrying the particles to the surface. The quantity f*k geo may be determined during a period of flow where no cleaning is taking place, in other words with no particles in suspension, so that density is known. Alternatively, a plot may be made of the difference between annulus pressure and wellhead pressure as a function of length of tubing in the wellbore, with a set of pre-defined constant density lines. Another alternative is to calculate fluid density at zero flow rate, which may be achieved using short pumping interruptions. As will be shown, this allows calculation of fluid density without the need of taking into account the friction. Such pumping interruptions may only be possible if the particle settling time is sufficiently long, for example with gel fluids.
The method may be a wellbore cleanout operation, and the methods may be monitored. In the context of wellbore cleanout operations, another aspect of the invention is a computation method comprising measuring wellhead pressure at surface, at the flow exit, measuring annulus bottom hole pressure, at the end of the CT string, and measuring the length of coiled tubing run in the wellbore, and determining the qualitative relationship between annulus fluid density and flow rate, without knowing the friction factor or k geo factor for the annulus. Knowing the latter two quantities allows a quantitative measure of annulus fluid density.
Methods of the invention may be used with one or more oilfield tool components. The term “oilfield tool component” includes oilfield tools, tool strings, deployment bars, coiled tubing, jointed tubing, wireline sections, slickline sections, combinations thereof, and the like adapted to be run through one or more oilfield pressure control components. The term “oilfield pressure control component” may include a BOP, a lubricator, a riser pipe, a wellhead, or combinations thereof.
Advantages of the methods of the invention include combining the operations of determining the wellbore schematic with one or more fluid flow regimes at a well site, thus saving time. Determination of a wellbore schematic during fluid injection also eliminates the need for an instrumented bottom hole assembly, possibly allowing more efficient wellbore operations, and provides the opportunity for obtaining more information on annular fluids without having to calculate friction coefficient of the annulus.
Methods of the invention may become more apparent upon review of the brief description of the drawings, the detailed description of the invention, and the claims that follow.
BRIEF DESCRIPTION OF THE DRAWINGS
The manner in which the objectives of the invention and other desirable characteristics may be obtained is explained in the following description and attached drawings in which:
FIG. 1 . is a schematic cross-sectional view of a wellbore illustrating calculation parameters for one method of the invention; and
FIG. 2 is a schematic cross-sectional view of a partially vertical and partially deviated wellbore illustrating calculation parameters for another method of the invention.
FIG. 3 is an illustration useful for a method of derivation of well deviation and TVD; and
FIGS. 4A , 4 B, and 4 C illustrate an example of application of the method of FIG. 3 .
It is to be noted, however, that the appended drawings are not to scale and illustrate only typical embodiments of this invention, and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
DETAILED DESCRIPTION
In the following description, numerous details are set forth to provide an understanding of the present invention. However, it may be understood by those skilled in the art that the present invention may be practiced without these details and that numerous variations or modifications from the described embodiments may be possible.
All phrases, derivations, collocations and multiword expressions used herein, in particular in the claims that follow, are expressly not limited to nouns and verbs. It is apparent that meanings are not just expressed by nouns and verbs or single words. Languages use a variety of ways to express content. The existence of inventive concepts and the ways in which these are expressed varies in language-cultures. For example, many lexicalized compounds in Germanic languages are often expressed as adjective-noun combinations, noun-preposition-noun combinations or derivations in Romanic languages. The possibility to include phrases, derivations and collocations in the claims is essential for high-quality patents, making it possible to reduce expressions to their conceptual content, and all possible conceptual combinations of words that are compatible with such content (either within a language or across languages) are intended to be included in the used phrases.
The invention describes methods for obtaining a wellbore schematic, defined as the relationship between true vertical distance (TVD) and measured distance (MD) of a tubular in a wellbore. Currently, in wellbore cleanout procedures and other procedures where liquids are pumped into the wellbore via tubing and out through the annulus, if hydrostatic head pressure may be removed, one has an accurate estimate of the wellbore pressure at the bottom of (entrance to) the annulus. However, the only way to remove the hydrostatic component from downhole data is to have a copy of the wellbore schematic in advance of the job. This schematic could have been obtained while drilling the well via measurement-while-drilling data, or after drilling by lowering a wireline inclinometer tool such as a gyroscope. However, no tool that is currently used for stimulating reservoirs is known to have an internal inclinometry platform, nor is there known any previously existing method to determine TVD strictly from pressure data and flow rate information. Another challenge is in so-called wellbore cleanout operations, wherein various fill materials are carried by a fluid injected down the wellbore, typically through coiled tubing or other tubulars, and flowed out through the annulus. The cleanout fluid carrying solid particles along the annulus is a suspension whose density correlates with the concentration of solid particles. For an effective cleanout the suspended particles must be transported all the way out of the well. The hydrodynamic pressure in the annulus is directly proportional to the suspension density. It would be an advance in the art if methods could be devised that provide information about the relationship between TVD vs. MD, in other words the wellbore schematic, while flowing fluids into the wellbore. It would further be an advance in the art to use the obtained wellbore schematic to monitor and/or control wellbore operations, such as wellbore cleanout procedures, via information about the annulus. There is a continuing need for systems and methods that address one or more of these challenges.
As used herein “wellbore schematic” means the relationship between true vertical depth and measured depth, where measured depth is the depth measured at the wellhead of coiled tubing that has entered the wellbore. As used herein “annulus fluid” and “annular fluid” may be used interchangeably and refer to the fluid traversing past a coiled tubing back to the surface. As used herein “wellbore servicing” means any operation designed to increase hydrocarbon recovery from a reservoir, reduce non-hydrocarbon recovery (when non-hydrocarbons are present), or combinations thereof, involving the step of pumping a fluid into a wellbore, or into coiled tubing that is or will be placed into the wellbore. This includes pumping fluid into a reeled or spooled coil of coiled tubing. The fluid pumped may be a composition to increase the production of a hydrocarbon-bearing zone, a composition pumped into other zones to block their permeability or porosity, a composition designed to flush or cleanout a wellbore or portion thereof, and the like. Methods of the invention may include pumping fluids to stabilize sections of the wellbore to stop sand production, for example, or pumping a cementatious fluid down a wellbore, in which case the fluid being pumped may penetrate into the completion (e.g. down the innermost tubular and then up the exterior of the tubular in the annulus between that tubular and the rock) and provide mechanical integrity to the wellbore. As used here in the phrases “treatment” and “servicing” are thus broader than “stimulation”. In many applications, when the rock is largely composed of carbonates, one of the fluids may include an acid and the hydrocarbon increase comes from directly increasing the porosity and permeability of the rock matrix. In other applications, often sandstones, the stages may include proppant or additional materials added to the fluid, so that the pressure of the fluid fractures the rock hydraulically and the proppant is carried behind so as to keep the fractures from resealing. The details are covered in most standard well service texts and are known to those skilled in the well service art so are omitted here.
Methods within this aspect of the invention include sending real-time pressure data to the surface during wellbore servicing using one or methods selected from wireless methods (such as mud-pulse electromagnetic telemetry), wire methods via a data-carrying wire (such as an eline cable), and fiber-optic lines. The wireless methods may be used particularly when running in joints of tubing. In other embodiments the tubing is brought to the well spooled onto a reel with a telemetry cable already inserted into the spool, but the invention is not so limited. The wireline may be inserted into the tubing at the well site. An advantage of fiber-optic telemetry is that the bottom-hole pressure may be measured without the need for downhole electronics. Indeed, if one has downhole electronics, then an inclinometer may be added to the electronic package for minimal additional cost, so one of the prime advantages of this invention is for bottom-hole assemblies without an electronics package. Fiber-optic techniques to measure pressure are well-known in the industry. One common device relies on interferometry to identify the size of a cavity, that cavity itself changing size based on the external pressure applied to the cavity. Such devices are made, for example, by FISO Technologies in Montreal, Canada and have been implemented in the bottom-hole assemblies.
Exemplary methods of the invention rely on running tubing into the bottom of a wellbore while pumping a fluid therethrough at varying rates while running in. The fluid may be one in which the friction drop down tubing, such as coiled tubing, behaves according to a power-law relationship:
friction pressure= A* (flow rate) n ,
where n is an exponent (typically between 1 and 2) and A depends on (i.e., is a function of) viscosity of the fluid, local friction effects and tubular internal diameter. The pressure measured at the bottom of the tubing will be given by the circulating pressure (measured at the surface) less the friction pressure through the tubing plus the hydrostatic pressure. The friction pressure in the coiled tubing may be best modeled as two components:
friction pressure= A 1 *(flow rate) n1 +A 2 *(flow rate) n2
where the first term to the right of the equal sign represents the pressure drop along that part of the coil wound around a spool, and the second term to the right to the equal sign represents the pressure drop along the unspooled coil. This latter component may be taken to be proportional to the length of coil run into the wellbore, so surface measurement of this length will be needed. Apparatus for such measurements are commercially available and well-known in the industry. For example, small wheels may be pushed against the coil and the rotation of those wheels will give the length of the coil run in. One embodiment is that known under the trade designation UTLM, from Schlumberger. The first component of the friction pressure may be modeled either as a formula which takes into account the changing diameter of the spooled coil, or more simply may be taken as proportional to the length of coil wound around the spool. Thus if there is a total of L T feet brought to the rig and MD(t) has been run into the ground at time t, then the friction pressure may take the form:
friction pressure= a 1 *( L T −MD ( t ))*(flow rate( t )) n1 +a 2 *MD ( t )*(flow rate( t )) n2 .
In order to determine the unknown coefficients a 1 and a 2 , and the exponents n 1 and n 2 , the flow rate and MD as the coil is run in may be varied with time. The hydrostatic pressure will be proportional to the density of the fluid times its TVD. In many embodiments the density of the pumped fluid varies with depth and flow rate; however, in some embodiments the density may be assumed to be fixed, so the hydrostatic term becomes:
hydrostatic pressure= TVD ( t )*density*gravity.
One method of the invention is thus to find a best fit of the parameters (TVD(t) vs. MD(t)) which matches up the sum of the theoretical friction pressure and hydrostatic pressure against the difference of the measured circulating and bottomhole pressures. This best fit may be done with a number of techniques for non-linear optimization. Such programs are readily available in software packages, such as Matlab. The result is then a cross-plot of TVD(t) versus MD(t) at each time. This is precisely the wellbore schematic. The terminology Y(t) may be used to denote the difference between theoretical pressure drop in the coil against the measured pressure drop.
In the unlikely event that the density of the fluid is not known at the beginning of the job, it may be estimated if the wellbore schematic is at least known at the top of the wellbore, e.g., if the top of the wellbore is vertical. This estimate could then be used for the rest of the inversion.
The nature of nonlinear parameter estimation means that the plot of TVD(t) versus MD(t) will be quite noisy. This estimation may be made more robust by adding additional information such as the maximum dogleg angle of the wellbore. A second piece of information is that the borehole inclination may only change quite slowly with depth. A standard practice in the industry is to assume that the borehole schematic follows a so-called minimum radius of curvature. While drilling the well, periodic measurements of inclination are passed to the surface. The inclination between two such measurements is determined by fitting an arc of a circle of fixed radius such that the inclinations at the ends of the arc match the measured inclinations. In effect, the wellbore schematic is that combination of arcs that has a fixed radius between each measurement of inclination. We may use this methodology in the derivation of the wellbore schematic from pressure.
The unknown parameters become a 1 , a 2 , n 1 and n 2 and a series of inclinations, θ(MD), where θ is the inclination angle and MD is the length of coil run into the well. The nonlinear estimation will then minimize the sum of Y(t) 2 +Z(t) 2 where Z(t) is a weighting term constraining the rate of change of θ. There are well-known techniques to constrain rate of change. One standard formula is the sum of the absolute value:
rate of change=|θ( MD ( j +1))−θ( MD ( j ))|
for a predetermined selection of depths MD( 1 ), MD( 2 ), . . . . A typical selection of depths would be fixed interval of 10 m or 30 ft along the length of the wellbore. The result of this optimization is not just the wellbore schematic. The parametric values in the friction expression are in themselves useful because they may give indications of viscosity and the nature of the flow—for example, the exponent of the flow is indicative of the flow profile, whether it is laminar or turbulent. See for example, Bird, et al., “ Transport Phenomena ”, Chapter 6, pp. 180-190, John Wiley & Sons (1960).
Once the wellbore schematic is estimated then the same information on the wellbore schematic and pressure of fluids may be used to analyze the annulus fluid around the coil. The pressure drop between the bottomhole and the wellhead is the sum of the hydrostatic and friction pressures in the annulus, plus the effect of the reservoir (e.g. whether it is causing a net increase in pressure in the annulus or a decrease). Also the hydrostatic pressure at a given depth may be subtracted from the annular bottomhole pressure to get directly the effect of the formation pressure (and the changes in that formation pressure vs. time). For example, if the tool is stationary then the hydrostatic pressure may be subtracted from pressure measurements during a fall-off and formation parameters may be estimated using standard well-testing techniques. If the tool is not stationary, then to be able to use such techniques requires subtracting of the varying hydrostatic pressure versus depth. Interestingly, if there is a small error in the input fluid density then there will be a corresponding error in estimated TVD, but this would not then translate into an error in the estimated hydrostatic versus depth.
It is important that the flow-rate be varied during the run in the well. If a fixed flow-rate is used then deriving the parameters a 1 , a 2 , n 1 and n 2 will be very unstable.
Note that there is a significant advantage in transmitting the bottom-hole pressure in real-time because then the wellbore schematic may be determined without having to extract the coiled tubing.
Further, note that in a typical coiled tubing operation, there will be repeated passes through the wellbore, so that during the course of the operation, the uncertainty in the wellbore schematic will be removed. The surface operator (or his computer) will need to monitor which fluids are being pumped, which in turn would allow parameters a 1 , a 2 , n 1 , n 2 and density to vary from one fluid to the next.
Referring now to the drawing figures, FIG. 1 is a schematic cross-sectional view of a wellbore illustrating general configuration, measurements and parameters involved for one method of the invention.
Measurements (see FIG. 1 ):
Wellhead pressure: WHP, measured at surface at the flow exit.
Circulation pressure: P circ , measured at surface, inside the CT at the ‘in’ extremity.
Annulus bottom hole pressure: P an , measured in the wellbore, at the end of the CT string.
CT bottom bole pressure: P CT , measured inside the CT, at the bottom end.
Parameters:
Total CT string length: L T
CT length in hole: MD
Wellbore, CT radii (resp. diameters): r w , r CT (resp. d w , d CT ).
Friction coefficient: f
annulus fluid velocity: υ an .
The four measured pressures are linked by the following relationships:
P an =WHP+F an +H an (1)
P CT =P circ −F CT +H CT (2)
P CT =P an +DP nozzle (3)
DP nozzle is the differential pressure across the nozzle fitted at the end of the CT.
Notations: F for friction pressure, H for hydrostatic pressure. The subscripts ‘an’ and ‘CT’ stand respectively for ‘in the annulus or wellbore’ and ‘inside the coiled tubing’.
With the annulus friction pressure—in theory calculable—and the measured annulus and wellhead pressures, the quantity of interest, the annulus hydrostatic pressure, is inferred from (1):
H an =P an −WHP−F an (1a)
The hydrostatic pressure is also:
H an =ρ an ·g·TVD (4)
wherein TVD is the vertical depth, equal to MD as defined above in a vertical well. We therefore obtain the average annulus fluid density ρ an :
ρ
an
=
H
an
g
·
TVD
(
4
a
)
Obtaining the annulus friction pressure:
The friction in the wellbore is given by (with the usual assumptions):
F an = f · ρ an · v an 2 · MD r w - r CT ( 5 )
Note: The density may vary along the annulus, i.e., ρ=ρ(MD). ρ an in (5) is the average annulus fluid density given by:
ρ an = ∫ ρ ( MD ) · ⅆ MD ∫ ⅆ MD ( 6 )
and the friction pressure is:
F an = ∫ f · ρ ( MD ) · v an 2 r w - r CT · ⅆ MD ( 7 )
Combining the two relations above leads to equation (5).
The annulus friction pressure is a function of the annulus fluid density, i.e., the friction term in (1a) cannot be accessed without knowing the density. An estimate of the density can be used in (5) to get the friction loss, and then re-adjusted at each computation cycle after the set of equations (1a, 4a) has been solved. The friction term could be very inaccurate, one of the reasons being that it requires the friction coefficient f, which has large uncertainties.
The following scheme gives the variations of the annulus fluid density without having to calculate the friction pressure.
Case 1: Vertical well.
Equation (5) may be re-written:
F an =MD ρ an fk geo υ 2 an (8)
where k geo is a constant that depends on the geometry of the system. Note that equation (8) is not specific to the vertical case where, as noted previously TVD is equal to MD.
From equations (1, 4, 8) one obtains equations (9) and (9a):
P
an
-
WHP
=
MD
·
ρ
an
·
g
·
(
1
+
f
·
k
geo
g
·
v
an
2
)
(
9
)
P
an
-
WHP
MD
=
ρ
an
·
g
·
(
1
+
f
·
k
geo
g
·
v
an
2
)
(
9
a
)
The difference between the downhole annulus pressure and the wellhead pressure is proportional to the hydrodynamic pressure and density for any given flow rate. It follows that:
Even without knowing the friction in the annulus, the measured quantity (P an −WHP)/MD gives the variations of the density in the annulus. With f*k geo known the method is quantitative (both f and k geo are accessible, an experimental method for estimating the product f*k geo is described further).
Case 2: Deviated well.
In a deviated well we lose the proportionality between H an and MD. Assuming a constant deviation, if m is the cosine (deviation angle), and reviewing FIG. 2 herein:
H an ρ an ·g·[MD 0 +m ·( MD−MD 0 )] (10)
and from equations (1, 8, and 10), equations 11 and 11a may be obtained:
P
an
-
WHP
=
ρ
an
·
(
f
·
k
geo
·
v
an
2
+
g
·
m
)
·
MD
+
ρ
an
·
g
·
(
1
-
m
)
·
MD
0
(
11
)
P
an
-
WHP
MD
=
ρ
an
·
(
f
·
k
geo
·
v
an
2
+
g
·
m
)
+
ρ
an
·
g
·
(
1
-
m
)
·
MD
0
MD
(
11
a
)
Equation (11) may be solved for ρ an , given the well configuration. Another option is a chart of (P an −WHP) vs. MD with a set of pre-defined constant-density lines.
Friction test, an experimental method for estimating the product f*k geo :
While in hole, a friction test could be performed based on equations (9) or (11).
Before starting cleaning, i.e., no particles in suspension, equations (9 or 11) may be solved for the quantity f*k geo which characterizes the friction. This must be done before reaching the treatment zone so as to have a density well defined (density of the injected fluid).
Interrupted Flow Test
While flowing, short pump interruptions (v an =0) will allow solving equations (9, 11) for “ρ an ” without the need of taking into account friction. Such pumping interruptions may only be possible when the particles' settling times are long enough, i.e., with gel fluids and the like.
Derivation of well deviation and TVD (cf FIG. 3 ).
The well has a vertical section of length MD 0 , the wellbore deviation is a function of the measured depth MD. The friction pressure is still given by (7):
F an = ∫ f · ρ ( MD ) · v an 2 r w - r CT · ⅆ MD ( 7 )
The hydrostatic pressure is:
H an =∫ρ( MD )· g ·cos [θ( MD )]· dMD (12)
From (1, 7, 12):
P an −WHP =∫ρ( MD )· g cos [θ( MD )]· dMD +∫ρ( MD )· f·k geo ν an 2 ·dMD (13)
Differentiating equation (13) with respect to MD one gets equation (14):
ⅆ ( P an - WHP ) ⅆ MD = ρ ( MD ) · g · cos [ θ ( MD ) ] + ρ ( MD ) · f · k geo · v an 2 ( 14 )
The left hand side of (14) is measured. Equation (14) may be solved for ρ(MD) given the well trajectory (i.e. cos [θ(MD)] vs. MD) or for cos [θ(MD) given the density (i.e. ρ(MD) vs. MD). After equation (14) is solved the TVD may be obtained through:
TVD =∫cos [θ( MD )]· dMD (15)
FIGS. 4( a, b, c ) illustrate an example of application of the method. In this example, given the diameter of the wellbore and fluid flow rate, the friction term is negligible compared to the hydrostatic term. The density, which is constant, is determined while in the vertical portion of the well.
In many cases, it is advantageous to drain a reservoir with a multiplicity of wellbore branches connected together downhole to a main trunk wellbore, in the similar way that the roots of a plant retrieve water from the soil. Such wellbores are referred to as multilaterals, with each branch being referred to as a lateral. In such circumstances, it is important to know which branch of the reservoir has been penetrated by the coiled tubing. Using one or more embodiments of the invention described herein, a wellbore schematic can be determined from parameters measured on the coiled tubing. The derived wellbore schematic can be compared to a schematic of the multilateral well, and thereby identify which of the laterals has been penetrated. Note that only an approximate schematic is needed of the overall multilateral reservoir. As the coiled tubing penetrates a particular lateral, then a more accurate description of the multilateral reservoir can be obtained. With the help of an entry sub at the end of the coiled tubing, it is possible to enter many, or all, the laterals and so obtain a complete multilateral schematic.
Knowing which lateral has been penetrated is also important to optimize the reservoir stimulation. For example, if a water is being produced out of one lateral and hydrocarbon out of a second, then the operator will desire to pump a stimulating fluid, such as acid, into the hydrocarbon-containing lateral, and the operator will desire to pump a non-stimulating or viscous fluid, such as a gel, into the water-containing lateral. If these fluids were to be pumped into the wrong laterals, then overall hydrocarbon recovery would be ruined. Similarly, if many laterals are penetrating hydrocarbon, then it will be efficient to add stimulating fluids to each lateral. If the coiled tubing should accidentally re-enter an already stimulated lateral, then it is disadvantageous to pump more stimulating fluid into that lateral. In this way, it can be seen that increasing knowledge of the wellbore schematic penetrated by the coiled tubing is a means to increase overall hydrocarbon productivity. The ability to selectively choose fluids is only one such example of how to use wellbore information to increase overall hydrocarbon productivity and other applications will be immediately apparent to those skilled in the art.
In certain embodiments of the invention communication from the communication line to a surface data acquisition system may comprise wireless telemetry. The surface data acquisition system need not be at the well site, for example it may be a networked system including a computer at the well site and a second system at some remote location. The data transmitted may optionally be used to control the operation, whereby the pump rate or the composition of a treatment fluid is adjusted based purely upon the downhole data collected and transmitted by the communication line, or from a combination of downhole data and surface measurements.
As used herein, “pumping” means using a “pumping system”, which in turn means a surface apparatus of pumps, which may include an electrical or hydraulic power unit, commonly known as a powerpack. In the case of a multiplicity of pumps, the pumps may be fluidly connected together in series or parallel, and the energy conveying the pumped fluid may come from one pump or a multiplicity. The pumping system may also include mixing devices to combine different fluids or blend solids into the fluid, and the invention contemplates using downhole and surface data to change the parameters of the fluid being pumped, as well as controlling on-the-fly mixing.
By the phrase “surface acquisition system” is meant one or more computers at the well site, but also allows for the possibility of a networked series of computers, and a networked series of surface sensors. The computers and sensors may exchange information via a wireless network. Some of the computers do not need to be at the well site but may be communicating via a communication system such as that known under the trade designation InterACT™ or equivalent communication system. In certain embodiments a communication line may terminate at the wellhead at a wireless transmitter, and the downhole data may be transmitted wirelessly. The surface acquisition system may have a mechanism to merge the downhole data with the surface data and then display them on a user's console. The surface acquisition system may also include apparatus allowing communication to the downhole sensors.
Data transmitted from the communication line may be used to monitor subsequent stages of reservoir or wellbore treatment. The data transmitted may optionally be used to control some or all of the treatment operation, whereby for example a pump rate or composition of a fluid being injected is adjusted based purely on the downhole data obtained by the communication line, or from a combination of downhole data and surface measurements. The downhole data transmitted may be that from one or more sensors attached to the end of one or more communication lines, and may supplement or be supplemented by a variety of other measurements. The data may be from a distributed section of a communication line such as distributed temperature along an optical fiber. The data collected may be stored on the acquisition system and the information used to optimize and/or model subsequent stimulation runs.
Although only a few exemplary embodiments of this invention have been described in detail above, those skilled in the art may readily appreciate that many modifications are possible in the exemplary embodiments without materially departing from the novel teachings and advantages of this invention. Accordingly, all such modifications are intended to be included within the scope of this invention as defined in the following claims. In the claims, no clauses are intended to be in the means-plus-function format allowed by 35 U.S.C. §112, paragraph 6 unless “means for” is explicitly recited together with an associated function. “Means for” clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents, but also equivalent structures.
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Methods are described for determining or estimating a wellbore schematic, one embodiment comprising running one or more measured distances of coiled tubing into a wellbore while pumping a fluid at varying flow rates through the coiled tubing, and calculating true vertical depth of the wellbore using pressure and flow rate data of the fluid. This abstract allows a searcher or other reader to quickly ascertain the subject matter of the disclosure. It may not be used to interpret or limit the scope or meaning of the claims. 37 CFR 1.72(b).
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BACKGROUND OF THE INVENTION
1. FIELD OF THE INVENTION
The invention relates to a mechanical latch having an hydraulic locking mechanism which permits selective and repeatable latching of a tubular string into a connector, such as a crossover assembly, and which permits locking and unlocking of the tubular string therein hydraulically and without requirement of rotation or longitudinal movement of the tubular string.
2. DESCRIPTION OF THE PRIOR ART
Subterranean oil and gas wells oftentimes are drilled through a plurality of producing zones. In order to isolate these zones for selective production purposes, plural tubing strings are inserted into the well during the completion or workover operations. For example, in a well having two production zones, a first or "long" string is inserted into the well. Near the lower end of the "long" string, a single bore packer mechanism may be provided for isolating the lower zone from the well bore thereabove. A crossover assembly is carried on the "long" string above the packer mechanism for receipt of a second or "short" string which may be utilized to, for example, pump corrosion inhibitor, other treating fluids, or kill fluids from the top of the well to the upper zone. In the event that it is desired to circulate the treatment fluid within the tubing strings above the packer and the lower production zone, a crossover assembly is utilized which contains a manipulatable valve or other assembly to permit selective opening and closing of a port therein for communication across the crossover assembly between the "long" and the " short" strings. Of course, the "short" string may be open-ended to permit production from the upper zone therethrough.
Heretofore, the "short" string has been landed on the cross-over assembly, stung therein and locked by mechanical means, such as by use of a J-slot assembly or a snap-type collet hatch. To lock or unlock the "short" string within a J-slot locking mechanism typically required righthand rotation of the "short" string to come out of the J-slot mechanism into either the locked or unlocked position therein. In deviated holes, such mechanical rotation is oftentimes extremely difficult and does not provide an accurate indication of the locked-unlocked position with respect to a given number of tubular rotations recorded at the top of the well of the "short" string. In addition, such mechanical means typically do not permit selective and repeatable latching into the crossover assembly prior to the locking mode, in order to permit initial setting and location of the "short" string and thus permit retrieval of the tubing for purposes of accurately spacing out the "short" string at the wellhead. Failure to permit selective and repeatable latching prior to locking heretofore has meant that the "short" string would have to be stung into the crossover assembly prior to accurate spacing. This, in turn, has resulted in considerable tension being applied at and upon the latch due to expansion and contraction of the "short" tubing string as the result of injection or transmission of fluid therein. Accordingly, considerable set down weight has been required for application to the "short" string while it is locked into the crossover assembly to overcome the mechanical forces caused by thermotic variation.
The reliability of the lock of the "short" string into the crossover assembly in such an apparatus has been directly dependent upon the strength of the mechanical locking mechanism which, in turn, has been affected by temperature and pressure variances within the interior of the "short" string.
Of course, the deeper the well bore, the more tubing set down weight which has been required to be applied to the locking mechanism. Moreover, since tubular rotation may be required to latch and/or lock and unlock the "short" string within the crossover assembly, such rotational movement obviously is considerably more difficult to accomplish in dual completion wells utilizing a plurality of tubular strings.
The problems associated with the above-described prior art locking mechanisms are solved by utilization of the present invention which permits latching of a "short" string, or any given tubular string, into a conduit therefor by longitudinal manipulation of the "short" tubular string. Thereafter, the "short" string may be repeatably latched and unlatched until such time as it is desired to lock the "short" string into the conduit. The locking procedure does not require tubular manipulation, but is accomplished by hydraulic means. Unlocking of the apparatus also is accomplished by hydraulic means.
SUMMARY OF THE INVENTION
The present invention provides an apparatus for selective mechanically activated latching and fluid activated locking and unlocking of an end of tubular string within an anchor assembly in a subterranean well bore. The anchor assembly has defined thereon a first co-engaging means for selective latching and locking of the tubular string end with the anchor assembly. The present apparatus generally comprises a housing containing a second co-engaging means which are complimentaraly operational with the first co-engaging means. A longitudinally shiftable sleeve is initially secured interior of and to at least one of the housing in the second co-engaging means and is initially positioned with respect to the second co-engaging means whereby the second co-engaging means is selectively and repeatably latchable with respect to the first co-engaging means. First seat means are provided for sealing receipt of a first sealing element, whereby said sleeve means may be converted to a fluid responsive piston element to longitudinally shift one of the sleeve means and the second co-engaging means relative to the other of the sleeve means and the second co-engaging means to a first position whereby the first relative shifting to the first position will lock said second co-engaging means with the first co-engaging means. Second seat means also are provided for sealing receipt of a second sealing element whereby the sleeve means is converted to a piston to longitudinally shift either the sleeve means or the second co-engaging means relative to the other of the sleeve and the co-engaging means to a second position. In the second position, the first and second co-engaging means are in unlocked position.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a somewhat diagramatic longitudinal section illustrating the present apparatus defined within a crossover assembly uitlized for the connection of dual production strings in a multi-zoned well, the "long" string carrying a packer mechanism therebelow for isolation and production of the lower zone through the "long" tubular string sealingly disposed therein.
FIG. 2 is an enlarged view of a crossover assembly incorporating the present apparatus, a "short" string being landed within the crossover assembly and prior to being selectively latched therein.
FIG. 3 is a view similar to that illustrated in FIG. 2, illustrating the position of the component parts of the present apparatus when the "short" string is latched into the crossover assembly.
FIG. 4 is a view similar to those illustrated in FIGS. 2 and 3, showing the "short" string in locked position within the crossover assembly.
FIG. 5 is a view similar to those shown in FIGS. 2, 3 and 4, illustrating the present apparatus when the "short" string is in unlocked position within the crossover assembly, subsequent to the locked position shown in FIG. 4.
FIG. 6 is a view of the upper portion of the crossover assembly within which a plurality of individual tubular strings are communicable, and is taken along lines 6--6 of FIG. 2.
FIG. 7 is a cross-sectional view taken along lines 7--7 of FIG. 3, illustrating the "short" string and the crossover assembly in latched relationship.
FIG. 8 is a cross-sectional view taken along lines 8--8 of FIG. 4, illustrating the "short" string locked within the crossover assembly.
FIG. 9 is an enlarged view of a preferred collet assembly utilized in the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In a preferred form, the present apparatus is illustrated in conjunction with a crossover assembly for use in association with dual tubing strings used in a dual completion.
The present apparatus generally comprises an anchor 100 for receipt within a longitudinally extending half portion thereof of a "short" string latch 200 which carries interiorally thereof a longitudinally extending sleeve 300. Also carried interiorally within the latch 200 is a shear ring 400.
Referring now to FIG. 1, a packer mechanism 17 is shown as anchored and in sealing engagement on the inner wall of casing 15 above a lower zone Z2, the zone Z2 having perforations P2 therethrough to permit fluid transmission thereacross. The casing 15 is secured within the well bore 13 by means of cement 14. An upper zone Z1 is defined above the packer 17 with perforations P1 being defined across the casing 15 to permit fluid transmission thereacross.
Now referring to FIGS. 1 and 2, the anchor 100 is exteriorally and longitudinally defined by an outer housing 101, cylindrical in configuration, and secured by threads 102 at its uppermost end to a long string 11 which, in turn, extends to the top of the well and is communicable therewith. Similar threads 103 secure the outer housing 101 to a longitudinally extending pup joint 12 below the anchor 100, the pup joint 12, in turn, being secured to a tubing joint 16 which is defined between the pup joint 12 and a tubing head 23.
A single bore packer assembly 17 having an elastomeric exteriorally protruding seal 18 and an anchor and slip mechanism 19 may be carried within the well on the tubing joint 16 or a setting string for location and setting on the casing 15 above the lower zone Z2. The packer 17 contains a valve head 21 which is held in open position by a tubing extension 16a having an open end 16b, the extension 16a being a continuation within the packer of the tubing joint 16 thereabove. A seal assembly 22 is carried on the extension 16a and within the bore 20 of the packer 17 to prevent fluid communication between the extension 16a and the packer 17.
The packer 17 may be carried in the well below the tubing joint 16 or may be located, anchored and set within the well bore above the zone Z2 with a setting string (not shown). Thereafter the setting string is removed from the well and the "long" string 11 carrying the crossover assembly or anchor 100 with the seal assembly 22 is inserted into the well bore 13. The tubing extension 16a, tubing joint 16, pup joint 12, anchor 100 and the tubing string 11 all together define what is commonly referred to as the "long" string.
A tubing section 24 is secured to the outer housing 101 of the anchor 100 by means of threads 104, the tubing section 24 being sealingly isolated from the zone Z1 by utilization of a closed-ended bull plug 26 being secured thereto by means of threads 25.
A frusto-conical surface 105 formed in the top of the anchor 100 having a center concident with the centerline of the short string 10 is inclined at the uppermost end of the outer housing 101 of the anchor 100 for location and landing within a bore 109 of a "short" string latch 200.
Thus, as described, the anchor 100 provides means for cross communicable engagement with a plurality of production strings weithin a well. Accordingly, the interior of the outer housing 101 provides on one side thereof a longitudinally extending "long" string bore 106 for communication at its upper end with the "long" string 11 and for communication at its lower end with the pup joint 12. Concurrently, a similar "short" string bore 107 is defined longitudinally and within the opposite side of the anchor 100 for communication between the tubing 24 defined lowerly thereof and the "short" string section 10 selectively receivable therethrough. An intrapassage 108 also is provided within the housing 101 for selective communication between the bores 106 and 107.
The "short" string bore 107 has a smooth interior wall 110 at its upper end for sealing engagement of a series of chevron seals 203 carried exterior of the "short" string latch 200 when it is received through the bore 107 to prevent fluid communication between the latch 200 and the outer housing 101 of the anchor 100.
Immediately below the intrapassage 108 and adjacent to the bore 107 of the housing 101 is an inwardly beveled downwardly extending shoulder 111 for guiding inward contraction of a collet 208 of the latch 200. The shoulder 111 terminates in a longitudinally extending slide 112 having an abbreviated inner diameter and, in turn, terminating at a companion shoulder 113 which has an expanded diameter for providing a grooveway 114 for latachable and locking receipt of a spoon element 209 of the latch 200 within the anchor 100. The grooveway 114 terminates lowerly in an inwardly extending bevel 115.
A top stop 116 is defined at the upper end of the outer housing 101 and defines the upper end of the "short" string bore 107, and will no-go engage with a companionly defined shoulder 201 on the latch 200 when it is inserted within the anchor 100.
The short string latch 200, which is inserted within the bore 107 in the housing 101 of the anchor 100, is defined at its upper end by a locator seal sub 202 which is secured to the short string 10 by means of threads 10a. The inwardly beveled shoulder 201 is defined at the upper end of a seal sub 202 to define a no-go when it engages with a companion top stop 116 on the housing 101 of the anchor 100. A chevron seal assembly 203 is exteriorally carried longitudinally around the locator seal sub 202 to prevent fluid communication between the seal sub 202 and the housing 101 of the anchor 100.
The locator seal sub 202 is secured by means of threads 204 to a collet latch 208. The collet latch 208 has defined through its uppermost end a plurality of transverse ports 205 which provide additional fluid communication. A shear screw 207 protrudes inwardly of the latch 208 for securement within the latch 200 of the longitudinally extending interior sleeve 300. As particularly viewed in FIG. 9, an outwardly protruding spoon 209, is defined exterior on the latch 208 and has an upper shoulder 210 which terminates into a longitudinally extending abbreviated outer wall 209a which itself bevels into a lowerly facing shoulder 211. The spoon 209 of the collet latch 208 has defined within its interior a downwardly extending shoulder 212 which is inclined inwardly of the latch 208. An inner wall 213 circumferentially extends inwardly within the spoon 209 which communicates with the exterior of the sleeve 300 as the sleeve 300 is shifted longitudinally within the interior of the latch 200.
The collet latch 208 continues longitudinally and lowerly of the spoon 209 and defines a transverse bore 214 thereacross for receipt therein of a plurality of shear pins 215 having an inwardly protruding end 215a extending interiorally of the collet latch 208 and received within a grooveway 401 having an upper end 401a of the slidable shear ring 400. The collet latch 208 has an open end 216 and an upwardly facing shoulder 217 interiorally and circumferentially defined for receipt of the lower end of the longitudinally shiftable shear ring 400 when it is disengaged from the shear pin 215. A beveled shoulder 216a is circumferentially defined around the lowermost exterior end of the collet latch 208 to guide the collet latch 200 into position within the bore 107 of the anchor 100.
A longitudinally shiftable sleeve 300 is carried within the latch 200 and is held in initial placement therein by means of the shear screw 207. The sleeve 300 consists of an outer housing 301 having a shoulder 301a for receipt thereupon of the shear screw 207. A beveled seat 309 is defined at the open upper end 304 of the housing 301 having an outer wall 310 with a protracted wall portion 310a, and provides a seal seat for a ball B-2 insertable within the short string 10, when it is desired to unlock the latch 200 within the anchor 100. Upper and lower circumferentially extending elastomeric O-ring seal elements 303 and 307 are carried within their respective grooveways 302 and 306 within the housing 301 to prevent fluid communication between the housing 301 and the locator seal sub 202, as well as to isolate a port 308 defined across the housing 301, the longitudinal shifting of the housing 301 permitting the port 308 to fluidly communicate with the ports 205 in the collet latch 208 to provide a fluid passageway across the latch 200 and to the "long" string bore 106 within the outer housing 101 of the anchor 100.
A lower and beveled diametrically contracted ball seal seat 311 is defined at the lower end of the housing 301 of the sleeve 300 for receipt of a ball element B-1 which is permitted to travel within the short string 10 from the top of the well and through the interior of the locator seal sub 202 and through the housing 301, when it is desired to lock the "short" strong latch 200, the sleeve 300 being transformed into a piston when the ball B-1 is sealingly engaged upon the seat 311 for hydraulic longitudinal shifting of the sleeve 300. The housing 301 has a lower open end 305 normally permitting fluid transmission therethrough and in communication with the "short" string bore 107 therebelow.
A ring-like shear element 400 is secured interior of the short string latch 200 by means of the end 215a of the shear pin 215, which is secured within the grooveway 401 of the ring 400. The ring 400 has upper and lower open ends 403 and 402, respectively, to permit fluid transmission within the interior of the ring 400. The upper end 403 of the shear ring 400 receives the lower end 305 of the sleeve 300 during the locking operation, the ring 400 preventing further downward longitudinal shifting of the sleeve 300 until the shear strength of the pins 215 is overcome.
OPERATION
When it is desired to stab the "short" string 10 into the anchor 100, the short string 10 is lowered into the well with the short string latch 200 secured to its lower end. As the short string 10 is lowered into the well, it is located at the depth immediate the anchor 100 and the open end 216 of the short string latch 200 will engage the guide 105 and slide into the bore 109 of the outer housing 101 of the anchor 100. After the lower end 216 of the latch 200 passes below the top stop 116 and into the bore 107 of the outer housing 101 of the anchor 100, the shoulder 211 of the spoon 209 on the collet latch 208 will contact the top stop 116, continued downward longitudinal travel of the short string 10 causing the spoon portion 209 of the collet latch 208 to contract inwardly. Thereafter, the outer wall 209a on the spoon 209 will free travel downwardly along the smooth wall 110 in the outer housing 101 of the anchor 100 until the shoulder 211 contacts the companion shoulder 111 on the outer housing 101 of the anchor 100. Again, continued lower longitudinal travel of the short string 10 will cause the spoon 209 to be contracted and flexed inwardly such that the outer wall 209a will pass downwardly along the slide 112 of the outer housing 101. When the outer wall 209a passes lowerly of the slide 112 and below the shoulder 113, the spoon 209 is permitted to expand outwardly and into the grooveway 114. After the spoon 209 is thus latched within the grooveway 114, the shoulder 201 on the latch 200 will no-go upon the top stop 116 of the outer housing 101 to prevent further lower longitudinal travel of the latch 200 within the anchor 100. In this position, the short string 10 is latched, but is not locked, into the anchor 100. It should be noted that in this position, the short string 10 may be moved longitudinally upwardly, such that, when doing so, the upwardly facing shoulder 210 of the spoon 209 of the collet latch 208 will contact the downwardly facing companion shoulder 113 on the outer housing 101 of the anchor 100, whereby the spoon 209 of the collet latch 208 is again caused to contract inwardly and permit retrieval of the short string 10 away from the anchor 100.
In the latched position as described above, it should be noted that the housing 301 of the inner sleeve 300 is secured to the collet latch 208 by means of the shear screw 207. Additionally, the shear ring 400 is in stabilized position by means of the side 215a of the shear pins 215 being inserted within the longitudinal grooveway 401 of the ring 400.
When it is desired to lock the short string 10 into the anchor 100, the sleeve 300 is converted into a piston for hydraulic shifting thereof by inserting at the top of the well and through the short string 10 the smaller diameter ball B-1, which may gravitate through the interior of the short string 10 until it becomes sealingly engaged upon the seat 311 on the housing 301 of the sleeve 300. When the ball B-l is positioned on the seat 311, pressure within the short string 10 will be increased until the shear strength of the shear screw 207 is overcome, at which time the shear screw 207 will be sheared and the housing 301 will be permitted to travel longitudinally downwardly within the interior of the collet latch 208 until the open end 305 contacts the open end 403 of the shear ring 400. Continued downward travel of the housing 301 will cause the shear ring 400 to move downwardly, slightly, until the shear pin 215 is shouldered at the upper end 401a of the grooveway 401 on the ring 400, and further lower longitudinal travel of the housing 301 is thus prevented. Now, in this position, the port 308 communicates with the port 205 and the inner passage 108 and the long string bore 106, such that an indication of the positioning of the housing 301 lowerly within the collet latch 208 may be physically confirmed at the top of the well by return fluid circulation through the long string 11.
As the housing 301 is shifted downwardly, the wall portion 310a will slide along the inner wall 213 of the spoon 209 of the collet latch 208 and will be secured in this position when the shear ring 400 is shifted downwardly until the pins 215 engage the upper end 401a of the ring 400. In this position, the housing 301 of the sleeve 300 has passed below and inwardly within the spoon 209 to prevent inward contraction of the collet latch 208, so that the shoulders 210 will upwardly no-go with the shoulder 113 if the "short" string 10 is moved upwardly, thus locking the spoon 209 and the "short" string 10 within the grooveway 114.
The "short" string 10 may be selectively unlocked from within the anchor 100 at any given time, for example, after production of the upper zone Z-1, or transmission of treating fluid such as corrosion inhibitor from the short string 10 to the long string 11 by again converting the sleeve 300 into an hydraulically activatable longitudinally shiftable piston. The larger diameter ball B-2 is inserted within the short string 10 at the top of the well and is permitted to gravitate until such time as it becomes sealingly engaged upon the upper seat 309 of the housing 301. When the ball B-2 is so engaged, pressure within the short string 10 thereabove can be increased until the shear strength of the shear pins 215 is overcome, at which time the pins 215 will shear, freeing the ring 400 from engagement with the collet latch 208. Accordingly, the sleeve 300 and the shear ring 400 are permitted to travel longitudinally downwardly within the interior of the short string latch 200 until the shear ring 400 bottoms out on the shoulder 217 on the short string latch 200.
When the sleeve 300 is shifted downwardly as described above, the wall 310, which has a smaller outer diameter than the outer diameter of the wall portion 310a therebelow, will pass across the inner wall 213 of the spoon 209 of the collet latch 208, and the spoon 209 will be free to contract inwardly once again to freely slide across the shoulder 113 of the housing 101. The interface between the open end 402 of the shear ring 400 and the shoulder 217 of the collet latch 208 may be physically detected at the top of the well when fluid flow around the ball B-2 and across the ports 205 is transmitted within the interpassage 108 and the long string bore 106, thence to the top of the well through the "long" string 11. Thereafter, the "short" string 10 is picked up at the top of the well, the shoulder 210 of the spoon 209 engages the upwardly beveled shoulder 113 of the outer housing 101, and the spoon 109 is contracted inwardly and out of locked engagement within the grooveway 114.
Although the invention has been described in terms of specifield embodiments which are set forth in detail, it should be understood that this is by way of 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 the disclosure. Accordingly, modifications are contemplated which can be made without departing from the spirit of the described invention.
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An apparatus is provided for selective mechanically activated latching and fluid activated locking and unlocking of a tubular string within an anchor assembly in a subterranean bore, wherein the anchor assembly has defined thereon co-engaging elements for selectively latching and locking of a tubular string with the anchor assembly. The apparatus comprises a housing which contains second co-engaging means which are complimentarily operational with the first co-engaging means. A longitudinally shiftable sleeve is initially secured to at least one of the housing and the second co-engaging means and is initially positioned with respect to the second co-engaging means whereby the second co-engaging means is selectively and repeatably latchable with respect to the first co-engaging means. A first seat is provided within said shiftable sleeve for sealing receipt of a first sealing element whereby the sleeve is converted to a fluid responsive piston for longitudinal shifting of the sleeve or the second co-engaging means relative to the other of the sleeve and the co-engaging means to a first position whereby the first relative shifting to the first position locks the second co-engaging means with the first co-engaging means. Second seat means for sealing receipt of a second sealing element is provided whereby the sleeve means is again converted to a piston to longitudinally shift either the sleeve means or the co-engaging means relative to the other of the sleeve means and the co-engaging means to a second position to unlock the first and second co-engaging means.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
This application is a Non-Provisional application, which claims benefit of co-pending U.S. Provisional Patent Application Ser. No. 60/363,137 filed Mar. 11, 2002, entitled “Modified Rumble Strip Cutter” which is hereby incorporated by reference.
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 the patent disclosure, as it appears in the Patent and Trademark office patent file or records, but otherwise reserves all copyright rights whatsoever.
Be it known that we, Stuart W. Murray, a citizen of the United States, residing at 9412 Ashford Place, Brentwood, Tenn. 37027; Scott F. Lyons, a citizen of the United States, residing at 5717 Cedar Ash Crossing, Nashville, Tenn. 37013; have invented a new and useful “Modified Rumble Strip Cutter.”
BACKGROUND OF THE INVENTION
The present invention relates generally to the art of cutting rumble strips along the shoulder of a highway. Rumble strips, sometimes referred to as “SNAPs” (sonic noise alert patterns) are a series of grooves or depressions formed or cut into the surface of the shoulder of highways, roads, interstates, etc. The grooves provide vibration and therefore noise, when the tires of a vehicle traverse them longitudinally. Road departments use these rumble strips as a safety device longitudinally adjacent the edge of a highway, or along the center line which divides opposing directional traffic flows, are the customarily locations of placement of these rumble strips. They act to alert a driver that his or her vehicle has extended beyond the normal driving surface. Obviously, beyond this normal driving surface many dangerous conditions exist for a vehicle traveling at or near the posted speed limit. These dangers include dirt or gravel shoulders, guardrail barriers, signs, mailboxes, intersecting roadways or driveways, disabled vehicles and oncoming traffic.
Various specifications for the placement and physical dimensions of the individual rumble strips can vary from State to State and even within a particular State. A common size and placement, used for illustration and not limitation, places the individual rumble strips 12 inches apart from the center of one depression to the center of the adjacent depression. The measurements of the individual depressions are generally 7 inches from leading edge to back trailing edge with a depth at the deepest point, of one half inch, and at lateral length across a depression of 16 inches.
It is a difficult, if not impossible, task to form the rumble strips or depressions in the highway surfaces when the surfaces are being created. Moreover, the rumble strips are generally formed in the shoulders of the highways, which are not of the same density and load bearing capacity as the normal highway surface. Forming the depressions in the shoulders would be even more difficult because of the decreased density of the shoulder material and the difficulty in forming depression to cure in the desired shape would be very difficult. For that reason, it is the common practice to pour the shoulder of the highway in the traditional fashion and then follow along afterwards and cut the rumble strips into the shoulder.
Experience with use of rumble strips along the shoulders of highways has demonstrated their tremendous value as a lifesaving tool. If a driver has been driving for a long period of time and is getting fatigued, there is a tendency to nod off or fall asleep and allow the vehicle to drift off of the highway. If the vehicle drifts off to the right, it could go over an embankment and kill or cause sever bodily injury to the driver. With the rumble strips cut into the shoulder, once the vehicle veers off onto the shoulder, the noise created by the tires passing over the rumble strips will immediately awaken the drive and cause him/her to regain control of the vehicle and pull back onto the highway. Likewise, if the driver veers off to the left of the highway, particularly on interstate type highways that are at least two lanes running in each direction with a median in between, the driver could veer into on coming traffic with the potential of resulting head-on collisions that could produce tragic results for many people. Again, the provision of rumble strips on the left hand side of the two lane highway will awaken the driven and cause him to pull back onto the paved highway and avoid these head-on collisions. The value of these rumble strips in terms of their lifesaving effect is no longer open for debate. For that reason, the highway departments of most States are moving rapidly to have all major thoroughfares retrofitted to incorporate rumble strips in the shoulders of those highways.
As would be obvious, there are tens of thousands of miles of highways that need rumble strips cut in their shoulders. The efficiency in cutting the rumble strips is therefore very important. It is also very important to consider the comfort of the person operating the machine to cut the rumble strips and there are potential problems associated with the comfort of the operator in current methods and machinery to carry out those methods under current practices.
More specifically, rumble strip cutters available on the market today generally have a fixed cutting drum. As mentioned above, the cutting drum is usually approximately 16 inches in length and most machines used to drive the rumble strip cutters are at least 4 feet wide. Often, the cutting drum is mounted in the middle of the machine, leaving the drum at least 16 inches from the outside edge of both sides of the machine. These physical arrangements of the cutting drum within the machine make it very difficult to cut rumble strips at places on the road where the shoulder is very narrow, either because there is a drop off of the topography, or other obstacles such as bridge abutments, pylons, guardrails and the like. Other machines are configured so that the rumble strip cutting drum is adjacent one side of the machine so as to enable the machine to make close cuts in situations where the shoulder of the road is very narrow for any of the reasons as indicated above. However, historically, the cutting drums of these machines are always fixed in place or, at a minimum, cannot be conveniently moved from one side of the machine to the other. Thus, on an interstate type highway where there are four lanes of traffic, two in each direction, if the drum is mounted to the right side of the machine, when cutting the rumble strips in the right shoulder, the machine can move in the direction of flow of the traffic and cut rumble strips on narrow shoulders. However, when cutting rumbles in the left shoulder, the machine must either be driven into the direction of traffic, creating major safety hazards for the operator, or the machine can function properly only in areas that have very wide shoulders. Even if the machine could be operated moving against the direction, traffic control becomes a major problem.
What is needed then is a rumble strip cutting machine that has a drum that can be conveniently shifted from one side of the machine to the other and a machine that will enable a method of cutting rumble strips close to obstructions on narrow shoulders while always driving the machine in the direction of moving traffic on the highway. Such a machine and method is not currently available in the prior art.
SUMMARY OF THE INVENTION
The present invention is directed to a machine and method of cutting rumble strips in the shoulders of highways.
More specifically, the rumble strip cutter of the present invention is generally mounted on a self-propelled vehicle so that the rumble strip cutter can be pulled or pushed along the shoulder of a highway and cut rumble strips in that shoulder as the machine progresses. Considering the size specified for rumble strips, with rumble strips normally being in the range of approximately 7 inches in width and cut on 12 inch centers, the cutting of 5,280 rumble strips per mile of road shoulder would be required. A project of this nature can be very expensive and it is therefore highly desirable to be able to cut the rumble strips at a very fast pace in order to control costs.
Further, the speed at which rumble strips can be cut is limited because of the vibrations transferred from the cutting machine to the operator of the machine. A machine that moves up and down to cut the rumble strips has to be driven relatively slowly by the operator because if driven at a high rate of speed, the machine will vibrate the operator to a point where he can only work for brief periods of time. One example of a rumble strip cutter in which the machine moves up and down is illustrated in the patent granted to one of the co inventors of this invention, namely U.S. Pat. No. 5,582,490.
Thus, it is a highly desirable objective to isolate the oscillatory movement employed to cut the rumble strips from the machine that is being used to pull or push the rumble strip cutter along the shoulder of the highway.
It is further a desirable objective for an efficient rumble strip cutter to be able to lift the cutter out of engagement with the road so that the machine can be driven at a relatively rapid rate of speed from one job site to another.
It is yet another desirable objective for a rumble strip cutter to have a machine in which the rumble strip cutting drum can be easily moved from one side of the machine to the other so that the rumble strip cutter can be driven in the direction of moving traffic on an interstate type highway regardless of which shoulder of the highway is being cut, while being able to cut close to obstructions and on narrow shoulders.
It would also be desirable to have a rumble strip cutter with a housing that can accommodate various cutter drum widths.
Another desirable feature for a rumble strip cutter is to have a device that will provide additional pressure to hold the rumble strip cutting drum in cutting engagement with the road surface as the machine is operated.
Another desirable objective for a rumble strip cutter is to have a machine on which the power supply belt can be adjusted to increase or decease the tension on the belt so as to maximize the efficiency of the drive train power system.
These and other desirable objectives for an efficient rumble strip cutter and method for cutting rumble strips are achieved by the present invention.
In summary, the present invention includes:
A method of cutting rumble strips in a highway shoulder, including positioning a piston wheel and rumble strip cutting drum on the left side of a power driven machine for cutting rumble strips on the left shoulder of a highway, and moving said piston wheel and rumble strip cutting drum to the right side of said power driven machine for cutting rumble strips on the right shoulder of a highway.
A method of cutting rumble strips in a highway shoulder, including providing a rumble strip cutter frame having a left side and a right side; providing a mechanism for attaching said frame to a self propelled machine; attaching a piston wheel and cutter drum to the right side of said frame for cutting rumble strips in the right shoulder of a highway, and repositioning said piston wheel and cutting drum to the left side of said frame for cutting rumble strips in the left shoulder of a highway.
An improved rumble strip cutting machine including a pair of spaced apart, generally parallel rails having opposing ends with one end of said rails having connectors for connection of said improved rumble strip cutting machine to a tractor and the opposite ends of said rails being connected by a cutting drum housing; an axle extending through said housing a power input source connected to said axle to rotatably drive said axle; a rumble strip cutting drum removable mounted to said axle adjacent one of said rails; and said axle including mounting structure adjacent the other of said rails whereby said rumble strip cutting drum can be removed from the position adjacent said one of said rails and attached to said mounting structure adjacent said other of said rails.
An improved rumble strip cutter for cutting rumble strips in a road surface including: a rumble strip cutter frame having opposing sides; a piston wheel for imparting up and down motion to a portion of said frame; a connector for connecting a portion of said frame to a tractor so that a portion of said frame can pivot in an up and down motion; a rumble strip cutting drum removably mounted on one side of said frame; lifting structure positioned between said connector and said drum for connection of said frame to a tractor enabling said rumble strip cutting frame to be lifted so that the cutting drum can be spaced from the road surface when the rumble strip cutter is being moved from one job site to another.
A rumble strip cutting machine including a frame having opposing side rails spaced from each other and an axle extending between said rails with a rumble strip cutting drum having a length of less than half the distance between the said rails and removably mounted on said axle adjacent one of said rails, the improvement including: a rumble strip motion wheel assembly including a piston wheel rotatably mounted in said assembly; said assembly pivotally mounted to said frame; and a connector between said assemble and said frame that can be adjusted in length so that said assembly can be pivoted to raise or lower said piston wheel in relationship to said rumble strip cutting drum in order to adjust the depth of cut of said cutting drum.
An improved rumble strip cutter including a frame having opposing rails spaced from each other and in substantially parallel relationship, said rails having opposing ends, a rumble strip cutter drum rotatably mounted on said frame at one end of said rails and adjacent one of said rails; including a pivotal connector adjacent the other end of said rails for pivotally connecting said frame to a tractor; a power input pulley rotatably mounted on said frame for supplying power to said rumble strip cutter drum; a belt for transmitting power from a power output source on a tractor to said power input pulley; and a rail length adjustment device on at least of one said rails to enable the tension on said belt to be adjusted.
BRIEF DESCRIPTION OF THE DRAWINGS
Having described generally the objectives and features of the present invention, a detailed description of a preferred embodiment of the invention will be described in conjunction with the following drawings, wherein:
FIG. 1 a illustrates generally the operation of the present invention on a two-lane highway;
FIG. 1 b illustrates the operation of the machine and method of the present invention on an interstate highway.
FIG. 2 a is a side view of a milling machine with the rumble strip attachment connected thereto.
FIG. 2 b is a top view of the machine and preferred embodiment of the rumble strip cutter with the piston wheel and cutting drum mounted on the right side of the machine.
FIGS. 3 a and 3 b are perspective views of the rumble strip cutting device of the present invention with the cutting drum mounted on the left and right respectively sides of the frame.
FIG. 4 is a cross sectional view of the rumble strip cutting drum and the mounting structure for that drum.
FIGS. 5 and 6 are perspective views of the device of the present invention with the piston wheel illustrated as mounted on the left and right sides of the machine respectively.
FIGS. 7 and 8 show perspective views of the piston wheel mounting assembly and drive motor for driving the piston wheel.
FIG. 9 shows a perspective view of the preferred embodiment of the device and illustrates in particular the mounting brackets for mounting the device to a transport vehicle and the power train pulley and belt structure of the invention.
FIG. 10 shows a perspective view of the machine that is shown in FIG. 9 taken from a different angle.
FIG. 11 shows the device with the mounting assembly that enables the tension on the drive belt to be adjusted.
FIGS. 12 and 13 shows in greater detail yet another perspective view of the machine.
FIG. 14 shows the device of the present invention mounted on a milling machine with the rear legs of the milling machine extended so as to lift the rumble strip cutting device out of engagement with the road shoulder.
FIG. 15 shows the rumble strip cutting device in the present invention mounted on road milling machine with a rumble strip cutter in the operating position.
FIGS. 16 and 17 illustrate an adjustment feature which allows the depth of cut of the cutting drum to be easily adjusted.
FIGS. 18 and 19 illustrate the power train drive system for driving the rumble strip cutter of the present invention.
FIG. 20 illustrates a cross sectional view, a feature of the present invention which allows the device to move relative to the machine that is driving the device without damaging the rumble strip cutter during rumbling operation, yet provide support of the rumble strip cutter frame laterally and provide pick-up support when raising the machine out of the cutting mode.
FIGS. 21 and 22 illustrate the mounting bolts in one configuration and in a reverse configuration for mounting the device of the present invention to a motorized vehicle. FIG. 22 also shows the movable water spray bar on the right side of the device.
FIG. 23 shows the water spray bar of the present invention on the left hand side of the device and illustrates the ability to move the water spray pipe.
FIG. 24 illustrates the machine configured with a texturizing drum that can be used to texturize a road surface.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, wherein like numbers refer to like parts throughout, a preferred embodiment of the machine and method constituting the present invention will be described. The description is, however, not to be considered a limitation of the invention as set forth in the claims appended hereto.
The environment in which the present invention operates is illustrated in FIGS. 1 a and 1 b . In FIG. 1 a , a two-lane highway is shown with cars moving in opposite directions over a highway 2 on either side of a centerline 3 . Outside the margins of the highway 2 are shoulders 2 ′ and 2 ″ on the right and left sides of the road respectively. In FIG. 1 a , the rumble strip cutter 10 is shown on the right side of the road moving in the direction of travel of the car in the right hand lane. The rumble strip cutter 10 is mounted to a self-propelled vehicle 12 for driving the rumble strip cutting machine along the shoulder 2 ′ of the highway 2 . The self propelled machine 10 can be a variety of products which can be generally referred to in this context as a tractor. The specific machine that the preferred embodiment of the present invention is designed to attach to is a Wirtgen milling machine, Model No. W600DC, which is readily available in the marketplace from Wirtgen America, Inc., the assignee of the present invention with headquarters in Nashville, Tenn. However, the rumble strip cutter invention which is the subject matter hereof could be adapted to a variety of motorized vehicles such as tow motors, pavers, graders or just a simple tractor type machine that has a combustible engine for providing power to drive the tractor along the highway and also to provide a power output for driving the rumble strip drum of the present invention.
Referring now to FIG. 1 b , there is illustrated the present invention in the particular circumstance to which the invention is most advantageous. Specifically, FIG. 1 b illustrates an interstate highway, or a four-lane highway, which has two lanes of cars traveling in one direction and two additional lanes of cars traveling in an opposite direction. In FIG. 1 b , cars 1 again are both traveling along highway 2 a in lanes 4 and 5 respectively on either side of center line 3 . Once again, the highway has right and left shoulders 6 and 7 , respectively.
As shown in FIG. 1 b , the machine 10 can be placed on either side of the highway to cut rumble strips in either the shoulder 6 or the shoulder 7 . However, as can be seen generally from the layout of the machines shown on FIG. 1 b , the machine that is cutting rumble strips on the right shoulder 6 has the drum mounted such that the rumble strips 8 ′ are cut generally on the right hand side of the machine so that the machine can comfortably pass by obstruction 9 and still be able to cut rumble strips in the narrow shoulder. Likewise, when the machine 10 is positioned to cut rumble strips in the left shoulder 7 of the highway, the rumble strips 8 ″ are cut with the cutting drum mounted on the left side of the machine so that the machine can continue to travel in the direction of travel of the cars 1 so that it will not be facing head-on to the direction of travel to the cars and yet still be able to cut rumble strips in the narrow portion of the shoulder 7 caused by the position of obstruction 9 .
Looking now at FIGS. 2 a and 2 b , there is a general illustration of the preferred embodiment of the improved rumble strip cutter 10 . The preferred embodiment of the improved rumble strip cutter 10 is designed to attached to a milling machine and specifically to a Wirtgen model W600 milling machine sold by Wirtgen America Inc. of Nashville, Tenn. However, other types of motorized vehicles milling machines, tractors, graders and the like could be used as the vehicle for moving the improved rumble strip cutter along the edge of the highway to cut the rumble strips in the shoulder of the highway.
The tractor 12 includes rear wheels 14 a and 14 b along with front wheels 16 for guiding the tractor. The wheels 14 a and 14 b preferable are of a known structure that can be raised and lowered to lower and raise the height of the drum cavity of the milling machine that is directly behind the wheels 14 a and 14 b.
Suspension plates 18 , which include a left side suspension plate 18 a and a right side suspension plate 18 b (see FIG. 9 ), are designed to be bolted to the side frame of the tractor 12 . These suspension plates 18 could be formed integrally with the tractor 12 or may be added as an after market product. The design of the suspension plates is such that they provide brackets for the attachment of rods that carry the improved rumble strip cutter, details of which will be described hereinafter.
The improved rumble strip cutter 10 has a frame constructed of side rails 20 (left side rail 20 a and right side rail 20 b , as can be seen in FIGS. 3 a and 3 b ), along with a cutter drum housing 46 . The rails have opposing ends 22 and 24 (see FIGS. 3 a and 3 b ). The ends 22 are connector ends for connection to the tractor 12 . Preferably, these connector ends 22 are connected to the front of the tractor, but they can be connected at other places along the chassis of the tractor. The opposing end 24 of the improved rumble strip cutter includes a cutter drum housing 46 extending between and connecting those two ends to form the improved rumble strip frame.
In the preferred embodiment of the invention, the rail 22 a has an offset 26 to facilitate the mounting of the rumble strip cutter to a Wirtgen W600 DC milling machine. To adapt to other milling machines or motorized vehicles for pulling the rumble strip cutter, the rail 20 may be differently configured in order to facilitate connection of the rumble strip cutter to the machine.
Inside the cutter drum house 46 is a rumble strip cutting drum 30 . The rumble strip cutting drum is generally well known in construction and configuration, having an outer perimeter with cutter drum teeth mounted thereon and a rim type shape. The specifics of the cutter drum will be described in more detail in conjunction with the description of the invention as shown in FIG. 4 .
Traversing the cutter drum housing is a rumble strip cutter drum axle 32 which has a pair of rumble strip cutting drum mounting flanges 34 spaced at opposite ends of the axle. Hingedly connected to the cutter drum housing 46 is a cutting drum housing closure 38 which has mounting steps on the back thereof. The mounting steps allow an operator to climb onto the tractor conveniently even with the improved rumble strip cutter attached to the machine. The cutting drum housing closure 38 can be opened to provide access to the cutting drum 30 , axle 32 and flanges 34 for reasons as will be more apparent hereinafter.
Looking at FIG. 4 , the rumble strip cutting drum 30 is more clearly illustrated. As can be seen from FIG. 4 , the rumble strip cutting drum 30 is cylindrically shaped having a hollow center 31 with an annular rib 33 protruding radially inwardly from approximately the center of the drum. The annular rib 33 is sized and shaped to mate with and fit over the mounting flange 34 in a snug fit. To attach the rumble strip cutting drum 30 to the axle 32 , the annular rib 33 is positioned about the flange 34 , and held in place by a mounting plate 41 . The mounting plate 41 is shaped generally in the form of a disc with a center opening to fit about the diameter of the axle 32 . The mounting plate 41 is split in half so that one half can be placed about one side of the axle 32 and the other half placed about the other side of axle 32 . Once in place, the mounting plate is rotated so that holes 35 in the annular rib 33 and holes 37 in the mounting flange 34 align with holes 35 ′ and 37 ′ in the mounting plate 41 . Next, bolts (not shown) are passed through the holes 35 ′, 37 ′ and screwed into tapped threads formed in holes 35 and 37 thus, the plate 41 transfers the power of the rotating axle 32 to the annular rib 33 of the drum 30 and causes the drum 30 to rotate so that the chiseled teeth on the drum will cut the rumble strips in the payment.
Looking at FIG. 4 , the drum is shown mounted on the left side flange on the axle 32 . The mounting flange 34 on the right side of the axle is covered by a protector plate 43 to keep the outer perimeter of the mounting flange 34 from becoming damaged because of flying debris inside the cutter drum housing. The protector plate 43 is bolted to the flange of 34 by another mounting plate 41 . Once again the protector plate 43 has holes that align with the holes 35 ′ 37 ′ of the mounting plate 41 so that bolts (not shown) can be passed through the holes 35 ′ 37 ′ and screwed into the tapped threads inside the holes on the protector plate and the holes 37 spaced radially about the flange 34 .
When it becomes desirable to shift the rumble strip cutter drum 30 from the left side of machine to the right side of the machine, the bolts that connect the protector plate to the mounting plate are unscrewed and the protector plate is removed. Similar to the mounting plate, the protector plate 43 is in two halves so that the two halves can be separated and moved from their position about the axle 32 . Next, the bolts that connect the mounting plate 41 to the flange and rib of the drum are disconnected and the mounting plate on the left side of the machine is removed. At that point, the drum 30 can be moved axially off of the mounting flange 34 on the left side of the axle and slid down the axle 32 to the right until such time as it is positioned over the mounting flange 34 on the right side of the machine. The mounting plate 41 for the right side of the machine is then bolted onto the mounting flange 34 and the annular rib 33 by passing the bolts through the mounting flange into the tapped holes of the rib and flange respectively. Next, the protector plate 43 is mounted to the mounting flange 34 on the left of the machine to protect the outer surface of the mounting flange from damage and the machine is now enabled to operate with the cutting drum on the right side of the machine.
Referring now to FIGS. 5 through 8 , the rumble strip motion wheel assembly 40 will be described. The rumble strip motion wheel assembly 40 includes a piston wheel 44 and piston wheel housing 42 . The piston wheel 44 is a multi-sided wheel which is mounted in the wheel housing. As the piston wheel 44 rotates over the highway surface, when the wheel is resting on a flat portion of the wheel, the frame of the rumble strip cutter is at its lowest point, allowing the cutting drum to make its deepest cut. As the wheel rotates, it passes over the apexes between flat surfaces on the wheel, thus lifting the rumble strip cutter frame and raising the drum out of the depression or rumble strip that has been cut in the highway surface and moves the drum forward to a point where it will make the next rumble strip cut. Thus, the wheel 44 is referred to as a piston wheel because it transmits at a piston like, or up and down, motion to the rumble strip cutter frame thereby causing the rumble strip cutting drum 30 to move in an up and down motion as the machine is advanced over the highway. The up and down motion that is transmitted to the rumble strip cutting drum occurs in conjunction with a forward motion of the rumble strip cutter so that as the rumble strip cutting drum (which will be driven in a continuous rotating motion) comes in contact with a road surface and the frame is lowered, the cutting drum will cut a rumble strip in the road surface and as the piston wheel is driven to move the frame forward, the rumble strip cutting drum is lifted out of the rumble strip and moved forward to the point where the next rumble strip is to be cut and the frame is lowered because of the action of the wheel to cut the next rumble strip.
As can be seen from FIGS. 5 and 6 , the piston wheel 44 can be mounted on either the left side of the frame or the right side of the frame. The piston wheel 44 is moved to the side of the frame on which the rumble strip cutting drum is mounted to impart the up and down motion to the rumble strip cutting drum. The opposite side of the frame remains relatively stationary so that the axle 32 actually has an arcuate up and down motion. This arcuate motion of the axle 32 also transmits a slightly arcuate up and down movement to the cutting drum 30 . This arcuate movement of the drum 30 is beneficial because the cutting process begins with the inner edge of the drum and as the drum is lowered the cutting process moves toward the outer edge of the drum. Thus, the need for power to drive the drum is gradually increased as the drum is eased into the full cut position. Stated in the negative, there is no need to cut across its full length of the drum to the same depth at the same time. This motion of the cutting drum allows the rumble strips to be cut easier and does not wear down the machine in quite the same fashion as a process which attempts to execute a cut parallel to the road surface.
Looking now at FIGS. 7 and 8 , the rumble strip motion wheel assembly 40 is illustrated in greater detail, and from these drawings the method for switching the piston wheel 44 from one side of the machine to the other will be described.
The drum housing 46 extends between the two side rails 20 a and 20 b and serves as a chamber for the rumble strip cutting drum 30 . The axle 32 extends through the housing 46 as has been previously described. The wheel housings 42 on either side of the frame each include a pair of panels 50 . The panels 50 are pivoted mounted to the housing 46 by mounting plates 48 . The panels 50 are held in a spaced fixed relationship relative to each other by the spacers 52 . Spacers 52 , in this instance, are shafts that are mounted to opposing panels 50 to hold the panels in a spaced fixed (relative to each other) relationship. The wheel shaft 84 also serves as a spacial support of opposing panels 50 .
The invention includes a cutting depth adjustment mechanism 54 (best illustrated in FIGS. 9 , 16 and 17 ) which includes a U bolt 56 attached to a boss 58 protruding from the housing 46 . The U bolt 56 is pivotally connected to the boss 58 by a pivot connector 60 , and a pivot shaft is pivotably mounted in bushings between opposing panels 50 . Rotationally mounted rod 62 extends from the U bolt and passes through a tapped hole in the pivot shaft 52 ′. A jam nut 64 is screwed onto the rod 62 . The jam nut can be loosened and rod 62 turned so that the pivot shaft moves relative to the U bolt 56 to change the distance “d” between the boss 58 and the pivot shaft 52 ′ (see FIGS. 16 and 17 ), which will rotate the rumble strip motion wheel assembly about pivot point 66 (see FIG. 10 ). When the rumble strip motion wheel assembly rotates in a counter clockwise direction about pivot point 66 , the distance “d” is reduced and the cutting drum is lowered to a greater cutting depth. When the nut 64 on the rod 62 is adjusted in a direction to lengthen the distance “d” between the pivot shaft 52 ′ and the U bolt 56 , the rumble strip motion wheel assembly 40 rotates in a clockwise direction as seen in the FIGS. 6 , 9 , 10 and 17 . When that motion of the rumble strip motion wheel assembly occurs, the rumble strip cutting drum 30 is raised so as to reduce the depth of the rumble strip cut.
FIGS. 9 and 10 illustrate the drive train that powers the rumble strip cutting drum. A drive output support plate 68 is provided for attachment to the tractor 12 . The support plate 68 carries a power transfer flange 98 that attaches to the power output source of the tractor 12 . The flange 98 has an output shaft that is connected to a drive output pulley 72 ; thus, power from the tractor 12 drives the pulley 72 . A drum drive input pulley 74 is mounted to the axle 32 and the drive output pulley 72 is connected to and transmits power to the drum drive input pulley 74 via the belt 76 . With this drive train, power is supplied to the axle 32 , which provides the power to drive the rumble strip cutting drum 30 attached thereto.
In order to keep the piston wheel 44 from sliding along the pavement, the wheel is driven through via power from a piston wheel drive motor 78 . The piston wheel drive motor 78 is mounted on one of the plates 50 . As can be seen in FIG. 10 , when the piston wheel is mounted on the left side of the machine, the piston wheel drive motor 78 is mounted on the inside plate 50 , and as is illustrated as FIG. 5 , when the piston wheel is mounted on the right side of the frame, the motor 78 is on the inside plate 50 of the right hand assembly. A hole in the plate 50 allows a shaft from the motor to extend to the space between the two plates 50 and a sprocket is provided on that shaft so that a chain 80 can be fitted about the sprocket on the motor output and the other end of the chain can be looped over a sprocket 82 mounted on the axle of the wheel 44 . Thus, as the motor 78 provides a power output through a shaft bearing a sprocket, the chain will transmit the rotational power to the wheel via a sprocket mounted on the axle of the wheel 44 .
To attach the piston wheel 44 to the rumble strip motion wheel assembly 40 , there is an axle 84 extending through the hub of the wheel. The axle 84 has flats 86 on either end and those flats fit within keyways 88 on the underside of the plates 50 . The flats have holes passing through them and bolts (not shown) are passed through the holes in the flats at the ends of the axle 84 and screwed into threaded holes in the underside of the plates 50 at keyways 88 . Thus, the axle is mounted to the wheel assembly and holds the wheel in place so that it can be driven to provide the up and down motion to the frame.
When it is time to shift the piston wheel from one side to the other, the bolts attaching the axle 84 to the plates 50 are loosened, and the piston wheel 44 is shifted to the other rumble strip motion wheel assembly 40 . When the wheel 44 is shifted, it is rotated about its vertical axis 180 degrees so that the sprocket 82 is on the inside of the frame. The flats 86 of the axle 84 are then put in position in the keyways 88 on the other assembly. Bolts are passed through the holes 90 in the flats into tapped holes in the face of the keyways 88 and connected so that the axle is held in place. Prior to connecting the axle, the sprocket chain is passed over the sprocket 82 and the piston wheel drive motor 78 is moved from one assembly to the other and remounted on the inside plate 50 of the other assembly. The shaft of the drive motor 78 will pass through a hole in the plate 50 and the sprocket on the shaft will be positioned to receive the chain about the sprocket and transfer the power from the motor to the wheel 44 .
The drive motor 78 is a hydraulic drive motor and because the motor has been rotated 180 degrees about a vertical axis to be mounted on the inside plate 50 of the other wheel assembly 40 , in order to run the wheel in the proper direction, the direction of the motor will have to be reversed. In that case, the input and output hoses for the hydraulic fluids driving the motor will be switched so as to drive the motor in an opposite direction and therefore drive the wheel 44 in a proper direction.
Referring now to FIGS. 10 and 11 , another feature of the present invention will be described. As can be seen from FIGS. 10 and 11 , a front mount plate 70 is provided which is designed to connect to the front of the tractor 12 . The front mount plate 70 has a beam 92 welded thereto. The beam 92 extends across the tractor 12 and the ends of the beam 92 can be connected to the rails 20 . As can be seen in FIGS. 11 and 12 , threaded take up rods 100 extend through take up blocks 102 . The take up blocks are mounted on the connection ends 22 of the rails 20 and thread into holes passing through opposite ends of the beam 92 . The opposite ends of the beam 92 also include grooves 104 that fit within slots 106 in the connecting ends 22 of the rails 20 . Thus, by screwing the take up rods 100 in one direction, the rails 20 will move forward relative to the chassis of the tractor 12 to reduce the distance between the two pulleys 72 and 74 to loosen the tension on belt 76 . More importantly, if the tension on the belt 76 gets slack, the take up rods 100 can be rotated in an opposite direction to move the rails 20 in a rearward direction relative to the tractor and therefore increase the tension on the belt 76 passing over the pulleys 72 , 74 and prevent any slippage in the transmission of power from the power output source on the tractor 12 to the cutter drum 30 .
Referring now to FIGS. 13 through 15 and 18 through 23 , additional features of the invention will be described. Specifically, looking at FIG. 13 , there is illustrated the unique connecting structure between the frame of the rumble strip cutting machine of the present invention and a tractor. As can be seen, the suspension plates 18 a and 18 b are designed to connect to either side of the tractor. Attached to the suspension plates 18 is a pair of rods, lifting/pressure rod 94 and support rod 96 . These rods are sometimes referred to as connectors and serve a function of connecting the rumble strip cutting machine frame to a tractor. The lifting/pressure rod 94 is attached to suspension plate 18 a through a sleeve (see FIGS. 20 and 21 ) with attaching nuts 138 on either side of the sleeve. An expansion spring 95 fits over rod 94 . Mounted on top of the expansion spring 95 is a tension cross plate 134 . The cross plate is held down by a nut screwed onto the rod 94 and seated above the plate 134 . The rod 94 passes through support rod plate 108 a and a support nut 140 is fit on the underside of the plate 108 a and screwed onto rod 94 . Thus, the rod 94 is fixed relative to the tractor 12 by its connection through the plate 18 a to the tractor and is fixed relative to the outside rail 20 a of the rumble strip cutting frame so that when the rod is lifted the frame will be lifted. However, the frame can move up and down relative to the rod against the pressure of expansion spring 95 . Thus, the expansion spring 95 applies downward force on the rail 20 a to force the rumble strip cutting drum down against the pavement and make a better cut. The tension cross plate 134 also has mounted on it a pair of guide rods 136 which extend through holes in the plate 108 a . Those guide rods also have expansion springs coiled about them to apply addition pressure against the top of plate 108 a to help keep the cutting drum 30 pressed against the road surface in order to make a better cut and reduce the possibility of the drum not fully penetrating the surface as the rumble strip is being cut. In softer material, spring pressure can be completely released. Spring pressure is adjusted by adjusting a nut directly on top of cross plate 134 .
The rod 96 is fixed relative to both the tractor 12 and the rumble strip cutting frame by the connection of the rod at either end to the suspension plate 18 b at the top and 108 b at the bottom. Thus, as can be seen in FIG. 21 for example, a configuration in which the drum is mounted on the near side of the rumble strip cutter as shown in the illustration, the side of the frame in which the rod 96 is employed is fixed relative to the tractor 12 and has very little movement whereas the side of the frame that is connected to the tractor 12 through the rod 94 is allowed to move in an up and down motion relative to the tractor as the piston wheel 44 rotates to raise and lower the frame of the rumble strip cutter on the side where the rumble strip cutting drum is mounted.
When the rumble strip cutting drum is moved to the other side of the rumble strip cutting frame, along with the piston wheel 44 , the mounting of the rods is reversed so that rod 96 will be on the near side of the frame as illustrated in FIG. 22 and the rod 94 will be on the far side of the frame. As can be seen in FIG. 21 , the support rod plate 108 b has three holes in it to allow the three rods that are a part of the rod system 94 to pass through those holes to apply downward pressure on the system when the system is configured for cutting rumble strips on the power input side of the system.
FIG. 20 is another illustration of the configuration show in FIG. 21 . As can be seen in FIG. 20 , the drum 30 is mounted on the right side of the machine as illustrated and the rod 94 is likewise on the right side of the machine with the rod 96 on the left side of the machine. When the drum 30 is moved to the left side of the machine, the rods will be switched so that the frame of the rumble strip cutting machine will be fixed relative to the tractor through the support plate 18 a , and the left side of the machine will be allowed to raise and lower relative to the tractor 12 as the piston wheel rotates to raise the lower the drum 30 in order to cut the rumble strips in their spaced relationships.
Since the power input side of the machine never changes, it is necessary to accommodate rocking motion of the rail 20 b when the cutter drum 30 is mounted adjacent the rail side 20 a . Further, when the cutter drum 30 is mounted adjacent the rail side 20 b , an accommodation must be made to allow the rail 20 b to move in an up and down motion without impairing the power input to the cutter drum. FIGS. 18 , 19 , 20 and 21 illustrate these features of the invention. The rail 20 b on the drive train side of the machine is provided with an elongated channel 118 having a height size to allow some movement of the rail 20 b in an up and down motion over spacer 120 . Nylon wear pads 122 are placed on either side of the rail 20 b and an anchor plate 124 is on the inside of the rail 20 b and fixedly attached to the drive output support plate 68 . The inside pad 122 fits between the anchor plate 124 and the inside surface of the rail 20 b . A retaining plate 126 is on the outside of the rail 20 b and the outer nylon wear pad 122 is fitted between the outside surface of the rail 20 b and the retaining plate 126 . The spacer 120 has a length slightly greater than the width of the rail 20 b and the retainer plate 126 , the pads 122 , the spacer 120 and the anchor plate 124 all have holes through them with the holes 130 in the anchor plate 124 being threaded. Bolts 128 pass through the holes in the plates, pads and spacers to hold the frame loosely connected to the tractor 12 . Using this structure for connecting the frame of the rumble strip cutting machine to the tractor 12 , the rail 20 b is allowed to move in a rocking motion as represented by the arrows 131 (see FIG. 20 ) when the drum is mounted on the right side of the machine (as seen in FIG. 20 ). Because the frame moves up and down on the right side, and the relative height of the frame on the left side is fixed because the rod 96 is fixed relative to the tractor, a rocking motion will occur in the rail 20 b . By having the spacer 120 being slightly longer than the width of the rail 20 b , the rail 20 b will be allowed to move between the plates 124 and 126 . The pads 122 will prevent wear on the inner surfaces of the plates 124 , 126 . This assembly also provides lateral support for the rear of the rumble strip cutter frame, regardless of whether the machine is cutting on the left or right side.
When the machine is configured so that the cutting drum 30 is on the left side of the machine, the rods 94 and 96 will be swapped and the rail 20 a will be in a fixed position relative to the tractor 12 , but the flexibility of the rod will allow the rocking motion of the rail 20 a to occur freely. On the other hand, with the drum 30 mounted on the left side of the machine, the rail 20 b must be allowed to move up and down as the rotation of the piston wheel causes the frame to move up and down so that the rumble strip drum can cut the rumble strips. The height of the channel 118 allows the rail 20 b to move up and down over the spacer 120 with the anchor plate 124 and retaining plate 126 holding the rail 20 b adjacent the side of the tractor 12 . At the same time, the rail 20 b is allowed to move up and down as the piston wheel rotates over the pavement. Likewise, the rod 94 when mounted on the left side of the machine, applies downward pressure on the drum to make a better cut and also allows the movement of the frame in an up and down motion relative to the tractor 12 .
When it is time to move the rumble strip cutter from one job site location to another, it is desirable to raise the frame of the machine out of engagement with the highway surface. Illustrated in FIGS. 14 and 15 are views of the machine in these two separate positions. In FIG. 14 , the telescoping wheel support 114 for the rear wheels of the tractor 12 are extended to raise the back of the tractor 12 . When the back of tractor 12 is raised, and the rumble strip cutting machine of the present invention is attached to the machine in the manner as previously described, the rods 94 and 96 lift the machine off the ground as is shown in FIG. 14 . Upon arrival at the new job site, the telescoping wheel support 114 is lowered and the rods 94 – 96 allow the rumble strip cutting machine of the present invention to be placed on the road surface as shown in FIG. 15 .
FIGS. 22 and 23 illustrate yet another feature of the present invention. FIG. 23 illustrates the machine set up for cutting rumble strips on the left side of the machine. As can be seen, the rod 94 is mounted on the left side of the machine and the rod 96 is on the right side of the machine. A water spray bar 142 is mounted on the left side of the machine when cutting on the left side and, as can be seen in FIG. 22 , on the right side of the machine when cutting on the right side of the machine. The water spray bar has nozzles that fit through the holds 143 and water from a tank carried on the machine is sprayed into the rumble strip cutting chamber to reduce dust during the process. When the rumble strips are cut on one side of the machine, the spray bar is mounted on that side of the machine and when the system is reconfigured to have the rumble strip drum on the other side of the machine the spray bar is likewise moved. Clips are provided to mount the spray bar in the appropriate location.
Finally, the machine is designed to be configured so as to carry full width milling drum for texturizing or smoothing ruff surfaces. Such a configuration is illustrated in FIG. 24 . In that configuration, a full width milling drum 144 is mounted on the axle 32 . In order to have the full width milling drum mounted for a level cut on the road surface, a brace 146 is mounted between frame rail 20 a and the support plate 18 a . Thus, with the rod 96 and the brace 146 , a fixed configuration is established between the tractor 12 and the frame of the device so that the full width milling drum will be held against the road surface and perform its desired function. In this configuration, obviously the piston wheel is removed so that the full width milling drum is simply carried along behind the tractor 12 to perform the texturizing or smoothing function of the machine.
Although there have been described particular embodiments of the present invention of a new and useful Modified Rumble Strip Cutter, it is not intended that such references be construed as limitations upon the scope of this invention except as set forth in the following claims.
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A rumble strip cutting machine having a drum that can be shifted from one side of the machine to the other. The machine includes a piston wheel that imparts an up and down motion to the frame so that rumble strips can be cut at desired intervals as the machine is driven along the road shoulder. The piston wheel includes a wheel mounting assembly on each side of the machine so that the wheel can be conveniently shifted from one side of the machine to the other. Additional structures allow for the flexing of the machine frame, applying pressure to the cutting drum, adjusting the depth of cut, tightening the belt used to drive the drum, and lifting the machine for job site transportation. The machine enables a method of cutting rumble strips close to obstructions on narrow shoulders while driving the machine in the direction of moving traffic.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an interlocking building block adapted to be correspondingly engaged with adjoining interlocking building blocks, thereby forming a secure, stable structure which may be quickly erected using smaller than usual quantities of cement.
2. Description of the Prior Art
The standard cinder block has for a long time been the primary building unit in many types of construction. The manner in which the cinder blocks are utilized has remained unchanged over time, and the building steps used today are basically the same as those used years ago. This common practice involves pouring an initial layer of cement wherein the first row of cinder blocks may be embedded. Following this initial base layer, a thin layer of cement must be spread along the top surface and both the left and right side surfaces. This layer of cement must be thin enough to allow the blocks to remain properly leveled and positioned, but must also be thick enough to secure the block as positioned. Finally, an upper layer of cement is laid, and usually, the exterior surface is covered with a layer of cement to provide a stable structure. Unfortunately, the intermediate step of putting a layer of cement between each of the individual blocks can be very time-consuming, costly, and leaves much room for error when constructing a uniformly oriented structure.
Other attempts have been made to design an interlocking building block, but as is evidenced by the continued use of a standard shaped cinder block, have not been effectively or widely accepted as beneficial. The two major types of design flaws with prior attempts to build an interlocking building block are either that the block is too difficult and expensive to construct, or that it is too difficult and time-consuming to place. The patents to J. Cook, U.S. Pat. No. 460,177, Vesper, U.S. Pat. No. 2,688,245, Amaral, U.S. Pat. No. 4,258,522, Risi, et al., U.S. Pat. No. 4,601,148, and Schwartz, U.S. Pat. No. 4,627,209, disclose attempts to make an effective and beneficial interlocking building block. The prime difficulty with many of these designs, particularly Cook, Vesper, Amaral, and Risi, et al., involves the lack of positionability of the blocks. All of these designs involve a complex series of interlocking sides and protruding surfaces which allow the blocks to be stacked only in a predetermined orientation by maneuvering the blocks until the plurality of interconnecting parts are engaged. Further, the designs disclosed in Cook and Amaral, have solid faces which do not allow the internal interconnection of the blocks, which is invaluable for wiring and insulating needs. The lack of wide-spread use of these various designs indicates the importance of the particular design characteristics not met by the referenced designs.
Applicant's invention as claimed utilizes interlocking ridges and channels which extend across the entire length of the block, thereby allowing the block to be easily slid into place oriented in any manner with regard to the block's beneath it. Additionally, applicant's invention enables the manufacture of a stable structure without the need for excess layers of cement, while assuring that the surfaces of the block, in particular, the exposed surfaces, are as smoothly and uniformly oriented as those of common cinder blocks, which many structures are designed to use. Accordingly, applicant's invention provides a beneficial improvement in the structure of construction blocks, and utilizes interlocking means which specifically overcome the shortcomings of other types of blocks.
SUMMARY OF THE INVENTION
The present invention is directed towards an interlocking building block to be used to more efficiently and effectively construct walls, supports, and other similar structures which normally utilize standard building blocks. The interlocking building block, which is equivalently sized with standard building blocks, is comprised primarily of a rigid solid block designed to be interconnectedly positioned with a like rigid, solid block. Each individual block includes at least one elongate rounded ridge along its top, and at least one elongate rounded channel on its bottom surface. The elongate, rounded ridge along the top surface is specifically designed to be easily and securely fitted within the elongate, rounded channel in the bottom surface of an adjoiningly stacked block, creating a securely stacked structure. The interconnecting block also contains at least one transverse bore through which insulation and wiring may be passed. Additionally, the block contains a rounded, vertical, cutout channel and a rounded, vertical, protruding ridge, both of which extend from the block's top surface to its bottom surface along different sides of the block. The rounded, vertical, protruding ridge of one block is structured and disposed to be positioned within the rounded, vertical, cutout channel of an adjacently positioned block.
There are various different embodiments using the stated design features, each of which is designed to facilitate a particular part of the construction process. In particular, and in addition to the basic design, there are embodiments specifically directed to, provide shorter end blocks when a full-sized block is not needed, provide an easy means of constructing thinner partition walls extending from an exterior frame, provide a facilitated means of constructing doorways, windows and arches, and providing easily made squared and rounded corners.
BRIEF DESCRIPTION OF THE DRAWINGS
For a fuller understanding of the nature of the present invention, reference should be had to the following detailed description taken in connection with the accompanying drawings in which:
FIG. 1 is a perspective view of the standard model of the interlocking building block.
FIG. 1A is a top view of the standard model of the interlocking building block.
FIG. 1B is an end view of the standard model of the interlocking building block.
FIG. 1C is an exploded view of the interlocking arrangement of the standard model of the interlocking building blocks.
FIG. 2 is a perspective view of a shortened standard model of the interlocking building blocks.
FIG. 3 is a perspective view of a standard model of the interlocking building block having a side protruding ridge for partition extension.
FIG. 4A is a perspective view of a narrow partition interlocking building block.
FIG. 4B is a perspective view of a shortened, narrow partition interlocking building block.
FIG. 5 is a perspective view of a door frame, window frame or archway interlocking building block.
FIG. 5A is a perspective view of a right side transition block used for changing from the standard model block to the archway type block.
FIG. 5B is a left side transition block used for changing from the archway type block back to the standard type block.
FIG. 6A is a top view of the archway type interconnecting block.
FIG. 6B is a bottom view of the archway type interconnecting block.
FIG. 6C is a left side view of the archway type interconnecting block.
FIG. 6D is a right side view of the archway type interconnecting block.
FIG. 7 is a partially exploded view of an archway construction.
FIG. 8 is an exploded view of a squared corner assembly.
FIG. 9 is a perspective view of a rounded corner assembly.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Depicted throughout FIGS. 1-9 are various embodiments of the applicant's invention as claimed. Turning to FIG. 1, the standard model of the interlocking building block 10 is comprised primarily of a rectangular block 30 having a front surface 32, a right surface 34, a rear surface 36, a left surface 38, a top surface 40, and a bottom surface 42. Adjacently disposed along the top surface 40 are two transverse bores 60 which pass through the top surface 40 and the bottom surface 42. As best seen in FIG. 1 and IA, there is a vertical, rounded, cutout channel 55 in the left face 38, which extends from the top surface 40 to the bottom surface 42 and is substantially centered between the rear surface 36 and the front surface 32. On said right face 34 is a vertical, rounded, protruding ridge 50 which extends from the top surface 40 to the bottom surface 42 and is also substantially centered between the rear surface 36 and the front surface 32. Extending along the top surface 40 from the left surface 38 to the right surface 34 are two elongate, rounded protruding ridges 45, best shown in FIGS. 1 and 1B, which are positioned on opposite sides of said transverse bores 60. In the bottom surface 42, and extending from the left surface 38 to the right surface 34 are two elongate, rounded, cutout channels 47, which are positioned on opposite sides of said transverse bores 60. As shown in FIG. 1C, the blocks are designed so that the vertical, rounded, protruding ridge 50 on the right surface 34 of one block 30 will engagedly fit within the vertical, rounded, cutout channel 55 in the left surface 38 of a second block 30. Additionally, the elongate, rounded, protruding ridges 45 are structured so as to be securely fitted within the elongate, rounded, cutout channels 47 on the bottom surface 42 of an adjacently stacked block 30.
Shown in FIG. 2 is a shortened end block 11, which only includes one transverse bore 60, and has a front surface 32, a top surface 40, a rear surface 36, and a bottom surface 42, which are generally half the length of those in the standard model of the interlocking building block 10.
Referring to FIG. 3, a second, vertical, rounded, protruding ridge 70 is positioned on the front face 32, extending from the top surface 40 to the bottom surface 42, and substantially centered between the left surface 38 and the right surface 34, thereby forming a standard model interlocking building block with a partition extension, generally indicated as 12.
Depicted in FIGS. 4A and 4B are partition block 13 and shortened, narrow partition block 14, respectively. The narrow partition block 13, has its left surface 38 and its right surface 34 at generally one-half the width of the left surface 38 and the right surface 34 of the standard model interlocking building block 10. The shortened, narrow partition block 14 has the same sized left surface 38 and right surface 34 as the narrow partition block 13, and further has its front surface 32, top surface 40, rear surface 36, and bottom surface 42 at generally one-half the length of those in the standard model interlocking building block 10.
Shown in FIGS. 5, 5A and 5B, are embodiments specifically directed towards facilitating the formation of door frames or archways. The three types of blocks included, are the archway block 15, the right side transition block 16, and the left side transition block 17. The transition blocks 16 and 17 are utilized to enable a builder to use the standard model interlocking building block 10 until a doorway, arch or window is needed. Located on the left surface 38 of the archway block 15 and the right side transition block 16 is a tapered, vertical, rounded, cutout channel 56, located on the right surface 34 of the archway block 15 and the left side transition block 17 is a tapered, vertical, rounded, protruding ridge 51. As best shown in the various views of the archway block 15 of FIGS. 6A, 6B, 6C and 6D, the tapered, vertical, rounded, cutout channel 56 is tapered such that its widest point is at the top surface 40 and its narrowest point is at the bottom surface 42. Additionally, the tapered, vertical, rounded, cutout channel 56 is tapered in width such that its narrowest point is at the left surface 38 and its widest point is within the block 30. The tapered, vertical, rounded, protruding ridge 51 is also tapered such that its widest point is at the top surface 40 and its narrowest point is at the bottom surface 42, and is tapered in cross-sectional width such that a narrowest point is at the right surface 34 and a widest portion is outside the block 30. As detailed in FIG. 7, the tapered, vertical, rounded, protruding ridge 51 is structured so as to be slidably and securely positioned within the tapered, vertical, rounded, cutout channel 56 of an adjacently positioned block 30.
Turning to FIG. 8, are a plurality of blocks 18, 19, and 20 designed to facilitate the formation of a squared corner. The first angled corner unit 18, has only one transverse bore 60, and has its right surface 34 angled with relation to its rear surface 36 so as to form a 45° angle 75. This first angled corner unit 18 is designed to be fitted with a second angled corner unit 19 which has its left surface 36 angled with relation to its rear surface 30 to form a 45° angle 75. When fitted together, the first angled corner unit 18 and the second angled corner unit 19 form a 90° corner which may be capped by a squared corner block 20. The squared corner block 20 has its vertical, rounded, protruding ridge 50, located on its front face 32, extending from the top surface 40 to the bottom surface 42 and substantially centered between the left surface 38 and the right surface 34. Additionally, the elongate, rounded, protruding ridges 45, are located on the top surface 40 along a length defined by the rear surface 36 and the right surface 34. The elongate, rounded, cutout channels 47 are located in the bottom surface 42 along a length defined by the rear surface 36 and the right surface 34. Accordingly, the squared corner block 20 may be easily fitted on top of the joined first angled corner unit 18 and second angled corner unit 19.
Shown in FIG. 9 is a rounded corner block 21. The rounded corner block 21, has its top surface 40, rear surface 36, bottom surface 42, and front surface 32 substantially curved so as to facilitate the formation of a rounded corner.
The various embodiments of applicant's invention employ the same basic interlocking means, and may be formed of various materials and in various sizes, thereby enabling their use in full scale construction as well as model construction.
Now that the invention has been described,
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An interlocking building block, to be used in constructing walls and building frames, the building blocks being adapted to be securely engaged without the need to use extra layers of cement. The interlocking building blocks include a series of ridges and channels disposed along the top and bottom surface of the block and at opposite distal ends, which are structured and disposed to be correspondingly fitted with the ridges and channels of adjoining blocks, thereby forming a secure interlocking structure.
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This application is a continuation-in-part of copending U.S. application Ser. No. 08/419,671, filed Apr. 11, 1995, and is incorporated by reference herein.
BACKGROUND OF THE INVENTION
A. Field of the Invention
The present invention relates broadly to load bearing and moment frame connections. More specifically, the present invention relates to connections formed between beams and/or columns, with particular use, but not necessarily exclusive use, in steel frames for buildings, in new construction as well as modification to existing structures.
B. Discussion of the Invention
In the construction of modern structures such as buildings and bridges, moment frame steel girders and columns are arranged and fastened together, using known engineering principles and practices to form the skeletal backbone of the structure. The arrangement of the girders, also commonly referred to as beams, and/or columns is carefully designed to ensure that the framework of girders and columns can support the stresses, strains and loads contemplated for the intended use of the bridge, building or other structure. Making appropriate engineering assessments of loads represents application of current design methodology which is compounded in complexity when considering loads for seismic events, and determining the stresses and strains caused by these loads in structures, are compounded in areas where earthquakes occur. It is well known that during an earthquake, the dynamic horizontal and vertical inertia loads and stresses, imposed upon a building, have the greatest impact on the connections of the beams to columns which constitute the earthquake damage resistant frame. Under the high loading and stress conditions from a large earthquake, or from repeated exposure to milder earthquakes, the connections between the beams and columns can fail, possibly resulting in the collapse of the structure and the loss of life.
The girders, or beams, and columns used in the present invention are conventional I-beam, W-shaped sections or wide flange sections. They are typically one piece, uniform steel rolled sections. Each girder and/or column includes two elongated rectangular flanges disposed in parallel and a web disposed centrally between the two facing surfaces of the flanges along the length of the sections. The column is typically longitudinally or vertically aligned in a structural frame. A girder is typically referred to as a beam when it is latitudinally, or horizontally, aligned in the frame of a structure. The girder and/or column is strongest when the load is applied to the outer surface of one of the flanges and toward the web. When a girder is used as a beam, the web extends vertically between an upper and lower flange to allow the upper flange surface to face and directly support the floor or roof above it. The flanges at the end of the beam are welded and/or bolted to the outer surface of a column flange. The steel frame is erected floor by floor. Each piece of structural steel, including each girder and column, is preferably prefabricated in a factory according to predetermined size, shape and strength specifications. Each steel girder and column is then, typically, marked for erection in the structure in the building frame. When the steel girders and columns for a floor are in place, they are braced, checked for alignment and then fixed at the connections using conventional riveting, welding or bolting techniques.
While suitable for use under normal occupational loads and stresses, often these connections have not been able to withstand greater loads and stresses experienced during an earthquake. Even if the connections survive an earthquake, that is, don't fail, changes in the physical properties of the connections in a steel frame may be severe enough to require structural repairs before the building is fit for continued occupation.
SUMMARY OF THE INVENTION
The general object of the present invention is to provide new and improved beam to column connections. The improved connection reduces stress and/or strain in beam to column connections caused by both static and dynamic loading. The improved connection of the present invention extends the useful life of the steel frames of new buildings, as well as that of steel frames in existing buildings when incorporated into a retrofit modification made during repairs to existing buildings.
A further object is to provide an improved beam to column connection in a manner which generally evenly distributes static or dynamic loading, and stresses, across the connection so as to minimize high stress concentrations along the connection.
Another object of the present invention is to reduce a dynamic loading stress applied between the beam and the column flange connection of a steel frame structure.
Yet another object of the present invention is to reduce the variances in dynamic loading stress across the connection between the column and beam.
It is yet another object of the present invention to reduce the variances in dynamic loading stress across the beam to column connection by incorporation of at least one, and preferably several slots in the column web and/or the beam web near the connection of the beam flanges to the column flange.
It is yet another object of the present invention to reduce the strain rate applied between the beam and column flange of a steel frame structure during dynamic loading.
It is yet another object of the present invention to provide a means by which the plastic hinge point of a beam in a steel frame structure may be displaced along the beam away from the beam to column connection, if this feature may be desired by the design engineer.
Finally, it is an object of the present invention to reduce the stresses and strains across the connection of the column and beam of a steel frame structure during static and dynamic loadings.
The present invention is based upon the discovery that non-linear stress and strain distributions due to static, dynamic or impact loads created across a full penetration weld of upper and lower beam flanges to a column flange in a steel frame structure magnify the stress and strain effects of such loading at the vertical centerline of the column flange. Detailed analytical studies of typical wide flange beam to column connections to determine stress distribution at the beam/column interface had not been made prior to studies performed as part of the research associated with the present invention. Strain rate considerations, rise time of applied loads, stress concentration factors, stress gradients, residual stresses and geometrical details of the connection all contribute to the behavior and strength of these connections. By using high fidelity finite element models and analyses to design full scale experiments of a test specimen, excellent correlation has been established between the analytical and test results of measured stress and strain profiles at the beam/column interface where fractures occurred. Location of the strain gauges on the beam flange at the column face was achieved by proper weld surface preparation. Dynamic load tests confirmed the analytically determined high strain gradients and stress concentration factors. These stress concentration factors were found to be 4 to 5 times higher than nominal design assumption values for a typical W 27×94 beam to W 14×176 column connection with no continuity plates. Stress concentration factors were reduced to between 3 and 4 times nominal stress level when conventional continuity plates were added. Incorporation of features of present invention into the connection reduces the high-non-uniform stress that exists with conventional design theory and has been analyzed and tested. The present invention changes the stiffness and rigidity of the connection and reduces the stress concentration factor to about 1.2 at the center of the extreme fiber of the flange welds. Explained in a different way, the condition of stress at a conventional connection of the upper and lower beam flanges at the column flange, the beam flanges exhibit non-linear stress and strain distribution. As part of the present invention it has been discovered that this is principally due to the fact that the column web, running along the vertical centerline of the column flanges provides additional rigidity to the beam flanges, primarily at the center of the flanges directly opposite the column web. The result is that the rigidity near the central area of the flange at the beam to column connection can be significantly greater than the beam flange rigidity at the outer edges of the column flange. This degree of rigidity varies as a function of the distance from the column web. In other words, the column flange yields, bends or flexes at the edges and remains relatively rigid at the centerline where the beam flange connects to the column flange at the web, thus causing the center potion of each of the upper and lower beam flanges to bear the greatest levels of stress and strain. It is believed that, with the stress and strain levels being non-linear across the beam to column connection, the effect of this non-linear characteristic can lead to failure in the connection initiating at the center point causing total failure of the connection. In addition, the effects of the state of stress described above are believed to promote brittle failure of the beam column or weld material.
To these ends, one aspect of the present invention includes use of vertically oriented reinforcing plates, or panels, disposed between the inner surfaces of the column flanges near the outer edges, on opposite sides, of the column web in the area where the upper and lower beam flanges connect to the column flange. The load or vertical panels alone create additional rigidity along the beam flange at the connection. This additional rigidity functions to provide more evenly distributed stresses and strains across the upper and lower beam flange connections to the column flange when under load. The rigidity of the vertical panels may be increased with the addition of a pair of horizontal panels, one on each side of the column web, and each connecting between the horizontal centerline of the respective vertical panels and the column web. With the addition of the panels, stresses and strains across the beam flanges are more evenly distributed; however, the rigidity of the column along its web, even with the vertical panels in place, still results in higher stresses and strains at the center of the beam flanges than at the outer edges of the beam flanges when under load.
Furthermore, as another aspect of the present invention, it has been discovered that a slot, preferably oriented generally vertical, cut into, and, preferably, completely through the column web, in the area proximate to where each beam flange connects to the column flange, reduces the rigidity of the column web in the region near where the beam flanges are joined to the column. The column slot includes, preferably two end, or terminus holes, joined by a vertical cut through the column with the slot tangentially connecting to the holes at the hole periphery closest to the column flange connected to the beam. The slot through the column web reduces the rigidity of the center portion of the column flange and thus reduces the magnitude of the stress applied at the center of the beam at the column flange connection.
As yet another aspect of the present invention, it has been discovered that, preferably, slots cut into and through the beam web in the area proximate to where both beam flanges connect to the column flange, further reduces the rigidity of the column web in the region where the beam flanges are joined to the column. The beam slots preferably extend from the end of the beam at the connection point to an end, or terminus hole, in the beam web. The beam slots are generally horizontally displaced. Preferably, one slot is positioned underneath, adjacent and parallel to the upper beam flange, and a second beam slot is positioned above, horizontally along, adjacent and parallel to the lower beam flange. The beam slots are located just outside of the flange web fillet area and in the web of the beam.
In accordance with conventional practice, it is also desirable to construct, or retrofit, steel frame structures such that the plastic hinge point of the beam will be further away from the beam to column connection than would occur in a conventional beam-to-flange connection structure. In accordance with this practice, it has also been discovered that, preferably, use of upper and lower double beam slots accomplishes this result. The first upper and lower beam slob are as described above. For each first beam slot, a second beam slot, each also generally a horizontally oriented slot is cut through the web of the beam. Each second beam slot is also positioned along the same center line as its corresponding first beam slot which terminates at the beam to column connection. It is preferred that each second beam slot have a length of approximately twice the length of its adjacent first beam slot, and be separated from its adjacent first beam slot by a distance approximately equal to the length of the first beam slot. The slots may vary in shape, and in their orientation, depending on the analysis results for a particular joint configuration.
As yet another aspect of the present invention, it has also been discovered that the column slots and/or beam slots of the present invention may be incorporated in structures that include not only the vertically oriented reinforcing plates as described above, but also with structures that include conventional continuity plates, or column-web stiffeners, as is well known in this field. When used in conjunction with conventional continuity plates, or column-web stiffeners, the generally vertically oriented column slots are positioned in the web of the column, such that the first slot extends vertically from a first terminus hole located above and adjacent to the continuity plate which is adjacent and co-planar to, that is, provides continuity to the upper beam flange, and terminates in a second terminus hole in the column web. A second column slot extends vertically downward from the continuity plate adjacent and co-planar to, that is, providing continuity with, the lower beam flange. In this aspect of the present invention, horizontally extending beam slots, whether single beam slots or double beam slots of the present invention, may also be used with steel frame structures that employ conventional continuity plates.
As yet another aspect of the present invention, it has also been discovered that, in conjunction with the horizontal beam slots of the present invention, the conventional shear plate may be extended in length to accommodate up to three columns of bolts, with conventional separation between bolts. The combination of the upper and/or lower horizontal beam slots and the conventional and/or lengthened shear plates may be used in conjunction with top down welding techniques, bottom up welding techniques or down hand welding techniques.
The present invention vertical plates with, or without, the slots of the present invention, or, the slots with, or without, vertical plates provide for beam to column connections which generally more evenly distribute, and reduce the maximum magnitude of, the stress and strain experienced in the beam flanges across a connection in a steel frame structure than are experienced in a conventional beam to column connection.
BRIEF DESCRIPTION OF THE DRAWINGS
The objects and advantages of the present invention will become more readily apparent to those of ordinary skilled in the art after reviewing the following detailed description and accompanying documents wherein:
FIG. 1 is a perspective view of a first preferred embodiment of the present invention.
FIG. 2 is an exploded view of the connection for supporting dynamic loading of FIG. 1.
FIG. 3 is a top view of the connection for supporting dynamic loading of FIG. 1.
FIG. 4 is a side view of the connection for supporting dynamic loading of the present invention of FIG. 1.
FIG. 5 is a graph of the stress and strain rates caused by dynamic loading in a conventional connection.
FIG. 6 is a graph of the stress and strain rates caused by dynamic loading in the connection of FIG. 1.
FIG. 7 is a three dimensional depiction of the graph shown in FIG. 5.
FIG. 8 is a three dimensional depiction of the graph shown in FIG. 6.
FIG. 9 is a side view of another preferred embodiment of the present invention including a column and beam connection, a conventional continuity plate, and vertical column slots and upper and lower beam slots of the present invention.
FIG. 10 is a top view of the FIG. 9 embodiment.
FIG. 11 is a detailed, perspective view of the upper, horizontal beam slot of the FIG. 9 embodiment.
FIG. 12 is a detailed view of a column slot of the FIG. 9 embodiment.
FIG. 13 is a side view of another preferred embodiment including a connection of two beams to a single column, upper and lower vertical column slots adjacent each of the two beams, and upper and lower horizontally extending beam slots for each of the two beams.
FIG. 14 is a side view of another preferred embodiment of the present invention including a column to beam connection with upper and lower, double beam slots and upper and lower vertically oriented column slots.
FIG. 15 is a side view of another preferred embodiment of the present invention, including a beam to column connection with the enlarged shear plate and column and beam slot.
FIG. 16 is a graphical display of the displacement, based on a finite element analysis, of the column and beam flange edges of a conventional beam to column connection when under a load typical of that produced during an earthquake.
FIG. 17 is a side perspective view of the FIG. 16 connection.
FIG. 18 is a graphical display of flange edge displacement, at the beam to column connection, in a connection using a conventional continuity plate and a horizontal beam slot of the present invention, when under a load typical of that produced during an earthquake.
FIG. 19 is a graphical display of flange edge displacement, at the beam to column connection, for a connection with a column having a conventional continuity plate and incorporating beam and column slots of the present invention when under a load typical of that produced during an earthquake.
FIG. 20 is a drawing demonstrating buckling in a beam, based on a finite element analysis of a beam with double beam slots of the present invention, when the beam is placed under a load typical of that produced during an earthquake.
FIG. 21 is a hyderises loop of a beam to column connection including column and beam slots of the present invention, under simulated seismic loading similar to that resulting from an earthquake.
FIG. 22 is a perspective view of a conventional steel moment resisting frame.
FIG. 23 is an enlarged, detailed perspective view of a conventional beam to column connection.
FIG. 24 is a side view of a beam to column connection illustrating location of strain measurement devices.
FIG. 25 is a drawing showing stresses in the connection at the top and bottom beam flanges.
FIG. 26 is a drawing showing stresses in the top beam flange top surface.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the FIGS., especially 1-4, 9-15, and 22-23, the skeleton steel frame used for seismic structural support in the construction of buildings in general frequently comprises a rigid or movement, steel framework of columns and beams connected at a connection. The connection of the beams to the columns may be accomplished by any conventional technique such as bolting, electric arc welding or by a combination of bolting and electric arc welding techniques.
Referring to FIGS. 22 and 23, a conventional W 14×176 column 282 and a W 27×94 beam 284 are conventionally joined by shear plate 286 and bolts 288 and welded at the flanges. The column 282 includes bolt shear plate 286 welded at a lengthwise edge along the lengthwise face of the column flange 290. The shear plate 286 is made to be disposed against opposite faces of the beam web 292 between the upper and lower flanges 296 and 298. The shear plate 286 and web 292 include a plurality of pre-drilled holes. Bolts 288 inserted through the pre-drilled holes secure the beam web between the shear plates. Once the beam web 292 is secured by bolting, the ends of the beam flanges 296 and 298 are welded to the face of the column flange 290. Frequently, horizontal stiffeners, or continuity plates 300 and 302 are required and are welded to column web 304 and column flanges 290 and 305. It has been discovered that, under seismic impact loading, region 306 of beam to column welded connection experience stress concentration factors in the order of 4.5-5.0 times nominal stresses. Additionally, it has been discovered that non-uniform strains and strain rates exist when subjected to seismic or impact loadings associated primarily with the geometry of the conventional connection.
Column Load Plates, Support Plates And Slot Features of the Present Invention
In a first preferred embodiment and for asserting in maintaining the structural support of the connection under static, impact or dynamic loading conditions, such as during an earthquake, a pair of load plates 16 and 18 are provided disposed lengthwise on opposite sides of the column web 20 of column 10 between the inner faces 22 and 24 of the column flanges 26 and 28 and welded thereto by a partial penetration weld within the zone where the beam flanges 29 and 30 of beam 12 contact the column flange 28. Respective horizontal plates 32 and 34 are positioned along the lengthwise centerline of the vertical plates 16 and 18, respectively, and connected to the vertical plates 16 and 18, respectively, and the web 20, for added structural support. The support plate surfaces 36 and 38 are, preferably, trapezoidal in shape. Plate 36 has a base edge 40 extending along the lengthwise centerline of the load plate 16, and a relatively narrow top which is welded along and to the web 20. The vertical plates 16 and 18 are preferably positioned along a plane parallel to the web 20 but at a distance from web 20 less than the distance to the respective edges of the column flanges 40 and 42. The preferred distance is such that the rigidity of the column flange is dissipated across its width in the zone where the beam flanges 29 and 30 are connected to the column 10. The horizontal and vertical support plates are, preferably, made of the same material as the column to which they are connected.
Experiments have shown that the load plates 16 and 18, by increasing rigidity, function to help avenge the stresses and strain rates across the beam flanges 29 and 30 at the connections and decrease the magnitude of stress measured across the beam flanges 29 and 30, but do not significantly reduce the magnitude of the stress levels experienced at the center region of the beam flange. The load or column flange stiffener plates 16 and 18 alone, by creating near uniform stress in the connection function adequately to help to reduce fracture at the connection; however, it is also desirable to reduce the magnitude of stress measured at the center of the beam flanges 29 and 30 and may be further reduced by a slot 44. The column web slot 44, cut longitudinally, is useful at a length range of 5 per cent to 25 per cent of beam depth cut at or near the toe 45 of the column fillet 47 within the column web 20 centered within the zone where the beam flanges 29 and 30 are attached proximate to the connection. The slot 44 serves to reduce the rigidity of the column web 20 and allows the column flange 28 center to flex slightly, thereby reducing the magnitude of stress in the center of the beam flanges. The vertical plates 16 and 18 with or without the web slot 44 function to average out the magnitude of stress measured across the beam connection 14. By equalizing, as much as possible, the stress and strain concentrations along the beam flanges 29 and 30, the stress variances within the beam 12 are minimized at the connection. In addition, a thus constructed connection 14 evenly distributes the magnitude of stress across the weld to ensure that the connection 14 is supported across the column flange 28 during static, impact or dynamic loading conditions. As shown in FIG. 8, when the load plates 16 and 18 and slot 44 are incorporated in the structure at column 10 proximate to the connection 14, strain rates measured across the beam flanges 29 and 30 appear more evenly distributed, and the magnitude of stress across the beam flange edge 46, has a substantially reduced variation across the beam in comparison to the variation shown in FIG. 7.
In a preferred embodiment, a conventional W 14×176 column 10 and a W 27×94 beam 12 are conventionally joined by mounting plate 48 and bolts 50 and welded at the flanges. The column 10 includes shear connector plate 48 welded at a lengthwise edge along the lengthwise face of the column flange 28. The mounting plate 48 is made to be disposed against opposite faces of the beam web 52 between the upper and lower flanges 29 and 30. The mounting plate 48 and web 52 include a plurality of pre-drilled holes. Bolts 50 inserted through the pre-drilled holes secure the beam web between the mounting plates. Once the beam web 52 is secured by bolting, the ends of the beam flanges 29 and 30 are welded to the face of the column flange 28. The combination of the bolt and welding at the connection rigidly secures the beam 12 and column 10 to provide structural support under the stress and strain of normal loading conditions.
Under the static, impact or dynamic loading of the connection 14, this configuration alone does not provide sufficient support for the stresses and strains experienced under such conditions. For purposes of this invention, stress is defined as the intensity of force per unit area and strain is defined as elongation per unit length, as shown in FIGS. 5 and 6, a seismic simulation of loads measured at seven equidistant points 70-78 width-wise across the beam flange in psi over time during an earthquake, results in a significantly greater stress magnitude measured at the center 73 of the beam flange. In addition, the slope of increasing stress levels shown in the graph represents uneven acquisition of strain at different points 70-76 along the beam flange. FIG. 24 shows the exact location of the strain measurement devices in relation to the center line of the column. As the measurements are taken further away from the center 73 of the column flange along the beam flange edge, the levels of stress are reduced significantly at each pair of measurement points 72 and 74, 71 and 75, 70 and 76, i.e., as the distance extends outward on the beam flange away from the center. The results show that the beam flange 29 at the connection 14 experiences both the greatest level of the stress and the greatest level of strain at the center of the beam web to column flange connection at the centerline of the column web. The connection 14 configuration represents the zone of either or both the upper 29 and lower 30 beam flange. The column web slot 44 cut lengthwise in the column web 20 centered within the zone of the lower beam flange connection 30 is generally about 3/4 of inch from the inner face of the column flange near the beam flange connection. In the preferred embodiment, slot widths in the range of 4 to 8 inches in length are preferred. The best results at 3/4 of an inch from the flange were achieved using a 4.5 inch length slot with a 0.25 inch width. Slots longer than eight inches may also be useful. A summary of the tests in which the preferred dimensions were discovered is disclosed in a 16-page test report entitled, "Moment Frame Connections Strain and Deflection for Tests #1-11-,30 & 33, 34 and 35" by Jay Allen, Ralph Richard and Jim Partridge on Feb. 10, 1995, enclosed with this application and incorporated by reference herein. Those skilled in the art will appreciate that the specific configurations and dimensions of the preferred embodiment may be varied to suit a particular application, depending upon the column and beam sizes used in accordance with the test results.
The load plates 16 and 18 and the respective support plates 32 and 34 are preferably made from a cut-out portion of a conventional girder section. The load plates comprising the flange surface and the support plates comprising the web of the cut-out portions. Alternatively, a separate load plate welded to a support plate by a partial penetration weld, with thicknesses adequate to function as described herein, would perform adequately as well. The horizontal plates 32 and 34, preferably, do not contact the column flange 28 because such contact would result in an increased column flange stiffness and as a consequence increased stress at that location, during dynamic loading such as occurs during an earthquake. Each support plate base 40 preferably extends lengthwise along the centerline of the respective load plates 16 and 18 to increase the rigidity of the load plate and is tapered to a narrower top edge welded width-wise across the column web 20. The, preferably, trapezoidal shape of the support plates surface provides gaps between the respective column flanges and the edges of the support plates. Such gaps establish an adequate open area for the flange to flex as a result of the slot 44 formed in the web within the gap areas.
Column Slots With Conventional Column Continuity Plates Features of the Present Invention
Referring to FIG. 9, column 100 is shown connected to beam 102 at connection 104, as described above. Upper conventional continuity plate, also commonly referred to as a stiffener, or column stiffener, 106 extends horizontally across web 108 of column 100 from left column flange 110 to right column flange 112. Plate 106 is co-planar with upper beam flange 114, is made of the same material as the column, and is approximately the same thickness as the beam flanges. Referring to the FIG. 10 top view, column 100, beam 102, column web 108 and top beam flange 114 are shown. Continuity plate 106, left and right column flanges 110 and 112 are also shown.
Again referring to FIG. 9, lower continuity plate 116 is shown to be co-planar with lower beam flange 118. Upper column slot 120 is shown extending through the thickness of column web 108, and is, preferably, vertically oriented along the inside of right column flange 112. The lower end, or terminus 122 of the slot 120, and the upper terminus 124 are holes, preferably drilled. In the case when the column is a W 14×176 inch steel column, the holes 120, 124 are preferably 3/4 inch drilled holes, and the slot is 1/4 inch in height and cut completely through the web. When connected to a W 27×94 steel beam, the preferred length of slot 120 is 6 inches between the centers of holes 122 and 124 and are tangential to the holes 122 and 124 at the periphery of the holes closest to the flange. The centers of holes 122 and 124 are also, preferably, 3/4 inch from the inner face 126 of right column flange 112. The center of hole 122 is, preferably, 1 inch from the upper continuity plate 106. Positioned below lower continuity plate 106 is lower column slot 130, with upper and lower terminus holes 132 and 134, respectively. Lower column slot 130 preferably has the same dimension as upper column slot 120. Lower slot 130 is positioned in web 108, the lower face 136 of lower continuity plate 116, right column flange 112 and lower beam flange 118 in the same relative position as upper slot 120 is positioned with respect to continuity plate 106 and upper beam flange 114. The holes may vary in diameter depending on particular design application.
Beam Slots Features of the Present Invention
Also referring to FIG. 9 invention is shown. Upper beam slot 136, shown in greater detail in FIG. 11, is shown as cut through the beam web and as extending in a direction generally horizontal and parallel to upper beam flange 114. A first end 138 of the beam slot, shown as a left end terminates at the column flange 112. The slot, for a typical W 27×94 steel beam, is preferably 1/4 inch wide and is cut through the entire thickness of beam web 103. The second terminus 140 of the upper horizontal beam slot is a hole, preferably, 1 inch in diameter in the preferred embodiment. The center of the hole is positioned such that the upper edge 142 of the slot 136 is tangential to the hole, as more clearly shown in FIG. 11. Also, for a W 27×94 steel beam, the center line 144 of the slot 136 is 3/8 inch as from the lower surface 146 of the upper beam flange 114, with the center 148 of the hole being 17/8 inches from the beam flange surface. The preferred slot length for this embodiment is 6 inches. Referring to FIG. 9, lower, horizontally extending beam slot 150 is shown. The lower beam slot 150 is tangential to the bottom of the corresponding terminus hole 152, and the dimensions of the slot and hole are the same as those for the upper beam slot. The lower beam slot 150 is positioned relative to the upper surface 154 of the lower beam flange 118 by the same dimensions as the upper beam slot 136 is positioned from the lower surface 146 of the upper beam flange 114.
Referring to FIG. 13, a single column 156 having two connecting beams 158, 160 is shown. The column 156 includes upper column slots 162, 164 and lower column slots 166, 168, as described in greater detail above, adjacent to each of the column flanges 170, 172 connected to each of the two beams 158, 160. Also, each of the two beams is shown with upper beam slots 174, 176 and lower beams slots 178, 180 as described in greater detail above. The column and beam slots associated with the connection of beam 160 to column 156 are the mirror images of the slots associated with the connection of beam 158 to column 156, and have the dimensions as described in connection with FIGS. 9-12.
The slots may vary in orientation from vertical to horizontal and any angle in between. Orientation may also vary from slot to slot in a given application. Furthermore, the shape, or configuration of the slots may vary from linear slots as described herein to curvilinear shapes, depending on the particular application.
Double Beam Slots Features of the Present Invention
In accordance with conventional practice, many regulatory and/or design approval authorities may require modification of the conventional beam to column connection such that the beam plastic hinge point is moved away from the column to beam connection further along the beam than it otherwise would be in a conventional connection. Typically the minimum distance many in this field consider to be an acceptable distance for the plastic hinge point to be from the connection is D/2 where D is the height of the beam. In accordance with the present invention, and as illustrated in FIG. 14, column 182 is shown with beam 184 and continuity plates 186, 188 as described above. Beam 184 has upper beam slots 190 and 192, and lower beam slots 194 and 196. The beam slots immediately adjacent to the column 182 are described in greater detail above. The centerlines of second beam slots 192, 196 are positioned to be co-linear with the centerline of the first beam slots 190, 194. The second beam slots 192, 196 function to move the plastic hinge point further away from the beam to column connection. The second beam slots 192, 196 have two terminus holes each, and are oriented in the same fashion as the first beam slot, as shown at 202, 204, 206, 208, respectively. In a W 27×94 steel beam the preferred length of the second beam slot is 12 inches from terminus hole 202 center to hole 204 center, with 1 inch diameter terminus holes as shown in FIG. 14. Also, preferably, the center of the first terminus hole 202 of the second, upper beam slot 112 is a distance of 6 inches from the center of the terminus hole 210 of the first, upper beam slot 190. The centerlines of the terminus holes are co-linear to each other just outside the fillet area. The second beam slot is cut just outside the fillet area of the flange and in the web and the terminus holes are tangential to the slot, on the side of the holes closet to the nearest beam flange. The width of the second beam slot is, preferably, 1/4 inch and extends through the entire thickness of the beam. Again referring to FIG. 14, second lower beam slot 196 is cut to be co-linear to the first lower beam slot 194. The second, lower beam slot 196 has dimensions, preferably, identical to the dimensions of the second, upper beam slot 192, and its position relative to the lower beam flange's upper surface 210 corresponds to the positioning of the second upper beam slot 192 relative to the lower surface 212 of the upper beam flange.
Although not shown in FIG. 14, the column slots, load plates, and/or support plates as described above may be used with the double beam slots.
Enlarged Shear Plate Feature of the Present Invention
Referring to FIG. 15, column 214, beam 216, continuity plates 218 and 220, upper beam slot 222, lower beam slot 224, upper column slot 226 and lower column slot 228 are shown with enlarged shear plate 230. Conventional shear plates typically have a width to accommodate a single row of bolts 232. In accordance with the present invention, the width of the shear plate 230 may be increased to accommodate up to three rows of bolts 232. The shear plate 230 of the present invention may be incorporated into the initial design and/or retrofitting of a building. In a typical steel frame construction employing a W 27×94 steel beam, a shear plate of approximately 9 inches in width would accommodate two columns of bolts. Typically, the bolt hole centers would be spaced apart by 3 inches. The enlarged shear plate inhibits the premature breaking of the beam web when the beam initiates a failure under load in the mode of a buckling failure.
Uses and Advantages of the Present Invention
The present invention may be used in steel frames for new construction as well as in retrofitting, or modifying, steel frames in existing structures. The specific features of the present invention, such as column slots and beam slots, and their location will vary from structure to structure. In general, the present invention finds use in the column web to beam flange interfaces where stress concentrations, as well as strain rate effect due to the stress concentrations, during high loading conditions, such as during earthquakes, are expected to reach or exceed failure. Identification of such specific connections in a given structure is typically made through conventional analytical techniques, known to those skilled in the field of the invention. The connection design criteria and design rationale are based upon analyses using high fidelity finite element models and full scale prototype tests of typical connections in each welded steel moment frame. They employ, preferably, program Version 5.1 or higher of ANSYS in concert with the pre-and post processing Pro-Engineer program. These models generally comprise four node plate bending elements and/or ten node linear strain tetrahedral solid elements. Experience to date indicates models having the order of 40,000 elements and 40,000 degrees of freedom are required to analyze the complex stress and strain distributions in the connections. When solid elements are used, sub-modeling (i.e., models within models) is generally required. Commercially available computer hardware is capable of running analytical programs that can perform the requisite analysis.
The advantages of the invention are several and respond to the uneven stress distribution found to exist at the beam flange/column flange connections in typical steel structures made from rolled steel shapes. Where previously the stress at the beam weld metal/column interface was assumed to be, for design and construction purposes, at the nominal or uniform level for the full width of the joint, the features of the present invention take into account and provide advantages regarding the following:
1. The stress concentration which occurs at the center of the column flange at the welded connection.
2. The strain levels in both the vertical and horizontal orientations across the welded joint.
3. The very high strain rams on the conventional joints at the center of the joint as compared with the very low strain rates at the edges of the joint.
4. The vertical curvature of the column and its effect on the conventional joint of creating compression and tension across the vertical face of the weld.
5. Horizontal curvature of the column flange and its effect on uneven loading of the weldment.
6. The features of the present invention can be applied to an individual connection without altering the stiffness of the individual connection.
7. Conventional analytical programs for seismic frame analysis are applicable with the present invention because application of the present invention does not change the fundamental period of the structure as compared to conventional design methods.
The stress in the conventional design without continuity plates in the column has been measured to 4 to 5 times greater than calculated nominal stress as utilized in design. With the improvements installed at a connection, we have shown a reduction in stress concentration factor at the "extreme fiber in bending" to a level of about 1.2 to 1.5 times the nominal design stress value. An added enhancement in connection performance has been created by elimination of a compression force in the web side of a flange which is loaded in tension. The elimination of this gradient of stress from compression to tension across the vertical face of the weld eliminates a prying action on the weld metal.
Example of Use of the Present Invention In Mathematical Models
Using a finite element analysis described above, several displacement analyses were performed on beam to column connections incorporating various features of the present invention, as well as on a conventional connection. Displacement of the edges of the column flanges and beam flanges was determined with the ANSYS 5.1 mathematical modeling technique.
Referring to FIG. 16, a display of the baseline displacement of the beam flange and column flange at a beam to column connection is shown for a conventional beam to column connection under given loading conditions approximating that which would occur during an earthquake. Line 234 represents the centerline of a column flange, with region at 236 being at the connection to a beam flange. Region 238 is near column flange centerline at some vertical distance away from the connection point of the beam to the column. For example, if region 236 represented a connection at an upper beam flange, then region 238 is a region near the column flange vertical centerline above the beam to flange connection. Line 240 represents a column flange outer edge. Line 242 represents the centerline of the connected beam flange and line 244 represents the beam flange outer edge. Referring to FIG. 17, a side perspective view of a conventional beam 246 to column 248 connection, the column centerline 234 is shown with region 238 vertically above the connection point center at 236. Similarly, beam flange centerline 242 is shown extending along the beam flange, in this case the upper beam flange, which is at the connection of interest. Outer column flange edge 248 and outer beam flange edge 244 are also shown. The distance "a" between the left vertical line 240 and the right vertical line 234 generally indicates the displacement of the flange edge during imposed loading. Thus, a great distance between the two lines indicates that there is a significant displacement of the edge 240 of the column flange compared to the column flange along its vertical center line 234 during the given loading event. Similarly, the distance "b" between beam center line 242 and the flange edge 244 is a measure of the displacement of the edge 244 of the beam flange from the center line 242 of the beam flange along its length from the column. FIG. 16 view shows the displacement for a conventional column 248 to beam 246 connection, not including any features of the present invention.
Referring to FIG. 18, a view of the displacement for a beam to column connection having a beam slot with a continuity plate is shown. In FIG. 18, area 250 represents the beam slot. Line 252 represents the column flange edge, line 254 represents the column center line, line 256 represents the beam flange edge and line 258 represents the beam center line. Distance "c" represents displacement of column flange edge from centerline and distance "d" represents displacement of beam flange edge from beam flange centerline during the loading condition. The distances "c" and "d" represent significant displacements of the edges of the column of angle and beam flanges compared to that of the column and beam centerlines separately. As is readily apparent in comparing the distance "a", FIG. 16, to distance "c", FIG. 18, and distance "b" to distance "d", the amount of displacement is significantly less in the case where the beam slot is employed in the steel structure. The reduction of displacement in flange edges between the conventional connection and the connection with beam slots indicates the forces imposed during the loading event are more evenly absorbed in the connection with the beam slot.
FIG. 19 is a view of the displacement of column and beam flange edges in a connection having beam and column slots as well as continuity plate for a W 14×176 column, connected to a W 27×94 beam. Region 260 represents the column slot, as described in greater detail above with reference to FIG. 9, 10, and 12 and region 262 represents a beam slot as described more fully above with reference to FIG. 9 and 11. Line 264 represents the column flange edge, line 266 represents the column center line, line 268 represents the beam flange edge and line 270 represents the beam flange center line. As is also readily apparent, the distance between the two vertical lines 264 and 266 and the distance between the two generally downwardly sloping, horizontal lines 268, 270, represent significantly less displacement between the edges of the flanges and the center line of the flanges for a connection having a column slot, beam slot and continuity plate than compared to the flange edge displacement in a conventional connection. This reduced displacement, as discussed above, indicates that the connection having beam and column slots with a continuity plate is able to more uniformly absorb the forces applied during the loading than is the conventional connection.
FIG. 20 illustrates buckling of a beam having the double beam slots of the present invention. Standard W 27×94 beam 272 includes lower first beam slot 274 and second, or double beam slot 276 as shown. Corresponding upper first and second beam slots are included in the analysis, but are not shown in FIG. 20 because they would be hidden by the overlapping of the upper beam flange. These double beam slots are as described above in regard to FIG. 14. Buckling of the beam is shown at region 278, the plastic hinge, in the upper beam flange, with the flange being deformed downward into a generally U-shape or V-shape. In the web of the beam deformation takes the shape of a region 280 of the web being forced out of its original plane and into a ridge, extending out of the page, as indicated in FIG. 20. As shown, the plastic hinge point is in the region of the web above and below the second upper and lower beam slots rather than at the beam to column connection itself.
FIG. 21 is a graph of a hysteresis of a beam to column connection incorporating upper and lower column slots and upper and lower beam slots of the present invention, as shown in FIG. 9. The "hysteresis loop" is a plot of applied load versus deflection of a cantilever beam welded to a column.
Referring to FIGS. 25 and 26, it has been discovered that the column 308 exhibits vertical and horizontal curvature due to simulated seismic loading. Due to the vertical curvature of the column flange 316, the beam 310 is subjected to high secondary stresses in the beam flanges 312 and 314. In addition, it has been discovered that horizontal curvature of the column flange 312 occurs due to the tension and compression forces in the beam flanges 312 and 314. Sharp curvature occurs in the beam flanges 312 and 314, which includes prying action in the beam flange 312 and 314 to column flange 316. The stresses converge toward the column web 318 and are highest in region 320. The purpose of the beam slot is to minimize the contribution of the vertical and horizontal curvature of the column flanges.
While the present invention has been described in connection with what are presently considered to be the most practical, and preferred embodiments, it is to be understood that the invention is not to be limited to the disclosed embodiments, but to the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit of the invention, which are set forth in the appended claims, and which scope is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures which may be applied or utilized in such manner to correct the uneven stress, strains and non-uniform swain rates resulting from lateral loads applied to a steel frame.
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The present invention relates to improvement of strength performance of connections in structural steel buildings made typically with rolled structural shapes, specifically in beam-to-column connections made with bolt or riveted weld web connections and welded flanges, to greatly reduce the very significant uneven stress distribution found in the conventionally-designed connection at the column/beam weld, through use of slots in column and/or beam webs with or without continuity plates in the area of the column between the column flanges, as well as, optionally, extended shear connections with additional columns of bolts for the purpose of reducing the stress concentration factor in the center of the flange welds.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
FIELD OF THE INVENTION
This invention relates to articles used to secure closures of wall openings against the force of an explosion. More particularly, the invention is concerned with an energy absorbing element for wall openings.
BACKGROUND OF THE INVENTION
With security being an increasing concern, many methods have been utilized to reduce the potential occurrence of injury and damage due to the force of explosions. In particular, protection is desired against inward (i.e., away from the direction of the explosion) displacement of the frame of a window or door due to the blast. Typically, protection from explosions has been provided by the use of passive barriers, such as steel reinforced doors and laminated windows. In order to maintain an adequate level of protection, as the risk has historically increased, new barrier systems have increased in weight, thickness and structural and material complexity. While this may be acceptable in certain situation where ascetics are not a concern, such a bank vault or the like, in uses such as residential homes or office buildings requiring such protection, such solutions are inadequate. In addition, they may draw attention to the high security of the building, rendering it a target for an attack.
U.S. Pat. No. 6,922,957 discloses an opening in a building wall closed by a building closure such as a window or door. A mounting part of the closure arrangement is received in a space between two countersupport surfaces formed by a U-channel or opposite L-members that protrude perpendicularly from the sill or jamb surface of the wall bounding the opening. Mounting brackets secure the U-channel or L-members to the wall. On one or both sides, a respective damping element is interposed between the mounting part and the respective adjacent countersupport surface. The damping element may be a plastically deformable metal strip. When an explosion force acts on the closure arrangement, the damping element is first plastically deformed to absorb energy, before the remaining force is transmitted into the building wall. The two damping elements on opposite sides damp forces from the positive and negative pressure waves of the explosion.
U.S. Pat. No. 6,216,401 discloses a blast resistant window framework and elements thereof. It describes the construction of the sash section for holding a window pane, being capable of effectively withstanding blast pressure if applied to it. This being achieved by the sash section comprising a main member enabling inter-engagement between the profiled sash member and the outer frame; a window pane holding member for accommodating and securing an end section of window pane in said sash profiled member; a reinforced member designed to support the end portion of the window pane and transmit blast pressure, if incidentally applied to the window pane, to the main member. The structured being resilient to blast pressure due to the applied blast pressure being transmitted to the main member, which deforms to utilize the energy. The sash section may be a profiled body or be composed of multiple inter-engaged segments.
SUMMARY OF THE INVENTION
According to one aspect of the present invention, there is provided an energy absorber used to secure the closure of an opening of a wall of a building from being blown inward from the force of a blast, such as one caused by a nearby explosion.
It should be noted that hereafter in the specification and claims, the term closure is meant to denote a member fitted within the opening formed in a wall, including, for example, a door or a window.
The wall comprises, at each opening, a perimeter surface facing the opening, and a closure substantially filling the space of each opening. Each closure has edges which are substantially parallel to said perimeter surface of the wall. The energy absorber has a planar wall connecting portion, a planar closure connecting portion, and a plastically deformable deforming surface therebetween. The connecting portions are substantially parallel to one another. The deforming surface is adapted to absorb, by plastic deformation, a force applied to the closure by the blast.
The energy absorber may be formed as a metal plate. It may further comprise slots formed along the plate. One of the slots may extend longitudinally along a central axis of symmetry of the absorber. The slot is centrally located along the length of the absorber parallel to the axis and, according to a particular design, is more than two thirds the length of the absorber.
According to one embodiment, the energy absorber is mounted such that the longitudinal slots extend parallel to the perimeter surface and to the respective edge and according to another embodiment the energy absorber is mounted such that the slots are perpendicular thereto.
The energy absorber may comprise two or more through-going apertures, disposed about an axis of symmetry thereof. They may optionally be disposed symmetrically thereabout. In addition, it may further comprise two additional through-going apertures, disposed symmetrically about a different axis of symmetry of the absorber. The apertures are for attachment of the absorber to the wall and the closure by inserting a fastening element therethrough.
According to another aspect of the present invention, there is provided a method of securing a closure to an opening in a building wall. The method comprises the steps of providing an energy absorber as described above, and securing the absorber to the opening and the closure such that is lies substantially parallel to facing surfaces of the wall and closure. In this way, a force applied of the closure will be absorbed/wasted by plastic deformation of the absorber.
The absorber may be secured to the closure such that a longitudinal axis thereof lies substantially parallel to the plane of the closure. Alternatively, it may be secured to the closure such that a longitudinal axis thereof lies substantially perpendicular to the plane of the closure. In such a case, it may be bent substantially into a J-shape.
According to a further aspect of the present invention, there is provided a closure for a wall opening installed according to the above method.
BRIEF DESCRIPTION OF THE DRAWINGS
In order to understand the invention and to see how it may be carried out in practice, embodiments will now be described, by way of non-limiting examples only, with reference to the accompanying drawings, in which:
FIG. 1 is a perspective view of an energy absorber according to the present invention;
FIG. 2 is a partial view of a typical window, with the absorber illustrated in FIG. 1 secured thereto;
FIG. 3A is a top close-up view of one of the absorbers secured to the window as illustrated in FIG. 2 ;
FIGS. 3B and 3C are cross-sectional views taken along lines III-III and IV-IV in FIG. 3A , respectively;
FIGS. 4A and 4B show examples of plastic deformation of absorbers;
FIG. 5 is a partial view of a the window illustrated in FIG. 2 , illustrating another method of securing the absorber illustrated in FIG. 1 thereto;
FIG. 6A is a top close-up view of one of the absorbers secured to the window as illustrated in FIG. 5 ;
FIG. 6B is a cross-sectional view taken along line V-V in FIG. 6A ;
FIG. 7 is a partial view of a the window illustrated in FIG. 2 , illustrating still another method of securing the absorber illustrated in FIG. 1 thereto;
FIG. 8A is a top close-up view of one of the absorbers secured to the window as illustrated in FIG. 7 ;
FIG. 8B is a cross-sectional view taken along line VIII-VIII in FIG. 8A ;
FIG. 9 illustrated a method of securing the absorber illustrated in FIG. 1 to a wall when the wall, in the immediate vicinity of the window, is made of a soft material; and
FIG. 10 illustrates a method of securing one or more absorbers illustrated in FIG. 1 to a wall in a cable catch system.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
As illustrated in FIG. 1 , there is provided an energy absorber, generally indicated at 10 . The absorber 10 comprises mounting apertures 12 a , ancillary through-going apertures 12 b , a first slot 14 extending a majority of the length of the absorber and located centrally along its width, and several secondary slots 16 . As seen, the first slot 14 extends in a direction perpendicular to an axis X, which extends between the two mounting apertures 12 a , and has a length which is greater than the distance between them. The absorber 10 is made of a material which deforms when subjected to high forces, such as those typical from an explosion. The absorber may be of any suitable thickness, but is typically within the range of between 0.5 to 3 mm.
During installation, several absorbers 10 are mounted to the jamb 18 of a window 20 , as illustrated in FIG. 2 . As seen in more detail in FIG. 3A , it is fastened by means of a fastener 22 , such as a screw or other suitable hardware, inserted through one of the mounting apertures 12 a and into the jamb. As seen in FIGS. 3B and 3C , the side of the absorber 10 , opposite that side which had been fastened, is raised, as permitted by the first slot 14 . Another fastener 22 is secured to the surface 24 of the wall which faces the opening into which the window is to be installed. In order to permit this, holes (not illustrated) may be provided in the window jamb 18 in order to provide access to the fastener while securing the absorber 10 to the wall.
It should be noted that when installing the window, the side of the absorber 10 which is fastened to the window should be closer to the interior of the structure, and the side of the absorber which is fastened to the wall should be closer to the exterior of the structure. This assumes that the explosion is expected to occur exterior to the building. When the absorber is being installed in order to protect from an explosion expected to occur in the building interior, the above should be reversed. If it is not known where an explosion will occur, or if explosions are expected in both the building interior and exterior, the number of absorbers could be doubled, with half being installed in one direction, and half in the other.
When an explosion happens in the vicinity of the windows, the building wall is typically able to withstand the force resulting from the blast. However, the window is pushed out of place by the force of the explosion. As it moves, it pulls the absorber 10 along with it, causing plastic deformation thereof. FIGS. 4A and 4B illustrated typical effects on the absorber 10 . (It should be noted that the absorbers illustrated in FIGS. 4A and 4B are of a slightly modified embodiment, which do no comprise ancillary through-going apertures 12 b .) The energy expended in the plastic deformation of the absorbers 10 reduces the amount of energy available to dislodge the window. Therefore, displacement of the window is minimized, and building fenestration is preserved.
The absorber 10 may also be utilized when the geometry of the window and/or the wall does not permit installation as described above. As illustrated in FIGS. 5 through 6B , the absorber 10 may be fastened to the window jamb such that it lies perpendicular thereto. A fastener 22 is inserted through one of the ancillary through-going apertures 12 b and secured to the window jamb 18 . The absorber 10 is bent slightly as illustrated in FIG. 6B , and secured to the surface 24 of the wall which faces the opening into which the window is to be installed. An explosion on the exterior of the building will cause the absorber 10 to plastically deform under compression, crushing it.
If desired, the absorber 10 may be bent into a J-shape after being secured to the window, as illustrated in FIGS. 7 through 8B . This may be useful in a situation when installation such as illustrated in FIGS. 5 through 6B is desired, but the available space is limited.
In order for the absorber to be effective, it must be secured to a solid portion of wall. However, there arise situations when it is desired to place the window above a relatively soft portion of construction, such as wood. In such a case, the absorber 10 may be installed as illustrated in FIG. 9 . The absorber 10 is secured to the window 20 with a fastener 22 in accordance with the present invention. A solid plate 32 is secured to the surface 24 of the solid portion 34 of the wall, such that a free end overhangs the soft portion 28 thereof. The absorber 10 is secured to the free end of the plate by an auxiliary fastener 30 . The absorber works in the same way as described above. It should be noted that the solid plate 32 is not expected to deform substantially in the event of an explosion.
The absorber 10 may further be used in a cable catch system, wherein taut cables are installed between opposite walls, or between a floor and a ceiling, behind a window. Thus, in the event of an explosion, the cable or cables prevent the window from being propelled inwardly. The area of attachment of such an arrangement to the wall (or ceiling/floor), and incorporating the absorber 10 according to the present invention, is illustrated in FIG. 10 . As seen, the cable 38 is secured to a first leg 40 a of a first L-bracket 40 , and a first leg 42 a of a second L-bracket 42 is attached to the surface 24 of the wall which faces the cable. Two absorbers 10 are attached to the second legs 40 b , 42 b of the L-brackets 40 , 42 . Optionally, a plate 44 may be provided between the two absorbers 10 , instead of the second leg of one of the L-brackets, with the L-bracket being fastened to the side of one of the absorbers, as shown in FIG. 10 . A covering 48 may be provided to conceal the absorber arrangement.
Those skilled in the art to which this invention pertains will readily appreciate that numerous changes, variations and modifications can be made without departing from the scope of the invention mutatis mutandis.
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An energy absorber for use in an opening of a wall of a building, the opening defined by a perimeter surface, the wall supporting a closure substantially filling the opening, the closure having respective edges which are substantially parallel to the perimeter surface of the opening. The energy absorber having a planar wall connecting portion, a planar closure connecting portion and a plastically deformable deforming surface therebetween. The connecting portions being substantially parallel to one another and, the deforming surface adapted to absorb, by plastic deformation, a force applied to the closure.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
A transfer joint of this type is known e.g. from East German Pat.DL-PS No. 55,868. This proposes a dish-shaped or ball-shaped transfer joint of material which can be cast or moulded and which should advantageously be non-metallic. Bushes with internal threads or thread bolts are inserted in the joint to enable it to receive appropriate bars. The joint is made by placing the connecting pieces such as bushes or thread bolts in a and mould then filling the mould with casting material or by moulding in the connecting pieces as inserts in a mouldable material with the aid of the mould.
The disadvantage of such a joint is that although the grouting materials in question have good resistance to pressure they have only relatively slight tensile strength. This means that such joints can only be used when one is sure that the bars connected by them have only to absorb weak tensile forces.
Another drawback of such joint is that it requires special connecting pieces and appropriate shaping of the ends of the bars, usually in the form of thread bolts. This involves a corresponding outlay on production and also makes assembly more difficult, since it can only be carried out in accordance with a suitably detailed plan if bars threaded at both ends are used.
SUMMARY OF THE INVENTION
The object of the invention is to provide a transfer joint which is suitable both for bars which are heavily loaded in compression and bars which are heavily loaded in tension, and where no special connecting pieces are required.
According to the invention this is achieved in that the joint member comprises a metal casing which forms the casting mould for the grout and which contains holes for insertion of the bars before the grout has set, and that casing has a rigid connection with the hardened grout, which enables forces to be transferred through the transfer joint.
The rigid connection between the grout and the metal casing is achieved by loading the grout in compression even when the bars are loaded in tension. A pressure cone forms in the part of the grout surrounding the tensioned bar and rests against the interior of the casing, causing the casing to absorb the tensile forces. However, compressive loads on the grout can also be increased since the casing prevents any migration of the grout in a plane perpendicular to the direction of the force.
Another advantage of the joint according to the invention is that the bars can be rapidly and securely linked with the joint members on the building site and that no complicated assembly plan is required to construct a rigid frame since, as e.g. in the case of a welded construction, it is immaterial which end of the bar is inserted in the corresponding joint. It is an advantage to provide the ends of the bars with recesses and/or projections in order to achieve a positive connection between the bars and the grout. In such cases and in the case of bars of a noncircular cross-section or even of a cross-section which increases towards the end, it is helpful to provide circular holes in the casing and to insert centering discs, preferably of divided construction, in these holes. Divided centering discs may be mounted in a radial direction on the bar already inserted in the casing and then pressed or screwed into the hole.
Centering discs provide a suitable guide for the bars and prevent the grout from flowing out, particularly in the case of non-circular bars.
If relatively large joint members are required and particularly if grouting materials of low tensile strength are used, it is advisable to fit reinforcements, which are preferably joined to the casing, during the manufacture of the joint member. Strength can be increased in this way. The internal surface of the hollow member may also be provided with elements appropriate to transfer forces, so that a clamping effect can be obtained between the grout and the hollow member as in a "composite construction".
The grout may consist of plastics, particularly fibreglass-reinforced plastics, high grade concrete or plastic mortars, possibly reinforced with asbestos fibers or with granulated metal, solder metals, glass and similar materials added to them. The grouts may be cast in by the action of gravity or injected under pressure.
For example, for joints which are entered predominantly by pressure bars -- in addition to bars loaded moderately in tension, inserted to considerable depth and with their ends shaped to allow a positive connection to the grout -- as in the case with single-shell bar grating cupolas and single-shell bar grating domes, it is possible to use conventional concrete mortar with a compressive strength from 600 to 800 kp/cm 2 after 28 days'hardening. The composition of such a mortar might comprise e.g. 1 part by weight high grade Portland cement (preferably Austrian Standard PZ 475), 2.5to 4 parts by weight of sand within grain limits 0.06 to 2 mm, which may be stirred with about 0.6 part by weight of water. In order to increase resistance to shearing, part of the coarse-grained parts of the sand, of grain size 1 to 2 mm, may be replaced by equal proportions (by volume) of granulated steel. Depending on requirements, optimum mixing ratios and screen lines may be planned for each specific case by testing samples for suitability.
The concrete mortars can preferably be injected into the casing at fairly high pressures instead of being poured in, in order to obtain a casting which is (a) as far as possible free from shrinkage because of the low water content and (b) as far as possible free of air pores.
For joints with bars which are highly loaded in tension specially shrink-proof mortar mixtures must be used if a suitably strong bond is to be obtained between the grout and the casing. For ecample, a cememt mixture in accordance with Austrian Pat. No. 298,321 may be used for such a purpose, although other shrink-proof concrete cement mixes on the market are also suitable.
A plastics mortar, preferably based on epoxy resin, may be used instead of concrete mortar. A plastics mortar of this type comprises e.g. a bonding agent making up 15 to 20% of the volume. The bonding agent is blended with and binds quartz sand, the grain distribution of the sand being graduated in accordance with control screen lines and part or all of the sand being replaced by granulated steel, depending on the modulus of elasticity desired. The quartz sand and/or granulated steel fillers preferably have a grain size up to about 3 mm, their function being to improve the modulus of elasticity, creep behaviour, temperature resistance and the favourable effect on reaction shrinkage. Granulated steel
The epoxy resin "Araldit GY 254", manufactured and marketed by Messrs. Ciba-Geigy AG of Basle, may be used e.g. as the bonding agent together with hardeners "YB 2606" or "YB 2625".
With the transfer joints according to the invention a plurality of load-bearing members may be joined at different angles enabling tensile and compressive forces as well as bending moments to be transferred. The joints may be used inter alia for multiple-chord skeleton girders, skeleton plates, rigid three dimensional frames, rigid grating frames, skeleton barrels, folded skeleton structures, single and multiple-layer skeleton cupolas and rigid frame cupolas, bar grating bearing structures and plane bearing structures.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be further explained with reference to the accompanying drawings, wherein:
FIG. 1 is a section through the casing of a joint member according to the invention,
FIG. 2 is a section through a transfer joint according to the invention
FIGS. 3, 4, 5, 8, 9 and 10 illustrate embodiments of the end portions of the bars according to the invention, and
FIGS. 6 and 7 are examples of the construction of centering discs according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
The casing 1 of a joint member according to the invention is shown in section in FIG. 1. Attachments 3 and 4 to improve the clamping of the casing to the grout are shown in the upper half of the Figure, and an example of the insertion of a reinforcement 5 is shown in the lower half. Attachment 3 has a free end which is divided, and the attachment is welded to the inside of the casing 1. The attachments for clamping the grout to the casing 1 may be shaped differently, e.g. like the attachment 4 in FIG. 1 where the shank also has a spiral 4' wound around it, thus providing a very good clamping action.
The reinforcement 5 comprises concentric rings connected by bridges. In order to obtain particularly high strength, reinforcement 5 is joined to the casing 1 by struts 6. The reinforcement 5 is inserted and/or joined to the casing 1 during the manufacture of the casing, which may have any shape. Reinforcements are appropriate particularly when the transfer joints are heavily loaded and when the grouts used do indeed have good resistance to compression but only poor tensile strength as in the case of conrete mortar.
The bars 8 are inserted in the joint member through holes 2, one hole being left free and acting as a pouring aperture 7. It is of course also possible for highly stressed bars to be guided through the joint member.
When the bars, which may be of any cross-sectional shape, have been inserted in the joint member, the joint member is filled by pouring grout into it or injecting it under pressure. It is an advantage to use grouts which will not shrink during hardening but which will rather expand. Where hot-cast materials are used it is an advantage to make the casing of a material which will expand more, at the casting temperatures used for the grout, than the grout will shrink during setting, so that the casing 1 will always be loaded in tension. The use of grouts which increase in size relative to the casing 1 also produces high adhesive stress at the bars 8 and consequently high resistance to extraction, so that the transfer joint can be appropriately loaded in tension. In the case of pure pressure or bending connections on the other hand, the bars are supported by having their ends or side surfaces seated on the cast member.
If the joint is exposed to high tensile forces it is an advantage to have not only a non-positive but also a positive connection between the bars and the grout. Examples of how the ends of the bars may be shaped in order to provide a positive connection between the bar 8 and the grout are shown in FIGS. 3, 4, 5, 8, 9 and 10. In the FIG. 3 example the end of the bar 8 is provided with a head which has raised portions 10 and recessed or lowered portions 11, the height of the raised portions 10 decreasing from the end towards the centre of the bar. A centering disc 9 is provided to centre the bar 8 in the hole in the casing 1. The disc 9 is either of divided construction or consists of one piece which is pushed onto the head of the bar before it is forged together.
If the bars 8 are tubular they must be sealed before the joint member is cast. This can be done, e.g. as shown in FIG. 4, by using an end piece 12 which is inserted in the tube and joined to it. The free end of the piece 12 is provided with corrugations 21 in order to achieve a positive connection.
Instead of fastening a tubular bar to the outside of the casing 1 of the joint member, it is also possible for the ends of the tube to be pressed flat and bent over. It is then advantageous to use centering discs. These may either be in the form of divided discs which are placed on the ready-deformed bar in a radial direction and pressed or screwed into the hole in the casing, or they may be discs in one piece which are pushed onto the bar before the ends are deformed and which are inserted in the hole when the bar has been placed in the joint member.
With bars 8 of non-circular cross-section the use of centering sleeves 9 is again very advantageous since it avoids the necessity of the provision in the casing of apertures adapted to the cross-section of the bars. Such specially shaped apertures are very costly to produce and therefore expensive, whereas apertures for the bars 8, particularly with divided centering discs where the components can be held together by spring rings 24 as illustrated e.g. in FIGS. 6 and 7, are far easier and cheaper to obtain. In order to achieve a positive connection between the grout and a bar 8 of non-circular cross-section, it is advisable to deform the end 13 of such a bar, e.g. as shown in FIG. 5 with reference to a bar having an L-shaped profile, to slit the end portion and to spread open the profiled sections.
Other possible shapes for the ends of the bars 8 are illustrated in FIGS. 8 to 10. Thus, as shown in FIG. 8, the end of the bar 8, which is tubular, may be incised in an axial direction, the slit 25 opened out and/or the divided ends 14 bent apart. A spreading plug 19 is provided to seal the tube and maintain the spreading action. In order to obtain a local increase in the strength of the grout the bar 8 is provided with a double spiral reinforcement 20. The ends 22 of the reinforcement are looped around the spread-out ends 14 of the bar 8 and the other ends 23 of the reinforcement are anchored in the centering sleeve 9, which has corrugations 18' but which is seated in a smooth hole in the casing 1. Before it is mounted the spiral reinforcement 20 has an external diamter which is smaller than the diameter of the hole 2. When the bar 8 has been placed in the joint member, the spacing disc 9, which is seated loosely on the bar 8 and joined to the ends 23 of the reinforcement 20 fixed to the splayed-out ends 14 of the bar, is turned in the direction of the pitch of reinforcement 20. This causes the diameter of the reinforcement 20 to increase and the reinforcement to take on a pear-like shape. In this way the favourable formation of a pressure cone within the grout is achieved when tensile forces act on the bar 8.
A positive connection between the bars 8 and the grout may be obtained by mounting components on the ends of the bars instead of by deforming the bars. As shown in FIG. 9, for example, a cage 15 made of square material may be fixed to the end of the bar. This can advantageously be done in an axial direction by means of welded seams. Such seams cause virtually no reduction in the cross-section of the bar 8 and, if they are of suitable length, tensions in the seams can be kept to a minimum.
Another way of fitting components which will provide a positive connection in the end portions of the bars 8 is illustrated in FIG. 10. The bar 8 is provided with grooves to receive split rings, e.g. Seeger rings 16, and possibly with grooves 17 to improve the tension gradient in the bar 8. The use of a centering disc 9 which is provided with thread 18 and screwed into the casing 1 makes it possible for forces to be diverted into the casing 1 by way of the centering sleeve, which is positively connected to the grout and to the casing 1.
It is not always necessary for the bars 8 to be anchored in the grout with a positive connection, but it is an advantage to use bars with a relatively rough surface at least at the ends in order to obtain a good adhesive connection.
The joint members may be either open members or closed members provided with a pouring aperture, which are filled with the grout once the bars 8 have been inserted.
Transfer joints which are very rigid and resistant to bending are obtained with the joints according to the invention. This has great advantages, particularly in view of the problems of stability with single-layer bar gratings and single-layer bar cupolas, since with single loads which may cause the joints to move into the other state of stability the elbow lever action can be avoided by joints which are resistant to bending. In addition, the bar-connecting point is no longer eccentric relative to the centre of the joint in the transfer joints according to the invention. In contrast with most known transfer joints therefore, those according to the invention are not in danger of tipping, since they have no hinge points or hinge-like points outside the centre of the joint. Another advantage of the transfer joint according to the invention is that it avoids any reduction in the cross-section of the bars at the critical or connecting points.
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The invention relates to a transfer joint for rigid frames comprising a solid joint member, the interior of which is made of hardened grout and has three or more bars joined to it with a non-positive and/or positive connection.
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REFERENCE TO GOVERNMENT CONTRACTS
[0001] Not applicable.
CROSS REFERENCES TO RELATED APPLICATIONS
[0002] Not applicable.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] This invention relates to elongated cable bolts useful for installation, with cooperating resin systems, in boreholes in underground mines, to achieve ground control and, when installed in mine roofs, are useful, in combination with trussing systems, support plates and the like, for delimiting dilation of mine roofs, thereby contributing to safety of workmen and machinery and deterring mine roof collapse. In particular, the invention pertains to designing cable bolt proximal ends and torque-applying devices therefor, for permitting the application of both axial thrust and also torque to cable bolts, to thrust these into boreholes and simultaneously axially spin the cable bolts so as to mix to desired degree, and without over-mixing, the pre-implanted resin systems within the boreholes, whereby to allow the latter to cure in optimal fashion and secure properly the respective cable bolts within their respective boreholes at the bolts' distal ends.
[0005] 2. Statement of Related Art
[0006] There is a great deal of prior art in the general field of cable bolts and their design, as well as torquing equipment for cable bolts. As to the present invention, the following art is noted: the article in “Wire Rope New & Sling Technology,” p. 56 (citing U.S. Pat. No. 5,741,092), October 1998; also, U.S. Pat. Nos. 906,040; 1,590,200; 3,161,090; 3,940,941; 5,531,545 (the inventor herein being patentee); 5,511,909; 5,230,589; 5,259,703 and 5,951,064. Many additional patents and other literature are cited in these references as background, all of which are fully incorporated herein by way of reference.
[0007] The art of introducing resin system capsules in a mine borehole and then advancing these to the blind end of a borehole by a cable bolt backing the capsules is well known. The spinning of the cable bolt ruptures the capsules and mixes the resin system supplied. The mixing should continue until the resin has a particular viscosity, but should not be overmixed. Otherwise, the holding power of the resin, now disposed between the cable bolt shank and the wall of the borehole, will become lessened. Failure can occur, either when the cable bolt plus resin, pulls out of the hole when the bolt is placed in tension, or when the bolt simply pulls through the resin sleeve, or when simply the resin does not make a secure anchor with the surrounding strata of the borehole. Manufacturers specify optimal mixing time needed to achieve the viscosity desired and, hence, the point of maximum holding power. The present invention precludes the optimal mixing from being exceeded, by supplying a relief feature whereby the cable bolt is not spun further once a particular torque resistance level is reached. None of the above art and references, taken either singly or in combination, is believed to anticipate this invention as described below.
BRIEF SUMMARY OF THE INVENTION
[0008] The invention resides in the combination, and also in the individual constituents therein, of a cable bolt and a torquing tool, the latter to be secured in and revolved by conventional, installation power equipment, or simply rotated manually, whereby the cable bolt can be axially spun and thrust home, by such tool and, e.g., its power equipment, within a borehole. This is achieved by a new design of the proximal end of the cable bolt and the design of the tool by which such proximal end is engaged. Since cable bolts, owing to high-volume use, must be manufactured at low cost, reliance is made herein upon the wedge barrel of the cable bolt having an outer peripheral surface of revolution, free of radial projections, and reliance being made of either (1) designing the wedge barrel so that its outer surface is conically tapered inwardly toward said proximal end, for effecting a mutual conical frictional engagement as between the wedge barrel and the tool designed to drive the same, and/or (2) where the wedge barrel and tool have releasably inter-engaging undulations or protuberances, to effect a releasable keying of the tool to the collar, for accomplishing the spinning function, or both.
[0009] The method inherent in the invention in setting a cable bolt in a mine borehole, provided with resin, comprises the steps of: (1) providing a cable bolt having an elongated shank and a wedge barrel, provided a peripheral surface of revolution, fixed to said shank and constructed for operational, releasable engagement by a spin-and axial-thrust providing tool; (2) providing a tool constructed and dimensioned for releasably engaging said wedge barrel in a manner whereby to axially spin said wedge barrel and thus said cable bolt through a predetermined permissible torque range and automatically to interrupt such axial spin function once said predetermined torque range is exceeded; and (3) operatively releasably engaging said tool with said wedge barrel. The over-all object of the invention is to provided, in a cable bolt structure and method of installing the same in a resin-provided borehole, both the means and the method of both spinning and thrusting home a cable bolt in its intended borehole and, in doing so, mixing the resin without chancing over-mixing the same, whereby to optimize the holding power of the resin anchor for the cable bolt.
[0010] The invention, both as to its objects and advantages, may best be understood by reference to the following description, taken in conjunction with the following drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] [0011]FIG. 1 is a perspective view of a cable bolt of the present invention, showing its installation in a borehole in an underground mine.
[0012] [0012]FIG. 2 is an exploded perspective of the cable bolt and torque producing tool, with the wedge elements which are supplied the wedge barrel of the cable bolt.
[0013] [0013]FIGS. 3A, 3B and 3 C are longitudinal sections, taken along the line 3 - 3 in FIG. 1, illustrating equivalent, greater, and lesser conical interior taper of the tool of the torque producing device relative to the corresponding taper of the wedge barrel outer peripheral surface.
[0014] [0014]FIG. 4 is similar to FIG. 2 but illustrated a further embodiment wherein the proximal edge of the wedge barrel, as well as, e. g., the base interior of the tool, have mutually cooperative undulating surfaces which selectively engage for spinning the cable bolt about its central axis.
[0015] [0015]FIG. 5 illustrates the tool in engaged position relative to the undulating end surface of the wedge barrel.
[0016] [0016]FIG. 6A is similar to FIG. 3A, but illustrates the engagement referred to in FIG. 5.
[0017] [0017]FIG. 6B is similar to FIG. 6A, but now showing the structure when the wedge barrel has a cylindrical exterior peripheral surface.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0018] In FIG. 1 mine roof strata 10 is provided the borehole 11 , having resin R, which receives the cable length 12 of cable bolt 13 . Cable bolt 13 includes a wedge barrel 14 having a rounded end distal end 15 . The proximal end 16 is received by the end of tool 17 that is driven by the shank 18 of standard installation mechanism 19 . The cable length 12 proceeds through aperture 20 of support plate 21 . Mesh 22 may be provided and be secured in place by support plate 21 .
[0019] In FIG. 2 the cable bolt is seen to include a pair of wedge elements 23 each having a cylindrically formed inner surface 24 that is serrated at 25 . In their combination, the wedge elements have a combined outer frusto-conical surface made up of peripheral surface segments 26 and 27 . These aligned elements are preferably retained in place by an elastomeric O-ring 28 , see FIG. 3A, when positioned in grooves 29 and 30 . The wedge elements are received in the frusto-conical interior of the wedge barrel 14 as will hereafter be pointed out. Tool 17 may now take the form as shown at 17 A.
[0020] [0020]FIG. 3A illustrates that the distal end 15 of wedge barrel 14 is rounded so as to adjustably seat at aperture 20 of support plate 21 . The position of proximal end 16 of the wedge barrel is likewise shown. In this figure the frusto-conically tapered interior wall 32 , of tool 17 , essentially exactly matches the frusto-conical peripheral surface of revolution 31 of the wedge barrel. Thus, a full friction contact is achieved as between the inter-cooperating and matching frusto-conical friction surfaces of the tool 17 and the wedge barrel 14 . FIG. 3B illustrates the case where the interior wall at 32 , now seen as 32 A, has a more pronounced taper than that of surface 31 of the wedge barrel. This condition still enables the tool 17 to frictionally engage and rotate the wedge barrel about its axis, howbeit at a reduced inter-cooperating surface area. FIG. 3C illustrates the reverse case, wherein the taper at 32 B, if any, of the interior cavity wall, of cavity C, of the tool 17 is less than the frusto-conical taper of peripheral surface 31 of wedge barrel 14 . Here again, there will be some frictional engagement contact between a restricted wall area of tool 17 and the peripheral surface of wedge barrel 14 . The frictional drive relative to FIGS. 3B and 3C will be somewhat less than the full surface friction drive of FIG. 3A. Nonetheless, all three embodiments will function satisfactorily in accordance with specific conditions present.
[0021] [0021]FIG. 4 is similar to FIG. 2 but this time illustrates that the wedge barrel 14 may include a proximal end surface 16 having an undulating surface 16 A comprised of a series of peaks, waves or protuberances 16 B mutually spaced apart by valleys or troughs 16 C. Correspondingly, the tool 17 A may include a base 17 B provided with an upstanding undulating surface 17 C comprised of interspaced peaks 17 D separated by troughs or valleys 17 E. Accordingly, the tool may be brought into engagement with wedge barrel 14 both at the inter-cooperating frusto-conical frictional surfaces of the two and, in addition, the undulating surfaces of both parts will be brought together in a releasable, temporary, positive drive. When the viscosity of the resin R increases to an optimal point, for maximum holding power of the cable within the borehole, then the structure may be so designed such that the tool and its undulating surface will simply ride over the undulating surface of proximal end 16 A so that no further rotation of the cable bolt takes place. FIG. 5 illustrates the condition just described prior to the torque threshold being achieved, at which point the tool backs off incrementally so as not to apply excess torque and additional spin to the cable bolt. FIGS. 6A and 6D are similar to FIGS. 3B and 3C, respectively, and this time illustrate the inter-cooperation of the corresponding undulating surfaces of the tool and wedge barrel.
[0022] In summary, the friction drive contact of the tool with wedge barrel 14 may be frusto-conical in nature, whereby to provide the necessary frictional drive to spin the cable bolt and advance the same along its central axis A. The tool, wedge barrel, and their inter-cooperating frusto-conical surfaces will be designed for specific, anticipated mine conditions such that, at and above a given torque threshold, the tool will spin over and not further rotate the cable bolt when optional resin viscosity, and the resultant holding power, is reached. In some instances it may be desirable to additionally include the undulating surfaces, inter-cooperating as between the wedge barrel and the torque-supplying tool so as to provide a positive spin to the cable bolt throughout a predetermined torque threshold. However, when that threshold is exceeded, then the tool will simply back off slightly and the undulations thereof will simply click over the corresponding undulations of the wedge barrel such that no further revolvement of the of the wedge bold barrel occurs. In this invention the method, inherent in the system, is to install a cable bolt in a mine borehole provided with resin, which comprises the steps of: (1) providing a cable bolt having an elongated shank and an enlarged head, e. g., wedge barrel, provided a peripheral surface of a revolution, fixed to said shank and constructed for operational, releasable engagement by a spin-and-axial-thrust providing tool; (2) providing a tool constructed and dimensioned for releasably engaging said enlarged head in a manner whereby to axially spin said head and thus said mine bolt through a predetermined permissible torque range and automatically to interrupt such axial spin function once said predetermined torque range is exceeded; and (3) operatively releasably engaging said tool with said enlarged head.
[0023] In brief summation: Standing alone, the concept of a wedge barrel having an interior conical taper of nominally 7 degrees, with corresponding wedges therein for gripping a cable bolt length passing through the wedge barrel or collar, is well known in the art and is widely practiced in the industry. The problem, heretofore, has been forming the proximal end of the barrel or collar, or the wedge elements themselves, with a positive drive head in the form of a hex-head, square head, or other non-circular head. This results in an undesirable, continuous positive drive wherein the torque imposed to spin the cable bolt is unrelieved even though the optional point of resin mix and torque resistance is passed, resulting in a lessening of the holding power of the resin surrounding the cable length in the borehole. The present invention overcomes this difficulty by having the wedge barrel provided with an exterior peripheral surface of revolution, e. g., cylindrical or conical, which thereby does not serve as a non-circular position drive. Where such surface is cylindrical, as in the present invention, then the end, and not the sidewall, is relied upon to produce the beginning operational engagement with the torque-supplying tool, by means of inter-engaging undulating end surfaces as between the wedge barrel and the tool. Consider the more or less pronounced degree of undulation lying between 0 to 1, 0 being a smooth surface-contact and 1 being a normal or 90 degree relationship, i.e., square slots and cooperating square-formed protruberances; both of these extremes (0 and 1) the present invention avoids. Rather, the design of the undulations is between these two extremes such that slippage can and does occur automatically when a particular torque resistance threshold is reached. For some mines, both the feature above described and also to inter-engagement of frusto-conical frictional surfaces of the tool and wedge barrel may be advantageously employed. In such event, a frusto-conical taper, relative to the surface of revolution of the wedge barrel and the cooperative interior of the torque-applying tool may be desirable, as fully described above, for rotating the cable bolt by friction-drive below a torque threshold, and then permit any additional spinning the tool to occur over the non-rotating cable bolt when torque resistance, owing the the setting and viscosity of the borehole resin, exceeds a predetermined level. In all instances, the further mixing of the resin beyond its optimal threshold is discontinued.
[0024] While particular embodiments have been shown and described, it will be understood that various changes and modifications may be made without departing from the invention in its essential aspects and therefore, the aim in the appended claims is to cover all such changes and modifications as fall within the true spirit and scope of the invention.
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Cable bolt wedge barrel, installation apparatus and method, for cable bolt installation in a mine borehole provided an interior resin system, wherein the wedge barrel of the cable bolt employed, and the tool used to revolve and supply thrust to the same, are mutually designed for (1) mutual, operative, wall-friction and/or end-detent drive engagement within a given torque range for the resin system employed, as applied by said tool, and (2) operative slippage when said range is exceeded, thereby precluding the emergence of the undesirable condition of over-mixing the resin system present in said borehole and consequent diminution of the resin system's holding power relative to the cable bolt within the borehole.
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RELATED APPLICATIONS
This is a continuation of application Ser. No. 217,987, filed Dec. 18, 1980, which is a continuation-in-part of application Ser. No. 216,813, filed Dec. 16, 1980, now abandoned, which is a continuation of application Ser. No. 923,344, filed July 10, 1978, now U.S. Pat. No. 4,238,907 which issued Dec. 16, 1980, which is a continuation-in-part of application Ser. No. 758,866, filed July 10, 1978 now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to windows, more particularly to double hung windows.
In Florida, in particular, it has been found desirable to replace jalousies utilized in many residential homes by double hung windows and also to place such windows on screened-in porches. However, to make such a replacement without damage to interior plaster or paint, the double hung window must be shallow having a depth of only two inches. In addition, especially with screened-in porches, the dimensions for receipt of such windows may vary considerably from porch to porch and, moreover, between uprights in any particular porch. Such a shallow double hung window which is capable of withstanding high wind and rain storm loads without leakage or undue deformation has not been available previous to the arrangements presented in the present invention. However, as indicated, such a window would have particular utility to waterproof a screened porch wherein the screening is supported by two inch studs. The window of the invention is also useful for thin walls ordinarily utilized in cabana construction.
Pertinent prior art includes U.S. Pat. No. 3,449,869 to A. J. Biro of June 17, 1969 for a window structure. This patent is directed specifically to a sliding meeting rail interlocking device and a side stabilizer. More particularly, it is directed towards a replacement window of a type which is not, however, suitable for screened-in porches and rooms where two-by-twos are used for the framing. Also attention is invited to U.S. Pat. No. 3,358,404 of Dec. 19, 1967 to D. J. Dinsmore which is directed to a readily removable double hung window. This patent discloses a counter-balancing unit of the type utilized in the instant invention but which is not claimed herein as such, as invention. Another prior art reference is U.S. Pat. No. 3,861,444 of Jan. 21, 1975 to J. E. Portwood which is directed to an extruded plastic window frame. The Portwood patent discloses an exterior mounting flange which is on the interior of the structure and has an offset flange whereby the window protrudes from the wall, a feature which is avoided in the instant invention.
SUMMARY OF THE INVENTION
The window of the invention is essentially of metal (aluminum) construction having individual panels with frames of less than one inch in thickness, two of such panels received in guides defined by the window frame. The frames both for the individual panels and for the window, as such, are constructed of extruded aluminum which provides stringers with grooves for receiving fastening screws, grooves for providing a complete weather sealing piles, space for receiving block and tackle sash balances which serve the dual purpose of counterbalancing the indivudual window panels and providing a lateral resilient force on each window panel allowing it to be positioned with ease. The extrusions also provide completely around the window frame a flange which may abut and be received flush between two by twos on existing screen porches or other supporting structure. Further provision is made by means of a double action leaf type stop connected to the window frame for disengaging the block and sash balances whereby the individual window panels can be removed by moving same laterally in a direction towards such block and tackle balances. The window so constructed withstands water resistant tests of up to 5.5 pounds per square foot, exterior wind load tests of up to 91 pounds per square foot, and interior wind load tests of up to 60.5 pounds per square foot with deformation of only 0.015 inches.
It is therefore, a principal object of the present invention to provide a new and improved double hung window of the type described.
Another object is to provide a shallow double hung window which is only two inches in depth having the wind and water resistance described above.
A further object is to provide such a shallow double hung window wherein the frame, rails, stiles and bars are all constructed of extruded aluminum shapes.
Further objects and advantages will become apparent from the following detailed description taken in connection with the drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front elevational view of a first embodiment of the present invention;
FIG. 2 is a cross-sectional elevation drawing of the invention illustration in FIG. 1 taken along the line 2--2;
FIG. 3 is a cross-sectional plan view of a portion of the embodiment of the invention illustrated in FIGS. 1 and 2 taken along the line 3--3 in FIG. 2;
FIGS. 4A, 4B, 4C and 4D are broken perspective detailed views in partial section showing the upper and lower corner constructions of an individual panel;
FIGS. 5 and 6 are front and side view respectively of a plactic headpiece for the individual window panel frames;
FIGS. 7 and 8 are side and front views respectively of block and tackle sash balances used with each individual window panel of the invention;
FIGS. 9A and 9B are sectional side views illustrating the two positions for the double action leaf spring stop which disengages the block and tackle sash balances from the individual window panels in the position as shown in FIG. 9A;
FIG. 10 is a side view of a window frame in accordance with the invention, the sectional view shown in FIGS. 9A and 9B being taken on section lines 9--9 of FIG. 10;
FIG. 11 is a front elevational view similar to FIG. 1 of a further embodiment of the invention;
FIG. 12 is an elevational view in cross-section of the embodiment of FIG. 11 taken on lines 12--12 of FIG. 11; and
FIG. 13 is a plan view in section taken on line 13--13 of FIG. 12.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Although this invention may be embodied in different forms, there is shown in the drawings and will herein be described in detail, an embodiment of the invention with the understanding that the present disclosure is an exemplification of the principles of the present invention and is not intended to limit the scope of the invention to the specific embodiments illustrated. The scope of the invention will be set out in the appended claims.
Referring to FIGS. 1 to 3, a window frame as seen from the interior generally indicated by reference numeral 9 comprises a top frame member 10 and a sill 12 joined by vertical jambs 11 and 14 having three vertical guides each 15, 16 and 17 extending normally in jamb 14 from a back plate 14a, and guides 18, 19 and 20 similarly extending from back plate 11a, jamb 11, for receiving an upper sash generally indicated by reference numeral 21 and a lower sash generally indicated by reference numeral 22. Spacer plates 15a, 16a, 18a, and 19a extend outwardly from guides 15, 16, 18 and 19 respectively. Members of frame 9 are stiffened by "C" shaped sections 23, 24, 25 and 26, which are adapted to receive metal screws. Top member 10, sill 12 and jambs 11 and 14 are preferably constructed of extruded aluminum bars with the "C" sections being an integral part thereof.
Frame 9 has an outer surface 27 and an inner surface 28. Surface 28 includes a perimeter part 28a which extends approximately five-eights of an inch farther outwardly beyond the perimeter of inner surface 28 on each side thereof as to facilitate mounting. Upper sash 21 consists of a top rail 31, vertical stiles 32 and 33, and a middle rail 34 which are secured together to form a rectangular frame which surrounds a glass pane 35 secured thereto by horizontal retainer plates 36, 37, 38 and 39, and vertical retainer plates 32a, 32b, 33a, and 33b. Such plates as indicated are integral extruded portions of the respective rails 31 and 34 and stiles 32 and 33. Lower sash 22 is composed of top rail 41, vertical stiles 42 and 43, identical to stiles 32 and 33, only stile 43 being shown in FIG. 2, and a bottom rail 44 which are secured together to form a rectangular frame which surrounds a glass pane 45 secured by retainer plates 46, 47, 48 and 49 and vertical retainer plates such as retainer plates 43a and 43b of stile 43. The rails and stiles, like the frame, are extruded aluminum shaped rods generally rectangular in shape and approximately seven-eights of an inch wide. Each is reinforced by a "C" shaped stringer which is an integral part of each rail and stile as indicated by "C" stringers 51, 52, 53 and 54. A latch 60 with an outwardly extending handle 61 is rotatably mounted on the top of top rail 41. A flange 63 extends outwardly from plate 39 forming an integral part of the middle rail 34 to provide a recess 64 which receives an extending portion 65 of latch 60 to lock the window in a closed position as indicated in Figures. It has been found helpful to reinforce the connection of the top of rail 34 and flange 63 by at least one metal screw 62 opposite or near where portion 65 is received in recess.
Inner surface 28 of frame 9 extends upwardly above sill 12 to overlap the bottom rail 44 of sash 22 as illustrated in FIG. 2. A flange 70 is mounted as an integral part of bottom rail 44 to extend inwardly over inner surface 28 of frame 9 whereby flange 70 may be utilized to raise and lower sash 22. Another flange 71 which forms an integral part of bottom rail 44 extends downwardly to mate with a central horizontal section 72 of the sill 12. A seal 74 is provided between flange 71 and rail sill 12 to provide a moisture and air barrier in a manner well known to those skilled in the art. Seal 74 is received in an extruded pocket 75 which is formed integral with sill 12.
With the thickness of the sashes being approximately seven-eights of an inch, the frame has a total depth of two inches. Perimeter part 28a which extends farther outwardly relative to outer surface 27 of frame 9 by about five-eights of an inch provides an easy method of mounting the shallow hung window while at the same time giving a pleasing appearance.
FIGS. 4A, 4B, 4C and 4D illustrate the corner arrangement of the upper sash 21. Except for minor differences, the structure at the corners of the lower sash 22 are identical. Thus, it will be noted from FIG. 4A, the top rail 31 is provided with a rectilinear shaped notch 66 which receives the top of the vertical stile 33 just under and flush with the headpiece 77. It will be noted from FIG. 3, as well as FIG. 4B, stile 33 is provided with a rectangular extruded part 80 which surrounds a groove 81 of rectangular cross section which receives a pile strip 82. Retainer plates 33a and 33b extend outwardly in a parallel relationship from the other side of vertical stile 33. Glass pane 35 is provided with wrap-around marine-type vinyl glazing 84 which is received within plates 36 and 37 and 33a and 33b. A bore 85 is provided on the interior face of vertical stile 33 which receives a self-threading screw 83 adapted to be threadably received within stringer 51 thus creating its own screw thread and drawing stile 33 against rail 31 within notch 66 whereby plates 33a and 33b grasp glazing 84 and engage retainer plates 36 and 37 to provide a strong 90° corner structure for window panel involved. With reference to the lower corner as indicated by FIGS. 4C and 4D, a further notch 68, similar to notch 66, is provided in rail 44 which receives the lower part of stile 33. Rail 34 is somewhat different from rail 44 in that it includes an extrusion part 86 of rectangular cross section which defines a groove 87, also of rectangular cross section, for receipt of a pile strip 90 similar to strip 82. Due to the presence of part 86, a recess 91 (actually an opening) is ground into the lower part of the stile 33 for receiving in a reasonably snug fashion part 86. Further, a bore 92 is provided in the interior face of stile 33 which is adapted to receive a self-threading screw similar to screw 83 which threads itself into the interior of stringer 52 whereby stile 33 is firmly secured within notch 66 and plates 33a and 33b grasp glazing 84 thus completing the corner construction as indicated in FIGS. 4C and 4D. It will be appreciated, as seen in FIGS. 4A, 4B, 4C and 4D, the lefthand corner arrangements are essentially mirror images of those illustrated thus completing the frame for the window panel identified as sash 21. As previously indicated, the window frame for sash 22 is practically identical to that illustrated in FIGS. 4A-4D. But, there is, of course, no necessity to provide a recess such as recess 91 in the vertical stiles involved inasmuch as lower rail 44 does not include a part similar to part 86. Further, the inclusion of flanges 70 and 71 in rail 44 and also flange 63 adjacent rail 34 do not obscure the essential arrangement of components at the corner, flange 71 being co-extensive with the vertical sides of rail 44.
Headpiece 67, received in the top of each of vertical stiles, includes a bore 85a which, when headpiece 67 is snugly received flush against the top of stile 33, it matches with the bore 85 to receive screw 83. Thus, headpiece 67 is secured firmly to vertical stile 33 and also to top rail 31 by screw 83. Headpiece 67, which is preferably composed of a hard wear resistant integral plastic part, is provided with a cap 94 which extends outwardly beyond the sides of vertical stile 33 and is flush with the sides of top rail 31 that define notch 66. It also includes a wedge shaped lower part 95. A protruding portion 88 is provided on the inward facing side of headpiece 67 to be received between guides 89 of the vertical stiles.
Block and tackle sash balances 96 as shown in FIGS. 7 and 8 are disposed between the vertical stiles such as stile 33 and stile 43 and back plate 14a. Each balance 96 includes an elongated rod 97 having a U-shaped cross section with a bolt 100 affixed in place across the upper end thereof. Spaced a short distance below bolt 100 is a further bolt 101 to which is connected a tension spring 102 that includes at its opposite ends a hook 104 to which is connected a pulley support 105. This support 105 rotatably supports a pair of pulleys 106 and 107 which form part of a block and tackle structure 110. Structure 110 includes also a lower pulley support 111 which rotatably supports a pair of pulleys 112 and 114 and a central pulley 115. A cable 116 is secured at one end to the lower portion of upper support 105 at location 117. Thereafter cable 116 is received by each of pulleys 106, 107, 112 and 114 in a manner well known in the art to form a block and tackle, the end of which terminates with a hook member 120 where cable 116 is received by pulley 115.
Balance 96 includes an upper stop member 121 and a lower biasing member 122. Stop member 121 which is secured to the rod 97 by means of bolt 100 is wedge-shaped at the top including a planar surface 124 which extends substantially at the same angle relative to the horizontal as the angle shown in lower part 95 of headpiece 67. Stop member 121 is preferably composed of the same or similar material as that utilized for headpiece 67. Lower biasing member 122, which includes a toe portion 125 and a heel portion 126, is also made out of a similar material. It is secured to rod 97 by means of bolt 127 spaced thereabove a short distance is a bolt 130 to which is secured to the lower part of support 111.
In operation, toe 125 bears against guides 89 of vertical stile 33 or 43 as the case may be.
As seen from the side in FIG. 10, back plate 14a is provided with a pair of openings 130 and 131, opening 130 being higher and for receiving hook member 120 of balance 96 which is utilized for sash 21 whereas the lower opening 131 receives hook member 120 of balance 96 which is utilized for lower sash 22. As will be noted from FIG. 7 a tab 132, which is part of member 121, extends slightly upwardly beyond rod 97. Tab 132 cooperates with a further plastic tab 134 which extends downwardly from the outward face of each headpiece 67. Thus, with the members 120 of balances 96 in their respective openings 130 and 131, spring 102 urges member 121 upwardly whereby surface 124 engages lower portion 95 urging headpiece 67 in the associated sash laterally until the surfaces no longer are in contact whereby tab 132 engages and interlocks tab 134 so each spring 102 is urging its respective sash 21 and 22 in an upward direction. At the same time, toe 125 and heel 126 are received in the lower interior part of the vertical stile 33 and 43 again preventing more than limited movement of the stile towards the back plate 14a. Two further circular openings 135 and 136 are provided in plate 14a to allow room for a knot which connects each cable 116 to its respective support member 120. Four further horizontal slit-like openings 140, 141, 144 and 145 are also provided in back plate 14a, each set 140/144 and 141/145 to receive a separate double action leaf spring stop 142. Slits 140 and 141 and slits 144 and 145 are respectively at the same levels.
Each leaf spring stop 142 has two positions as shown in FIGS. 9A and 9B whereby when in position as shown in FIG. 9A, the spring is pulled outwardly relative to the face 14a and acts to engage member 121, thus disengaging balance 96 from headpiece 67 and the associated stile. In this position, when the sash involved (sash 21 in this particular case) is moved still further upwardly, it can then be moved laterally to the right relative to FIG. 9A so that the lower rail no longer engages member 122 and headpiece 67 no longer engages balance 96. In such, condition, the left side of the sash relative to FIG. 9A is moved whereby stile 32 for sash 21 is no longer confined by extensions 18 and 19 and thus the window panel can be removed. When each stop 142 is in position as shown in FIG. 9B, its thickness and width are such that stop member 121 straddles rather than engages same and therefore, the balance 96 continues to engage the associated sash whereby weight of the sash is balanced and at the same time, the sash cannot be removed from its corresponding groove, the grooves being defined by extensions 15, 16 and 17 on one side and and 18, 19 and 20 on the other. Stop 142 is composed of a resilient spring steel and is not stable except in the two positions shown in FIGS. 9A and 9B. However, it can be moved from one such position to the other easily by finger pressure. Thus, when in the position shown in FIG. 9A, with the corresponding sash pulled down to expose stop 142, it can be pushed to the position shown in FIG. 9B by simply pushing same by one's fingers. By the same token, when stop 142 is in the position shown in FIG. 9B and it is similarly exposed, it can be moved to the position shown in FIG. 9A by placing a fingernail or another object between the lower part of the stop 142 and plate 14a and pulling. Hence, through the cooperation of balances 96 for each sash 21 and 22 and stops 142, each sash is permitted full up and down travel with its weight being supported by the associated balance 96 and with the lateral tension also being provided thus permitting the window to be held in any desired position. With the proper structural dimensions, neither lubrication nor adjustment is required.
All of the weather stripping such as, for example, strips 82 comprises a high-density pile type weather stripping. Such stripping is available in sizes and lengths whereby it can be easily cut and inserted into groove involved.
Glazing 84 is provided with ribs 145 which cooperate with grooves 146 provided in each of the retainer plates, such as retainer plates 36 and 37, thus insuring that glazing 84 is held positively and firmly in position. Glazing 84, in turn, tightly grips panes 35 and 45 in a shock-resistant, non-rattling relationship and further provides an effective weather seal.
With frames for the individual sashes as well as the window frames as such all being extruded, the windows are easily manufactured to size quite simply by cutting the extruded frame parts at predetermined lengths according to the size required. In this connection, peripheral flange part 28a assists in locating and securing the windows to the 2×4's or otherwise by a series of screws 147 spaced around part 28a and received by the framing structure. If necessary or desired, sealing or insulating material is placed in the space formed by the surfaces 27 and 28 and frame guides 15a, 16a, 18a and 19a or the latter can be easily abraded or bent to narrow same as necessary to accommodate the framing structure. However, although this capacity exists, it is generally not necessary inasmuch as windows produced in accordance to the invention are easily accurately dimensioned according to specifications. A further advantage of the invention lies in the circumstance only eight screws are required to connect the window frame together as such; thus screws 150 (FIG. 10) are received in the stringers 23, 24, 25 and 26 in which they are self-threading and provide a strong connection for the frame. By the same token, each sash 21 and 22 requires only four screws 126 as previously described. In consequence, an entire window with two sashes may be entirely connected with a total of only sixteen screws, and then mounted to the framing structure by means of a plurality of screws 147.
Referring to FIGS. 11 to 13, the window frame of a further preferred embodiment, as seen from the exterior, is generally indicated by reference numeral 149. It comprises a top frame member 150 and a sill 152 joined by vertical jams 151 and 154. For identical or substantially identical components the same reference numerals have been applied to this embodiment as to the first disclosed embodiment in FIGS. 1 through 10. This embodiment differs from the first embodiment primarily due to modifications whereby it may be installed and secured to the exterior of the wall structure receiving the window rather than the interior as with the first embodiment. The modification is obtained by providing a wider outer surface 167 in frame 149 than outer surface 27 of frame 9 and narrowing the perimeter of the inner surface 168 as compared to inner surface 28 of the first embodiment whereby the outer surface 167 includes a perimeter part 167a which extends approximately five-eights of an inch farther outward beyond the perimeter of the inner surface 168 on each side thereof to facilitate mounting.
In addition, sill 152 is provided with an outside flange 166 and top frame member 10 is provided with a similar opposing outside flange 165. It will be noted that both flanges 165 and 166 include 90° angles and on each side of the flanges aluminum angle beams 155 and 156 are provided. Either or both of angle beams 155 and 156 may be part of the extrusions for the respective vertical jambs 151 and 154. However, at least one such vertical beam 154 and 155 and preferably both in order to minimize the number of extrusions needed to construct the window are connected to their respective jambs 151 and 154 by self-threading screws 160 received in jambs 151 and 154.
The purpose of flanges 165 and 166 together with angle beams 155 and 156 is to hold a screen 169 (shown in part in flange 166 of FIG. 12) or an outside pane for additional insulating reasons or some other type panel whereby solar radiation may be reduced, enhanced or otherwise utilized.
The peripheral flange part 167a assists in locating and securing the windows to 2×4's or otherwise by a series of screws 161 spaced around part 167a and received by the framing structure.
Except for the provision of an outer rather than an inner peripheral flange part and the provision for receiving a panel for a screen or the like in the space defined by flanges 165 and 166 and angle beams 155 and 156, the embodiment shown in FIGS. 11 through 13 is essentially identical to that shown in FIGS. 1 through 10, and has substantially the same characteristics and advantages. Except for the differences disclosed, the same parts may be used interchangeably in the embodiments.
Windows as disclosed in accordance with the invention meet or exceed all South Florida Building Codes. One such test involved an aluminum double hung window thirty-eight inches in width by sixty-four inches in height overall. The window was glazed with double strength annealed glass using channel vinyl glazing. Single pile weather stripping was provided at each frame head, frame sill and the interior of the top vent bottom rail. A double pile was provided at each vent jamb rail. Spring and pulley balances were utilized as indicated and there were no muntins or weepholes. A plastic cam lock provided at the midspan of meeting rails with a one-eight by five-sixteenths inch slot in the lip of the cam lock. One plastic guide was provided at the top of each vent jamb rail. In order to meet specifications it was required that with the water resistance test there would be no leakage at 2.86 pounds per square foot; with the exterior wind load test that the window be capable of withstanding forty pounds per square foot; and for the interior wind load test that the window be capable of withstanding twenty pounds per square foot--all to be accomplished without permanent deformation of more than 0.14 inches. The window in accordance with the invention as described above met such test results showing no leakage at 5.5 pounds per square foot in the water resistance test; bearing a load of 91 pounds per square foot in the exterior wind load test and 60.5 pounds per square foot in the interior wind load test, the permanent deformation being only 0.015 inches. As a result of the tests, the aluminum double hung window as described was approved for elevations up to one hundred feet.
As previously indicated, the terminology used in the claims should be construed not only to cover the corresponding structure described in the specification but also equivalents thereof.
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A shallow two inch deep double hung window which is sufficiently water and wind resistant to replace jalousies, which can be used in cabana walls and which fits screen porches, utilizing existing screening. Block and tackle sash balance counter balance the weight of individual panels and provide a lateral resilient action to maintain panels in position. A double action leaf spring stop for each panel selectively disengages the sash balances therefrom so that by moving a panel laterally it is removable. Window and panel frame members consist of aluminum extrusions which facilitate construction of custom windows made to selected sizes. Inside or outside flanges for securing the window to the wall structure are optionally provided.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
FIELD OF THE INVENTION
[0001] This invention relates generally to a method of trenching and, more particularly, a method of trenching below the water table in a porous formation.
BRIEF DESCRIPTION OF THE PRIOR ART
[0002] The making of trenches is as old as civilization itself. Canals and aqueducts have been built to move water from one location to another. However, at the beginning of recorded time, such channels or aquaducts were built by hand. Later, domesticated animals were used in some of the digging or trenching.
[0003] As the industrial revolution progressed, machines were used to dig or excavate trenches. The machines varied in size from a hand held walk behind machines to large earth moving devices. When encountering rock, in addition to the machines, dynamite and other blasting devices were used to break up the rock. In approximately the 1970s, milling machines with cutting teeth having carbide hardened tips were used to mill away or cut the rock. By this century, the most common way of excavation or cutting new road beds through rocky portions of the earth's crust was the use of rock milling type machines.
[0004] Similar types of milling processes were used in the excavation or digging of trenches in rock formation, except the cutting teeth would be on trenching chains rotating around a boom that could be raised and lower. One of the largest manufacturers of trenching equipment is Astec Industries, Inc. which manufactures and sells a line of trenchers under that mark Trencor®.
[0005] The Trencor® products range from walk behind trenchers, ride on trenchers, track mounted trenchers to road milling equipment.
[0006] Another large manufacturer of similar type of trenching equipment is sold under the mark Vermeer®. Again, the various types of trenching equipment sold under the Vermeer® brand range from walk behind trenchers, ride on trenchers, rock wheels, and track trenchers.
[0007] More and more trenches are now being excavated or dug in which to bury electrical cables, water pipes, sewer lines and alike. Many times the trenches being dug for public utilities are dug along existing streets or right of ways. If a trench is being dug along an existing street, it is very important there be a minimum amount of interruption with the normal traffic flow, plus a minimum clean up effort afterwards. In some areas, due to environmental constraints, the excavation or digging of the trench cannot interfere with natural habitat in the area. This means waste from the trenching may not wash off, or be disposed of, in the environmentally sensitive area.
[0008] A particularly unique environmentally sensitive area in which applicant has worked is the Florida Keys. Typically the surface of the earth is only a few feet above the water table. Because the rock in the Florida Keys is coral that has formed on the ocean floor, it is still porous. Therefore, when trenching below the water table in the porous rock, the material removed (sometimes called “spoil”) is very pliable like wet cement due to inflowing water. The wet spoil will spread over everything and is almost impossible to remove. However, in the same area when trenching above the water table, the spoil removed is relatively dry.
[0009] The problem with trenching below the water table in the Florida Keys is the wet spoil will inevitably get on everything, and despite the best efforts to clean up, some will remain. The part that remains will wash into the natural habitat surrounding the Florida Keys causing damage to the environment.
[0010] Areas other than the Florida Keys that have shallow water tables encounter the same problem of wet spoil when trenching below the water table. The wet spoil flows everywhere and is almost impossible to remove.
SUMMARY OF THE INVENTION
[0011] It is an object of the present invention to provide a method for trenching below the water table in the earth's surface.
[0012] It is yet another object of the present invention to provide for trenching below the water table in the earth's surface, yet maintaining wet spoil in the trench.
[0013] It is still another object of the present invention to excavate or dig relatively dry spoil from the earth's surface down to the water table in a first pass and excavate or dig from the water table to the completed depth in a second pass, while maintaining the wet spoil inside the trench during the second pass.
[0014] It is yet another object of the present invention to prevent spoil removed from a trench from polluting the environment, especially in areas where trenching occurs below the water table.
[0015] In an environmentally sensitive area such as the Florida Keys, a first pass is made with a trencher having a boom with a digging chain thereon. During the first pass, the boom is lowered so that the digging chain excavates or digs the trench to an intermediate depth from the earth's surface to the water table. The relatively dry spoil removed during the first pass can be moved to one side of the intermediate depth trench.
[0016] Thereafter, a second pass occurs where the intermediate depth trench is excavated or dug from the water table to a full depth trench in a second pass. During the second pass, wet spoil is dug up, but drops back into the full depth trench and is retained therein. Also, during the second pass, the belts or conveyors are tuned OFF causing the wet spoil to drop back in to the full depth trench.
[0017] Because during the first pass, the relatively dry spoil was removed from the intermediate depth trench, during the second pass, even with the expansion of the wet spoil, the full depth trench can accommodate the wet spoil even with its expansion.
[0018] In digging the trench, a predetermined line is normally followed as to where the trench will go. The trencher, which is normally a track mounted trencher, follows the predetermined line with the boom and digging chain excavating or digging along the predetermined line in a first direction to excavate from the surface to the water table. However, during the second pass, it can be by either of the following two methods.
[0019] In the first method, a second digging machine moves in the same direction with the digging chain reversed and the belts or conveyors turned OFF so that the wet spoil removed when digging from the water table to the full depth will fall back into the full depth trench. The full depth trench has enough space to accommodate the wet spoil even with expansion.
[0020] The second method is for the first digging machine after making the first pass along the predetermined line to dig from the earth's surface to the water table, simply operates in reverse, but with the belt and/or conveyors turned OFF and raised, plus the boom lowered, to dig from the water table to the full depth trench. The wet spoil drops back into the full depth trench. Again, the full depth trench can accommodate the wet spoil plus the expansion. The only problem is that in this second method, the digging is on the end of the boom which causes more vibrations back in the trencher than would be caused using the first method.
[0021] Also, during the second pass of either method, the speed of the trencher and the digging chain should be slowed down during the second pass (1) to prevent spillage of the wet spoil outside of the completed trench and (2) to provide the best trenching performance.
[0022] A third method may be used wherein the first digging machine makes a first pass along the predetermined line, but has the digging chain rotating in a counter clockwise direction so that the upwardly rotating side of digging chain digs on the downward rotation. Some of the loosened spoil will travel up the digging chain onto the belt and be removed to the side of the trench being dug. During the first pass the trench is dug from the surface to the water table.
[0023] Thereafter, the same digging machine makes a second pass in the same direction, but (1) with the boom lowered so that the trench is dug from the water table to the full depth and (2) the belt is turned OFF. By turning the belt OFF, the wet spoil will accumulate, ride up the digging chain, but will fall back into the trench. Due to a removal of a portion of the dry spoil when digging from the surface to the water table, the trench now has enough space to accommodate the wet spoil and have room for expansion.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] FIG. 1 is a side elevational view of the present method with the earth's crust being cut away to show a trench being dug.
[0025] FIG. 2A is a cross-sectional view of FIG. 1 taken along section lines 2 A- 2 A of FIG. 1 illustrating the first pass.
[0026] FIG. 2B is a cross-sectional view of FIG. 1 taken along section lines 2 B- 2 B of FIG. 1 illustrating the second pass.
[0027] FIGS. 3A and 3B are sequential side elevated views of a trench being dug in the earth's surface to illustrate an alternative embodiment of the second pass.
[0028] FIGS. 4A , 4 B, 4 C, 4 D and 4 E are sequential views showing a method of completion of a trench dug according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0029] When trenching in an area of South Florida or the Florida Keys, the surface 10 may be only a few feet above the water table 12 as shown in FIG. 1 . In the Florida Keys, most of the rock is porous coral rock that allows the water to flow therethrough. Therefore, as the tide of the ocean rises and falls, the water table 12 will rise and fall accordingly. If a hole is dug below the water table 12 , it will quickly fill up with water due to the porous nature of the rock.
[0030] In the present invention as shown in FIG. 1 , a first trencher 14 makes a first pass in the direction indicated along a predetermined line along which a trench is to be dug or excavated. The boom 16 is lowered so that the cutting teeth 18 dig into the earth's crust 20 digging and excavating an intermediate trench 22 from the surface 10 down to approximately the water table 12 . The belt 24 is lowered and rotating to remove relatively dry spoil 26 from the intermediate trench 22 to the opposite side of first trencher 14 . The belt 24 is rotating so the digging chain 28 rotates in the direction indicated by the arrows, cutting teeth 18 dig into the earth's crust to excavate relatively dry spoil 26 therefrom, which relatively dry spoil 26 will be moved to one side to a wind row 30 (see FIG. 2A ). However some of the relatively dry spoil 26 will fall down into mounds 32 on either side of the intermediate trench 22 (see FIG. 2A ).
[0031] Forward movement of the first trencher 14 is controlled by tracks 34 on either side thereof. The tracks 34 have the proper amount of rotation to maintain the cutting teeth 18 in excavating contact with the earth's crust 20 and to maintain close to optimum cutting conditions for digging the intermediate trench 22 . A better view of the cutting chain 28 with the cutting teeth 18 thereon is shown in FIG. 2A . Also, a better illustration of the removal of the relatively dry spoil 26 into wind row 30 and mounds 32 is illustrated.
[0032] If the trenching as shown in FIG. 1 is occurring in the Florida Keys, the boom 16 will have to be raised or lowered as the tide comes in or goes out, which tide causes the water table 12 to fluctuate accordingly. In other words, according to the time of day the intermediate trench 22 is dug or excavated, the depth will vary.
[0033] After the first pass by the first trencher 14 , a second trencher 36 makes a pass along the same predetermined line so that the intermediate trench 22 is dug in to increase the depth from approximately the water table 12 to the completed depth 38 to form a full depth trench 40 . However, in making the second pass and digging from the water table 12 to the completed depth 38 , wet spoil 42 is created. While the amount of water content and consistency of the wet spoil 42 varies depending upon a number of factors, it is normally very pliable and flowable. The wet spoil 42 is similar in texture to wet concrete with gravel therein.
[0034] In making the second pass with the second trencher 36 , the digging chain 44 is reversed so that the cutting teeth cut on the way down because the direction of rotation of the digging chain 44 for second trencher 36 is the opposite of the direction of rotation of the digging chain 28 of first trencher 14 , both directions being shown with the direction of the arrows. Also, the belt 48 is turned OFF and raised. The wet spoil 42 will tend to be carried upward on the boom 50 where the digging chain 44 is moving upward as is shown in FIG. 1 . In this manner, the digging action is as close to the second trencher 36 as is possible. Also, the wet spoil 42 simply falls back into the full depth trench 40 . The part of the full depth trench 40 that was the intermediate trench 22 will take care of any expansion of the wet spoil 42 after being dug from below the water table 12 to the completed depth 38 to form the full depth trench 40 .
[0035] Tracks 52 will control the forward motion of the second trencher 36 . It has been found the operation of the second trencher 36 and the rotational speed of the digging chain 44 may have to be adjusted downward to prevent wet spoil 42 from spilling outside of the full depth trench 40 . Also, by slowing the speed of the digging chain 40 and forward motion of second trencher 36 , the cutting teeth 46 will cut larger size chunks for including in the wet spoil 42 . Both the rotational speed of the tracks 52 and the rotational speed of the digging chain 44 control the spillage of wet spoil 42 from the full depth trench 40 , plus the size of the rock in the wet spoil 42 .
[0036] FIG. 2B shows an end view of the second trencher 36 along section lines 2 B- 2 B of FIG. 1 . The wet spoil 42 is retained inside of the full depth trench 40 with portions of the relatively dry spoil 26 being shown in mounds 32 and wind row 30 . The full depth trench 40 is dug from the surface 10 through the water table 12 to completed depth 38 . The digging chain 44 with the cutting teeth 46 will tend to drag the wet spoil 42 upwards, which wet spoil 42 will fall back into the full depth trench 40 due to gravity.
[0037] Referring now to FIGS. 3A and 3B , an alternative method of digging a trench below the water table 12 is shown. The trencher 54 is identical to the first trencher 14 with a boom 16 , digging chain 28 , cutting teeth 18 and belt 24 . The trencher 54 operates on tracks 34 , the same as first trencher 14 . Trencher 54 digs and excavates from the surface 10 to approximately the water table 12 in a first pass to form a first trench 56 therein. The relatively dry spoil 26 is excavated out of the first trench 56 into either a wind row 30 or mounds 32 as shown in conjunction with FIG. 2A . The trencher 54 is moving in the direction indicated by the arrow along a predetermined line where a trench is to be dug. The digging chain 28 is rotating in the direction indicated by the arrows in FIG. 3A .
[0038] After completing the first pass as shown in FIG. 3A , the same trencher 54 has the belt 24 raised, the boom 16 lowered and is operated in the opposite direction as indicated by the direction of the arrow. The digging chain 28 is rotating in the same clockwise manner in FIG. 3B as in FIG. 3A . The trencher 54 digs a second trench 58 below the first trench 56 , which second trench 58 is dug from approximately the water table 12 to the completed depth 38 . Because the belt 24 is turned OFF and raised, the wet spoil 42 falls back into the combined first trench 56 and second trench 58 . Due to the combination of the first trench 56 and second trench 58 , expansion of the wet spoil 42 is accommodated without spillage outside of the combined trenches.
[0039] One of the problems with the second pass as shown in FIG. 3B , is that the cutting by the cutting teeth 18 on the digging chain 28 is on the far end of the boom 16 . This can cause vibrations along the boom back to the trencher 54 . Also, the speed of the tracks 34 and the cutting chain 28 will have to be adjusted to accommodate the backward digging of the trencher 54 as shown in FIG. 3B . Normally the rotational speed of the tracks 34 and the digging chain 28 will have to be reduced for the second pass as shown in FIG. 3B .
[0040] If the methods as shown either in FIG. 1 or FIGS. 3A and 3B are followed, a trench can be dug below the water table in an environmentally sensitive area such as the Florida Keys without spillage of wet spoil 42 outside of the full depth trench 40 . However, normally there is a requirement to use a road surface if the full depth trench 40 is being dug in a road, before the item going in to the trench (such as electrical cables, water pipe or sewer lines) are ready to install. It may be weeks or even months later before installation occurs inside the full depth trench 40 . Therefore, referring to FIGS. 4A-4E respectively, a sequence of steps is shown so that the surface 10 can be used before completing installation in the full depth trench 40 . The relatively dry spoil 26 may be pushed by a scoop 60 attached to a suitable tractor (not shown) into full depth trench 40 . The scoop 60 moves the relatively dry spoil 26 on top of the wet spoil 42 in the full depth trench 40 (see FIG. 4A ). Thereafter, the relatively dry spoil 26 and the wet spoil 42 are compacted into the full depth trench 40 by a roller/compactor 62 (see FIG. 4B ). After the relatively dry spoil 26 and the wet spoil 42 have been compacted into the full depth trench 40 , the surface 10 may again be used by traffic or other types of designated use.
[0041] Months later when the decision is made to lay, for example, a sewer line in the full depth trench 40 , a backhoe 64 may be used to excavate the relatively dry spoil 26 and the wet spoil 42 from the full depth trench 40 (see FIG. 4C ). The combined relatively dry spoil 26 and the wet spoil 42 may be loaded into a truck and hauled away. Assuming a sewer line 66 is installed as shown in FIG. 4D , first a bed of gravel 68 or other suitable material is placed in the bottom of the full depth trench 40 (see FIG. 4D ). Thereafter, the sewer line 66 is laid thereon. Next, the sewer line 66 is covered with more gravel 68 and other suitable surface material 70 is applied above the gravel 68 . The suitable surface material 70 may be pavement, concrete or even part of the removed spoil, depending upon the circumstances. Thereafter, the surface 10 as shown in FIG. 4E is complete and can be utilized for its normal purpose.
[0042] By use of the methods just described, a trench can be dug or excavated below the water table in an environmentally sensitive area such as the Florida Keys. The relatively dry spoil 26 can be easily controlled and scooped up. However, wet spoil 42 flows everywhere and is almost impossible to remove under normal trenching conditions. By use of the current method, the wet spoil 42 is retained inside of the trench until it is excavated with a backhole 64 and carried away. This prevents the spoil from contaminating the environment therearound, especially in environmentally sensitive areas like the Florida Keys.
[0043] A third method of digging or excavation of a trench in an environmentally sensitive area is illustrated in FIGS. 5A and 5B . Referring to FIG. 5A , the trencher 14 is identical to the first trencher 14 shown in FIG. 1 ; however, the digging chain 28 has been reversed and the direction of rotation thereof as indicated by the arrows has been reversed. The digging chain 28 now has the cutting teeth 18 digging the intermediate trench 22 during the first pass. Some of the relatively dry spoil 26 rides up the outside of the digging chain 28 and is deposited on the belt 24 . The relatively dry spoil 26 on the belt 24 is moved to the side into wind rows 30 (see FIG. 2A ); however, some of the relatively dry spoil 26 will remain in intermediate trench 22 or on the banks thereof.
[0044] The same trencher 14 can be used for a second pass as illustrated in FIG. 5B ; however, the belt 24 will need to be turned OFF. During the second pass, the trencher 14 will dig from the water table 12 to the completed depth 38 . Because the belt 24 is turned OFF, all of the wet spoil 42 being dug, along with any remainder of dry spoil 26 that is in the intermediate trench 22 , will fall into the full depth trench 40 as shown. The digging by teeth 18 is on the downward part of the counter clockwise rotation as shown in the arrows of FIG. 5B . In both FIGS. 5A and 5B , the digging chain 28 is rotating in a counter clockwise direction and the digging is on the downward rotation by the digging teeth 18 .
[0045] The rotational speed of the tracks 34 and digging chain 28 may have to be adjusted in FIG. 5B to retain the combination of wet and dry spoil in the full depth trench 40 .
[0046] After digging of the full depth trench 40 as explained in conjunction with FIGS. 5A and 5B , the sequential steps as explained in conjunction with FIGS. 4A-4E may be utilized.
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A method for trenching below the water table in environmentally sensitive areas such as the Florida Keys is shown. A first pass made by a trencher digs a first trench from the surface to the water table. During the first pass, relatively dry spoil is removed from the first trench. Next, a much deeper second trench is dug below the first trench; however, wet spoil remains in the now combined first and second trench, the combined first and second trench being large enough to accumulate the wet spoil with expansion. Thereafter, the combined first and second trench may be filled with the relatively dry spoil, packed and driven upon. Later, the packed spoil may be removed and water pipes, electric cables, sewer lines or the like buried in the trench. According to the requirements of the work area, the spoil may be used to partially fill the combined first and second trench or be hauled away.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
FIELD OF THE INVENTION
[0001] The present invention relates generally to a modular non-contact visitation station for use in visitation and processing of individuals in a custodial setting such as jails or prisons to isolate an inmate from visitors.
BACKGROUND OF THE INVENTION
[0002] Visitation stations are used to provide non-contact or visitation between individuals in settings such as jails, security institutions, or hospitals to allow visitation without allowing physical contact between the visitors. Prior art visitation stations are custom enclosures having see-through windows or facilities for mounting telephone equipment, video monitors or other communication equipment.
[0003] Prior art visitation stations are constructed of wood or plastic or metal and may be limited by the strength and size of interlinking parts. Interlinking adjacent stations together may be unsafe due to utility connections daisy chained between adjacent stations and in intensive use applications the integral linking of stations may create safety hazards or expensive retrofits. In addition, in intensive use applications such as prisons and jails, wood or other components may be disassembled to fashion weapons from the resulting pieces.
[0004] Multiple stations are formed by building individual stations ganged together to create a multi user assembly. Inter-station wiring is run by drilling though adjacent or intermediate walls along wire raceways in legs or the enclosure.
[0005] This application is a continuation of co-pending U.S. Provisional Application Ser. No. 61/929,766 filed Jan. 29, 2014 and claims the benefit of the filing date of said co-pending provisional Application Ser. No. 61/929,766.
FIELD OF THE INVENTION
[0006] The present invention relates generally to a modular non-contact visitation station for use in visitation and processing of individuals in a custodial setting such as jails or prisons to isolate an inmate from visitors.
BACKGROUND OF THE INVENTION
[0007] Visitation stations are used to provide non-contact or visitation between individuals in settings such as jails, security institutions, or hospitals to allow visitation without allowing physical contact between the visitors. Prior art visitation stations are custom enclosures having see-through windows or facilities for mounting telephone equipment, video monitors or other communication equipment.
[0008] Prior art visitation stations are constructed of wood or plastic or metal and may be limited by the strength and size of interlinking parts. Interlinking adjacent stations together may be unsafe due to utility connections daisy chained between adjacent stations and in intensive use applications the integral linking of stations may create safety hazards or expensive retrofits. In addition, in intensive use applications such as prisons and jails, wood or other components may be disassembled to fashion weapons from the resulting pieces.
[0009] Multiple stations are formed by building individual stations ganged together to create a multi user assembly. Inter-station wiring is run by drilling though adjacent or intermediate walls along wire raceways in legs or the enclosure.
[0010] Each of these prior art designs requires additional labor cost and time to install and configure. Therefore, it is desirable to provide a modular visitation station for adaptation in single or multi-ganged installations mounted on a floor or wall. It is further desirable to provide an expandable visitation station allowing a common utility connection to be expanded to adjacent units and having an interconnecting means between stations of sufficient strength and adaptability to interconnect a large number of visitation stations. The expandable visitation station allowing expandability to a back-to-back far side by side configuration.
BRIEF SUMMARY OF THE INVENTION
[0011] One embodiment of the present invention is directed to a modular visitation station having modular sides built on an expandable base to form a side by side or back to back station with integral wiring pathway in the base, divider panels and modular legs. The visitation station comprises a plurality of interwired and attached visitation modules adapted to provide a use with non-contact with another user. The base may have a modular design having a plurality of fastener holes on the bottom surface, a wire raceway extending through the base from the bottom surface to the top surface and a sloped writing top surface to discourage the placement of drinking cups. The wiring raceway is provided in the base to facilitate power and communication connections from the floor to the equipment enclosure. A single base may be configured for a single visitation module or may be configured for multiple visitation modules separated by divider panels. Additional bases may be attached to the modular visitation station to expand the number of interconnected modules.
[0012] A panel being an end panel or isolating divider panel is placed at both sides of each module to isolate adjacent visitors and provide privacy from passers by. Each end panel has a sound absorber surface adjacent the base and an outside surface. The sound absorbers may have an opening on an inside surface of the end panel or isolation panel adjacent the base plate. The isolation or divider panel is mounted between side-by-side adjacent visitation modules. The divider panel may have a sound absorber on both sides to provide privacy from adjacent users.
[0013] The visitation station may have a faceplate on the base and spaced from the outer edge of the base to allow use of a writing area. The faceplate may be a window, a mounting surface, video screen or mounting surface for a camera, display, or other equipment to facilitate non-contact visitation. The faceplate may be in wiring communication with an adjacent equipment enclosure. The visitation station may further be configured with integral seating adapted to position the user in front of the faceplate.
[0014] An equipment space is defined between the end panels or isolation panels and behind the faceplate. This equipment space forms an enclosure having wire openings in the base, divider panel, top and back panel and to the faceplate for mounted equipment, utility connections and interwiring adjacent visitation modules. The back-to-back visitation station may have an equipment space configured between opposing faceplates. Single sided side-by-side modules may define the equipment space between a back panel and faceplate. The equipment enclosure is further enclosed by the base, an end panel or divider panel on either side and top panel on the top. Equipment mounted in the equipment enclosure may provide lighting, video or audio communication to a user of the visitation station. Power and communication connections may also be mounted in this space. Each equipment enclosure is in wiring communication with attached equipment enclosures on the visitation station.
[0015] The means for supporting the modular visitation station may comprise a wall mount adapter for attaching to an existing wall or legs to hold the visitation station in a stand alone configuration or both wall mount and legs. Legs may be attached to the bottom surface either ganged together or attached individually. The legs may have a foot adapted to engage the floor on one end and a flange adapted to engage the base on another end. The wire raceway may be integral to the leg to extend from an opening in the foot through the flange and the base to the equipment enclosure defining an enclosed wiring path for wiring utilities accessed through the floor. The wall mount adapter may include a wiring access through the back panel of the visitation station which may be joined to conduit in the wall providing utility wiring such as power, communication and sensors. The wiring access extends into the equipment enclosure.
[0016] The invention may provide interconnection between adjacent modules to allow indefinite number of side-by-side visitation modules ganged together. The module interconnection provides secure attachment between adjacent modules using divider panels. Wiring may be connected to adjoining visitation stations from the equipment enclosure through the top panel conduit opening, the wire raceway in the base, the wire channel in the divider panel or the wire access in the back panel. Back-to-back visitation station may be interwired through the equipment enclosure. Side-by-side visitation stations may be interwired through the wire channel in the divider panels.
[0017] A top panel may be used on top of each visitation station to secure equipment and connections behind the faceplate. The top panel may enclose the equipment enclosure defined behind the faceplate for mounting communication or video equipment. The faceplate may further comprise a solid mounting surface for externally mounted devices such as telephone equipment or microphones and cameras. A transparent window may be used to isolate the visitor from video equipment such as a video monitor for a visual interface between visitors. Each visitation module is thereby defined by the faceplate, writing surface on the base and end or divider panels. The top panel and the end panels having an anti-ligature configuration.
[0018] The above description sets forth, rather broadly, the more important features of the present invention so that the detailed description of the preferred embodiment that follows may be better understood and contributions of the present invention to the art may be better appreciated. There are, of course, additional features of the invention that will be described below and will form the subject matter of claims. In this respect, before explaining at least one preferred embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of the construction and to the arrangement of the components set forth in the following description or as 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.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0019] FIG. 1 is substantially a perspective view of a first embodiment of the invention.
[0020] FIG. 2 is substantially a perspective exploded view of the base of the first embodiment of the invention.
[0021] FIG. 3 is substantially a perspective exploded view of the top of the first embodiment.
[0022] FIG. 4 is substantially an exploded view of the front panel assembly of the first embodiment.
[0023] FIG. 5 is substantially an exploded perspective view of the final assembly of the first embodiment.
[0024] FIG. 6 is substantially a perspective view of a second embodiment.
[0025] FIG. 7 is substantially a perspective view of a third embodiment.
[0026] FIG. 8 is substantially a side elevation of the third embodiment.
[0027] FIG. 9 is substantially a top plan view of the third embodiment
DETAILED DESCRIPTION OF THE INVENTION
[0028] In the following detailed description of the preferred embodiments, reference is made to the accompanying drawings, which form a part of this application. The drawings show, by way of illustration, specific embodiments in which the invention may be practiced. It is to be understood that other embodiments may be utilized and structural changes may be made without departing from the scope of the present invention.
[0029] Referring to FIG. 1 , the modular visitation station is generally referred to by the number 10 shown in a back-to-back or double sided configuration having a first visitation module 12 in the front and a second visitation module 14 attached in a back-to-back configuration. Each visitation module 12 , 14 may further comprise a base 16 , legs 18 , end panels 20 and a first faceplate 22 . Visitation station 10 components may be formed from steel, stainless steel, aluminum, engineered plastic such as Lexan® by GE, or other durable materials suitable for intensive use applications.
[0030] Continuing to refer to FIG. 1 , the base 16 may further comprise a top 24 and a front edge 34 . The top 24 may be adapted as a writing surface. The first faceplate 22 may further comprise, a right side 26 , a top panel 40 , a first bottom 35 and a transparent window 28 having an outside frame 29 mounted thereon and may be further adapted for mounting communication equipment such as hand set 30 . A first seat 36 may be adapted to hold a visitor (not shown) seated in front of first visitation module 12 defined by base 16 , front edge 34 , first and second end panels 20 and faceplate 22 . The first seat 36 is connected to the station 10 by first station link 37 and supported by first seat leg 38 . Legs 18 may have feet 21 for securing to floor 128 with fasteners 39 . Each end panel 20 may have an inside 44 and an outside 46 . A sound absorber portion 48 may be formed on inside surface 44 of end panel 20 .
[0031] Referring to FIG. 2 , visitation station 10 may comprise base 16 having a front edge 34 , first left end 52 , first right end 54 , back edge 56 and wire raceway 50 extending through base 16 . Base 16 may further comprise an elongate configuration comprising a purality of side-by-side visitation modules between left end 52 and right end 54 . Leg 18 a may further comprise, a wire conduit 57 in the leg 18 a , the wire conduit 57 having a bottom end opening to foot 21 and a top end in wiring communication with wire raceway 50 by wire opening 58 through the base flange 106 , The wiring opening 58 adapted to align with wire raceway 50 when leg 18 a is attached to base 16 .
[0032] Referring to FIG. 3 , the top portion of visitation station 10 may comprise a pair of faceplate frames 78 , 78 a mounted in spaced relation between end and divider panels 20 , 60 . Divider panel 60 may have sound absorber portion 48 on both sides 65 to isolate visitor noise from adjacent visitors and surrounding people. In this back-to-back configuration, first faceplate frame 78 and second faceplate frame 78 a may be mounted in spaced relation between first end panel 20 and first divider panel 60 . End panels 20 and divider panels 60 may have a similar rectangular form with each having a top edge 68 , a bottom edge 72 and opposing outside edges 74 . Top edge 68 may have an anti-ligature configuration having rounded or sloped corners 69 . Mounting plate 70 may comprise spacer bar 61 , first panel flange 62 and second panel flange 64 . Mounting plate 70 may be attached to faceplate 22 at fasteners holes 59 on spacer bar 61 and further attached to end panels 20 by panel flange 62 , 64 on panel inside 44 and divider panels 60 at either first side 65 or second side 66 .
[0033] Continuing to refer to FIG. 3 , First faceplate frame 78 and mounting plate 70 may be attached between panels 20 , 60 by first panel flange 62 attaching to inside 44 with threaded fasteners 85 or the like in fastener holes 59 and second panel flange 64 likewise attaching to divider panel 60 . First faceplate frame 78 may be attached to end panel 20 at first left member 80 and to divider panel 60 at first right member 82 by threaded fasteners 85 extending through members 80 , 82 . Second faceplate frame 78 a may likewise be attached to divider panel 60 at second right member 82 and to end panel 16 at second left member 80 . An equipment space configured as an equipment enclosure 92 may be defined between frames 78 , 78 a , end panel 20 , divider panel 60 and base 16 with wiring raceway 50 formed in base 16 between first frame 78 and second frame 78 a and wire channel 150 in divider panel 60 . Equipment enclosure 92 provides space for mounting and power and communication connections for faceplate 22 and attached equipment (not shown). Both wiring raceway 50 and wire channel 150 open to enclosure space 92 to provide wiring between adjacent visitation stations and wiring to utility sources outside the visitation station 10 .
[0034] Referring to FIG. 4 , the back-to-back visitation station 10 may define first visitation module 12 and second visitation module 14 . Faceplate 22 may attach to a top plate 40 adapted to close the top of the equipment enclosure 92 . Equipment such as camera 90 on faceplate 22 has wires 93 extending into equipment space 92 for connection to transmitter 95 . Top plate 40 may be attached to top 84 of faceplate frame 78 and between end panels 20 and divider panel 60 above faceplate 22 . Top plate 40 may further attach to both faceplate frames 78 , 78 a . Front panel 76 may be attached to frame 78 to close the equipment enclosure 92 between panels 20 , 60 . Top panel 40 may be attached to frame top 84 and to end or divider panels 20 , 60 . Top plate 40 may have panel flanges 94 for attaching to end and divider panels 20 , 60 . Conduit opening 250 may be formed in top plate 40 to provide wire access to equipment enclosure 92 from above visitation station 10 . Faceplate 22 may further be disposed between top plate 40 and frame 78 to provide tamper resistant mounting and prevent removal without tools. Fasteners 85 may be used on faceplate 22 adjacent base 16 to hold faceplate 22 on equipment enclosure 92 .
[0035] Referring to FIG. 5 , visitation station 10 upper assembly 96 and lower assembly 98 may be separately assembled and attached to each other at the mounting site. Upper assembly 96 may comprise end panels 20 joined in spaced relation by mounting plate 70 and faceplate frame 78 attached to the inside surface 44 of each end panel 20 or divider panel 60 . Lower assembly 98 may comprise base 16 having bottom surface 102 . Legs 18 are attached to bottom surface 102 at flange 104 . Faceplate frame screws 85 extend through base 16 to engage faceplate frame 78 . Base ends 52 , 54 are generally similar having a base flange 106 extending from base bottom surface 102 with panel fastener holes formed through base flange 106 . Panel fastener holes in base flange 106 on first end 52 may be used to interconnect base 16 to end panels 20 or divider panels 60 .
[0036] Referring to FIG. 6 , modular visitation station 100 may comprise an additional visitation module 112 mounted side-by-side with first visitation module 12 . Modular visitation station 100 may have a respective first and second end panel 20 . Base 16 may extend between first end panel 20 and second end panel 120 or may be formed by assembling first base portion 116 a with second base portion 116 b . Divider panel 60 may be disposed between respective base portions 116 a , 116 b , faceplates 22 , 22 a and top panels 40 , 140 . The first base portion 116 a is connected to the second base portion 116 b by connecting both base portions 116 a , 116 b to divider panel 60 .
[0037] Referring to FIG. 7 , modular visitation station 200 may have a plurality of single sided visitation modules 142 , 144 adapted in a side-by-side configuration. First visitation module 142 and generally similar second visitation module 144 may be divided by divider panel 360 . First visitation module 142 may have a base top 124 surrounded on three sides by first end panel 320 , first faceplate 322 and divider panel 360 . First end panel 320 may be connected to first faceplate 322 and first base 316 . First visitation module 142 may further comprise back panel 356 on first base 316 to enclose and define equipment enclosure 392 . The first visitation module 142 may be attached side-by-side to similarly configured second visitation module 144 . Base 316 on first visitation module 142 may be connected between end panel 320 and divider panel 360 or configured as part of an elongate base 316 extending between the respective end panels 320 , 320 a . Base 316 may extend between end panels 320 , 320 a thereby supporting a plurality of visitation modules 142 , 144 . Additional visitation modules 144 may be added by replacing one end panel 320 with a new divider panel 360 and connecting faceplate 322 , top 340 and base 316 to new divider panel and likewise reconnecting end panel 320 to close the new configuration. Equipment enclosure 392 is between base 316 , top 340 end panel 320 , divider panel 360 , faceplate 322 and back panel 356 . Conduit opening 550 may be formed in top 340 , wire raceway 350 in leg 318 a extending through base 360 and wire channel 450 in divider panel 360 each provide access to wiring 126 to enter equipment enclosure 392 . Divider panel 260 may be connected between visitation modules 142 , 144 and back panel 356 .
[0038] Continuing to refer to FIG. 7 , side-by-side second base 316 a may be generally similar to first base 316 both of which may be attached to divider panel 360 . Second faceplate 322 a and second end panel 220 a may be attached to second base 316 a to form second visitation module 144 . First seat 36 is fixed to first visitation module 142 and second seat 36 a is fixed to second visitation module 144 . Back panel 356 may extend between end panels 320 or be individually configured for each visitation module 142 , 144 to be sized and connected similar to the respective faceplate 322 . End panel may have vent 321 opening to equipment enclosure 392 .
[0039] Referring to FIG. 8 , modular visitation station 200 wire raceway 350 may open into equipment enclosure 392 from floor through leg 318 a at wire track 350 extending through base 316 . First visitation module 142 and second visitation module 144 may be attached and interwired to each other by wire channel 450 . Modular visitation station 200 may have faceplate 322 , 322 a spaced from back panel 356 having equipment enclosure 392 between faceplate 322 and back panel 356 . Rear wire access 650 on back panel 356 may extend through back panel 356 to open into equipment enclosure 392 . Wall mounted modular visitation stations 200 may not require legs 318 .
[0040] Referring to FIG. 9 , visitation station 200 may comprise several visitation modules 142 , 144 each having equipment enclosures 392 , 392 a , 392 b , faceplates 322 , 322 a , 322 b and separated by divider panels 360 , 360 a . Equipment enclosures 392 , 392 a , 392 b may be interwired by wire channel 450 in each divider panel 360 , 360 a to allow a single utility connection to service all attached equipment enclosures 392 , 392 a , 392 b . Conduit access 550 , 550 a , 550 b in top panel 340 , 340 a , 340 b provides wiring access from above modular visitation station 200 . Wire raceway 350 in base 316 provides wire access from below visitation station 200 and may provide interwiring access between equipment enclosures 392 , 392 a , 392 b . Rear wire access 650 may provide wiring access through the back panel 356 .
[0041] Although the description above contains many specifications, these should not be construed as limiting the scope of the invention but as merely providing illustrations of some of the embodiments of this invention. Thus, the scope of the invention should be determined by the appended claims and their legal equivalents rather than by the examples given. Further, the present invention has been shown and described with reference to the foregoing exemplary embodiments. It is to be understood, however, that other forms, details, and embodiments may be made with out departing from the spirit and scope of the invention which is defined in the following claims.
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The invention is directed to a modular visitation station having an expandable construction to adapt to provide individual visitation modules interwired together in a combination of back-to-back or side-by-side configurations. The visitation station may utilize single utility access for power or communications to connect each attached visitation module. Wiring access is provided between modules, and to the floor, wall or ceiling access points.
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CROSS REFERENCE TO RELATED APPLICATIONS
This is a U.S. national stage of application No. PCT/EP2010/004084, filed on 7 Jul. 2010. Priority is claimed on German Application No. 20 2009 009 548.7 filed 10 Jul. 2009, the content of which is incorporated here by reference.
BACKGROUND OF THE INVENTION
Field of the Invention
The present invention is directed to a ceiling track system including a guiding rail, in which at least one wall element is received via a carriage unit, wherein at least one encasing element is affixed to the guiding rail.
Ceiling track systems including a guiding rail are utilized to maintain and to displace wall elements in the guiding rail, which are received therein via carriage units. In addition to manually displaceable wall elements, carriage units with drive units driven by a motor, are known, to displace the carriage units and as a consequence the wall elements in the guiding rail. The guiding rails of such ceiling track systems are mounted to the ceiling of a room, wherein the wall elements can be displaced between a parking position and a position in which they form a partition wall. The rooms in which such partition wall systems are utilized are very often conference rooms, self-service restaurants, reception areas in business premises, or customer service areas in banks.
Laterally disposed encasing elements, which laterally cover the travel space of the carriage units between the guiding rail and the wall elements, can be affixed to the guiding rails. The encasing elements are manually fastened to the guiding rail wherein a mechanic installer has to perform the fastening while working overhead. Fastners are known that consist of sliding blocks, received in the guiding rail, and screw elements screwable into said sliding blocks. Therefore mounting the encasing elements, which have a conventional length of up to three meters and more, is very complicated. Following the first installation, very often the encasing elements need to be temporarily removed to perform maintenance work on the carriage units, which are received in the guiding rail.
Furthermore, manipulating and mounting the encasing elements is difficult, because very often the ceiling track systems need to be mounted adjacent to walls or at suspended ceilings, wherein the connecting plane between the carriage unit and the wall element is located on a level with the suspended ceiling. As a consequence, the encasing elements need to be connected to the guiding rail in the space above the suspended ceiling or adjacent to the room wall. Conventionally known connectors, such as sliding blocks and associated screw elements cannot be utilized for such a ceiling arrangement.
SUMMARY OF THE INVENTION
Therefore, it is an object of the present invention to further develop a ceiling track system including a guiding rail and at least one encasing element to be affixed to the latter, such that mounting the encasing element to the guiding rail is simplified.
The invention includes a guiding rail that has a latching geometry, into which a latching hook, disposed at the encasing element, is latchable in such a way that, from a unidirectional joining direction, the encasing element can be affixed in a self-retaining way to the guiding rail.
One embodiment of the invention utilizes a latching of the encasing element to the guiding rail to simplify the installation of the encasing element in an overhead position for the mechanic installer. The installer just needs to latch the encasing element into the guiding rail. The joining direction is configured to be unidirectional, i.e. the joining can only be done from a single direction and the encasing element just needs to be moved in one plane towards the guiding rail. In this case, the latching hook disposed at the encasing element will latch with a latching geometry of the guiding rail. Both the latching hook and the latching geometry, individually or together, may be configured continuously across the entire length of the guiding rail respectively, wherein likewise a certain amount of individual latching hooks with associated latching geometries may be provided at the guiding rail.
The guiding rail is affixed to the ceiling of a room and the unidirectional joining direction extends vertically underneath the guiding rail in such a way that the encasing element can be joined from underneath in a direction towards the guiding rail. The mechanic installer can move the encasing element in vertical direction upwards towards the guiding rail in such a way that, on account of the inventive latching arrangement of the latching hook and the latching geometry, the encasing element can be hooked to the guiding rail in a self-retaining manner. As a consequence, a one-man mounting of an encasing element to the guiding rail is possible, because a first mechanic installer does no longer have to hold the guiding rail while a second mechanic installer performs the screw connection of the encasing element to the guiding rail.
The encasing element is configured in the shape of an L-profile with a long and a short leg, wherein the long leg extends in the vertical joining direction. The shape of the encasing element is defined by the area to be covered, which is determined by the travel space of the carriage unit in the longitudinal direction of the guiding rail. The long leg of the encasing element forms the vertical exterior surface of the encasing, wherein, in the installed condition, the short leg of the encasing element forms a cladding, in order to minimize as much as possible the slot which can be seen at the ceiling of the room. The width of the slot is defined by the connecting geometry of the wall element to the carriage unit configured in the shape of a carrying bolt. The diameter of said bolt is smaller than the width of the guiding rail such that the difference width is covered by the short legs of the encasing elements which are affixed on both sides.
For latching the encasing element to the guiding rail, the latching hook is disposed at the end of the long and vertically extending leg of the encasing element and extends in the prolongation of the leg axis. On the outside, the latching hook may merge homogeneously with the long leg of the encasing element such that no visual interruption between the area of the latching hook and the area of the long and vertically extending leg of the encasing element is created.
In this case, the encasing element, neighbouring the area of the cross-sectional constriction, has a web with a projection, wherein the guiding rail has a groove into which the projection engages to keep the encasing element at the guiding rail in a self-retaining manner. The projection comes to abut against a flank of the groove and constitutes the counter-retaining part to the latching of the latching hook in the latching geometry provided in the guiding rail. It is only by the cooperating effect of the form closure, which is generated by the projecting web at the flank of the groove, with the latching of the latching hook in the latching geometry, that the encasing element can be affixed to the guiding rail in a self-retaining manner, and a certain releasing force needs to be applied to release the encasing element from the guiding rail in the opposite direction to the joining direction. The rigidity of the latching hook is dimensioned such that the releasing force is larger than the weight of the encasing element. In this case, the recovery. of the latching hook forms the only resiliency within the connecting system such that the self-retaining force of the encasing element at the guiding rail is thereby determined.
Adjacent to the groove, the guiding rail has a screw reception in which a screw element is screwable, wherein, by screwing the screw element in, a clamping action of the web at the guiding rail is created. The self-retaining latching of the encasing element at the guiding rail just serves during the pre-installation and the final attachment of the encasing element at the guiding rail is realized by a screw connection. If the screw element is screwed into the screw reception, the web is clamped against the guiding rail, because the web extends at least partially under the screw head of the screw element. The web may be configured in a length that extends beyond the screw reception and the screw element may be led through a hole in the web, wherein the screwing of the encasing element to the guiding rail is realized via the web. Furthermore, the screw element can be affixed to the web of the encasing element in a captive arrangement such that, by simply latching the encasing element to the guiding rail, the screw element is already positioned in the screw reception for the screwing action.
The screw reception is oriented at an angle with respect to a vertical joining direction to screw the screw element from the direction of the symmetry plane of the guiding rail. On the left and right sides of the travel path of the carriage unit, the guiding rail is configured to be symmetrical such that one plane of symmetry is located on half the width of the guiding rail. The L-shaped encasing element is affixed to the guiding rail such that the short leg of the L-shape points into the direction of the plane of symmetry. As the screw reception is located on the inside, with the encasing element being in place, a slanted screw reception allows for utilizing a tool, such that screwing the screw element into the screw reception from the outside is possible, in that the tool is passed manually through the gap that extends between the opposing encasing elements affixed to the guiding rail. It is thereby possible to proceed to screwing the encasing elements to the guiding rail from the underside of the ceiling, such as screwing, while utilizing a tool, is possible even if the guiding rail and the encasing elements are located behind the intermediate ceiling or neighbouring a room wall, because lateral accessibility to the encasing elements, for the purpose of screwing them to the guiding rail, is not required.
Another embodiment of the ceiling track system has a latching hook with a nose conformation, which, in the joined position of the encasing element, engages into an undercut, which constitutes the latching geometry and is provided on the outside of the guiding rail. The latching action of the nose conformation and the latching geometry is realized in that, at any time, the nose conformation can be removed from the latching geometry. The latching hook is resiliently led in the direction towards the outside of the encasing element, if the latter is moved along the guiding rail. As the nose conformation latches with the latching geometry, the latching hook snaps back from the resilient position and a. form closure is created between the nose conformation of the latching hook and the latching geometry at the guiding rail. For an improved resiliency of the latching hook at the encasing element, the transition area from the encasing element to the latching hook has a cross-sectional constriction. The rigidity of the connection between the latching hook and the encasing element is thereby reduced, such that the latching hook is able to yield resiliently already under a low action of force, and the nose conformation can move across the latching geometry at the guiding rail.
Another advantageous embodiment of the guiding rail has butt-joint arrangements, in order to interconnect several guiding rails in the traveling direction of the carriage unit. A ceiling track system consists of a plurality of guiding rails, wherein straight elements and curved elements are interconnected. The connection is realized via butt joint arrangements introduced into a reception geometry at the end side of the guiding rail. The butt connectors comprise metal webs which, at their first side, can be screwed to a first guiding rail and, at their second side, to a second guiding rail. The screw connection of the butt joint arrangements is realized from the joining direction, from which the encasing elements can be affixed to the guiding rails.
The cross-section of the guiding rail is configured to be box-shaped wherein the guiding rails are preferably formed from an aluminum extruded profile. Essentially the box-shaped profile of the guiding rail has a rectangular form, wherein topside fastening conformations are provided for affixing the guiding rail to the ceiling of the room. The latching geometries, described in the introduction, are provided laterally on both the left outside and the right outside of the guiding rail. On the underside, the guiding rail has two areas pointing to the direction of the plane of symmetry, wherein the groove, the screw reception and the butt joint arrangement are provided in the lower outside of the guiding rail. The mentioned geometries may extend over the entire length of the guiding rail wherein the screw reception is either provided as bores at regular intervals or extends as a longitudinal groove along the guiding rail and the screw element is a self-cutting screw, which, when being screwed in, forms a thread in the flanks of the groove-shaped screw reception.
In one embodiment, the screw reception is configured as a longitudinally extending screw channel or as a longitudinal groove with a thread such that a metrical screw can be repeatedly screwed in at any given position.
It is advantageous if the guiding rail presents guiding surfaces that are inwards oriented and cooperate with a guiding device disposed at the carriage unit for guiding the carriage unit. In this case, the guiding rail does not present a closed box-shaped profile; but the areas, in which at least the groove, the screw reception and the butt-joint arrangement are disposed at the underside, extend to the left side and the right side in the direction of the symmetry axis, and terminate in opposite guiding surfaces, which cooperate with a guiding device for the purpose of guiding the carriage unit. The carriage unit is subdivided into a roller carriage, rolling in the guiding rail and being disposed above the guiding device, and a drive unit disposed below the guiding rail, wherein the encasing elements form the lateral covering of the drive unit. The roller carriage on the contrary is received within the hollow space of the guiding rail. As a consequence, the connection between the roller carriage and the drive unit is configured by the guiding device, which, for example, may comprise a guiding roller. This guiding roller rolls along the inwards oriented guiding surfaces such that guidance within the guiding rail is provided for the carriage unit.
According to one embodiment of the invention, the roller carriage has at least two rollers that roll on rolling surfaces configured in the direction of the symmetry axis of the guiding rail. The rolling surfaces are configured on the areas of the guiding rail, in which, on the underside, at least the screw reception, the groove and the butt-joint arrangement are fitted. The roller carriage may have two or four rollers, wherein the rollers may consist of plastic material, in order to roll on the rolling surfaces of the guiding rail which consists of aluminum. Furthermore, the rollers may be manufactured from a metal, wherein the rolling surfaces of the guiding rail are configured to receive rolling inserts, in order to provide for a minimum wear rolling contact between the rollers and the rolling inserts. The rolling inserts may consist for example of spring steel, in order to avoid contact between the aluminum material of the guiding rail and the rollers consisting of metal.
To feed and/or to control a drive motor, which is received in the drive unit and serves to displace the wall element in the guiding rail, the roller carriage has at least one current collector, which cooperates with at least one associated power rail in a power transmitting and/or signal transmitting manner. Three power rails may be mounted in the guiding rail and are received inside the guiding rail by insulators. Current collectors, which, according to the principle of a pantograph of an electric train, pick off the current from the current rails, and are located at the roller carriage. In case three current collectors are provided, one of the three current collectors represents the ground such that a second current collector with respect to ground allows for power supply and the third current collector with respect to ground allows for signal transmission.
According to one embodiment of the invention, a ceiling track system including a guiding rail is provided, which can be simply manufactured in a continuous casting process, and fulfils all functions for operating self-propelled carriage units for displacing wall elements. The guiding rail offers the possibility to latch encasing elements thereto, and, if required, to screw the encasing elements with a tool to the guiding rail via an access on the underside. As a result, a ceiling track system is created, which allows for a considerably simplified mounting of the encasing elements and nevertheless, by the specially configured guiding rails, fulfills all functions of an automatically operating ceiling track system for displacing wall elements.
BRIEF DESCRIPTION OF THE DRAWINGS
Hereinafter, further measures enhancing the invention will be illustrated in more detail in conjunction with the description of preferred embodiments of the invention based on the Figures, in which
FIGS. 1 a to 1 c : are cross-sectional views of a ceiling track system including a guiding rail and encasing elements mounted to said rail in different mounting stages;
FIGS. 2 a to 2 b : are cross-sectional views of the ceiling track system and a carriage unit, which consists of at least one roller carriage, a guiding device and a drive unit, wherein different types of rollers and rolling surfaces are illustrated;
FIG. 3 : is a detailed view of the latching connection of an encasing element at the guiding rail, and
FIG. 4 : is a carriage unit guided in the guiding rail and has a current collector to feed a drive motor received in the drive unit.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 a shows a ceiling track system 1 including a guiding rail 2 , to which respectively one encasing element 3 is mounted on the underside on both the left longitudinal side and the right longitudinal side. In order to provide for preliminarily latching the encasing elements 3 to the guiding rail 2 prior to subsequently screwing the encasing elements 3 to the guiding rail 2 , the guiding rail, on both the left exterior longitudinal surface and the right exterior longitudinal surface, has a respective latching geometry 4 , into which a respective latching hook 5 , disposed at the encasing element 3 , is latchable in such a way that the encasing element 3 can be fitted to the guiding rail 2 in a self-retaining manner from a unidirectional joining direction 6 . The joining direction 6 is suggested by an arrow, wherein on the right side the encasing element 3 to be latched is already pushed in the joining direction 6 so far that the latching hook 5 is disposed just prior to latch with the latching geometry 4 . The left encasing element 3 is still on the joining path such as to be illustrated offset below the encasing element 3 shown on the right side.
As shown in FIGS. 1 a - 1 c , the encasing elements 3 have webs 8 , which point into the direction of the plane of symmetry 12 of the guiding rail 2 . Projections 8 a , which can engage in an associated groove 9 within the guiding rail 2 , are fitted to the webs 8 . According to FIG. 1 c , the screw elements 11 are screwed into the screw receptions 10 with a tool 24 , the screw elements 11 clamp the webs 8 to the guiding rail 2 .
To connect several guiding rails 2 to each other, butt-joint arrangements 13 are provided. They consist of web elements that extend across the butt-joint connection of the guiding rail 2 and are screwed within each of the guiding rail 2 . As a consequence, a transition between two guiding rails 2 is assured, without an offset being present between the two guiding rails 2 .
FIG. 1 b is a ceiling track system 1 with a guiding rail 2 and one encasing element 3 on the left side and one on the right side, wherein the encasing element 3 on the right side is already latched with the guiding rail 2 . On the other hand, the encasing element 3 shown on the left side is positioned prior to latching such that a resilient yielding of the latching hook 5 is shown to move the element over the latching geometry 4 at the guiding rail 2 . Once the latching action has taken place, the encasing elements 3 may be screwed by a screw element 11 and an associated tool 24 , wherein the tool 24 can be introduced from the underside of the guiding rail 2 . In case the encasing elements 3 are located behind an intermediate ceiling 25 , as suggested in FIG. 1 a , the screw elements 11 can nevertheless be inserted into the associated screw receptions 10 .
FIG. 1 c shows the ceiling track system 1 including the guiding rail 2 and the associated encasing elements 3 in the condition in which the encasing elements 3 are already firmly latched with the guiding rail 2 . It can be seen that both, on the left side and on the right side, respective latching hooks 5 are latched with undercuts in the exterior surface of the guiding rail 2 , which undercuts are formed by the latching geometry 4 .
The FIGS. 2 a and 2 b show the ceiling track system 1 including the guiding rail 2 and two respectively disposed encasing elements 3 in a cross-sectional view. A carriage unit, which consists of a roller carriage 16 and a drive unit 17 , is shown in cross-section. A guiding device 15 , having the function of guiding the carriage unit within the guiding rail 2 , is shown between the roller carriage 16 and the drive unit 17 . The guiding device 15 consists of a plastic material roller, which is guided on the left and right sides in the guiding rail 2 .
A first embodiment of the rollers 18 supported in the roller carriage 16 , is shown in FIG. 2 a . In this case, at least one of the two rollers 18 may be driven by the drive motor 22 , which is a component of the drive unit 17 . Via a transmission 26 , the drive motor 22 drives the at least one roller 18 , which rolls on an inner surface in the guiding rail 2 . If the rollers 18 are manufactured from plastic material, the possibility is given to establish a rolling contact directly between the rollers 18 and the surface of the rolling surface in the guiding rail 2 .
The embodiment according to FIG. 2 b has a ceiling track system 1 including rollers 18 , which are manufactured from metallic material. In order to establish a rolling contact between the metallic rollers 18 and the guiding rail 2 , which is manufactured from aluminum, the rolling surfaces 23 of the guiding rail 2 are configured to receive rolling inserts 19 . The inserts may consist of steel, in order to offer a rolling contact at minimum wear. The guiding device is represented by a guiding roller that comprises plastic material. The latter rolls on the guiding surfaces 14 , which are configured on the inside of the guiding rail 2 .
In a detailed view FIG. 3 shows the latching arrangement of an encasing element 3 at the guiding rail 2 . The joining direction for latching the encasing element 3 is illustrated by the arrow 6 . The transition from the encasing element 3 to the latching hook 5 includes a cross-sectional constriction 7 , to allow for an improved yielding resiliency of the latching hook 5 , when the nose conformation 5 a at the end of the latching hook 5 is moved over the latching geometry 4 in the guiding rail 2 . The latching hook 5 is shown in a partially resiliently yielding position in which the non-deformed position of the latching hook 5 is shown by a dash-dotted contour.
To form a counter-holder for the latching system at the latching geometry 4 , a web 8 , which has a projection 8 a , is conformed to the encasing element 3 . In the joined position, the projection 8 a extends into a groove 9 , which is fitted into the guiding rail 2 . Neighbouring the groove 9 , the guiding rail 2 has a screw reception 10 , which is fitted at an angle a with regard to the joining direction 6 . The screw element can be screwed into the screw reception 10 and the terminal side of the web 8 is clamped at the guiding rail 2 . The screw reception may be configured as a longitudinally extending screw channel or as a longitudinal groove with threads such that a metrical screw can be repeatedly screwed in at any given position.
FIG. 4 shows another cross-section through the ceiling track system 1 including a carriage unit, which, with regard to its essential structural components, consists of the guiding device 15 , the top side roller carriage 16 and the bottom side drive unit 17 . Guiding the guiding device 15 is realized on both the left side and the right side via a respective guiding surface 14 fitted to the guiding rail 2 . Furthermore, the ceiling track system 1 has current collectors 20 to allow the power rails 21 provided in the guiding rail 2 to convey supply current to the drive motor 22 and/or to transmit signals. As a consequence, the carriage unit can be displaced in the guiding rail 2 , and current, respectively a signal is transmittable to the carriage unit independently from the displacement position. The power rails 21 are received in the guiding rail 2 via insulators 26 .
The invention in its configuration is not limited to the above presented preferred embodiment. On the contrary, a wide number of variants is conceivable, which make use of the described solution likewise with basically different types of configurations. In particular the latching geometry 4 may be configured to be continuous in displacement direction along the guiding rail 2 , or the latching geometry 4 is located at regular intervals at the outside of the guiding rail 2 . In the same way, the encasing elements 3 may have a continuous latching hook 5 , or the latter is adapted to the respective distances of the latching geometry 4 at the guiding rail 2 such that a plurality of latching hooks 5 is conformed to the encasing element 3 .
Thus, while there have shown and described and pointed out fundamental novel features of the invention as applied to a preferred embodiment thereof, it will be understood that various omissions and substitutions and changes in the form and details of the devices illustrated, and in their operation, may be made by those skilled in the art without departing from the spirit of the invention. For example, it is expressly intended that all combinations of those elements and/or method steps which perform substantially the same function in substantially the same way to achieve the same results are within the scope of the invention. Moreover, it should be recognized that structures and/or elements and/or method steps shown and/or described in connection with any disclosed form or embodiment of the invention may be incorporated in any other disclosed or described or suggested form or embodiment as a general matter of design choice. It is the intention, therefore, to be limited only as indicated by the scope of the claims appended hereto.
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A ceiling track system including a guiding rail, in which at least one wall element is received and an encasing element that is affixed to the guiding rail. A long leg extends in a vertical joining direction and has a latching geometry, into which a latching hook can be latched such that the encasing element is affixed to the guiding rail in a self-retaining manner. The long leg has a web with a projection. The guiding rail has a groove into which the projection engages for the purpose of self-retaining the encasing element. Adjacent to the groove the guiding rail has a screw reception into which a screw element is screwable by which a clamping action is achieved. The screw reception is at an angle with regard to the vertical joining direction.
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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 safe protection wherein an attempted forced opening of the safe releases a repulsive chemical agent to deter further entry by the burglar. The present invention relates more particularly to a safe or vault protection system which deters attempted forced entry into the safe particularly when peeling the safe door at its edge portions is the attempted means of forced entry.
2. General Background and Prior Art
Presently known in the art is the use of breakable glass vials or tubes filled with repulsive chemical agent located in a metal base attached to the inside of the safe door. The base is so located so that when the combination dial mechanism is hammered or drilled into, or if the mechanism is pulled away from the safe door, a rod leading from the mechanism to the chemical retaining breakable glass vials, and attached to a metal bar or disc, applies pressure to the glass tubes sufficient to break the tubes in the base and release the gas into the atmosphere. Such a prior art type safe protector is seen in U.S. Pat. No. 2,804,029 issued to J. P. Fitzgerald and entitled "Safe Protector".
The present state of the art falls short of the full protection against safe break-ins since the singular use of the glass-tube base mechanism guards only against break-ins through the combination dial mechanism. The present invention is an improvement over such prior art safe protectors by providing a means for protecting against break-ins which occur as a result of forced attempts to "peel" the safe. "Peeling" a safe refers to forced attempts to gain entry to the safe by peeling or forcing the safe door away from its normal position using leverage, crow bars, jacks or the like. In like fashion, peeling refers to attempts to peel back layers of metal and or other materials comprising the safe door, or otherwise forcibly dismantling the door other than the combination dial portion itself.
GENERAL DISCUSSION OF THE PRESENT INVENTION
The present invention provides a safe protection apparatus comprising a metal base adapted to be fastened to the inside of a safe door having a tumbler in line with which the base is fashioned. A sub-assembly provides a pair of molded rubber mounts each of the mounts having a plurality of tube receiving recess openings. A plurality of hermetically sealed tubes containing a repulsive chemical agent (as tear gas) have their ends frictionally fitted into the mount recess openings to form the sub-assembly. The sub-assembly is rewired to the inside of the metal base. Through an opening in the metal base are passed a plurality of pull wires which wrap at one end portion about the plurality of tubes and diverge after exiting the metal base opening to the edge portions of the safe door. During forced entry to the safe, particularly by "peeling" the safe door, the wires are stressed, breaking the tubes at their attachment to the pull wires.
One object of the present invention is to provide a safe protector apparatus to protect a safe from forced break-ins through either the destruction or damage of combination dial mechanism or through "peeling" away portions of the safe door.
Another object of the present invention is to provide a safe protection apparatus utilizing a noxious chemical agent to repulse burglars during forced entry to a safe by either "peeling" the safe door or damaging the combination dial mechanism.
Another object of the invention is to provide for a safe protection apparatus which is easily attached to existing safes.
BRIEF DESCRIPTION OF THE DRAWINGS
For a further understanding of the nature and objects of the present invention, reference should be had to the following detailed description, taken in conjunction with the accompanying drawings, in which like parts are given like reference numerals and wherein:
FIG. 1 is a partial front view of the preferred embodiment of the safe protector apparatus, of the present invention, part being broken away and shown in section for sake of illustration;
FIG. 2 is a view in side elevation of the safe protector viewed in FIG. 1 with part broken away and shown in section for sake of clarity and illustration;
FIG. 3 is a sectional view of a safe protector embodying the present invention mounted on a safe door and showing in particular the tube-breaking metal bars pinned to the curb or tumbler core ;
FIG. 4 is a fragmentary view in side elevation of the tube-breaking bars and mounting pin, with base removed;
FIG. 5 is a fragmentary section view showing the means of securing the tube pads to the base of the safe protector;
FIG. 6 is an elevational view of a typical safe door illustrating attachment of the preferred embodiment of the apparatus of the present invention attached thereto for operation, and illustrating the pull wires extending from the base portion to the corners of the safe door; and
FIG. 7 is a sectional view taken along lines 7--7 of FIG. 6.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The safe protector shown in FIGS. 1 and 2 of the drawings has a shallow pan-like metal base 10. The side walls are slightly recessed as indicated at 12 so that when the base 10 is placed against a flat surface such as the inner wall of the door of the safe, there will be opening for the escape of tear gas. At each end of the base 10 there are pads 14 having openings 16 therethrough. The pads 14 serve to absorb the impact of a sudden jolt to the safe door during the normal use of the safe. The openings 16 accommodate screws or the like for fastening the protector to the safe door. The base 10 may be cast or stamped from sheet metal or aluminum casting.
The sub-assembly which is placed in the base consists of a pair of moulded rubber mountings 18 and a plurality of glass tubes 24. The rubber mountings 18 have formed therein recesses 20 for receiving and gripping the ends of the tubes 24. In this embodiment there are eight such recesses. The eight glass tubes 24 are hermetically sealed and contain tear gas or like repulsive chemical agent. Each tube has its end inserted in the recesses 20 of each mounting 18. The diameter of the recesses 20 is such as to frictionally engage the end of the glass tubes 24 and this makes a solid sub-assembly which may be easily stored and handled during other steps of assembly. The rubber mountings of the sub-assembly are adhered to the base with a screw 34 through the base 10. The rubber mountings 18 protect the tubes 24 during such handling and assembly. In addition to this, the rubber mountings 18 project slightly beyond the outer edge of the base 10 so that they act as resilient protectors for the tubes 24 during shipment and installation.
The present invention includes a mechanism for breaking the glass tubes 24 no matter whether the tumbler core is pushed in or withdrawn. To illustrate this embodiment the safe protector is shown secured by screws 34 to the inside of a safe door 36 which includes a combination 38 operated by a dial 40 and a tumbler curb 42. All such parts are shown diagrammatically and the curb 42 is deemed to be connected to the tumbler core of the combination so that movement of the one causes movement of the other. Before securing the safe protector to the door of the safe, the inner wall is drilled to provide a hole 44 for the pin 48 and the curb 42 is drilled and tapped as indicated at 46 to receive the threaded end of a bar operating pin 48. The pin 48 has an outer end of reduced diameter which forms a shoulder 50 at the inner end of the hole 44. The pin 48 is then threaded into fixed place on the curb 42 with its outer reduced and threaded end projecting from the inside of the safe door. A first bar 52 is then placed over the reduced end of the pin 48 so that it will be engaged by the shoulder 50 if the pin 48 is driven inwardly and forced against the tubes 24. The safe protector with a second bar 54 is placed between the vials 24 and the side wall of the base 10. Base 10 is then placed against the door 36 so that the pin 48 projects between the tubes 24, through the bar 54 and into the hole 32. A nut 56 is then threaded on the pin 48 so that if the tumbler core is withdrawn, the pin 48 will cause the bar 54 to smash the vials 24 against the wall of the safe. While not necessary, it is desirable to insert a compression spring 58 on the pin 48 between the bars 52 and 54 to prevent rattling of such bars in normal opening and closing of the safe door. The above safe protection is disclosed in U.S. Pat. No. 2,804,029, issued Aug. 27, 1967 to J. P. Fitzgerald, incorporated herein by reference. It should be understood that the present invention is an improvement to that type of safe protector, in that forced entry to the safe in addition to entry by pushing/withdrawing the tumbler core is protected.
The present invention thus provides a means for protecting against forced break-ins to a safety by "peeling" away the safe door; i.e., deforming, prying, stripping away the metal layers of the door, or otherwise disfiguring the safe door until access is had into the safe. Phantom lines in FIG. 7 illustrate such "peeling" of door 36, or 60.
The stripping method usually occurs from one of the corners of the safe door by utilizing of levers, jacks or other such burglar tools.
FIGS. 1, 6-7 illustrate best the preferred embodiment of the apparatus of the present invention.
In FIG. 6 there is seen an elevational view of the back 69 of the present invention attached thereto. Extending outward from opening 62 is a plurality of pull wire lines 64-67, which lines are directed to the four corners of the inside layer of metal of the safe door 60 after being pulled taut. It should be noted that opening 62 of base 10 could be an opening 62 independent of opening 32 and should be of a diameter large enough to accommodate the diameters of pull line wires 64-67. Alternatively, hole 32 of base 10 (FIG. 3) could be large enough to accommodate the projection of pin 48 and also accommodate the strands of pull lines 64-67.
FIG. 1 further illustrates the placement of the ends of the lines 64-67 inside of base 10. Each pull line 64-67 is wrapped around the entire assembly of tubes 24 at the area of the recessed neck 25 portion of each tube, so that each strand of wire encircles all tubes 24. Thus the eight tubes 24 would have four strands of wire wrapped around the group of tubes and fastened thereby by tying for example.
The end portion of each pull line 64-67 is affixed to the extreme corner portions of door 60. Attachment to door 60 at corner positions 70-73 is by any suitable means such as screws, eyelets, welding, gluing or the like.
When the "peeling" of door 60 begins, in all probability the peeling will be situated at one of the corners of the safe door or otherwise at the door extremities. When the inner layer 65 of door 60 is peeled away at a corner 70-73 of door 60, the pulling away will produce tension in pull lines 64-67. Since pull lines 64-67 enter base 10 at the center of the base 10 through opening 62 or 32 the pressure on lines 64-67 will pull on all tubes 24. Since the tubes 24 are of a rather thin-walled glass material which is readily breakable, the lines should rupture most if not all tubes 24, thus releasing tear gas or like repulsive chemical agent into the safe and the room. This same occurrence would take place should the peeling occur at any one of the four corners of the safe door. A peeling of the door 60 itself between any two corners will likewise rupture tubes 24 since the two adjacent pull lines would be stressed by such disfiguring of safe door 60.
Because many varying and different embodiments may be made within the scope of the inventive concept herein taught, and because many modifications may be made in the embodiments herein detailed in accordance with the descriptive requirement of the law, it is to be understood that the details herein are to be interpreted as illustrative and not in a limiting sense.
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The invention relates to safe or vault protection system which deters attempt forced entry into the safe or vault by releasing a repulsive chemical agent particularly when peeling the safe door at its edge portion.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
[0001] The present invention relates to a door drive for garage, garden, hall or factory doors, comprising a motor unit which comprises a drive motor and a motor output shaft, an output transmission, which on the input end can be connected with the motor output shaft and on the output end includes a transmission output shaft for driving a door moving element, in particular a door shaft, a release clutch for releasing the motor output shaft with respect to the door moving element as well as a damping element for damping drive shocks.
[0002] For driving doors such as garage doors, garden doors, hall doors or also large factory doors, there are regularly used electric motors which drive a door moving element, mostly a door shaft, via an output transmission, in order to wind up for instance a door cable or a door chain to which the door is attached. It is appreciated that other door moving elements can be used as well. To be more precise, there are actually provided two transmissions between the actual drive motor and the door moving element. First of all, the regularly very high speed of the electric motor is reduced for instance via a worm gear stage to the speed of the motor output shaft. However, this first gear stage forms part of the motor unit, so to speak, and often forms part of the purchased electric motor or the motor unit. In order to adapt the speed of the motor output shaft to the requirements of the door drive, there is also used a further gear stage, which is seated on the motor output shaft and together with the transmission output shaft drives the door moving element.
[0003] For this output transmission, a transmission housing usually is provided on the motor unit, in which the transmission elements, mostly a spur gear stage, are disposed and on which the transmission output shaft is supported.
[0004] Dimensional tolerances of many individual parts, however, often lead to inaccuracies inside the transmission. Damping and release additionally are provided at various points, so that generally long tolerance chains are obtained. In addition, the motor unit must separately be adjusted for the respective application.
SUMMARY OF THE INVENTION
[0005] Proceeding therefrom, it is the object underlying the present invention to create an improved door drive as mentioned above, which eliminates the disadvantages of the prior art and develops the latter in an advantageous way. In particular, an adaptation of the drive motor to the door to be driven should be provided with simple means and long tolerance chains inside the output transmission should thereby be avoided.
[0006] In accordance with the present invention, this object is solved by a door drive as described herein. Preferred aspects of the invention are subject-matter of the description herein.
[0007] Thus, it is proposed to no longer integrate the output transmission in the motor unit or the housing of the motor unit. In accordance with the present invention it is rather provided that the output transmission has a transmission housing formed separate from the motor unit and together with the release clutch and the damping element forms an independent, modular drive attachment which on the one hand can be connected to the motor unit and the motor output shaft thereof and on the other hand to the door moving element. For the door drive, a modular structure is proposed. The separate drive attachment thus can close the gap in the drive train between the drive motor and the door moving element. On the one hand, the motor unit appropriate for the respective door can be attached to or mounted on the drive attachment, for which purpose the drive attachment includes connecting means adapted to the respective motor unit. On the other hand, the drive attachment includes connecting means adaptable to the respective door moving element, so as to be connectable to the respective door moving element. By forming the output transmission as a separate drive attachment, a long tolerance chain is avoided. In addition, integrating the release clutch and the damping element in this drive attachment thus can provide a complete package which meets the necessary requirements for a door drive, such as release and, damping of drive shocks, independent of the design of the motor unit.
[0008] In accordance with a development of the invention, further functional components of the door drive can be integrated in the separate drive attachment. In accordance with a development of the invention, a travel sensing means, preferably a pulse disk, for detecting the door position is integrated in the drive attachment, in particular accommodated inside the transmission housing. The travel sensing means advantageously is disposed on the output end of the release clutch, and when the travel sensing means is formed with a pulse disk, the latter can directly be seated on the transmission output shaft. Advantageously, the associated pulse reader likewise is disposed inside the transmission housing.
[0009] Alternatively or in addition, a release detection means for detecting the release position of the release clutch can also be integrated in the separate drive attachment, so that the function of monitoring the release is also realized by the drive attachment. The release detection means can include a limit switch which detects the release position of the release clutch and in addition can effect a shutdown of the energy supply of the motor unit when the release of the release clutch is detected. The limit switch can be attached to the transmission housing and monitor the actuation of a release lever which actuates the release clutch and likewise can be mounted on the transmission housing.
[0010] To be able to connect the appropriate drive motor in a suitable orientation, various and/or variable connecting means for the motor unit are provided on the motor connection end of the drive attachment in accordance with a development of the invention, so that various motor units and/or the same motor unit in various orientations can be attached to the drive attachment relative to the same. The connecting means can comprise, for instance, a plurality of sets of bores, through which the drive attachment can be screwed to the respective motor unit. In particular, the connecting means are provided on the transmission housing, in order to screw the same to the motor unit.
[0011] Alternatively or in addition, the drive attachment can also include on its output end various and/or variable connecting means for connecting various door moving elements and/or the same door moving element in various orientations.
[0012] Particularly advantageously, the motor-end connecting means of the drive attachment can comprise a quick locking device for quickly locking the drive attachment with respect to the motor unit. According to one embodiment of the invention, the quick locking device can be designed so as to be actuatable without any tool. In particular, a bayonet lock can be provided between the motor unit and the drive attachment, by means of which the drive attachment can be attached to the motor unit particularly quickly. The quick locking device is characterized in that motor-end engagement means and engagement means adapted thereto, which are provided on the drive attachment, can be brought in a positive locking engagement by combining an axial movement and a rotary movement. According to an advantageous embodiment of the invention, there can be provided engagement claws rotatably mounted about the motor output shaft or about an axis of rotation parallel thereto, which can be brought in engagement with engagement recesses formed complementary thereto.
[0013] In principle, the transmission housing can have various designs. According to a preferred embodiment of the invention, it consists of two shells which can be placed on top of each other and one of which includes the connecting means for connecting the motor unit and the other one includes bearing means for supporting the transmission housing with respect to the driving forces or torques.
[0014] Advantageously, various gear stages can be inserted in the transmission housing of the drive attachment, in order to realize various step-up or step-down ratios between the motor output shaft and the transmission output shaft. By means of such a replaceable gear stage, the speed provided by the motor output shaft can be adapted to the requirements of the respective door, without a completely different drive attachment having to be provided each time.
[0015] In particular, the replaceable gear stage can include a pair of spur gears, which comprises a smaller and a larger spur gear. To this end, the step-up or step-down ratio provided by the gear stage can simply be changed in that the two spur gears are exchanged for each other, which is possible with the axial distance remaining the same. Alternatively or in addition, other pairs of spur gears can also be inserted in the transmission housing, in order to achieve completely different or further variations of the step-up or step-down ratio.
[0016] In principle, the gear stage can be mounted in the transmission housing in various ways. According to an advantageous embodiment of the invention, all transmission gear wheels of the gear stage are supported on the same transmission housing shell. Thereby, a precise mounting can be achieved, which is not influenced by connection tolerances of various housing parts.
[0017] The damping element for absorbing drive shocks can be integrated in the drive attachment in various ways. According to a preferred embodiment of the invention, the damping element is disposed on a damping element carrier, which is releasably connected with the transmission housing, preferably attached to the outside of the transmission housing. The damping element carrier preferably can consist of a damping sheet, which on the end face is releasably attached, in particular screwed to the transmission housing in the vicinity of the exit of the transmission output shaft, and includes a damping element seat radially spaced from the transmission output shaft. The damping element can for instance be pivotally mounted on a door frame or another component supported with respect to the door moving element, so that drive shocks induced by the driving forces or torques can be absorbed. Advantageously, the damping sheet is screwed to the transmission housing on several points around the exit of the transmission output shaft, so that the drive shocks are absorbed centrally. Preferably, the damping element carrier and/or the transmission housing includes several and/or variable connecting means, in order to provide for connection of the damping element carrier to the transmission housing in different positions. The damping element carrier can in particular be screwed to the transmission housing in various positions, for instance rotated by a specified angular offset, in order to provide for attachment in the most favorable way.
[0018] Alternatively or in addition to such damping element, a damping element can also be provided between the drive attachment and the motor unit, wherein this damping element advantageously includes damping means acting radially with respect to the motor output shaft and/or in peripheral direction around the motor output shaft. According to an advantageous embodiment of the invention, the damping element can form an annular damping disk, which is seated between the motor unit and the drive attachment mounted thereon and preferably is in positive engagement with said two components. The annular damping disk can have axial and/or radial engagement protrusions and/or recesses, by means of which it is in positive engagement with the motor unit and the drive attachment or with interposed components each connected therewith.
[0019] In particular, the damping element can be formed and/or arranged such that it can be fixed between the drive attachment and the motor unit by the aforementioned quick locking device. The damping element is integrated, so to speak, in the quick locking device.
[0020] To achieve a small-size arrangement, at least the locking and unlocking elements of the release clutch are disposed inside the transmission housing. In particular, the release clutch can be disposed between the transmission output shaft and one of the transmission gear wheels of the gear stage, which is seated on said transmission output shaft or connected therewith. The release clutch can include an actuating pin at least partly movably received in the transmission output shaft, which can be actuated by an actuator disposed on the outside of the transmission housing. Said actuating pin can actuate a feather key which is axially movably mounted on the transmission output shaft and depending on the axial position locks or releases the transmission gear wheel seated on the transmission output shaft with respect to the same.
[0021] In accordance with a development of the invention, the gear stage provided in the drive attachment is not the only gear stage of the entire door drive. In particular, the motor unit itself can also include the commonly used gear stage for reducing the speed of the electric motor to the speed of the motor output shaft. For instance, between the electric motor shaft and the motor output shaft a worm gear stage or also a straight bevel gear stage can be interposed, which, however, forms an integral part of the motor unit and is accommodated inside the motor housing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] The invention will subsequently be explained in detail with reference to preferred embodiments and associated drawings, in which:
[0023] FIG. 1 : shows a perspective exploded view of a door drive with a drive attachment according to a preferred embodiment of the invention; and
[0024] FIG. 2 : shows a perspective exploded view of a door drive with a drive attachment according to another preferred embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0025] The door drive 1 shown in FIG. 1 comprises a motor unit 2 with an electric motor 3 as well as a motor output shaft 4 , which in the illustrated embodiment extends transverse to the longitudinal axis of the electric motor 3 . As an electric motor 3 , different types of motor can be used. The motor output shaft 4 advantageously is coupled to the motor shaft of the electric motor 3 via a transmission 5 , in order to convert the usually rather high speed of the electric motor 3 into a relatively lower speed of the motor output shaft 4 . The transmission 5 is accommodated in the housing 6 of the motor unit 2 and in principle can have various designs. In particular, a worm-gear transmission or a straight-bevel-gear transmission can be provided, in order to realize the speed reduction in the desired way. Said transmission 5 is part of the motor unit 2 .
[0026] On the motor output shaft 4 of the motor unit 2 a drive attachment 7 can be mounted, which includes an output transmission 8 and further functional door drive components. By means of this transmission attachment, a required adaptation of the speed of the motor output shaft 4 to the desired speed, for instance of a door shaft, can again be realized, for instance to be able to use the motor unit 2 for various doors. The drive attachment 7 constitutes an independent functional block, which can be interposed, so to speak, between the motor unit 2 and the door moving element to be moved, which is not separately shown in the drawing, and forms the part of the drive train between the motor unit 2 and the door moving element. By means of this drive attachment 7 , which forms a complete functional unit, the door drive 1 obtains a modular structure, which allows to assemble the door drive 1 from individual modules and adapt the same to the requirements of the respective use. The drive attachment 7 comprises a motor-end interface, so that it can be connected with various motor units, and on the other hand an output-end interface for connecting the drive attachment 7 with the respective door moving element. Said interfaces comprise suitable connecting means 9 and 10 , to provide for a torque-transmitting connection of the drive attachment 7 to the motor unit 2 or the door moving element. In the illustrated embodiment, a screw connection is provided as a motor-end connecting means 9 , by means of which the housing 11 of the drive attachment 7 can releasably be attached to the housing 6 of the motor unit 2 .
[0027] As shown in FIG. 1 , the drive attachment 7 comprises an output transmission 8 , which in the illustrated embodiment constitutes a spur-gear transmission with two spur gear wheels 13 and 14 . The output transmission 8 is disposed in the transmission housing 11 of the drive attachment 7 . In the illustrated embodiment, said transmission housing 11 has a two-shell configuration. A lower housing shell 15 can be attached to the motor unit 2 in the way mentioned above and can be closed by an upper housing shell 16 .
[0028] The lower housing shell 15 comprises suitable bearing means 17 for supporting the transmission elements of the output transmission 8 . It is appreciated that the upper housing shell 16 can also have corresponding bearing means for supporting the spur gear wheels 13 and 14 .
[0029] The spur gear transmission stage 12 as shown in the Figure allows to easily change the step-up or step-down ratio of the output transmission 8 , without the axial distance of the spur gear wheels 13 and 14 and hence the corresponding bearing means 17 having to be changed. One can change, for instance, from a step-down ratio to a step-up ratio by replacing a smaller spur gear wheel 13 by a larger spur gear wheel and a larger spur gear wheel 14 by a smaller spur gear wheel.
[0030] On the motor end, the output transmission 8 can be connected with the motor output shaft 4 . For this purpose, the spur gear wheel 14 can non-rotatably be connected with the motor output shaft 4 , when the transmission attachment is mounted on the motor unit 2 . On the output end, the spur gear wheel 13 drives a transmission output shaft 18 , on which said spur gear wheel 13 is seated and which on the end face protrudes from the upper housing shell 16 or is accessible from the outside through an output recess 19 , in order to be coupled to the door moving element.
[0031] Between said spur gear wheel 13 and the transmission output shaft 18 a release clutch is provided, by means of which the transmission output shaft 18 can be unlocked with respect to the motor unit 2 . In the illustrated embodiment, the coupling element of the release clutch 20 is integrated in the transmission output shaft 18 or the spur gear wheel 13 . As shown in the Figure, the release clutch 20 comprises a feather key 21 , which is axially movably, but non-rotatably mounted in a feather key recess 22 in the transmission output shaft 18 . On the spur gear wheel 13 , a feather key recess likewise is provided in the end face of the internal recess, so that depending on the position of the feather key 21 the spur gear wheel 13 is non-rotatably locked with respect to the transmission output shaft 18 or is released with respect to the same and hence rotatable therewith. The feather key 21 is biased into its locking position by a spring means in the form of a compression spring 23 . Said compression spring 23 is accommodated in an axial bore inside the transmission output shaft 18 . On the opposite side of the compression spring 23 , an actuating pin 24 is seated in the same axial bore in the transmission output shaft 18 , which protrudes from the end face of the transmission output shaft 18 and also protrudes from the same through an actuating recess in the lower housing shell 15 or can be actuated from the outside of the lower housing shell 15 . For actuating the actuating pin 24 and hence the release clutch 20 , a release lever 25 is provided, which is mounted on the transmission housing 11 , in particular on the lower housing shell 15 . The release lever 25 is pivotally and/or movably mounted between a non-engagement-position and an engagement position, and in the last-mentioned engagement position it is in engagement with the actuating pin 24 and urges the same into the transmission output shaft 18 , so that the feather key 21 is urged into its non-engagement position.
[0032] The lower housing shell 15 advantageously comprises a plurality of bearing means for the release lever 25 , so that the same can be mounted on the outside of the lower housing shell 15 in various orientations.
[0033] The position of the release lever 25 is monitored by a limit switch 26 , which on a suitable point is firmly mounted on the transmission housing 11 . When the release lever 25 is moved into its release position, this is detected by the limit switch 26 , which can provide a corresponding message to the control means of the door drive, and can in particular interrupt the power supply for the entire door drive 1 , in particular the motor unit 2 .
[0034] Furthermore, a travel sensing means 27 is integrated in the drive attachment 7 , which includes a pulse disk 28 that is coupled to the transmission output shaft 18 such that it rotates in a predetermined way corresponding to the rotation of the transmission output shaft 18 . In the illustrated embodiment, the pulse disk 28 advantageously is directly non-rotatably seated on the transmission output shaft 18 . Since the pulse disk 28 is coupled to the transmission output shaft 18 , the travel sensing means 28 always, in particular also when the release clutch 20 is disengaged, knows the position of the transmission output shaft 18 and hence of the door to be driven. The pulse disk 28 cooperates with a pulse reader, which advantageously likewise is accommodated inside the transmission housing 11 of the drive attachment 7 . Like the limit switch 26 , the travel sensing means 27 is connected with the control means of the door drive 1 in a non-illustrated way.
[0035] With its end protruding from the upper housing shell 16 , the transmission output shaft 18 has coupling means on its end face for coupling to a door shaft not shown in the Figure. In the vicinity of the exit of the transmission output shaft 18 from the transmission housing 11 , a damping means 29 is attached to the transmission housing 11 , in order to absorb drive shocks. As shown in the Figure, the damping means 29 comprises a damping element 30 which in principle can have various configurations. In the illustrated embodiment, the damping element 30 is formed by a spring. The damping element 30 is attached to a damping element carrier, which in the illustrated embodiment constitutes a damping sheet 31 . In the vicinity of the exit of the transmission output shaft 18 , the damping sheet 31 is seated on the upper housing shell 16 and itself includes a recess 32 , through which the transmission output shaft 18 can extend. The damping sheet 31 can non-rotatably be attached to the transmission housing 11 by means of a screw connection 33 . Advantageously, the bores 34 in the damping sheet 31 and/or in the upper housing shell 16 are formed and/or distributed such that the damping sheet 31 can be attached to the transmission housing 11 in several positions that are rotated with respect to each other.
[0036] FIG. 2 shows another advantageous embodiment of a door drive, which in many aspects corresponds to the door drive as shown in FIG. 1 and includes corresponding components, so that for corresponding components the same reference numerals are used as in FIG. 1 , and in so far reference is made to the preceding description. The embodiment as shown in FIG. 2 substantially differs in the formation of the connecting means of the drive attachment 7 for attachment to the motor unit 2 as well as in a damping element disposed on the motor end between the drive attachment 7 and the motor unit 2 .
[0037] In particular, the drive attachment 7 can be attached to the motor unit 2 by a quick-locking device 36 , as shown in FIG. 2 . The quick-locking device 36 comprises a bayonet lock 37 , by means of which the drive attachment 7 can be positively coupled to the motor unit 2 by combining an axial movement substantially parallel to the motor output shaft 4 and a rotary movement around the same. Advantageously, an only rather small rotary movement, for instance about an angle of rotation less than π, is sufficient.
[0038] As shown in FIG. 2 , the bayonet lock 37 comprises a rotary locking plate 41 with radially protruding engagement arms or claws 38 , said rotary locking plate 41 including a central recess by means of which it can be moved over the motor output shaft 4 . Said rotary locking plate 41 can be rotatably mounted on the motor unit 2 , in particular the housing 6 of the motor unit 2 , namely about an axis of rotation parallel, in particular coaxial to the motor output shaft 4 . In the illustrated embodiment, the rotary locking plate 41 can be fixed at the motor unit 2 by a spacer plate 42 , which itself can be screwed to the housing 6 of the motor unit 2 . The rotary locking plate 41 is rotatable with respect to the spacer plate 42 .
[0039] On the housing shell 15 of the drive attachment 7 , the bayonet lock 37 on the other hand includes engagement recesses 39 not shown in the drawing, which cooperate with the aforementioned engagement claws 38 of the rotary locking plate 41 and are adapted to the shape thereof. For fastening the drive attachment 7 , the same merely is mounted on the motor unit 2 in an axial direction parallel to the motor output shaft 4 , the engagement claws 38 moving into the engagement recesses 39 . Then, locking can be effected merely by a relative rotation of engagement claws 38 and engagement recesses 39 .
[0040] As is furthermore shown in FIG. 2 , the damping element 40 is seated between the motor unit 2 and the drive attachment 7 , which in the illustrated embodiment constitutes an annular damping disk through which the motor output shaft 4 extends. In the illustrated embodiment, said damping element 40 concretely is seated between the aforementioned spacer plate 42 firmly connectable with the motor unit 2 and the housing shell 15 of the drive attachment 7 . As shown in FIG. 2 , damping recesses 43 are formed in the spacer plate 42 , which engage in the engagement protrusions 44 on the damping element 40 , so that the damping element 40 is positively retained at the spacer plate 42 . Said engagement protrusions 44 also extend towards the housing shell 15 of the drive attachment 7 , where they engage in likewise formed damping recesses. Via said positive engagement means 44 , the damping element 40 both acts radially and in peripheral direction. The damping element 40 is made of a suitable shock-absorbing and/or vibration-absorbing material.
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The present invention relates to a door drive for garage, garden, hall or factory doors, comprising a motor unit which comprises a drive motor and a motor output shaft, an output transmission, which on the input end can be connected with the motor output shaft and on the output end includes a transmission output shaft for driving a door moving element, in particular a door shaft, a release clutch for releasing the motor output shaft with respect to the door moving element as well as at least one damping element for damping drive shocks. In accordance with the invention, the door drive is characterized in that the output transmission includes a transmission housing formed separate from the motor unit and together with the release clutch and the damping element forms a separate, modular drive attachment, which can be connected on the one hand to the motor unit and on the other hand to the door moving element.
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This application claims the benefit of U.S. Provisional Application No. 60/446,214 filed Feb. 10, 2003.
BACKGROUND OF THE INVENTION
This invention relates generally to ladders that incorporate safety features, and more particularly to ladders that provide warnings to a user that the ladder is about to tip.
Conventional household ladders (including step ladders and extension ladders) have enjoyed near universal acceptance by combining their ability to facilitate reaching remote areas with portable, human-carryable packaging. Nevertheless, conventional household ladders tip over when the combined center of gravity of a user (i.e., climber) and the ladder moves to a point beyond the foot of the ladder. In such a case a moment is produced, and while the frictional force of the wall tends to counter the torque caused by the moment, often it is not enough to prevent the ladder from tipping. Unbalance leading to ladder tipping typically occurs in one of two ways. In the first, the climber leans over too far to one side such that the center of gravity is beyond the ladder footprint. In the second, the ladder is placed leaning to one side, such as due to being placed on an uneven surface. In this latter case, the vertical line from the center of gravity of the ladder may not initially be beyond a foot of the ladder; however, as the climber moves higher up the ladder, the combined center of gravity of the ladder and the climber moves outside the ladder feet. Even though the imbalance leading to tipping of a ladder develops only gradually in this second instance, the climber remains unaware of the hazard until it is too late and the ladder tips over.
Accordingly, there exists a need for improvements in ladder design to enhance ladder safety, especially as it relates to ladder tipping. Moreover, there exists a need for notorious warnings that can alert a ladder user that a dangerous operating condition is imminent. Furthermore, there exists a need for a ladder that can deploy additional stabilizing members in response to dangerous ladder operating conditions. In addition, there exists a need for such a ladder that provides the above while being inexpensive and without sacrificing its human-carryable attributes.
SUMMARY OF THE INVENTION
These needs are met by the present invention. According to a first aspect of the present invention, a ladder configured to be carried by at least one human user is disclosed. The ladder includes a plurality of legs and rungs, one or more weight sensors coupled to at least one of the plurality of legs or rungs, a controller signally coupled to the one or more sensors a tip warning system and a power source to energize at least the tip warning system. The tip warning system is responsive to the controller such that upon attainment of a predetermined signal threshold, at least one of an audio or visual alarm provides notorious indicia to the user.
Optionally, the ladder is configured such that the one or more weight sensors are disposed adjacent the first end. Furthermore, the one or more weight sensors are disposed beneath the first end such that when the first end is placed upon a ladder-supporting surface, the sensor (or sensors) can measure a weight imposed by the ladder (when no one is standing on it) or by the combined weight of the ladder and a user standing on the ladder. In one form, the predetermined signal threshold can be a sensed weight that falls below a predetermined minimum. For example, if the signal threshold is set such that a sensed weight reading of close to zero (or some other predetermined number) registers with the controller (which would indicate that the weight sensor in question is detecting a significantly reduced load corresponding to the predetermined number), then the tip warning system would activate to alert the user of the unstable condition. In another form, a plurality of weight sensors can be deployed on the ladder so that the predetermined signal threshold could either be the predetermined minimum weight reading as discussed above, or another parameter such as the difference or ratio between the plurality of weight sensors, where the difference exceeds a predetermined maximum. In this configuration, it is a weight differential (either in the form of a simple difference or a ratio of readings from the disparate sensors) that is the triggering signal rather than the absolute value of the single weight sensor configuration above. This could be used, for example, in conjunction with laterally-spaced weight sensors so that the onset of a side-to-side imbalance could be sensed prior to such an imbalance becoming dangerous. The controller can be analog-based, utilizing comparator integrated circuits, or digital-based, using analog to digital (A/D) converters and a microprocessor.
The ladder may further include a movable counterbalancing weight responsive to the controller such that it deploys upon attainment of the predetermined signal threshold. At least one of the alarms can be disposed adjacent the second end. For example, where the alarm is a visual alarm (such as lights or a display, both discussed in more detail below), such an arrangement beneficially places the visual alarm relatively close to a user's eye such that early recognition of a potentially unsafe ladder operating condition is being approached. In yet another option, the power source can be a battery, solar cell or the like. Moreover, the ladder is preferably a household ladder, such as a stepladder or an extension ladder. As mentioned above, the visual alarm may be made up of one or more lights, where in the case of a plurality of lights, each of the plurality of lights corresponds to particular ladder safety category, such as a first safety category, a second safety category and a third safety category, or to a system operational status (for example, indicating whether the system is on or off). Similarly, the audio alarm can be one or more buzzers, a prerecorded verbal warning or the like. In the case of a buzzer, the alarm can be configured to emit tones of progressively higher frequency or volume as the ladder gets closer to an unstable, imbalanced position.
According to another aspect of the invention, a tip-sensing ladder is disclosed. The ladder includes a plurality of legs defined by a first end and a second end, a plurality of rungs disposed between the legs and a tip warning system. The system includes a plurality of weight sensors coupled to legs or rungs, a controller signally coupled to the weight sensors, a plurality of alarms comprising an audio alarm and a visual alarm, and a power source. The alarms are responsive to the controller such that upon attainment of a predetermined signal threshold in the controller, at least one of the alarms activates.
According to still another aspect of the invention, a method of using a ladder is disclosed. The method includes configuring a ladder similar to that of at least one of the previously-described aspects, placing the tip warning system in an operational condition, placing the ladder against a ladder engaging surface, climbing the ladder such that indicia is provided to a climber thereof to indicate at least one of an operational status or a ladder safety category. Optionally, the ladder safety category comprises at least two first ladder safety categories, where the first is indicative of no imminent tipping, while a second is indicative of a possible tipping condition.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
The following detailed description of specific embodiments of the present invention can be best understood when read in conjunction with the following drawings, where like structure is indicated with like reference numerals and in which:
FIG. 1 illustrates a ladder according to an embodiment of the present invention;
FIG. 2 illustrates a Wheatstone bridge circuit incorporating weight sensors R 1 and R 2 ;
FIG. 3A illustrates one form of visual display used to indicate the level of imbalance;
FIG. 3B illustrates another form of visual display used to project a warning sign;
FIG. 4 illustrates a modified Wheatstone bridge circuit incorporating the weight sensors R 1 and R 2 ;
FIG. 5 illustrates the circuit of FIG. 4 integrated with a quad comparator to sense ladder imbalance;
FIG. 6 illustrates MOSFET logic using input from the comparator of FIG. 5 to control a plurality of colored lights and buzzers; and
FIG. 7 illustrates an optional counterbalance weight attached to the ladder of FIG. 1 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring initially to FIGS. 1 , 3 A and 3 B, a ladder 10 according to an embodiment of the present invention is shown placed on a ladder-engaging surface 5 (such as a floor, the ground or the like). Ladder 10 includes a pair of legs 12 each defined by a first end 12 A positioned on ladder-engaging surface 5 , and second end 12 B opposite first end 12 A, and a plurality of rungs 14 that connect the legs 12 together. It will be appreciated by those skilled in the art that while the embodiment depicted in the figure is a fixed household ladder, the present invention is equally suitable to extension ladders, step ladders, folding ladders or the like. In the present context, the phrase “household ladder” is not meant to limit applicability to ladders used in private, residential settings. As such, the phrase is understood to include commercial and non-residential variants, so long as the ladder is portable by being human-carryable, such as those that can be carried by an individual. Ladders that generally do not qualify as “household” or “human-carryable” are those that form an integral part of a larger structure, such as a ladder that is permanently or semi-permanently secured to a fire-engine or related safety vehicle.
Ladder 10 includes weight sensors 20 , controller 30 and one or more audio alarms 40 and visual alarms 50 , where visual alarm 50 is shown in one form as a series of lights 50 A, 50 B, 50 C. Visual alarm 50 can be made up of a series of lights, where the lights are color-coded. For example, a green light 50 A can indicate a first ladder safety category, while a yellow light 50 B can indicate a second ladder safety category (possibly coinciding with a condition requiring caution), and a red light 50 C to indicate a third ladder safety category (possibly coinciding with a dangerous operating condition with a significant amount of imbalance). Together, weight sensors 20 , controller 30 and alarms 40 and 50 make up tip warning system 60 , where tip warning system 60 can give the ladder “smart” features such that it can sense and convey to the user indicia of an impending dangerous operating condition faster than the user can.
Referring with particularity to FIGS. 3A and 3B , two variations on an alternate embodiment of the visual alarm is shown, where in the first variation of FIG. 3A , a meter 100 registers the degree of imbalance, while in a second variation of FIG. 3B , a warning display 200 responds to controller 30 by highlighting various words dependent upon the ladder safety category (also known as the imbalance status), where the aforementioned first ladder safety condition is accompanied by a green color display 200 A of the word SAFE, a moderate amount of imbalance (commensurate with the aforementioned second ladder safety condition) is indicated by a yellow display 200 B of the word CAUTION, and a hazardous condition (equivalent to the aforementioned third ladder safety condition) indicated by a red display 200 C of the exclamation DANGER! as shown. Also as previously discussed, the hazardous condition could also be accompanied by an audible warning from audio alarm 40 .
Referring with particularity to FIG. 1 , weight sensors 20 are placed at the bottom of each leg 12 . In a preferable form, the weight sensors 20 are of lightweight construction such that they do not appreciably add to the overall weight of ladder 10 . In one form, the sensors 20 are of the laminated thin-film variety, where the electrical conductance is substantially proportional to the applied force or weight upon them. In the present context, the term “substantially” is utilized to represent the inherent degree of uncertainty that may be attributed to any quantitative comparison, value, measurement, or other representation. As such, it refers to an arrangement of elements or features that, while in theory would be expected to exhibit exact correspondence or behavior, may in practice embody something slightly less than exact. The term also represents the degree by which a quantitative representation may vary from a stated reference without resulting in a change in the basic function of the subject matter at issue. Although shown with two weight sensors 20 , it is also within the scope of the present invention to configure the ladder 10 with a single weight sensor 20 , mounted at or near the first end 12 A of one of the legs 12 . As previously discussed, the sensors 20 can either be coupled so that they send a difference or ratio signal to controller 30 , or they can be independent, where each can respond to a predetermined weight threshold stored in the memory of controller 30 . For example, the stored threshold may be an equivalent to an absolute force value, such as something at or near zero pounds force, zero being the condition prerequisite on one of its legs 12 for ladder 10 tipping. By using weight sensors 20 rather than a conventional pendulum-based indicator, the present invention allows a more accurate reading to be taken, as the weight sensor (or sensors) 20 can account for user-generated moments that a pendulum-based or switch-based device would not be sensitive to. This additional sensitivity is possible because the tip warning system 60 of the present invention can discriminate against user weight on the lower rungs 14 A, as such condition is not as likely to produce a tipping condition as that when the user is on the middle or upper rungs 14 B, 14 C. By contrast, a pendulum-based or switch-based device is responsive only to the angle the switch or pendulum registers relative to a predetermined axis.
Referring next to FIG. 2 , a Wheatstone (or resistance) bridge type electrical circuit 36 was formed incorporating two weight sensors 20 that demonstrate variable resistance R 1 and R 2 and two fixed resistors 22 that demonstrate substantially fixed resistance R 0 , where the imbalance between the sensor voltages provided a measure of the weight imbalance at the legs 12 . As mentioned in the previous paragraph, weights measured by the sensors 20 can be used to send a weight difference or a weight ratio to the controller 30 . For example, the measure of imbalance between the two weight sensors 20 can be given by the simple ratio of (W 1 −W 2 )/(W 1 +W 2 ), where W 1 and W 2 represent the measured weight at each of the sensors 20 , respectively. In such circumstance, it will be readily appreciated that the range of imbalance is normalized between −1 and 1, thereby removing the need for calculating actual weight values and making the range of imbalance applicable for climbers of various weights. A zero reading means an exact balance (W 1 =W 2 ) between the two sensors 20 , and an imbalance measure of ±1 means instability resulting from either of the two sensors 20 registering a weight value that approaches zero. Thresholds for the aforementioned heightened alert displays 200 B and 200 C can be set by a choice of the values for the imbalance measure.
Battery 32 (for example, a conventional nine-volt battery) provides power to controller 30 , although it will be appreciated that other power sources could be employed, including, for example, solar cells or related photovoltaic devices. When equal weight is applied to both sensors 20 , R 1 will equal R 2 and the corresponding output voltages V 1 and V 2 will be equal. Contrarily, a weight imbalance on ladder 10 shows up as a difference between V 1 and V 2 . In the simplest system, output voltages V 1 and V 2 could be wired directly to meter 100 , as shown in FIG. 3A . In a preferred (but by no means necessary) system, the output voltages V 1 and V 2 will be further processed by either digital or analog electronics in controller 30 to provide a more reliable warning system. In one preferred embodiment, voltages V 1 and V 2 will be read by controller 30 that would include an analog-to-digital (A/D) converter and a microprocessor (not shown). The microprocessor will control the tip warning system 60 according to a program stored into its memory where, as previously discussed, the tip warning system 60 may include one or more of the aforementioned alarms, such as the lights 50 , meter 100 , display 200 , audio system 40 or some combination thereof. The measured values from the weight sensors 20 are then used to calculate the imbalance according to an algorithm and compared to a predetermined threshold. If controller 30 detects imbalance beyond the predetermined threshold, at least one of the audio and visual alarms 40 , 50 are activated to alert the user. Tip warning system 60 can be programmed such that the companion audio alarm 40 responds either progressively (with, for example, a loudness or frequency level that increases concomitant to the aforementioned ladder safety category) or selectively (for example, not until a predetermined threshold). The indicia enabled by audio alarm 40 is beneficial in that a ladder user need not constantly maintain line-of-sight contact with a visual alarm to be apprised of a potentially dangerous ladder 10 operating condition. The two separate forms of indicia made possible by combining audio and video alarms 40 , 50 further improves the chances that a user will be alerted that a potentially dangerous ladder operating condition has been, or is about to be, reached. Operational status of tip warning system 60 could be ensured by including a confirmation signal, such as a simple, slow-period (i.e., low frequency) beep from the audio alarm 40 or a slow-period flash of light from the visual alarm 50 .
Referring next to FIGS. 4 through 6 , an approach to sensing and alerting a user as to the presence of a ladder imbalance is shown. Referring with particularity to FIG. 4 , a modified Wheatstone bridge 80 incorporating the weight sensing resistors 20 (again capable of registering variable resistance R 1 and R 2 ) is shown. FIG. 5 shows how the various connections a, b, c, d, e, f and g of the Wheatstone bridge 80 of FIG. 4 are integrated with a quad comparator 90 to provide the imbalance triggers that are then fed into the controller 30 logic circuit shown in FIG. 6 . While one way to operate the tip warning system 60 is to monitor in real time the weight on each leg 12 such that one or both of the alarms 40 , 50 are activated whenever the sensed weight on either leg 12 falls below preset limits, it is more reliable and more independent of the user's weight to implement tip warning system 60 in the manner described next.
The construction of modified Wheatstone bridge 80 is such that two voltage divider chains 82 , 84 comprise three resistors each. The first chain 82 includes resistors R 3 , R 4 and R 5 while the second 84 includes resistors R 6 , R 7 and R 8 . In one implementation, the resistors R 3 , R 5 , R 6 and R 8 are 10 kilo-ohms each, while resistors R 4 and R 7 are each a 22 kilo-ohms adjustable potentiometers. The resistor junctions d, e, f and g provide convenient reference voltages for comparator 90 to analyze the voltage appearing at the junction b between the weight sensors 20 (with the aforementioned variable resistances R 1 and R 2 , respectively). As shown in FIG. 5 , the four comparator circuits 92 , 94 , 96 and 98 within comparator 90 were set up to compare the voltage appearing at junction b with that at junctions d, e, f and g, respectively. Circuit 91 is arranged with two pairs of comparators that are wired such that switch signals occur at points A and B at certain levels of ladder imbalance as the values measured by weight sensors 20 vary. The variable resistors R 4 and R 7 can be adjusted to select the levels of imbalance between weight sensors 20 at which A and B switch to a low voltage reading. By choosing resistor R 7 to be greater than resistor R 4 , point A is ensured to switch from a high voltage to a low voltage before point B does. Initially, with weight sensors 20 being comparable in value, the output voltage at points A and B are both high. Analysis shows that point A stays high as long as (R 3 /(R 4 +R 5 ))<(R 1 /R 2 )<((R 4 +R 3 )R 5 ) and switch to the low state outside this range (where R 1 corresponds to the weight sensor 20 located between points b and c in FIG. 4 and R 2 corresponds to the weight sensor 20 located between points a and b). With resistor R 3 chosen equal to resistor R 5 for symmetric switching, the magnitude of resistor R 4 determines the point at which point A would switch. The larger the value of resistor R 4 , the greater the imbalance between R 1 and R 2 required for the switch to occur. As an example, if R 3 =R 5 =R 6 =R 8 and R 4 is twice the value of R 3 , and R 7 is three times the value of R 3 , then point A would stay high for a ratio of R 1 to R 2 (or R 2 to R 1 , depending on which of the weight sensors 20 registers the larger load) less than three, and would switch to low when the ratio becomes greater than three. Similarly, point B will switch from high to low when the ratio of R 1 to R 2 (or R 2 to R 1 for the reason mentioned above) is greater than four. The switching of points A and B can be exploited to activate the audio alarm 40 and the lights 50 A, 50 B, 50 C or displays 100 , 200 , shown and described previously when a state of imbalance is approached or achieved.
Referring with particularity to FIG. 6 , specific implementation of the embodiment of tip warning system 60 employing the series of lights 50 A, SOB, 50 C is shown. The simplest logic implementation was achieved using four MOSFETs 52 , 54 , 56 and 58 as shown. The output from point A is connected to the gate of MOSFET 52 while point B is connected to the gate of MOSFET 56 . With points A and B registering high voltages, only the green light 50 A is turned on. When point A switched to a low voltage, the yellow light 50 B comes on while green light 50 A is turned off. With point B also switching to a low voltage (while point A stays low), the red light 50 C is turned on while yellow light 50 B is turned off. Audio alarm 40 connected in parallel with the lights 50 A, 50 B, 50 C can provide audio warnings. As previously mentioned, different sounds (or even different audio alarms 40 ) can be used to give a user a distinguishable audible warning depending on the severity of the imbalance, where variations in tone, volume or any other easily-perceivable quantity can be utilized. In the case of tone variation, the audio alarm 40 can emit a slow beep or, alternatively, a low frequency signal for a first ladder safety condition, with progressively higher frequency signals for the second and third ladder safety conditions.
The attributes of tip warning system 60 hitherto described are of a passive nature; while the system 60 senses force values and reports possible ladder imbalance conditions, it does nothing to correct a potentially dangerous situation. Referring next to FIG. 7 , ladder 10 may incorporate active tip-prevention features that utilize the imbalance information generated in the tip warning system 60 by deploying one or more members that are attached to the ladder 10 . In one form, the tip-prevention member is made up of one or more deployable counterbalancing weights 15 . These weights 15 can be released upon appropriate signal from controller 30 to motor 18 that drives a screw 17 that turns gear 16 to which weight 15 is attached. When user 1 leans too far to one lateral side of ladder 10 , sensors 20 detect the weight shift, causing controller 30 to activate motor 18 , screw 17 , gear 16 , which in turn causes deployment of counterbalancing weight 15 to the opposing lateral side of ladder 10 . In other configurations, the weight 15 could be spring-loaded or even manually adjustable.
Having described the invention in detail and by reference to specific embodiments thereof, it will be apparent that modifications and variations are possible without departing from the scope of the invention defined in the appended claims. More specifically, although some aspects of the present invention are identified herein as preferred or particularly advantageous, it is contemplated that the present invention is not necessarily limited to these preferred aspects of the invention.
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A ladder with a tip warning system. The ladder is configured to be carried by at least one human user, and includes a plurality of legs with rungs disposed between the legs, and a tip warning system. The tip warning system includes an audio alarm and a visual alarm, a power source, one or more weight sensors and a controller signally coupled to the weight sensors. Imbalance conditions, such as due to the weight of a climber extending beyond the footprint of the ladder, generate an imbalance signal that activates the tip warning system to provide notorious indicia of such condition to the user. In one form, a counterweight activated by the imbalance signal may be incorporated to correct dangerous operating conditions.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. application Ser. No. 11/700,545, filed Jan. 31, 2007, now U.S. Pat. No. 7,693,623 which claims the benefit of U.S. Provisional Patent Application Ser. No. 60/763,713, filed Jan. 31, 2006, and Ser. No. 60/844,866, filed Sep. 15, 2006. The above applications are incorporated herein by reference in their entirety.
TECHNICAL FIELD
This invention relates to railroad snow removal systems. More particularly, the present invention relates to a monitoring and control system for a network of snow removal devices.
BACKGROUND OF THE INVENTION
During the winter it is not uncommon for snow and ice to accumulate on and around railroad tracks. To maintain optimal track performance it is desirable to keep certain areas of the track free of snow and ice year round. For example, it is particularly desirable to keep the areas where tracks cross each other (frogs) and where tracks merge or split (switches) free of snow and ice. Though the system of the present disclosure will be described herein primarily with reference to railroad track switches, the description is not meant to be limiting. It should be appreciated that the system is applicable to other applications as well.
Railroad track switches are used to divert a train from one train track to another train track. The railroad switches typically include a pair of rails that move from a first position to a second position. The switches typically include moving parts that are exposed to the environment. Snow and ice build-up on the switch can cause the switch to malfunction.
A number of different types of railroad track switch snow removers are known. See, for example, U.S. Pat. No. 5,824,997 to Reichle et al.; U.S. Pat. No. 4,391,425 to Keep, Jr.; and U.S. Pat. No. 4,081,161 to Upright. The railroad track switch snow remover often includes a blower that blows heated air or ambient air across the switch. Though some heaters and blowers of the snow removing devices are electric powered, most are gas powered, as they are typically located in remote locations. Sometimes the snow removers include temperature and moisture sensors so that an operator at a remote location can determine when to turn the devices on or off. Some devices are programmed to automatically turn themselves on or off depending on the reading from the sensors.
A problem with the existing systems is that malfunctioning device can be difficult to identify. In some cases, the devices are turned on when it is not snowing or turned off when it is snowing. In the first case, fuel is wasted, and in the second, the switch may malfunction due to undesirable snow accumulation in the tracks. Moreover, existing switch snow removal control systems are not configured to collect, store, and/or report data regarding performance and other conditions of the device. A system that can be used to effectively monitor and control snow removal devices located in remote locations is desirable.
SUMMARY OF THE INVENTION
The present invention relates to a system for controlling and monitoring snow removal devices. According to one embodiment, the snow removal devices include sensors for measuring data, and a processor remotely transmits the measured data to a base station. In some embodiments the measured data is environmental data that can be accessed by an operator remotely on a handheld device or at a computer terminal operably connected to the snow removal devices. In such an embodiment, the operator can monitor the device and choose to override the automated operation of the snow removal devices.
According to another embodiment, the geographic location of each snow removal device is stored in a memory location on the device or at the base station, and the base station is configured to query the weather conditions at the stored geographic location.
In one embodiment, the measured data is compared with the queried data. If the measured data is within a certain predetermined acceptable range compared to the queried weather data, the snow removal device is characterized as being operational. However, if the sensor reading is outside of a predetermined range the operator is alerted. In an alternative embodiment the query data is processed to determine whether the snow removal device that corresponds with the particular geographic location should be on or off. The base station then determines whether the snow removal device is in fact on or off. If there is a discrepancy, the base station automatically notifies an operator.
In another embodiment the queried and measured data relate to the operational conditions of the device rather than environmental conditions. For example, the data may relate to the amount of fuel consumed by the device or amount of fuel remaining in the device. The measured data can be compared with data stored on a database that can be accessed by the base station. If a discrepancy is detected, the operator is alerted.
According to another embodiment the user can monitor and control the device via a computer or a handheld wireless computing device. The data is represented graphically to the operator via icons on a map, and the devices can be controlled by the user remotely.
A variety of additional inventive aspects will be set forth in the description that follows. The inventive aspects can relate to an individual feature or to a combination of features. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the broad inventive concepts upon which the embodiments disclosed herein are based.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a flow chart of a method of monitoring and controlling railroad switch snow removal devices in accordance with an embodiment of the invention;
FIG. 2 is a flow chart of an alternative method of monitoring and controlling railroad switch snow removal devices in accordance with an embodiment of the invention;
FIG. 3 depicts the network including a plurality of railroad switch snow removal devices according to an embodiment of the invention;
FIG. 4 is a schematic block diagram of a snow removal control unit according to an embodiment of the invention;
FIG. 5 depicts a user interface according to an embodiment of the invention;
FIG. 6 is a schematic illustration of a fuel tank monitoring system according to one embodiment of the invention;
FIG. 7 is a schematic illustration of several possible scenarios that are used to describe the operations of the invention;
FIG. 8 is a screen shot that displays a summary of the operating conditions of related snow melters according to an embodiment of the invention;
FIG. 9 is a screen shot that displays the detailed operating conditions of a selected snow melter according to an embodiment of the invention;
FIG. 10 is a screen shot that displays the control modes and on/off parameters of a selected snow melter according to an embodiment of the invention;
FIG. 11 is a screen shot that displays user rights to snow melters according to an embodiment of the invention;
FIG. 12 is a screen shot that displays fault notifications of snow melters according to an embodiment of the invention;
FIG. 13 is a screen shot that displays the location and identification of snow melters according to an embodiment of the invention;
FIG. 14 is a schematic diagram of an embodiment of the network according to the present disclosure; and
FIG. 15 is a schematic diagram of the embodiment of the network shown if FIG. 14 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring primarily to FIGS. 1 and 3 , a method of monitoring railroad switch snow removal devices 200 is shown. The first step includes identifying 10 a device and checking if the device 200 (shown schematically in FIG. 4 ) is on or off. In some embodiments the geographic location is stored at the base station 202 corresponding to a particular device identification number. In another embodiment the geographic location is stored at a memory location 301 at snow removal device 200 . The geographic location can be any number of references. In some embodiments, the geographic location is identified as specific geographic coordinates (e.g., longitude and latitude), while in other embodiments the geographic location is identified as a particular zip code. For example, referring to FIG. 13 , the snow melter is shown associated with a serial number, name, zip code, latitude, longitude, region, division, subdivision, and mile post. In some embodiments the above information is recorded and tracked by a provider upon installation of the snow removal devices.
Next, the base station 202 collects 20 weather data from a secondary source 204 that corresponds to the particular identified geographic location. Some exemplary secondary sources for weather data include: www.weather.com, www.cnn.com/weather/, and www.wunderground.com. Once the weather data is queried, the base station 202 determines 30 whether the device 200 should be on or off and checks 40 for any discrepancy. For example, if the secondary source indicates heavy snow at the particular geographic location, then the device should be on. In contrast, if the secondary source indicates that it is warm and sunny at the particular geographic location, the device should probably be turned off. If a discrepancy is detected, an operator 206 is alerted 50 so that the operator can investigate the discrepancy.
Referring to FIGS. 2 and 4 , an alternative method of monitoring and controlling railroad switch snow removal devices 200 is shown. The first step includes measuring 100 operating and environmental conditions. This step, for example, may include the step of measuring the ambient temperature, the ambient moisture content, and the available fuel. The next step is processing the data 112 by comparing 120 the measured data to a predetermined set of criteria. This step can include comparing the data with a predetermined set of criteria saved in a local memory location 301 to determine if snow is falling and if the device has enough fuel to run properly. In some embodiments this step is accomplished locally by the processor 300 that is located at the snow removal device 200 . In some embodiments, depending on the rate of snowfall, the ambient temperature, and the available fuel, the snow removal device 200 may automatically turn on or off as appropriate to ensure that snow and ice do not accumulate on the rails 402 of the switch 400 . In some embodiments the temperature of the heating or lack thereof is determined based on the measured criteria. For example, if the snow is determined to be dry and light, the heater 302 of the snow removal device 200 may be left off to conserve fuel and only the blower 304 will be turned on.
Referring primarily to FIGS. 2 , 3 and 4 , in some embodiments if the measured values are outside of a predetermined set of values an alert is transmitted 116 to the base station 202 . In some embodiments the base station 202 is configured to translate the received signal and determine, for example, whether a particular sensor 306 , 308 , 310 , 312 has malfunctioned or if the device is out of fuel. When an alert is sent, an operator 206 can view the alert remotely when connected to the base station 202 . In some embodiments the base station 202 is configured to page the operator 206 whenever a certain type of alert is received. For example, the base station 202 may be programmed to page the operator 206 when a snow removal device 200 has run out of fuel and snow is falling at that particular location. Such an alert enables an operator 206 to anticipate the failure of the particular switch 400 and make alternative arrangements as necessary.
Still referring primarily to FIGS. 2 , 3 and 4 , in the depicted embodiment the base station 202 measures 100 data from the snow removal devices 200 according to a maintenance check schedule. In some embodiments the collection of data is accomplished by configuring the snow removal devices 200 to periodically or continuously transmit measured data back to the base station 202 . In other embodiments, the base station 202 is configured to query data from the snow removal devices 200 at certain times or on command. The base station 202 also collects 118 a comparable set of data from a secondary source 204 . It should be appreciated that the step of collecting data from a secondary source can occur before, after, or simultaneously with the step of collecting data from the devices 200 . The secondary source 204 in some embodiments includes real time weather information. In other embodiments the secondary source includes maintenance records, such as the last time the snow removal devices 200 were refueled. Subsequently, the data collected from the snow removal devices 200 is compared with the data collected from the secondary sources 204 . If the datum from the snow removal devices 200 and the secondary sources 204 are outside of an acceptable range, an alert is triggered at the base station.
An alert may indicate, for example, that the snow removal device 200 is apparently low on fuel, even though the secondary source 204 maintenance records indicate that the snow removal device 200 was recently refueled. Once alerted to the discrepancy, the operator can investigate the issue further to determine if the snow removal device 200 is leaking, if the secondary source 204 maintenance records are inaccurate, or if the fuel sensor is inaccurate. If the operator 206 decides that the measured value is inaccurate, the operator 206 can reset (e.g., recalibrate) 122 the sensor or otherwise dismiss 126 the alert. In some embodiments the recalibration can be accomplished remotely, and in other embodiments the recalibration is accomplished via the user interface 314 located locally on the snow removal device 200 . In such embodiments the device 200 includes a receiver in addition to the transmitter 612 .
Alternatively, an alert may indicate, for example, that the measured temperature is substantially different than the temperature collected from the secondary weather data source that corresponds to the particular geographic location, which is measured and stored in a memory location. Once alerted of the discrepancy, the operator 206 may choose to override 124 the automatic on off control of the snow removal device 200 if appropriate, or otherwise dismiss 126 the alert. In such embodiments the device 200 includes a receiver in addition to the transmitter 612 . An operator 206 can check other nearby sensors or other secondary sources to determine whether the measured data or the queried data is more likely accurate.
Finally, the base station 202 can be configured to store 128 all the dates and times that the measured data from each snow removal device 200 was checked against data from a secondary source 204 . In some embodiments the next date and time that the measured data from that particular snow removal device 200 is check against data from a secondary source 204 is dependent on when the last check occurred and the outcome of the last check. In some embodiments, a number of different types of measured data is stored at the base station for maintenance purposes.
Referring primarily to FIG. 5 , according to one embodiment of the invention the data transmitted and processed at the base station can be accessed via an internet webpage. The data can in some embodiments be graphically represented via icons 401 , 403 , 404 , 406 , and 408 along tracks 410 on a map displayed on a computer screen 414 . The user can check the operational parameters and the measured data by clicking on the icon that corresponds with the snow removal device 200 of interest. In some embodiments an alert is indicated on the map by a flashing icon or an icon that turns a particular color, such as orange or red. In other embodiments, the color of the icon 401 , 403 , 404 , 406 , and 408 corresponds with whether the particular corresponding snow removal device 200 is on or off or is full or low on fuel.
According to some embodiments the data can be accessed by the operator 206 wirelessly on a handheld device 500 . In such an embodiment the operator can be in transit to service a particular snow removal device 200 and access real time data regarding the snow removal devices 200 in the field.
Referring to FIG. 6 , an embodiment is shown where fuel tank related data is measured to determine if the tank 600 is expected to be operational. To be operational the tank 600 must be able to supply fuel to the burner 604 . In the depicted embodiment the supplied fuel 618 is in gas form (e.g., propane or natural gas). To enable larger amounts of fuel 602 to be stored within the tank 600 , the fuel 602 in the depicted embodiment is pressurized so that most of the fuel 602 in the tank 600 is in liquid form. Fuel must change phase from liquid to gas to be effectively used. Accordingly, the mere fact that the tank 600 is not empty does not necessarily mean that the tank 600 is expected to be operational. Since whether a particular liquid will change into a gas is dependent on the temperature of the liquid and the pressure in the tank 600 , the temperature of the fuel 602 within the tank 600 and the pressure within the tank 600 factor into whether the tank 600 is operational (the colder a liquid is, the less likely the liquid will vaporize at a given pressure). In view of the above, as compared to only knowing the amount of fuel 602 in the tank 600 , also knowing the temperature of the fuel 602 , and the pressure within the tank 600 enables one to more accurately predict whether the tank 600 is operational.
According to one embodiment, to accurately estimate whether the tank 600 will be operational under certain conditions, preferably at least the following types of data are measured: the temperature in the tank 600 or the fuel 602 therein, the pressure within the tank 600 , and the level of liquid fuel within the tank 600 . Accordingly, to such an embodiment the system includes a temperature sensor 606 , a pressure sensor 608 , and a fuel level sensor 610 . It should, however, be appreciated that in alternative embodiments sensors measuring different data may be included. It should also be appreciated that alternative embodiments may include more or fewer sensors in part depending on the specific methodology used to analyze the data, which will be discussed in greater detail below. It should be appreciated that in alternative embodiments an electric heat non-combustion source may be employed (e.g., electric calrod heater). Such systems could include a system for measuring whether the necessary electric energy exists, similar to the fuel tank monitoring system described above.
In the depicted embodiment the sensors are connected to a transmitter 612 that is configured to transmit the measured data to a remote base station 614 or a network server 616 or both. In one embodiment the base station 614 uses equations to calculate whether or not the tank 600 is expected to be operational based on the measured data and known or inputted data. In other embodiments the base station 614 relies on empirical data to make its determination regarding the operability of the tank 600 . In yet other embodiments, a combination of empirical charts and equations are used in the analysis. In embodiments where empirical data is used in the analysis, the empirical data may be stored locally on a remote database and accessible via a network. In the depicted embodiment the empirical data is stored on a remote server 616 and accessible via the internet 620 . Base station 614 can be connected to the transmitter 612 via the cellular telephone network directly, or via a short range wireless communication system such as any of a variety of 802.11 wireless networks (e.g., Wi-MAX or Wi-Fi) or any radio or other wireless or wire communication systems.
In some embodiments the base station 614 tracks and stores the measured data to analyze the fuel usage history. For example, in some embodiments the level of fuel in the tank 600 is tracked over a set period of time. Such tracking can be used for many purposes including, for example, determining whether the measured data is likely accurate or inaccurate, or whether the sensors are operable and/or whether the tank 600 is leaking. For example, if the tracked history indicates that the tank 600 was initially full and has been in use for a very short period of time or no time at all but is now empty, the tank 600 may be leaking or the measured data may be inaccurate. In some embodiments the base station 614 is configured to alert the operator when a potential problem is detected.
The system disclosed in FIG. 6 , may also be used by an operator in determining the type of fuel that should be used for a particular application. In some embodiments the conditions, such as the expected ambient temperatures, may make a certain type of fuel preferable. The effectiveness and efficiency of particular fuels can be analyzed at the base station 614 based on the data collected by the sensors 606 , 608 , and 610 . It should be appreciated that many other analyses can be conducted based on data measured by the sensors and/or data queried from a local or remote server 616 .
Referring to FIG. 7 , the process of determining when it is appropriate to alert the operator of a failure or otherwise initiate the process of override, the operations of a failed device is illustrated. It is desirable to avoid false detection of device failures, which are the results of normal error. For example, for a period of time the device might be ON while it is snowing. During this period the operation of the system may be characterized by the upper left quadrant (i.e., the device is ON and the device should be ON). The snow might stop, but for a relatively short period of time the device might still be ON. During this period the operation of the system can be characterized as having moved to the lower left quadrant (i.e., the device is ON and the device should be OFF). During this time period, fuel is being wasted. This might occur because the sensors on the device, or the empirical data, or both, are slightly off. To avoid alerting the operator relating to small discrepancies which in time correct themselves, the system can be set up such that the system must operate in the lower left state for more than an hour before an alert is sent to the operator or a failure is otherwise deemed. On the other hand, the system be might be operating in the upper left quadrant and move to the upper right quadrant. This would occur if snow continue to fall, but the device turns itself off (i.e., the device is OFF and the device should be ON). Since it is important to prevent railroad switch failure, the system might be set to alert an operator or otherwise consider the discrepancy a failure after a relatively shorter period of time, for example, 10 minutes instead of an hour.
Still referring to FIG. 7 , as discussed above the time period for acceptable discrepancies is dependent on the type of discrepancy (i.e., if the device is ON when it should be off versus the device is off when it should be on). Another factor can relate to the context (i.e., what quadrant was the device previously operating in). For example, there may exist reasons to set different acceptable time periods of discrepancies based on whether the device moves into the upper right quadrant from the upper left quadrant or from the lower right quadrant. If the device moves to the lower right quadrant from the upper right quadrant (i.e., it starts from the state where it is OFF and it should be OFF, and moves to the state where it is OFF but should be on), the period of time of acceptable discrepancy might be longer than if the device moves to the same quadrant from the upper left quadrant. The latter occurrence might more likely indicate a failure, whereas the former might more likely indicate normal sensor variations.
Referring to FIGS. 8-13 , a specific embodiment of an internet based system is described in greater detail below. FIG. 8 is a screen shot showing a summary of the operating condition of snow melters under the control of a particular user. In the depicted embodiment, the summary of the snow melters can be organized by the user according to region, division, subdivision, mile post, or site group. In the depicted screen shot the designated region is North and the designated division is Twin Cities. Three snow melters fall within this category (i.e., East Wayzata, West Delano, and West Wayzata). The subdivision, mile post, and temperature for each of the three melters are displayed. In addition, the status and whether the melters are running are also displayed. From this screen the user can select any one of the three snow melters for further analysis.
FIG. 9 is a screen shot that corresponds with the East Wayzata snow melter shown in FIG. 8 . In addition to the summary information regarding the snow melter, detailed information relating to the control and operation parameters are displayed. In the depicted screen shot, East Wayzata is not running due to the air temperature, as shown under the machine status column. Other status options include Idle, Running-OK, Not Running-Faulted, Not Running-Timed Out, Not Running-Should Be-Weather, Running-Should Not Be-Weather, and Communication Failure. In the depicted embodiment, action is called (not running due to air temperature) for by the Weather Watcher system, which is driven by the secondary source data. In the depicted embodiment the secondary source data can be used as a check on the local sensors and controls on the snow melter, or it can be used to drive the system. If the local controls and sensors are used to drive the action of the system, the secondary weather data is used as a check and issues alerts when a discrepancy is detected.
Still referring to FIG. 9 , from this view the user can view an array of current status data that includes: fuel tank level, temperature set points, run time data, air temperature, rail temperature, motor voltage, duct pressure, gas pressure, total gas used, motor current, etc. Also, a link is provided to view a snapshot of the site to enable the operator to view the site. The fuel tank level is used to determine if the tank needs to be refilled, and also to calculate whether the tank is operational based on the temperature and other factors. The motor voltage and current are used to determine if the snow melter motor is operational, and also if the motor is running optimally or likely to fail. The duct pressure and gas pressure are used to troubleshoot, and also used to determine if the tank is expected to be operational. In addition, from this view the user clicks on tabs to further investigate the last fault reading, the operational history, and other control settings.
FIG. 10 is a screen shot that corresponds with the Controls tab of FIG. 9 . From this view the user can remotely operate the snow melter. The user can turn on or off the snow melter, adjust the temperature set points, and adjust the run times. In the depicted view the snow melter is configured to turn on continually when the air temperature is less than one degree Fahrenheit. The air temperature set point can also be used to prevent the snow melter from turning on. For example, the system can be configured such that if a sensed temperature is above a certain level, the device does not turn on.
Referring to FIG. 11 , a screen shot of the user assignment page is shown. The user assignment function allows for different levels of access rights to be assigned to different operators. Some operators can be authorized only to view the system, and others can be authorized to edit and modify the system. Moreover, those who are authorized to edit and modify the system may be authorized to edit and modify specific aspects of the system (e.g., gas, run hours, fault counts, and overtemp latch). In the depicted embodiment, all of the operators have full authorization to the system.
Referring to FIG. 12 , a screen shot of the notification setup is shown. The notification function allows for selective notification. Particular types of notification can be sent to particular users via particular means. For example, in the depicted embodiment, Peter Molenda is set to receive notification of fuse 2 faults by email only, whereas Eric Schneider is set to receive fuse 1 faults via cell phone, temperature faults via pager, and fuse 2 faults via email and work phone. In the depicted embodiment, the system administrator is set to receive notification of all of the faults. This system enables the messages to be sent to the person who is responsible for or best suited to dealing with the particular issue. FIG. 13 , as discussed above, is used to log in the identifying information of each of the snow melters.
Referring to FIGS. 14 and 15 , a general overview of a particular embodiment of a network according to the present disclosure is included below. The components of the network architecture include: SMC—Snow Melter Controller; RCC—Remote Communications Controller; WEB—Web services and portal hosting; SQL—SQL Server database; RR—Railroad client accessing web portals.
The general messaging flow scenarios are summarized below in outline form:
1. SMC Initiated
SMC RCC SMC detects a change of operating state (i.e. from off to running) and initiates a conversation with the RCC. SMC sends a message to the RCC containing the current snow melter operating and configuration parameters. RCC accepts and acknowledges the message from the SMC. SMC closes the conversation with the RCC after 1 minute of idle time. RCC captures the parameter values from the message. RCC WEB RCC initiates a conversation with the WEB. RCC sends the current snow melter parameters to the WEB. WEB acknowledges the message from the RCC. RCC closes the conversation with the WEB immediately. WEB captures the parameter values from the message. WEB updates the SQL database with the snow melter parameter values. WEB USER WEB analyzes the snow melter change of state to determine notification requirements. WEB issues notification messages to railroad clients for new snow melter conditions.
2. RCC Initiated
RCC SMC RCC initiates a conversation with the SMC. RCC sends a message to the SMC containing the command number. SMC accepts and acknowledges the message from the RCC. Included in the acknowledgement are all SMC parameter values. RCC closes the conversation with the SMC after 1 minute of idle time. RCC captures the parameter values from the message. RCC WEB RCC initiates a conversation with the WEB. RCC sends the current snow melter parameters to the WEB. WEB acknowledges the message from the RCC. RCC closes the conversation with the WEB immediately. WEB captures the parameter values from the message. WEB updates the SQL database with the snow melter parameter values. WEB USER WEB analyzes the snow melter change of state to determine notification requirements. WEB issues notification messages to railroad clients for new snow melter conditions.
3. WEB Initiated
WEB RCC WEB user presses the “Refresh Values” button on a web page. WEB initiates a conversation with the RCC. WEB sends a message to the RCC containing the command number. RCC accepts and acknowledges the message from the WEB. RCC SMC RCC initiates a conversation with the SMC. RCC sends a message to the SMC containing the command number. SMC accepts and acknowledges the message from the RCC. Included in the acknowledgement are all SMC parameter values. RCC closes the conversation with the SMC after 1 minute of idle time. RCC captures the parameter values from the message. RCC WEB RCC initiates a conversation with the WEB. RCC sends the current snow melter parameters to the WEB. WEB acknowledges the message from the RCC. RCC closes the conversation with the WEB immediately. WEB captures the parameter values from the message. WEB updates the SQL database with the snow melter parameter values. WEB USER WEB analyzes the snow melter change of state to determine notification requirements. WEB issues notification messages to railroad clients for new snow melter conditions.
From the foregoing detailed description, it will be evident that modifications and variations can be made in the devices and methods of the disclosure without departing from the spirit and scope of the invention.
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A snow removal system wherein snow removers located in remote locations can be monitored and controlled at a computing device. Data collected by sensors on the snow removal unit or data collected from a secondary source can be used to control the operation of the snow removers. In one embodiment, data regarding whether it is snowing at a particular location can be collected by moister sensors on the snow removal device and verified by on-line contemporaneous weather reports corresponding to the same location.
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CLAIMS OF PRIORITY
[0001] This patent application claims priority from the Provisional Patent Application No. 2689/CHE/2012 and No 2690/CHE/2012 filed on 4 Jul. 2012. It also claims priority from Provisional patent applications No 3042/CHE/2012, No 3044/CHE/2012 and No 3045/CHE/2012 filed on 25 Jul. 2012.
FIELD OF TECHNOLOGY
[0002] This disclosure relates generally to technical fields of Occupational Health protection from sun light, and comfort, involving mechanism and computer, and in one embodiment to a device to shade a person in large open space, from a height by means of shading units moving at large height in synchrony with the movement of the person.
SUMMARY
[0003] A device, system, and method to provide shade from bright sunshine from large height, by means of shading units which moves in synchrony with a person, a animal to be shaded and synchronized with the angle of solar radiation so that the place where the person is present is always shaded and additionally cool air applied to small local area by directed pulsed air jets, is disclosed. In one aspect, the device addresses the problem of occupational hazard from bright sunshine for people working in large open spaces, involved in sports, in recreation at beach etc, leading to long periods of exposure to sun and especially professional players with long practice sessions. The devise is a recreation enabler in sports for corporate executives for whom hot sunshine and high temperature is a disincentive and discouraging and this device allows full utilization of stadiums when not having tournaments.
[0004] In another aspect, the prior art has shading structures covering entire stadium which is expensive to build and the natural effect of open sun light is obstructed and diminished. The present invention maintains the beautiful natural effect of sunlight. Prior art has devises wherein hydrogen balloons tied by string to the person to be shaded from small height, but this obstructs the activity and the view of spectators. People have thought of large artificial cloud and shading structures held by helicopters to shade from great height but this is going to be expensive and consumes high power and also high noise level, aerodynamic stability and safety problems especially when large crowds are present below. Air conditioning of entire stadium is very expensive and a power guzzler. The present invention is low on infrastructure cost and low on power consumption compared to prior art while still giving the comfortable condition for work and play in the most economical and compact manner.
[0005] Prior art quoted by preliminary search authority under PCT being general state of art, are US 2011315811 A1 where a lighter than air vehicle is used for shading and has the problem of wind management as wind effects increase with size and air vehicle has low maneuverability and serious safety problem for persons below on ground in case of the unit or a component falling off from large height and does not involve dynamic matching of person to be shaded with the position of the air vehicle. The Japanese patent quoted being JP 2008212421 A uses flying shading unit to shade a person does not use cameras to capture the fast changing position of the person and does not synchronize shading unit with anticipated movement with manual support where necessary, as required in a sport event and also does not correct the problem due to wind specially when shading unit is at large height and has no feedback of shading unit position error. The other quoted patent U.S. Pat. No. 2,693,230 being general state of art. The present invention over comes the problems in the prior art.
[0006] The matching of the pattern of shade in small-required area to the pattern of location of person dynamically within required time as in sport event using image of person being shaded and image of shading unit for feedback and correction with wind management and particularly since the shading unit is small and is located at large height, the pattern matching is the inventive major step in working of the device. The use of aerodynamic control for the shading unit and split arrangement of film in shading unit is the most essential ingredient for the proper working of the device since it is at large height and subject to wind. Drive for the shading unit is one by means of cable and one by on board electric motor and one by compressed air jet. The suspension of shading unit is by cable, which is ideal for most continuous use conditions. For rapid and urgent deployment, the shading unit with propeller drive to lift and move, having a single cable wire to supply electrical power to the propeller drive motor, is used in spite of difficulty in stabilization under windy condition. The presence of flexible and light structure of shading unit is essential for safety, using water filled rubber bags for counter weight in cantilever suspension, along with safety cable to hold the unit.
[0007] The plurality of camera capture position coordinates of the person to be shaded selected with distinguishing color of dress and tag when attached, based on the coordinates of person to be shaded, the right shading unit is selected as per deployment plan and shading unit is moved to the required position calculated, thereafter the persons location is tracked and predicted by software by extrapolation and velocity calculation and where needed predicted by the help of operator who sees image on monitor screen and moves cursor pointer from his experience and direction of movement of the person, taking into account sharp changes in direction as it occurs.
[0008] The scope of the invention extends to workers in construction site and agricultural farms and sea rigs, where wearing full clothing to cover in hot humid weather will be uncomfortable due to sweat accumulation and resulting uneasiness, so when shaded by the device dynamically the uncomfortable itching sensation is not there leading to improved productivity of work. Tourists in beach specially in tropical areas can enjoy the beach side at any time of the day of their choice due to the shading device. The device allows horse racing to be conducted even in hot countries. No where in the world is present a shading system as of the sort of above device in any sports stadium where the shade pattern follows the location of the player. It is surprising, by looking at old to present books on sports and open space activities, the way people have been tolerating blazing sun through out history with some relief from hat and umbrella where fast activity is not involved. It is unfair that sports heros are being subjected to hot sun while the spectators of sports sit under shaded comfort. People with sun allergy will benefit from the device. Women who generally avoid sunshine to protect their fair white complexion can participate in sports.
[0009] The device, systems, and methods disclosed herein may be implemented in any means for achieving various aspects, and may be executed in a form of a machine-readable medium embodying a set of instructions that, when executed by a machine, cause the machine to perform any of the operations disclosed herein. Other features will be apparent from the accompanying drawings and from the detailed description that follows.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] Example embodiments are illustrated by way of example and not limitation, in the figures of the accompanying drawings, in which like references indicate similar elements and in which:
[0011] FIG. 1 is a aerial view of stadium with dynamic shading devise showing stadium with shading units at large height, according to one embodiment.
[0012] FIG. 2 is a view of person in shaded zone, with shade from shading unit, according to one embodiment.
[0013] FIG. 3 is a cross section view of shading unit, cable drive, positioning and aerodynamic wind control cable, according to one embodiment.
[0014] FIG. 4 is shading unit having slot with flap for wind management, according to one embodiment.
[0015] FIG. 5 is a shading unit with cantilever arm suspended from supporting cable, according to one embodiment.
[0016] FIG. 6 is a Cantilever arm with shading unit near border and camera unit on gimbal mounting, according to one embodiment.
[0017] FIG. 7 is a shading unit with propeller drive and buoyancy balloon, according to one embodiment.
[0018] FIG. 8 is a shading unit with on board motor drive and remote radio receiver according to one embodiment.
[0019] FIG. 9 is a shading unit with pneumatic drive, according to one embodiment.
[0020] FIG. 10 is a cross section view of double layer based shading unit, according to one embodiment.
[0021] FIG. 11 is a side view of double layer based shading unit, according to one embodiment.
[0022] FIG. 12 is a system view of a multiple cable spool drive, according to one embodiment.
[0023] FIG. 13 is a system view of entire device for race course for horses, according to one embodiment.
[0024] FIG. 14 is a system view of dynamic shading with cantilever unit at curves, according to one embodiment.
[0025] FIG. 15 is a system view of entire device on the beach with floating towers based cable hold, according to one embodiment.
[0026] FIG. 16 is a system view of entire device for shading construction workers, according to one embodiment.
[0027] FIG. 17 is a system view of dynamic shading of workers at road under construction, according to one embodiment.
[0028] FIG. 18 is a view of pulsed cold air pipe line with rotating popup nozzle, according to one embodiment.
[0029] FIG. 19 is a view of cold air nozzle with rotation drive motor and retraction solenoid, according to one embodiment.
[0030] Other features of the present embodiments will be apparent from the accompanying drawings and from the detailed description that follows.
DETAILED DESCRIPTION
[0031] A device, system, and method to provide shade from bright sunshine from large height, in one embodiment about 100 feet from ground, by means of shading units which move in synchrony with the movement of person, animal to be shaded and the angle of solar radiation so that the place where the person is present is always shaded, is disclosed. Although the present embodiments have been described with reference to specific example embodiments, it will be evident that various modifications and changes may be made to these embodiments without departing from the broader spirit and scope of the various embodiments.
[0032] FIG. 1 is a aerial view of stadium with dynamic shading devise showing stadium with shading units at large height, according to one embodiment. Particularly, FIG. 1 illustrates a stadium 101 , spectator gallery 102 , cable tower 103 which is taller than floodlights generally used in stadium, shading unit 104 present at a high level, cantilever arm with shading unit near border 105 , player who is shaded 106 , the bright sun 107 , and cable of shading unit 108 , according to one embodiment.
[0033] In example embodiment, the shading units do not obstruct the view of spectators
[0034] FIG. 2 is a view of a person in shaded zone, according to one embodiment. Particularly, FIG. 2 illustrates the shading unit at large height which moves to a position calculated based on the suns angular position in such a way that the shade forms a zone around the person 201 who has no need to wear a cap, the shaded zone 202 , a shading unit 203 , cable of shading unit 204 , the sun 206 , according to one embodiment.
[0035] FIG. 3 is a cross section view of shading unit, cable drive and aerodynamic wind control cable, according to one embodiment. Particularly FIG. 3 illustrates the cable tower 301 , shading unit 302 , electric motor with cable spool 303 , electric motor for wind control cable 304 , wind control cable 305 .
[0036] The cable spools and drive motor in case of stadium is on the roof of spectator gallery.
[0037] FIG. 4 is a shading unit having slot with flap for wind management, according to one embodiment. Particularly, FIG. 4 illustrates a shading unit 400 , support cable of the shading unit 401 , cable for wind control 402 , slot 403 to equalize pressure on both sides over which sits flap, drive cable for the shading unit 405 , according to one embodiment.
[0038] FIG. 5 is a shading unit with cantilever arm suspended from supporting cable, according to one embodiment. Particularly, FIG. 5 illustrates the shading unit which moves on the cantilever arm 501 , cantilever arm 502 , counter weight 503 made of water filled rubber bag, supporting cable 504 , cable for movement and rotation of arm 505 , control and stabilizer cable for shading unit 506 , according to one embodiment.
[0039] FIG. 6 is a cantilever arm with shading unit near border and camera unit on gimbal mounting, according to one embodiment, Particularly, FIG. 6 illustrates the tower 601 , cantilever arm 602 , shading unit 603 , camera unit on gimbal 604 for getting persons location coordinates, and shading unit position for feedback, pole for fixing camera unit 605 , drive cable for shading unit 606 , electric drive motor 607 , person shaded 608 according to one embodiment.
[0040] The rotation of cantilever arm and movement of shading unit is by means of electric motor controlled by computer.
[0041] FIG. 7 is shading unit with propeller drive and buoyancy balloon, according to one embodiment. Particularly, FIG. 7 illustrates the shading unit 701 , electric motor for driving propeller 702 , propeller 703 , buoyancy balloon with hydrogen gas 704 , slot with flap for wind pressure reduction 705 , frame 706 , power and control signal cable 707 , micro controller for propeller and motor control 708 , according to one embodiment.
[0042] FIG. 8 is shading unit with on board motor drive and remote radio receiver according to one embodiment. Particularly, FIG. 8 illustrates the shading unit 800 , frame 801 , electric motor 802 to move shading unit by winding in cable 803 on spool 804 , flap for wind management and control of shading unit 805 , flap moving electric motor with cable 806 , radio control receiver with microprocessor 807 , according to one embodiment.
[0043] FIG. 9 is a shading unit with pneumatic drive using compressed air, according to one embodiment. Particularly, FIG. 9 illustrates the shading unit 901 , flexible hose pipe for compressed air 902 , control valve 903 , nozzles 904 and 905 , according to one embodiment.
[0044] FIG. 10 is a cross section view of double layer based shading unit, according to one embodiment. Particularly, FIG. 10 illustrates the frame 1001 , upper layer film 1002 , lower layer film 1003 , suspender through which the support cable passes 1004 , according to one embodiment.
[0045] This arrangement is mainly to manage wind.
[0046] FIG. 11 is a a side view of double layer based shading unit, according to one embodiment. Particularly, FIG. 11 illustrates frame 1101 , upper layer film 1102 , lower layer film 1103 , drive cable 1104 , wind control cable 1105 , according to one embodiment.
[0047] FIG. 12 is a system view of a multiple cable spool drive, according to one embodiment. Particularly, FIG. 12 illustrates the drive motor 1201 for forward drive, shaft 1202 , belt drive 1203 , clutch unit 1204 for forward drive, brake and hold unit 1205 , drive cable 1206 on spool 1207 , brake control cable 1208 and clutch control cable 1209 both operated by solenoids controlled by computer, clutch for reverse drive 1210 , drive motor 1211 for reverse drive, according to one embodiment.
[0048] The actuate and de actuate timing of the clutch and brake is calculated by the computer based on the position needed for shading unit. The cable spool at one end winds up while the cable spool at other end unwinds.
[0049] FIG. 13 is a system view of entire devise for race course, according to one embodiment. Particularly, FIG. 13 illustrates the race course with horse track 1301 , horse with rider 1302 , tower at border 1303 , main support cable 1304 , shading unit 1305 , support cable for shading unit 1306 , drive cable of shading unit 1307 , cool air dispenser 1308 , wind control cable of shading unit 1309 , the bright sun 1310 , according to one embodiment.
[0050] FIG. 14 is a system view of dynamic shading with cantilever unit at curves, according to one embodiment. Particularly, FIG. 14 illustrates the horse track at curve 1401 , horse with rider 1402 , tower for cantilever 1403 , cantilever 1404 , shading unit 1405 , electric motor with cable drive for shading unit 1406 , the bright sun 1407 , according to one embodiment.
[0051] FIG. 15 is a system view of entire devise on the beach with floating towers based cable hold, according to one embodiment. Particularly, FIG. 15 illustrates the beach 1501 , the sea 1502 , tower near sea front 1503 , main support cable 1504 , support cable for the shading unit 1505 , shading unit 1506 , drive cable for shading unit 1507 , wind control cable of shading unit 1508 , person on beach 1509 , person in the sea 1510 , the bright sun 1511 , camera on gimbal 1512 , floating platform with tower 1513 anchored by cables to sea floor, tower arm holding the cable end support with sliding clutch 1514 to which the main support cable is connected, according to one embodiment.
[0052] The person on Beach to be shaded is identified by unique color tag.
[0053] FIG. 16 is a system view of entire devise for shading construction workers, according to one embodiment. Particularly, FIG. 16 illustrates the building under construction 1601 , tower to hold cables 1602 , main support cable 1603 , support cable for suspension of shading unit 1604 , shading unit 1605 , drive cable of shading unit 1606 , wind control cable of shading unit 1607 , cantilever unit at border 1608 , worker on the ground 1609 , worker on roof 1610 , the manager on ground 1611 , cool air pulsed jet dispenser 1612 , air cooler and pump unit 1613 , the bright sun 1614 , according to one embodiment.
[0054] The device is most useful to workers on oil rigs and large ship platform where weather condition is very harsh.
[0055] FIG. 17 is a system view of dynamic shading of workers at road under construction, according to one embodiment. Particularly, FIG. 17 illustrates the road being constructed 1701 , road paving by one of asphalting machine 1702 , tower with wheel base to allow shifting of the devise 1703 , main support cable 1704 , support cable for shading unit 1705 , shading unit 1706 , cable drive for shading unit 1707 , the worker 1708 , the bright sun 1709 , according to one embodiment.
[0056] The towers are mounted on wheels for mobility
[0057] FIG. 18 is a view of pulsed cold air pipe line with rotating popup nozzle, according to one embodiment. Particularly, FIG. 18 illustrates the cold air supply pipe 1801 , nozzle 1802 , person provided with cool air 1803 , ground 1804 , air cooler and pump along with storage tank 1805 , according to one embodiment.
[0058] FIG. 19 is a view of cold air nozzle with rotation drive motor and retraction solenoid, according to one embodiment. Particularly, FIG. 19 illustrates the nozzle 1901 , swivel joint 1902 , rotation drive electric motor 1903 , cold air supply pipe line buried in ground 1904 , retracting solenoid 1905 , power supply cable and control signal cable 1906 , ground 1907 , according to one embodiment.
[0059] The area where the person is present only is locally cooled by pulsed air jets.
[0060] Although the present embodiments have been described with reference to specific example embodiments, it will be evident that various modifications and changes may be made to these embodiments without departing from the broader spirit and scope of the various embodiments.
[0061] In addition, it will be appreciated that the various operations, processes, and methods disclosed herein may be embodied in a machine-readable medium and/or a machine accessible medium compatible with a data processing system (e.g., a computer system), and may be performed in any order (e.g., including using means for achieving the various operations). Accordingly, the specification and drawings are to be regarded in an illustrative rather than a restrictive sense.
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A device, system and method of shading person large open area from large height without obstruction to view, work and play by matching shade pattern formed by shading unit for the given sun position and the location of the person on land and building, by means of shading units moved by control from computer and by manual control and providing local cooling by directed, pulsed cold air jet. Shading unit supported by cables and at periphery shading unit on cantilever based support is used and for small areas. The above devise and system is to protect people from occupational and environmental harmful effect of bright sunshine causing skin cancers and allergy and which so far has been tolerated quietly by people involved in sports, construction, agriculture, sea rigs, and recreation in beach.
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TECHNICAL FIELD
[0001] The present invention relates to the field of data center flooring.
[0002] More particularly, the present invention relates to improvements in air flow in relation to data center flooring.
RELATED ART
[0003] The growth of computer networking, and particularly the rapid growth of the use of the Internet, has resulted in a rapid increase in demand for server computers. Most commonly a number of modular server units, for example the modular computing units known as “blade” servers, are removably mounted in equipment racks. Typically, a large number of such racks are housed in a building known as a data center. In a data center, one or more large rooms are provided. Each room houses rows of equipment racks and their mounted servers, and associated cabling and network communication equipment.
[0004] A modern rack when fully loaded with blade servers consumes a large amount of electrical power when operating. In consequence, a large amount of waste heat is produced. Many data centers now employ individual racks of blade servers in which each rack develops 20 kW or more of waste heat. To avoid damage to the servers by overheating, this waste heat must be removed.
[0005] In a commonly used arrangement, data center rooms are cooled by computer room air conditioning units (termed CRACs) which circulate cooled air which passes through the rack units for heat removal. Typically, a data center room comprises a raised floor above a plenum chamber through which cooled air is blown by CRAC units. Rows of server racks are mounted on the floor separated by aisles. Networks of grilles in the floors of the aisles between rows of server racks allow cooled air from the plenum to rise into the aisles. From here it is typically drawn through the front of the racks by fans mounted in the racks. Heated air passes out of the other side of the rack and is drawn up into a roof plenum chamber for removal or recirculation through the CRAC units. In a commonly used arrangement, an aisle comprises two rows of server racks whose fronts face each other with the floor of the aisle space between comprising a number of grilles through which cooled air rises. This is termed a cold aisle. Behind each row of racks is a hot aisle to which heated air passes after flowing through the racks and then rises for removal by way of the roof plenum chamber.
[0006] In such an arrangement, it is important that the raised floor be impervious to air flow except at the grilles which allow cool air to flow from the sub-floor plenum into the cold aisles. The large number of server computer units in the typical data center described above requires a large amount of electrical power supply cabling and network cabling, and sometimes other service conduits to provide additional water cooling, for example. Much of this service provision, such as cabling, is routed below the raised floor of the data center through the sub-floor plenum chamber. This necessitates the piercing of the raised floor. To maintain as far as possible the impervious nature of the raised floor to air flow, some form of sealing is required around the cabling or other conduit at the point where it passes through the raised floor to prevent air leakage here. The conventional solution to this problem is to provide a grommet closure device through which the cabling or other conduit passes. A hole of the required size is cut in one of the floor tiles which make up the raised floor covering, a grommet inserted, and cabling or conduit passed through the grommet.
[0007] Typically, the grommet opening is rectangular and sealed by multiple flexible elements akin to brush bristles protruding from two opposite sides of the opening to meet along the center line of the opening. Cabling is passed through the bristles which are deflected by the cabling and spring back to substantially fill the remaining space and so minimize air passage through the bristles.
[0008] United States published patent application no. US 2003/0079897 comprises a floor grommet for use in building and office structures supplied with air conditioning via under floor plenum. Directed flow of conditioned air is optimized by limiting the escape of air from the plenum into the space above the floor by leakage through floor openings provided for power cables, data cables and the like. Specialized floor grommets installed in the cable openings are comprised of a surrounding frame mounting sealing elements comprised of thin, flexible elements which are anchored at one end in the grommet frame and extend toward the center of the opening, from each side, to effectively close the opening against significant flow of conditioned air from the plenum below. Cables passing through the grommet opening cause minimal deflection of the flexible elements to limit the escape of conditioned air. Preferably, the resilient, flexible elements are filamentary in nature. The grommet arrangements of the prior art impose restrictions on the user as the grommets are generally available only in a limited range of sizes and shapes. It is sometimes necessary when rearranging the rack positions and cabling or other service conduits in a data center to provide new holes in the raised floor. It would be desirable to provide a solution to the lack of flexibility in available hole sealing arrangements.
SUMMARY OF THE INVENTION
[0009] Viewed from a first aspect, the invention provides a barrier element suitable for forming a component of a floor covering of a floor in a data center. The barrier element comprises a substantially laminar part, the laminar part comprising a surface, the surface further comprising a cross member. The cross member further comprises a plurality of filaments mounted on the cross member.
[0010] In an embodiment, the present invention provides a barrier element in which the cross member has a length dimension substantially larger than either a width dimension or a depth dimension, the cross member being attached to the surface of the barrier element so that the length dimension occupies substantially the whole of a distance between a first edge of the surface of the barrier element and a second edge opposite the first edge. The width dimension is approximately equidistant between a third edge of the surface of the element and a fourth edge opposite the third edge.
[0011] In an embodiment, the present invention provides a barrier element which is a floor covering element.
[0012] In an embodiment, the present invention provides a barrier element which is a floor tile.
[0013] In an embodiment, the present invention provides a barrier element in which one of the plurality of filaments is mounted firmly but not fixedly by holding in the cross member so that the filament may be pushed through the cross member.
[0014] In an embodiment, the present invention provides a barrier element in which the holding comprises a push fit in a hole through the full width of the cross member.
[0015] In an embodiment, the present invention provides a barrier element in which the hole is through an elastomeric material in the cross member.
[0016] In an embodiment, the present invention provides a barrier element in which one of the filaments is a flexible filament.
[0017] In an embodiment, the present invention provides a barrier element in which one of the filaments has a length approximately the same as the distance between the cross member and the third edge.
[0018] In an embodiment, the present invention provides a barrier element in which the plurality of filaments form a layer substantially impervious to air flow.
[0019] In an embodiment, the present invention provides a barrier element in which a portion of the laminar part may be removed.
[0020] In an embodiment, the present invention provides a barrier element in which the removed portion of the laminar part comprises a cut-out or cut-away portion.
[0021] In an embodiment, the present invention provides a barrier element in which an item is positioned to pass through the barrier element by way of the removed portion.
[0022] In an embodiment, the present invention provides a barrier element in which the item comprises a service conduit.
[0023] In an embodiment, the present invention provides a barrier element in which the service conduit comprises an electrical cable.
[0024] In an embodiment, the present invention provides a barrier element in which a plurality of filaments is pushed through the cross member to at least abut the item passing through the removed portion so as to render the removed portion substantially impervious to air flow.
[0025] Viewed from a second aspect, the invention provides a method for covering a framework suitable for forming a floor in a data center. The method comprises providing a barrier element for covering the framework, the barrier element comprising a substantially laminar part, the laminar part comprising a surface, and providing a cross member on the surface. The method further provides the cross member with a plurality of filaments mounted on the cross member.
[0026] In an embodiment, the present invention provides a method in which the cross member has a length dimension substantially larger than either a width dimension or a depth dimension. The method further involves attaching the cross member to the surface of the barrier element so that the length dimension occupies substantially the whole of a distance between a first edge of the surface of the barrier element and a second edge opposite the first edge, and in which the width dimension is approximately equidistant between a third edge of the surface of the element and a fourth edge opposite the third edge,
[0027] In an embodiment, the present invention provides a method in which the barrier element comprises a floor covering element.
[0028] In an embodiment, the present invention provides a method in which the floor covering element comprises a floor tile.
[0029] In an embodiment, the present invention provides a method further comprising mounting one of the plurality of filaments firmly but not fixedly by holding in the cross member so that the filament may be pushed through the cross member.
[0030] In an embodiment, the present invention provides a method in which the holding comprises push fitting in a hole through the full width of the cross member.
[0031] In an embodiment, the present invention provides a method in which the hole is through an elastomeric material in the cross member.
[0032] In an embodiment, the present invention provides a method in which one of the filaments is a flexible filament.
[0033] In an embodiment, the present invention provides a method in which one of the filaments has a length approximately the same as the distance between the cross member and the third edge.
[0034] In an embodiment, the present invention provides a method in which the plurality of filaments form a layer substantially impervious to air flow.
[0035] In an embodiment, the present invention provides a method further comprising removing a portion of the laminar part.
[0036] In an embodiment, the present invention provides a method in which the step of removing further comprises cutting through the laminar part to form a cut-out or cut-away portion.
[0037] In an embodiment, the present invention provides a method further comprising positioning an item to pass through the barrier element by way of the removed portion.
[0038] In an embodiment, the present invention provides a method in which the item comprises a service conduit.
[0039] In an embodiment, the present invention provides a method in which the service conduit comprises an electrical cable.
[0040] In an embodiment, the present invention provides a method further comprising pushing a plurality of filaments through the cross member to at least abut the item passing through the removed portion so as to render the removed portion substantially impervious to air flow.
BRIEF DESCRIPTION OF THE DRAWINGS
[0041] Embodiments of the invention will now be described in detail by way of example only with reference to the following drawings.
[0042] FIG. 1 is a cross-section of a prior art data center in which embodiments of the invention may be employed.
[0043] FIG. 2 is a cross-section of an equipment rack and aisles as illustrated in the data center of FIG. 1 in which embodiments of the invention may be employed.
[0044] FIG. 3 a is a perspective view of a tile according to embodiments of the invention.
[0045] FIG. 3 b is a plan view of the underside of a tile according to embodiments of the invention.
[0046] FIG. 3 c is an edge on view of a tile according to embodiments of the invention.
[0047] FIGS. 4 a and 4 b are plan views of the underside of a tile illustrating aspects of the operation of embodiments of the invention.
[0048] FIGS. 5 a and 5 b are perspective views illustrating aspects of the operation of embodiments of the present invention.
[0049] FIGS. 6 a and 6 b are plan views of the underside of a tile illustrating the operation of embodiments of the invention.
[0050] FIG. 6 c is a plan view of the underside of a tile illustrating the operation of embodiments of the present invention.
[0051] FIG. 6 d is a plan view from above of the tile illustrated in FIG. 6 c.
DETAILED DESCRIPTION OF THE INVENTION
[0052] FIG. 1 illustrates a cross-section of a data center room 100 suitable for incorporating embodiments of the present invention. A conditioning unit, for example, a computer room air conditioning unit (CRAC) 110 comprises chiller and blower components for, respectively, chilling and impelling fluid for circulating in the data center room. The circulating fluid functions for removal of heat generated by equipment operating in data center room 100 . In embodiments, the circulating fluid is a gaseous fluid, and the fluid is the ambient air of data center room 100 . In embodiments, CRAC 110 blows chilled air through grille 115 a into a sub-floor plenum chamber 120 . The sub-floor plenum chamber 120 extends over substantially the whole floor area of data center room 100 . The floor 122 is suitably supported above the sub-floor plenum chamber 120 to carry rows of equipment racks such as 140 a and 140 b as illustrated. The equipment racks 140 a, 140 b each comprise a rack framework suitable for mounting modular data processing units, for example server computing units such as blade servers.
[0053] Air flows through the sub-floor plenum chamber 120 as shown by arrow 125 . Air flows from the sub-floor plenum chamber 120 up through grilles 115 b, 115 c into a cold aisle 150 a. From here air is drawn through the front of the racks 140 a, 140 b by air movers, such as fans, mounted within the racks 140 a, 140 b. Air flow 145 a, 145 b is shown entering the front of the rack 140 a and air flow 145 c, 145 d entering the front of the rack 140 b. Air exits 155 a, 155 b from the rear of the rack 140 a into a hot aisle 150 b. Similarly, air exits 155 c, 155 d from the rear of the rack 140 b into a hot aisle 150 c. Air is then drawn upwards from the hot aisle 150 b through a grille 115 d in the roof 132 into roof a plenum chamber 130 . Similarly, air is drawn upwards from the hot aisle 150 c through a grille 115 e in the roof 132 into the roof plenum chamber 130 . The roof plenum chamber 130 extends over substantially the whole roof area of data center room 100 . Air flows 135 through the roof plenum chamber 130 and re-enters the CRAC 110 by way of a grille 115 f.
[0054] FIG. 2 illustrates the rack 140 a as shown in FIG. 1 . In the cold aisle 150 a, air flow 145 a, 145 b is shown rising from the grille 115 c in the raised floor 122 and entering the front of the rack 140 a. In the hot aisle 150 b, air flow 155 a, 155 b is shown exiting the rear of the rack 140 a. Power and/or networking cabling 210 is shown passing from the rear of the rack 140 a, through a grommet 220 as known in the prior art, and into the plenum chamber 120 below the raised floor 122 . Typically, the raised floor 122 comprises a framework of metal or other structural material on to which are laid floor covering elements. The floor covering elements may themselves be structural or, where allowed by the raised floor framework, they may comprise barrier elements such as floor tiles which serve to maintain the impervious nature of the raised floor. In areas where passage of cabling is allowed by the skeletal nature of the supporting framework of the raised floor 122 , covering floor tiles may be cut to allow the insertion of a grommet 220 .
[0055] It will be apparent that although the invention is described with reference to embodiments in a floor structure of a data center, other embodiments may apply to other environments in which it is desirable to keep the fluid contents of two volumes from admixing. In some embodiments the framework may comprise a wall structure for example, and the barrier elements will then form components of a wall covering.
[0056] FIG. 3 a illustrates a perspective view of a barrier element according to embodiments of the present invention in which the barrier element is a component of a floor covering for a raised floor 122 in a data center 100 . As shown, the barrier element comprises a floor tile 300 . The floor tile 300 has a top surface 310 and a bottom surface 320 . A cross member 330 is attached to the bottom surface 320 of the tile 300 . FIG. 3 b illustrates a plan view of the bottom surface 320 of the tile 300 . The cross member 330 is attached approximately equidistant from opposite edges 350 a and 350 b and extends over substantially the whole of the width of the bottom surface 320 between opposite edges 350 c and 350 d. In embodiments, the cross member 330 does not extend over the full width of the bottom surface 320 but terminates a short distance from each of the edges 350 c and 350 d, relative to the full width of the bottom surface 320 . The floor tile 300 may be used in like manner to a conventional floor tile of the prior art laid over structural framework of the raised floor 122 of FIG. 2 .
[0057] In embodiments, the cross member 330 also comprises a plurality of thin elements, for example, flexible elements or filaments 340 akin to brush bristles as shown in FIG. 3 a and FIG. 3 b . As shown in FIG. 3 b , the flexible filaments 340 may occupy most of the width of the tile 300 between the tile edges 350 c and 350 d, and extend for most of the distance between the cross member 330 and the tile edge 350 a. FIG. 3 c shows an edge on view of the tile 300 , with the top surface 310 , the bottom surface 320 , the cross member 330 and the flexible filaments 340 forming a layer of thickness A. Although shown for clarity in FIGS. 3 a , 3 b and 3 c as individual filaments spaced apart from each other, the flexible filaments 340 are so arranged and spaced as to form a layer of thickness A in FIG. 3 c so that the layer is essentially impervious to air flow.
[0058] As depicted in FIG. 4 a , in embodiments, the underside 320 of the tile 300 comprises a cross member 330 and flexible filaments 340 . The flexible filaments 340 are mounted at a proximal end in the cross member 330 , allowing the distal end of each flexible filament 340 to move from side to side and up and down. The proximal end of each flexible filament 340 is mounted firmly but not fixedly by inserting in the cross member 330 in such a way as to allow each flexible filament to be pushed through the cross member 330 but not allow filament lateral movement within the cross member 330 . In embodiments, the mounting is a push fit in a cylindrical hole through the cross member 330 . In embodiments, the cylindrical hole is through an elastomeric material in the cross member 330 . As illustrated in FIG. 4 b , flexible filaments 340 b have been pushed through cross member 330 whilst flexible filaments 340 a have not.
[0059] As depicted in FIG. 5 a , in embodiments, the tile 300 comprises a top surface 310 and a bottom surface 320 . The cross member 330 comprises flexible filaments 340 as previously described. Also illustrated is section 510 of the tile 300 . The section 510 may be of any convenient size or shape and is cut away using a knife or similar implement and removed. FIG. 5 b shows the tile 300 of FIG. 5 a in operation. The tile portion 510 has been removed and power and/or network cabling 520 has been passed through the resulting hole. The flexible filaments 340 have been pushed through the cross member 330 to abut the cabling 520 . It will be apparent to those skilled in the art that the filaments 340 may be pushed further so as to be bent out of shape by pressure of the cabling 520 so as to potentially enhance the sealing effect. Also shown is an adjacent tile 550 , but it will be apparent that the tile 300 may be used in other arrangements, for example against a wall or the rear surface of an equipment rack.
[0060] FIG. 6 a illustrates a plan view of the underside 320 of the tile 300 of FIG. 5 a according to embodiments of the present invention. The flexible filaments 340 are illustrated all on one side of the cross member 330 . Also illustrated is the section 510 delimited by a dotted line and which is removed using a knife or similar implement. FIG. 6 b illustrates the underside 320 of the tile 300 after removal of the section 510 . A portion 340 e of the flexible filaments 340 have been pushed through the cross member 330 to cover the missing section 510 and render this section effectively impervious to air flow when the tile 300 is placed on a suitable floor support framework. The portions 340 c and 340 d of the flexible filaments 340 remain in their starting position.
[0061] FIG. 6 c illustrates a plan view of the underside of tile 300 in operation according to embodiments of the present invention. A cross section of the cabling 520 is illustrated passing through the cut away section 510 of tile 300 . The flexible filaments in the regions 340 c and 340 d remain as before. In the region 340 e, some of the flexible filaments 340 f have been pushed through the cross member 330 only so far as to abut the cabling 520 . The remaining flexible filaments in the region 340 e are pushed fully through the cross member 330 as in FIG. 6 b . In operation, this configuration ensures that parts of the cut away section 510 not occupied by the cabling 520 are occupied by the flexible filaments 340 and so rendering the section 510 effectively impervious to air flow.
[0062] FIG. 6 d illustrates a plan view of the top side 310 of the tile 300 depicted in FIG. 6 c . The cross section of the cabling 520 is illustrated passing through the cut away section 510 in the tile 300 . As in FIG. 6 c , in the region 340 e, some of the flexible filaments 340 f have been pushed through the cross member 330 only so far as to abut the cabling 520 . As in FIG. 6 c , the remaining flexible filaments in the region 340 e are pushed fully through the cross member 330 , so that the cut away section 510 is rendered effectively impervious to air flow. An adjacent tile 550 is illustrated, but as before it will be apparent that the tile 300 may be used in other arrangements, for example against a wall or the rear surface of an equipment rack.
[0063] It will be appreciated that although embodiments of the invention have been described in relation to use as floor coverings in a raised floor data center, other arrangements are possible without departing from the invention and will be apparent to those of ordinary skill in the art.
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A barrier element for forming a component of a floor covering of a floor in a data center includes a substantially laminar part, the laminar part having a cross member attached to one surface. The cross member mounts a plurality of filaments which can form a layer impervious to air flow.
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CROSS REFERENCE TO RELATED APPLICATION
This application claims the benefit of and priority to U.S. provisional application Ser. No. 60/892,630, filed Mar. 2, 2007.
BACKGROUND OF THE INVENTION
The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.
This invention relates generally to the field of treating a subterranean formation to increase the production of hydrocarbon from a formation. More specifically, the invention provides a method using a treatment fluid and diversion agent.
Hydraulic fracturing involves injecting fluids into a subterranean formation at pressures sufficient to form fractures in the formation, and the resulting fractures increase flow of production fluids from the formation to the wellbore. In chemical stimulation, flow capacity is improved by using chemicals to alter formation properties, such as increasing effective permeability by dissolving materials in or etching the subterranean formation. A wellbore may be an open hole or a cased hole where a metal pipe called a casing is placed into the drilled hole and often cemented in place or isolated with devices that expand to seal between the casing and wellbore. In a cased wellbore, the casing is perforated in specified locations to allow hydrocarbon flow into the wellbore or to permit treatment fluids to flow from the wellbore to the formation.
To access hydrocarbon effectively and efficiently, it is desirable to direct the treatment fluid to target zones of interest in a subterranean formation. There may be target zones of interest within various subterranean formations or multiple layers within a particular formation that are preferred for treatment. In such situations, it is preferred to treat the target zones or multiple layers without inefficiently treating zones or layers that are not of interest, e.g. nonproducing zones or zones with high water and/or gas content. In general, treatment fluid flows along the path of least resistance. For example, in a large formation having multiple zones, a treatment fluid would tend to dissipate in the portions of the formation that have the lowest pressure gradient or portions of the formation that require the least force to initiate a fracture. Similarly in horizontal wells, and particularly horizontal wells having long laterals, the treatment fluid dissipates in the portions of the formation requiring lower forces to initiate a fracture, often near the heel of the lateral section, and less treatment fluid is provided to other portions of the lateral. Once treatment of a zone or formation is completed it is desirable to treat another zone. Also, it is desirable to avoid stimulating undesirable zones, such as water-bearing or non -hydrocarbon bearing zones. Thus it is helpful to use methods to divert the treatment fluid to target zones of interest or away from undesirable zones.
Diversion methods are known to facilitate treatment of a specific interval or intervals. Ball sealers are mechanical devices that frequently are used to seal perforations in some zones thereby diverting treatment fluids to other perforations. In theory, use of ball sealers to seal perforations permits treatment to proceed zone by zone depending on relative breakdown pressures or permeability. But frequently ball sealers prematurely seat on one or more of the open perforations, resulting in two or more zones being treated simultaneously. Likewise, when perforated zones are in close proximity, ball sealers have been found to be ineffective. In addition, ball sealers are useful only when the casing is cemented in place. Without cement between the casing and the borehole wall, the treatment fluid can flow through a perforation without a ball sealer and travel in the annulus behind the casing to any formation. Ball sealers have limited use in horizontal wells owing to the effects of formation pressure, pump pressure, and gravity in horizontal sections, as well as the possibility that laterals in horizontal wells may not be cemented in place.
Other mechanical devices used for diversion include bridge plugs, packers, down-hole valves, sliding sleeves, and baffle/plug combinations; and particulate placement. As a group, use of such mechanical devices for diversion tends to be time consuming and expensive, making them operationally unattractive, particularly in situations where there are many target zones of interest.
Chemically formulated fluid systems are known for use in diversion methods and include viscous fluids, gels, foams, or other fluids. Many of the known chemically formulated diversion agents are permanent (not reversible) in nature and some may damage the formation. In addition, some chemical methods may lack the physical structure and durability to effectively divert fluids pumped at high pressure or they may undesirably affect formation properties. The term diversion agent herein refers to mechanical devices, chemical fluid systems, combinations thereof, and methods of use for blocking flow into or out of a particular zone or a given set of
Degradable materials have been used for fluid loss control. Examples include rock salt, graded rock salt, benzoic acid flakes, wax beads, wax buttons, oil-soluble resin material, etc. Degradable materials have also been used to facilitate proppant transport, such as disclosed in U.S. Pat. No. 7,275,596. Commonly assigned U.S. Pat. No. 7,565,929 discloses degradable material assisted diversion methods and compositions.
A method of reliably treating target zones in a subterranean formation using a diversion agent without plugging or bridging the next zone or formation in the treating sequence would be desirable. A method in which producing zones in the same well bore could be treated serially using the same downhole equipment without intervening wireline operations would also be desirable. Ideally, such methods might facilitate an upper-to-lower zone treatment protocol or mixture of order based on best completion options in the appropriate circumstances, rather than the prevailing lower-to-upper protocol currently in use.
SUMMARY OF THE INVENTION
The present invention in various embodiments provides a method for treating a well with a circulated degradable material assisted diversion (CMAD), and a CMAD method for multilayer treatment or diversion, wherein a slurry of degradable material is circulated in the wellbore of a completed well to facilitate diversion procedures. In one embodiment, the method comprises the steps of: deploying a tubular string to a position at or below a target interval; treating the target interval; and circulating a plugging slurry past the target interval at a higher pressure than is in the formation and back up out of the well or on to another interval.
In an embodiment, the degradable material can form a temporary plug such that after a selected duration under the downhole conditions no additional intervention is needed to remove the plug. The temporary plug formation allows other well operations to be performed without damaging the existing fracture or producing formation, or without interference from the existing fracture or producing formation. Circulation of the slurry in the well bore facilitates placement of the degradable material diversion plug in one or more formations while avoiding bridging or plugging within the wellbore proper. Using this technique, the circulation can allow the plugging or treatment, especially fracturing in one embodiment, of multiple formations using the same tool or tubing insertion, i.e. without intermediate removal and replacement of the tubing and/or tool between plugging(s) and treatment(s).
As used herein, “circulated” or “circulating” means that the slurry flows along the well bore both toward a reference zone and away from the reference zone, either simultaneously or in separate steps in the same procedure, either in a separate conduit or annulus or by reversing the flow direction. Preferably the flow of the slurry is sufficiently continuous to inhibit solids settling or bridging within the borehole and confine plug formation to an adjacent formation, i.e. in the perforations or openings at a surface of the borehole leading into the formation.
In one embodiment, the method of well treatment can include: (a) injecting an aqueous or oil based slurry into a completed well bore penetrating a formation, wherein a solids phase of the slurry comprises an insoluble degradable material; (b) circulating the slurry through at least a portion of the well bore in contact with a surface comprising one or more openings in fluid communication with a first permeable formation; (c) consolidating the degradable material to form a plug of the degradable material in the one or more openings to block fluid communication between the well bore and the first permeable formation, wherein a flow of the slurry is maintained in the well bore during the circulation and consolidating steps to inhibit gravitational settling of the solids in the wellbore; (d) performing a downhole operation in the well while the degradable material assists diversion from the plugged first permeable formation, wherein the downhole operation can be hydraulic fracturing, acidizing, well repair, installation of downhole equipment, and combinations thereof, and (e) degrading the consolidated degradable material to remove the plug and restore fluid communication with the first permeable formation. The downhole operations can include slickwater fracturing and acid fracturing as further examples.
In an embodiment, the slurry circulation can include flow through a circulation loop comprising a tubular and an annulus between the tubular and the well bore, wherein the tubular has a fluid opening past the first permeable formation. The tubular can be pipe or tubing, for example. In an embodiment, the flow can be into the tubular at a location opposite the fluid opening, e.g. at the surface or another location above the first permeable formation, with flow out of the fluid opening past the formation surface where the plug is formed, to return though the annulus, e.g. to the surface or a second permeable formation. Alternatively, the flow can be down into the annulus, past the formation surface where the plug is formed, and through the fluid opening into the tubular for return. As the slurry flows past the formation surface, a portion enters or bleeds into the formation to screenout or otherwise deposit solids at the surface and eventually form the plug.
As used herein, the terms “above” and “up” and similar ones are used to encompass a relative location or flow in the wellbore toward the surface, whereas conversely “down” and “below” and similar terms are used to encompass a relative location flow or away from the surface, even though the wellbore may be formed laterally (i.e. a horizontal well) or even with an upward slope.
In an embodiment, the degradable material can be a polymer of monomer-derived units such as esters, aromatic acids, amides, and the like, and combinations thereof. In an embodiment, the degradable material can be polymers and copolymers of lactide and glycolide; polyethyleneterephthalate (PET); polybutyleneterephthalate (PBT); polyethylenenaphthalenate (PEN); partially hydrolyzed polyvinyl acetate; and derivatives thereof, and combinations and mixtures thereof, and the like. In one embodiment, the solids phase can include fiber. In one embodiment, the solids phase is essentially free of inert particles, i.e. materials which are not degradable so as to inhibit or prevent removal of the plug. In one embodiment the solids phase of the slurry contains less than 0.6 g/L (5 lbm/1,000 gal) inert particles such as proppant, for example.
In an embodiment, the degradable material and optionally other solids can be present in the slurry in a wide range of concentration, for example, from a lower volume fraction limit of solids in the slurry of 0.05 to a maximum upper limit of 0.56. Lower volume fractions can require excess liquid carrier and result in lost fluid to the formation. Higher volume fractions can cause bridging of the wellbore inside the annulus. The method can include inducing a screenout of the solids phase at the surface of the first permeable formation to consolidate the degradable material.
In one embodiment, the degradation can be triggered by a temperature change, and/or by chemical reaction between the degradable material and another reactant. Degradation can include dissolution of the degradable material.
In an embodiment of the method, a fluid phase of the slurry can include a viscoelastic surfactant (VES), a co-surfactant, a rheology modifier, a polymeric friction reducer, a surfactant friction reducer, a polymeric drag reduction enhancer, a monomeric drag reduction enhancer, an aqueous brine, viscous oil base (for example, the fluid phase can comprise an invert emulsion) or the like, or a combination or mixture thereof. In other embodiments of the invention, the slurry of degradable plug material is viscosified with and/or placed by a high viscosity polymer based fluid (such as a polysaccharide, such as guar or a guar derivative, linear or crosslinked); or a low viscosity polymer based fluid (for example a polyacrylamide); or a high viscosity surfactant based fluid (such as by example a VES based fluid system, or a VES plus a hydrophobically modified polymer, or a VES plus a rheology modifier); or a low viscosity polymer friction reducer based fluid, or a low viscosity surfactant based friction reducer fluid (such as by example a surfactant friction reducer plus a polymeric drag reduction enhancer, and/or a monomeric drag reduction enhancer) and combinations thereof. Hydrocarbons of sufficient viscosity, or those sufficiently thickened to suspend the degradable material using thickening materials common to the industry, can be used. VES containing systems are preferred.
In a particular embodiment, the present invention can provide a CMAD fracturing method that can include the steps of: (a) injecting well treatment fluid into a well penetrating a multilayer formation to propagate a hydraulic fracture in a layer of the formation; (b) circulating an aqueous slurry past the fracture, wherein the slurry comprises fibers of an insoluble, degradable material in a solids phase to form a plug of the consolidated fibers and isolate the hydraulic fracture from the wellbore, wherein the degradable material is present in the slurry at a concentration of at least 1.2 g/L (10 lbm/1,000 gal), and wherein a fluid phase of the slurry comprises a viscoelastic surfactant, a co-surfactant, a rheology modifier, a polymer friction reducer, a surfactant friction reducer, a polymeric drag reduction enhancer, a monomeric drag reduction enhancer an aqueous brine, or a combination or mixture thereof, (c) with the plug diverting from the previous hydraulic fracture, injecting well treatment fluid into the well to propagate a subsequent hydraulic fracture in another layer of the formation; and (d) thereafter degrading the degradable material to remove the plug. The well treatment fluid in step (a) can include in various embodiments, a polymer friction reducer, or a low viscosity surfactant based friction reducer, a viscoelastic surfactant, a co-surfactant, a rheology modifier, an aqueous brine, or a combination or mixture thereof; preferably the fluid includes a friction reducing formulation.
In one embodiment, the CMAD fracturing method can also include sequentially repeating steps (b) and (c) one or a plurality of times for diversion from the previous hydraulic fractures and propagation of subsequent hydraulic fracture(s) in other layer(s), wherein the plugs are thereafter removed in step (d) by degrading the degradable material.
In an embodiment, a well treatment fluid passageway in the wellbore can be maintained open between the formation layers for the subsequent hydraulic fracturing, wherein the previous fracture is isolated from the wellbore by the plug, e.g. without using bridge or sand plugs or other isolation device in the wellbore. In a preferred embodiment, the well treatment fluid passageway is unrestricted by solids accumulation from the slurry. In an embodiment, the CMAD fracturing method can include perforation in advance of the fracture propagation in steps (a) and (c).
In an embodiment, the removal of the plug can be assisted by a wash. In one embodiment, any un-degraded material is produced with produced fluid without any need to assist in its removal.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 schematically illustrates an embodiment of the present invention showing the tubular string below the target zone wherein the slurry flows down the tubing and up the annulus.
FIG. 2 schematically illustrates an embodiment of the present invention showing the tubular string below the target zone wherein the slurry flows down the annulus and up the tubing.
FIG. 3 schematically illustrates an embodiment of the present invention showing the tubular string positioned below the subsequent target zone following circulating-slurry plugging of the previously treated zone in either of FIG. 1 or 2 .
FIG. 4 (with FIGS. 5-8 ) schematically illustrates an embodiment of a multi-zone treatment method according to the present invention showing the initial step of treating the first formation wherein the treatment fluid is injected through a tubular string and the annulus is closed.
FIG. 5 schematically illustrates the multi-zone treatment method of FIG. 4 showing the step of plugging the first formation with slurry circulated past the first formation and transfer of the excess slurry into the annulus.
FIG. 6 schematically illustrates the multi-zone treatment method of FIGS. 4-5 showing the step of treating the second formation through the tubular string while the excess slurry is retained in the annulus.
FIG. 7 schematically illustrates the multi-zone treatment method of FIGS. 4-6 showing the step of plugging the second formation by reversing the flow direction to circulate the slurry retained in the annulus into the tubular string.
FIG. 8 schematically illustrates the multi-zone treatment method of FIGS. 4-7 showing the step of treating the third formation through the annulus while the excess slurry is retained in the tubular string.
DESCRIPTION OF THE INVENTION
The present invention will be described in connection with its various embodiments. However, to the extent that the following description is specific to a particular embodiment or a particular use of the invention, this is intended to be illustrative only, and is not to be construed as limiting the scope of the invention. On the contrary, it is intended to cover all alternatives, modifications, and equivalents that are included within the spirit and scope of the invention, as defined by the appended claims.
The description and examples are presented solely for the purpose of illustrating the preferred embodiments of the invention and should not be construed as a limitation to the scope and applicability of the invention. While the compositions of the present invention are described herein as comprising certain materials, it should be understood that the composition could optionally comprise two or more chemically different materials. In addition, the composition can also comprise some components other than the ones already cited. In the summary of the invention and this detailed description, each numerical value should be read once as modified by the term “about” (unless already expressly so modified), and then read again as not so modified unless otherwise indicated in context. Also, in the summary of the invention and this detailed description, it should be understood that a concentration range listed or described as being useful, suitable, or the like, is intended that any and every concentration within the range, including the end points, is to be considered as having been stated. For example, “a range of from 1 to 10” is to be read as indicating each and every possible number along the continuum between about 1 and about 10. Thus, even if specific data points within the range, or even no data points within the range, are explicitly identified or refer to only a few specific, it is to be understood that inventors appreciate and understand that any and all data points within the range are to be considered to have been specified, and that inventors possession of the entire range and all points within the range.
Embodiments of the invention relate to methods for temporarily blocking wellbores, perforations, or formation fractures so that other work (e.g., fracturing of other zones, workover, well repair, installation of downhole equipment, etc.) can be performed more efficiently or without damaging existing fractures. The temporary blocking is achieved by consolidating solids including degradable materials that will degrade within a desired period of time. As applied in fracturing, the techniques of the invention in one embodiment can be similar to the induced stress diversion technique (ISDT) that is currently used for wells, such as those located, for example, on land in North America.
The present invention uses degradable particulates in a slurry to bridge either the wellbore or formation off to prevent the inflow of treatment fluids intended for a different interval or zone. In the past, pumping these types of slurries has been limited by the fact that the plugging slurry has not had enough volume to plug the interval. Further, an excess amount of the plugging slurry in the prior art methods has the concomitant requirement for a removal technique to prevent plugging of the next interval.
The method of the present invention comprises the steps of circulating the plugging slurry past the area to be plugged, e.g. in an annulus between the wellbore and the injection or return tubing, and back up out of the well or on to another zone. Past the interval to be plugged, only a portion of the plugging slurry will be allowed to proceed. This allows excess material to be used at the area to be plugged to insure diversion, while the circulation of the slurry permits removal of the slurry without settling or significant contact with non-diverted areas of the wellbore so that the diversion slurry will not be detrimental to the next interval.
In a well bore there is an interval that has open access to the formation and that formation has/can have fluids flowing through the access point, e.g. at perforations. Stopping or severely reducing the flow through the access point is often a primary objective so that fluids may stop flowing from the well bore or to another interval.
The method of the present invention utilizes in one embodiment an inner tubular string pointed pipe or coiled tubing) that is run at or below the interval to be diverted from as illustrated in FIG. 1 . Once the inner tubular string 10 is at or below the selected interval 12 in the well bore 14 , a diverting slurry is pumped down the inner tubing 10 and returned via the annulus 16 between the inner tubing and wellbore 14 . The diverting slurry can in embodiments follow a fracture treatment, acidizing treatment, fluid injection or well circulation, whichever is more advantageous to the cost, timeliness, and reliability of the operation. As it contacts the interval 12 , a diverting plug 18 is formed due to a higher pressure in the well bore 14 than in the interval 12 where there is fluid communication between the interval 12 and the well bore 14 , and a subsequent treatment can be applied to another zone (not shown). The subsequent treatment can be the same or different than the treatment applied to interval 12 , i.e. independently a fracture treatment, acidizing treatment, fluid injection or well circulation. In one preferred embodiment, the treatments of interval 12 and the subsequently treated interval comprise hydraulic fracturing.
Alternatively or additionally as shown in FIG. 2 , the slurry can be pumped down through the annulus 16 in contact with the interval 12 and returned via the inner tubing 10 .
With reference to either FIG. 1 or FIG. 2 , in an embodiment of the invention, sometime before the diverting slurry has been circulated past the interval 12 to be diverted from, i.e., in advance of the slurry circulation at the interval 12 , the pressure in the well bore 14 can be raised above the injection pressure of the interval 12 at the interval itself. The pressure increase may be achieved by: 1) increasing the flow rate of the diverting slurry and thus the friction pressure of the return flow slurry; 2) restricting the flow at the surface or down hole with a valve or choke apparatus (not shown) on the return flow stream; or 3) pumping a heavier weighted fluid ahead of the diverting slurry to increase the hydrostatic pressure of the return stream. Ideally, the pressure restriction is not performed against the diverting slurry. The above described methodology improves known practices by eliminating bridging in the wellbore or at an unwanted spot that could cause pipe sticking.
The ratio of the flow of diverting slurry that is injected into the interval may start off at 100% into the interval before bridging starts to occur. Once there is evidence of the beginning of diversion or bridging, then the ratio of return slurry can be increased to prevent wellbore sticking or plugging. If one is unsure of the ability of the interval to take the diverting slurry before bridging, then the initial return rate could be set to 100% and this would be lowered as the interval accepted the slurry fluid. An intermediate or split initial return rate can also be used in an embodiment, but the proportions of slurry volume injected into the interval and into the return line should total 100%, i.e. no slurry should be lost in the wellbore. Evidence of bridging can include, for example, higher injection pressure at the same or lower rates and pressures above the injection pressure. The pressure can be measured from the inner tubing or from the surface pressures on the annulus or inner tubing. Evidence may also be see in temperature measurements, RA tagging and measurement of microseismic events.
More than one interval can be diverted from at a time provided the inner tubing is below the first interval. Multiple intervals can also be diverted from at different times or treatments.
FIGS. 4 through 8 illustrate an exemplary sequence of events in one embodiment of a multiple interval treatment according to the present invention. In FIG. 4 , the first formation 12 is treated by injecting the treatment fluid down the tubular string 10 which is lowered to adjacent the first formation 12 . The annulus 16 is shut in to force the treatment fluid into the formation 12 and/or to form a and propagate a fracture.
In FIG. 5 , the treatment fluid is followed by the plugging slurry which is similarly injected down the tubular string 10 and circulated past the first formation 12 to form the plug 18 . The annulus 16 is open for excess slurry return fluid flow to the surface, while maintaining sufficient pressure in the wellbore 14 to prevent fluid from entering from the formation 18 , i.e. a positive pressure is maintained in the wellbore to inhibit premature fluid production from the formation 18 while subsequent treatments are effected. The excess slurry is transferred into the annulus 16 , and can be followed with a solid-free flush to clear the tubing 10 . In an embodiment, the slurry displaces solid-free fluid from the annulus 16 , but the flush only has sufficient volume to clear the tubing 10 , leaving the excess slurry stored in the annulus 16 .
In FIG. 6 , following the placement of the plug 18 in FIG. 5 , the tubing string 10 is lowered so that it is below the second formation 20 , and treatment fluid is again injected to treat the formation. The annulus 16 is closed to direct substantially all of the treatment fluid into the formation 20 , while the excess slurry from the previous placement of plug 18 is stored or retained in the dead space in the annulus 16 . Following injection of the treatment fluid, the flow direction is reversed as shown in FIG. 7 so that the slurry previously stored in the annulus 16 is displaced to flow back down past the just-treated formation 20 and deposit the plug 28 to seal the formation. Tubing string 10 can be opened to allow a fluid flow back equal to any excess slurry circulated past the formation 20 . Following displacement by a flush or additional slurry introduced into the top of the annulus 16 , any excess slurry can now be stored in the tubing string 10 in preparation for plugging the next formation to be treated.
The tubing string 10 holding the excess slurry is then lowered to near the next formation to be treated, third formation 30 , as shown in FIG. 8 . The tubing string 10 is shut in while the treatment fluid is injected at the top of the annulus 16 and into the third formation 30 . In this manner, by repeating the steps of injecting the treatment fluid in one flow passage, reversing the flow direction for circulating the slurry to plug the formation from the other flow passage, storing the excess slurry in one of the annulus or the tubing string while repositioning the tubing string for the next treatment zone, any number of formations can be treated in any desired order. The plugging slurry is kept out of the treatment zone until the treatment is complete, or introduced as an end stage of the treatment. The tubing string can be left in the wellbore and multiple zones treated without tripping the equipment back in and out of the wellbore.
The diverting slurry can be made up of materials commonly used in well stimulation and/or lost circulation techniques. These are often viscous polymer or VES fluids that bridge via high viscosity going into the formation. Solids maybe used to bridge open cracks. These can be fibers, sand, calcium carbonate or other materials found in the industry. Those materials circulated out may be reused in the diversion process.
In one embodiment, the degradable materials may be in any shape: for example, powder, particulates, beads, chips, or fibers. Preferred embodiments may use these materials in the form of fibers. The fibers may have a length of about 2 to about 25 mm, preferably about 3 to about 18 mm. Typically, the fibers have a linear mass density of about 0.111 dtex to about 22.2 dtex (about 0.1 to about 20 denier), preferably about 0.167 to about 6.67 dtex (about 0.15 to about 6 denier). The fibers preferably degrade in one embodiment under downhole conditions, which may include temperatures as high as 180° C. (about 350° F.) or more and pressures as high as 137.9 MPa (20,000 psi) or more, in a duration that is suitable for the selected operation, from a minimum duration of 0.5, 1, 2 or 3 hours up to a maximum of 72, 48, 24, 12, 10, 8 or 6 hours, or a range from any minimum duration to any maximum duration. Although it is normally not necessary, the degradation may be assisted or accelerated by a wash containing an appropriate dissolver or one that changes the pH and/or salinity or hydrocarbon solvents. The degradation may also be assisted by an increase in temperature, for example when the treatment is performed before steam flooding. Herein, when we use the term degradable, we include all of these suitably dissolvable materials.
The degradable materials may be sensitive to the environment, so there may be dilution and precipitation issues. The degradable material used as a sealer preferably should survive in the formation or wellbore for a sufficiently long duration to accomplish pumping, for example, a minimum of 2 hours. The duration should further be long enough to perforate (if needed) the next pay zone, subsequent fracturing treatment(s) to be completed, etc. The degradable material may be sufficiently durable to last as long as 2 weeks, for example, to complete extended well work in one embodiment.
It must also be considered that degradable material sealers can inhibit flowback, and as a Various degradable materials are used with embodiments of the invention. Such materials could theoretically include inorganic fibers, for example of limestone or glass, but are preferably polymers or co-polymers of monomer-derived units such as esters, amides, or other similar materials. As used herein, polymers may be referred to in terms of either the monomers or the as-reacted form of the monomers, and it is understood that reference to the monomer is construed in the specification and claims as to the polymerized form of the derivative resulting from the polymerization of the monomer.
The degradable polymers may be partially hydrolyzed at non-backbone locations. Polymers or co-polymers of amides, for example, may include polyacrylamides, polyamides such as Nylon 6,6; Nylon 6; KEVLAR, and others.
Materials that dissolve at the appropriate time under the encountered conditions are also used, for example polyols containing three or more hydroxyl groups.
In one embodiment, lifetimes of fiber plugs made of polylactic acids (PLA) can be controlled by selecting the appropriate molecular weights. The higher molecular weight fiber plugs generally have longer lifetimes. For example, the plug having a polymer with a molecular weight of about 80,000 may have a lifetime of several hours, while plugs made of higher molecular weight polymers have longer lifetimes (up to 60 hours).
Some embodiments of the invention use degradable fiber plugs as described above. In one embodiment, the slurry is essentially free of inert particles or non-degradable particles which may tend to render the plug non-degradable or excessively delay plug removal. Other embodiments of the invention use plugs that are formed of degradable fibers and another material, such as inert proppants (including sand), or degradable absorbents (such as polyacrylic acid-co-acrylamide). The inclusion of an absorbent material may help fill pores inside a plug and make it stronger. PLA fiber with proppant having a multimodal particle size distribution (PSD) can provide a suitable mix.
In accordance with some embodiments of the invention, degradable materials are used in combination with methods of increasing the solid content of a slurry using particle-size distribution technology. With a properly chosen multi-modal distribution of particle sizes, smaller particles fill the void spaces between larger ones, resulting in a slurry requiring less water. Typical distributions use two or three distinct particle size ranges. This provides a slurry with improved flow properties without dehydration and faster plugging times.
With this approach (i.e., multi-modal particle size distribution), various combinations of temporary perforation sealers can be achieved with excellent properties. Because degradable or dissolvable materials, such as a polylactic acid fiber, may be selected to be compatible with formation fluids and their downhole lifetimes can be easily varied (e.g., by adding delay agents to increase their lifetimes), this approach is very attractive in the CMAD technique.
One of ordinary skill in the art can appreciate that various acid fracturing methods may be used with embodiments of the invention, including methods of generating acid downhole (using an emulsified acid, encapsulated acid, or solid acid precursor). For example, U.S. Pat. No. 7,166,560 to Still discloses the use of solid acid precursors to provide controlled release of acid by hydrolysis or dissolution. The solid acid precursor may be lactide, glycolide, polylactic acid, polyglycolic acid, a copolymer of polyacetic acid and polyglycolic acid, a copolymer of glycolic acid with other hydroxyl-, carboxylic acid-, or hydroxycarboxylic acid-containing moieties, a copolymer of lactic acid with other hydroxyl-, carboxylic acid-, or hydroxycarboxylic acid -containing moieties, or mixture of the preceding. The solid acid may be mixed with a second solid that reacts with an acid to increase the rate of dissolution and hydrolysis of the solid acid precursor.
In accordance with embodiments of the invention, degradable materials are preferably compatible with different pH fracturing fluids and with brines that are used in the wellbore containing different concentrations of salts (such as sodium chloride NaCl, calcium chloride CaCl 2 , sodium bromide NaBr, potassium chloride KCl, and others). The degradable materials should be compatible with temperature ranges as wide as possible. It is preferred that the degradable materials are compatible with temperatures greater than 0° C. (32° F.). Degradable materials may be compatible with weighted brines or completion fluids as well.
The use of surfactant based fluids is recommended because appropriate VES fluids can provide a high zero shear viscosity and more effective proppant and/or fiber placement, and cause less damage than polymer based fluids. Furthermore, when a VES fluid system is used to deliver the degradable material plug for diversion, and when a surfactant fluid system is also used for friction reduction in, for example, slickwater fracturing, then after the degradable material plug degradation, there is no polymer remaining in the system to cause damage such as might hinder fluid flow from the formation.
While the description herein uses hydraulic fracturing to illustrate embodiments of the invention, one of ordinary skill in the art would appreciate that methods of the invention may be used in traditional propped fracturing treatments independent of the method of viscosifying the fluid selected to provide the proppant and fiber carrying capacity. Polymer based or surfactant based fluid may be used and the methods and compositions of the invention may be used in other types of fracturing, including slickwater (or waterfrac) and acid fracturing.
The method of the invention can be used in single stage or multiple stage treatments such as, by non-limiting examples: fracturing, matrix treatments, squeeze treatments, and water control treatments. The use of circulated fiber diversion in any fluid may impact a wide range of applications. While methods of the invention may be used in fracturing, workover, or other types of operations, for clarity, the following description will use hydraulic fracturing as an example to illustrate embodiments of the invention. Of course, other sequences are possible, depending upon the stress profile. One of ordinary skill in the art can appreciate that this is not intended to limit the scope of the invention to hydraulic fracturing. Instead, methods of the invention may also be used in other operations, such as temporary plugging of fractures.
Whereas sequential fracturing has usually started at the bottom of a vertical well, or the distal end of a horizontal well, and progresses towards the wellhead, with the use of the present CMAD method it is now possible to routinely fracture sequentially downward, i.e. starting at an upper zone and progressing to lower zones. In the downward sequence, for example, the fracturing fluid can be pumped down the annulus followed by the slurry of degradable plugging materials which can be circulated past the fracture and excess material removed via tubing to the surface. The circulation and return of excess material keeps the degradable material from plugging or bridging the wellbore below the lower end of the tubing. Once the fracture is plugged, the excess diverting slurry is circulated out of the wellbore via the tubing, the tubing lowered to adjacent or below the next zone to be fractured, and the sequence repeated.
Some embodiments of the invention relate to temporarily blocking of already-created fractures so that other zones may be fractured. As applied to multi-stage fracturing, at the tail end of a fracturing treatment, a degradable or dissolvable material can be circulated in the wellbore as described herein to temporarily plug a completed fracture. The temporary plug locks the proppants in a fracture, making them immobile and causing substantial stress increase and diversion in upper or lower zones by means of a significant net pressure increase due to the high likelihood of proppant bridging with the degradable materials. In accordance with an embodiment of the invention, it is not necessary to create a temporary packer or form a plug in the wellbore, and in one embodiment it is preferred to avoid the formation of a temporary packer or plug in the well bore below the completed fracture, for example by removing the excess slurry and maintaining sufficient and continuous flow rates to avoid particle settling within the well bore.
With this system, the fracture is protected and successive fracturing treatments, up and/or down the hole, can be performed without the need for lengthy wireline intervention, as only perforation is required to initiate a subsequent fracturing treatment. The degradable material will dissolve with time and unplug the fracture. These methods may be performed with any suitable equipment known in the art, including coiled tubing (CT) that has been installed in the wells for jetting new perforations. If desired, a perforating gun or jetting tool can be carried on the tubing in conjunction with a fluid inlet or outlet valve that can be selectively operated for the slurry circulation and/or treatment fluid supply. These methods of the invention are similar to the ISDT's that are currently used on land in North America. However, the circulated degradable material assisted diversion (CMAD), in accordance with embodiments of the invention, can provide much higher and more reliable stress diversion without plugging the wellbore, and can proceed up or down the wellbore.
Embodiments of the invention can provide diversion methods that are more reliable than conventional ISD by adding degradable materials to enhance the net stress of the pay zone that was just fractured. In accordance with embodiments of the invention, to achieve a greater net pressure in the first fracture, high concentrations of special degradable materials can be used at the tail ends of fracturing treatments. The degradable materials may be fibers, powders, or any other forms. At high concentrations of fibers, the proppant-fiber slurry can bridge in the fracture. As a result, the job may screen out. This will lead to a significant increase in the net pressure and to good near-wellbore proppant placement. Such a procedure may be called a “tail screenout.” Fiber bridging is a complicated phenomenon, which requires special modeling to design such a job properly. U.S. Pat. No. 6,837,309 to Boney discloses methods and compositions designed to cause tip screenouts.
High degradable material concentrations at the tail end of a treatment may also be used in embodiments to: (a) sustain proppants, i.e. to reduce settling rate during and after treatments and to reduce proppant flowback; and (b) ensure larger net surcharge pressure in the preceding stages.
Furthermore, appropriate designing and laboratory experiments known to those skilled in the art can be used in an embodiment to ensure that the CMAD techniques in accordance with embodiments of the invention work properly. In addition to design and laboratory experiments, modeling may also be used to design proper parameters for CMAD. Various formation modeling techniques are available for hydraulic fracturing, such as Schlumberger's FracCADE stimulator™ and the methods disclosed in U.S. Pat. No. 6,876,959. Other available software, for example, includes pseudo three-dimensional (P3D) hydraulic fracture simulators and planar three -dimensional (PL3D) hydraulic simulators (including GOHFER™ from Stim-Lab and Marathon Oil Co.). Embodiments of the invention are not limited to any particular modeling method.
In accordance with some embodiments of the invention, modeling is used to simulate induced stress diversion for the formation of interest. Then, the types and amounts of fluids to be used, and the durations and pumping rates for the fracturing job, including the slurry circulation, are accordingly selected. Embodiments of the invention provide efficient methods for diverting stress/pressures for staged fracturing. One of ordinary skill in the art would appreciate that these methods may be applied in any type of well, including vertical, deviated or horizontal wells, and open or cased hole.
Good knowledge of formation and reservoir fluid properties is important to employ the CMAD techniques appropriately for multiple fracturing treatments. The following parameters are important ones to consider in optimizing a CMAD job: in-situ stress profile; in-situ stress differential between pay sand and shales; reservoir fluid composition and its compatibility with degradable material; and proppant sustaining in the fracture. Some of these parameters may be available from downhole measurements, while others may not be available. As noted above, embodiments of the invention may use a modeling technique to optimize the CMAD job. Any parameters not available may be optimized using a suitable modeling method known in the art.
As illustrated in the above description, embodiments of the invention use circulated degradable materials to block a zone, perforation or fracture temporarily so that work may be performed in other zones. In accordance with some embodiments of the invention, at the tail end of a fracturing treatment, a degradable material is pumped at a high concentration to temporarily plug a completed fracture, and to lock the proppant in a fracture making it immobile and causing substantial stress increase and diversion from lower zones by means of a significant net pressure increase due to a higher likelihood of proppant bridging. With this system, the fracture is protected and a subsequent fracturing treatment further up or down the hole may be performed without the need for lengthy wireline intervention, as only perforation is required to initiate a subsequent treatment.
As noted above, methods of the invention that form temporary bridges or seals in the perforations, fracture(s), formation, or any combination of these are used for subsequent fracturing or for other operations to be performed downhole. In accordance with some embodiments of the invention, after the temporary seal is formed, the well may undergo various treatments instead of subsequent fracturing. For example, the wellbore may be repaired (acid treatments), or installation of an electric submersible pump (ESP) may be performed. The plugging agent can be selected to last sufficiently long to protect the formation over the expected time period of the subsequent downhole operation.
Therefore, in accordance with some embodiments of the invention, a fracture is temporarily sealed or blocked with a circulated degradable material. The circulated degradable material is used to temporarily protect the fracture from post-job workover fluid damage, or to temporarily protect downhole equipment from fracture flowback damage. The selection of the circulated degradable materials depends on the expected damage, bottomhole conditions, and the durations needed for protection.
The addition of the circulated degradable materials in accordance with embodiments of the invention may be practiced with existing equipment. One of ordinary skill in the art would appreciate that various methods used in the field may be adapted for use with methods of the invention. For example, the circulated degradable materials may be mixed with proppants in blenders or batch mixing tanks. The circulated degradable materials can mix with proppant or simply follow the proppant in the casing to cause the bridging.
The methods of the invention may also be combined with methods of using fibers to assist in the transport of proppant, for example in slickwater treatments, for example as described in U.S. Pat. No. 7,275,596. The methods may also be used in treatments in which fibers are also used in proppant-free fluids such as in the pads of fracturing treatments, or in prevention of fluid loss into natural fractures, for example as described in US 2006-0042797. Preferably, the same fiber is used in all stages of these combination treatments. As an example, the same degradable fiber is used in the pad of a fracturing treatment stage, and/or in the main fracturing fluid of the stage to assist proppant transport, and at the end of the stage for circulated degradable material assisted diversion.
All references identified herein, including any priority documents, are hereby incorporated herein by reference to the extent not inconsistent with the present invention, and for all jurisdictions where such incorporation by reference is permitted.
Those skilled in the art will recognize that many combinations of stimulation and diversion apparatuses and methodologies not specifically mentioned in the examples will be equivalent in function for the purposes of this invention. 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. 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.
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Methods are circulated degradable material assisted diversion (CMAD) for well treatment in completed wells. A slurry of solid degradable material is circulated in the well with return of excess slurry, a plug of the degradable material is formed, a downhole operation is performed around the plug diverter, and the plug is then degraded for removal. Degradation triggers can be temperature or chemical reactants, with optional accelerators or retarders to provide the desired timing for plug removal. In multilayer formation CMAD fracturing, the plug isolates a completed fracture while additional layers are sequentially fractured and plugged, and then the plugs are removed for flowback from the fractured layers.
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BACKGROUND OF THE INVENTION
1. Technical Field
The present invention relates in general to downhole gas separators and, in particular, to an improved system, method, and apparatus for a submersible pump assembly having a gas separator that produces a liquid stream for reintroduction upstream of the pump.
2. Description of the Related Art
Subsea wells typically connect to a subsea manifold that delivers the well fluid to a production platform for processing, particularly for the removal of water and gas. The oil is then transmitted to a pipeline or other facility for export from the production platform. Production of fluids from a medium to deep subsea environment requires compensation for the effects of cold temperatures, high ambient pressures and fluid viscosity as a function of break out of gas in the fluid stream. In flowing wells, particularly those with light API fluid, these conditions may be mitigated by the nature of the producing reservoir. In wells with low API oil and insufficient pressure to drive the fluid to the surface, some form of artificial lift will be required.
One type of artificial lift for wells employs a submersible pump, which is a type that has been used for many years on land-based wells. One type of submersible pump assembly has an electrical motor, a rotary pump and a seal section located between the pump and the motor for equalizing wellbore pressure with the internal pressure of lubricant in the motor. In applications where there is a high free gas content in the fluid production stream, the gas content is typically separated upstream from the rotary pump intake.
In other types of applications, the recycling of discharge liquids back to the suction to reduce the free gas content percentage also is known. However, in a traditional gas separation application, the gas stream has entrained liquids that are together recycled back to the inlet of the pump below the gas outlet. Although this design is workable for some application, an improved solution for increasing the hydraulic efficiency of the system and improving flow conditioning through the pump would be desirable.
SUMMARY OF THE INVENTION
Embodiments of a system, method, and apparatus for a subsea well having a submersible pump assembly with a gas separator are disclosed. The gas separator is located adjacent the discharge of the submersible pump and separates gas from the high pressure liquid stream exiting the pump.
The invention is particularly well suited for gaseous environments as a portion of the discharge is a high pressure liquid that is recycled back to the inlet of the pump to maintain a liquid-rich inlet stream for the pump. The recycled portion of the discharge, which is essentially 100% liquid, may be returned internally or externally relative to the pump housing. The remainder of the pump discharge is mixed flow. The separator may utilize a centrifuge or static device (e.g., enhanced gravity). In addition, the stream may be reintroduced via a jet pump venturi eductor whereby the stream acts as the power fluid.
This design has the advantages of flow conditioning and some pressure recovery to improve the hydraulic efficiency of the system. Dispersal of gas homogeneously through the intake liquid is a significant aspect of pumping gassy fluids. The same venturi also may be linked at the vena contracta to a gas accumulation location in order to draw in and mix any gas accumulations. In one embodiment, the recycled liquid stream has entrained gas bubbles that are less than approximately 10 μm in size. A limited amount of gas acceptably enters the pump since a separator can only achieve one relatively clean stream.
In other embodiments, the recycled liquid stream may have a feedback flow control that monitors fluid density and/or mass flow rate. In addition, the recycle feature of the invention may be suspended when the inlet flow for the pump exceeds a minimum threshold density. The venturi itself may be used as a flow conditioner to measure density by pressure drop or Coriolis effect.
The foregoing and other objects and advantages of the present invention will be apparent to those skilled in the art, in view of the following detailed description of the present invention, taken in conjunction with the appended claims and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
So that the manner in which the features and advantages of the present invention, which will become apparent, are attained and can be understood in more detail, more particular description of the invention briefly summarized above may be had by reference to the embodiments thereof that are illustrated in the appended drawings which form a part of this specification. It is to be noted, however, that the drawings illustrate only some embodiments of the invention and therefore are not to be considered limiting of its scope as the invention may admit to other equally effective embodiments.
FIG. 1 is a sectional side view of one embodiment of a downhole assembly constructed in accordance with the invention; and
FIG. 2 is a high level flow diagram of one embodiment of a method constructed in accordance with the invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1 , embodiment of a system, method and apparatus for a subsea well having a submersible pump assembly with a gas separator are shown and described. The submersible pump assembly 11 may be located within a capsule 13 having an inlet 14 for receiving intake fluids having mixed liquids and gas, and an outlet 16 for discharging outlet fluid. Alternatively, the components of the submersible pump assembly 11 may be secured to each other inside a permanent well casing 13 .
The pump assembly 11 may be supported by a support (not shown) located on the lower (i.e., left) side of housing 13 . A variety of other devices could be employed to mount the pump assembly 11 within housing 13 . The pump assembly 11 may be secured to the support to transmit thrust to the housing 13 . Pump assembly 11 is of a type that is conventionally installed downhole within a subsea well for pumping well fluids to the surface.
The pump assembly 11 includes a submersible electrical motor 15 , such as a three-phase AC motor. Motor 15 is supplied with power through a power cable (not shown) that extends sealingly through the top or sidewall of the housing 13 . The motor 15 is coupled to a seal section 17 that protects the motor from ingress of production fluid, which could contaminate the clean lubricant contained within motor 15 . Seal section 17 also reduces any pressure differential between the exterior of motor 15 and the pressure of the lubricant within motor 15 . Seal section 17 is connected to a pump 19 , which may comprise a centrifugal pump or a static device with enhanced gravity. Motor 15 , seal 17 , and pump 19 may be mounted coaxially within housing 13 .
In one embodiment, the pump 19 is made up of a plurality of stages of impellers and diffusers located within a cylindrical pump housing. Pump 19 has an intake 21 located at its upstream end. Pump 19 also has a discharge tube 23 that is in fluid communication with a gas separator 25 . The gas separator 25 is located downstream from the pump 19 and adjacent to the outlet 16 for receiving the outlet fluid from the pump 19 .
The gas separator 25 discharges (1) a mixed flow stream 31 of gas and liquid to the outlet 16 , and (2) a recycled liquid stream 33 . In one embodiment, the mixed flow stream 31 is a substantially dry gas stream. The recycled liquid stream 33 may have gas bubbles on the order of approximately 10 μm. Thus, the recycled liquid stream 33 is essentially 100% liquid. In one embodiment, only a fraction of the total stream is recycled (e.g., 30%) and making this stream substantially liquid is possible provided that the inlet liquid percentage exceeds, for example, 40% liquid. An inlet fluid having at least 40% liquid is derived as the minimum amount of liquid when about 20% of the total input stream is recycled (with 100% liquid in recycle), as the maximum amount of gas that can be tolerated is about 30%.
A conduit 35 extends from the gas separator 25 for recycling the liquid stream 33 to the inlet 14 for maintaining a liquid-rich inlet stream for the pump 19 . The conduit may be located external to the pump housing 13 as shown, or extend internally through the capsule/well casing (not shown). The conduit 35 may be provided with feedback flow control 37 for monitoring fluid density and/or mass flow rate of the liquid stream 33 .
In one embodiment, the inlet 14 comprises a jet pump type venturi eductor 41 and the liquid stream 33 is reintroduced via the jet pump venturi eductor 41 as shown. If structure 13 is a capsule, the jet pump components may be integrally formed as part of the capsule. Alternatively, if structure 13 is a permanent well casing, the eductor 41 may be mounted to an insert, such as a packer.
The jet pump venturi eductor 41 may comprise a flow conditioner for measuring a density of the intake fluid by pressure drop, mass flow rate or Coriolis effect. In the latter case, high pressure is recovered by reflowing the recycled liquid through the venturi. Recycling of the liquid stream 33 may be suspended when the intake flow for the pump exceeds a minimum threshold density. In another embodiment, the system includes a gas accumulator 43 for accumulating gas, wherein the jet pump venturi eductor 41 has a vena contracta 45 for introducing gas from the gas accumulator 43 .
Referring now to FIG. 2 , one embodiment of a method of producing production fluids from a well in accordance with the invention is shown. The method starts as indicated and comprises locating a submersible pump assembly in the well (step 101 ); drawing intake fluids comprising a liquid and a gas into an inlet of the submersible pump assembly (step 103 ); producing an outlet fluid with the submersible pump assembly (step 105 ); receiving the outlet fluid with a gas separator (step 107 ); discharging a mixed flow stream of gas and liquid from the gas separator to an outlet (step 109 ); discharging a liquid stream from the gas separator and recycling the liquid stream to the inlet for maintaining a liquid-rich inlet stream for the submersible pump assembly (step 111 ); before ending as indicated.
In other embodiments, the method comprises discharging an essentially 100% liquid stream. The liquid stream quality is such that the entrained gas bubbles are less than approximately 10 μm in size. The method also may comprise receiving the intake fluids and liquid stream with a jet pump venturi eductor at the inlet, respectively. The method may further comprise accumulating gas with a gas accumulator, and introducing gas from the gas accumulator to the jet pump venturi eductor through a vena contracts. In still other embodiments, the method may comprise monitoring at least one of fluid density and mass flow rate a feedback flow control; and/or suspending recycling of the liquid stream when the intake fluids exceeds a minimum threshold density.
While the invention has been shown or described in only some of its forms, it should be apparent to those skilled in the art that it is not so limited, but is susceptible to various changes without departing from the scope of the invention.
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A subsea rotary gas separator system has a separator located adjacent the discharge of the pump for separating gas from the high pressure liquid stream exiting the pump. Some of the high pressure liquid is recycled back to the inlet of the pump to maintain a liquid-rich inlet stream for the pump.
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RELATED APPLICATIONS
[0001] This application claims the benefit of Ser. No. 60/532,933, entitled “Expandable Sand Screen Utilizing Near Neutrally Buoyant Particles Outside of Screen,” filed provisionally on Dec. 29, 2003.
TECHNICAL FIELD OF THE INVENTION
[0002] This invention relates generally to the field of well bore completion and, more particularly, to an expandable screen utilizing near neutrally-buoyant particles outside of the screen.
BACKGROUND OF THE INVENTION
[0003] Sand control is important during completion and subsequent production of a wellbore that is in hydraulic communication with Earth formations susceptible to production of solid materials from the formation. Such formations are known in the art as “unconsolidated” and, if not protected with suitable wellbore equipment, may produce solid materials of a character and quantity so as to damage the wellbore, or at least reduce its capacity to produce oil and gas from the formation. Devices known in the art as “sand screens” are typically used to protect such unconsolidated formations. Sand screens include a structural member, called a “base pipe”, having apertures therein to maintain the mechanical integrity of the sand screen (meaning to provide mechanical support for the screen. A “filter layer” is typically disposed outside the base pipe. Many different types of filter layer are used, including, for example, wound wire and mesh screen.
[0004] More recently, radially plastically deformable sand screens, called “expandable sand screens” have been used in some wellbores to increase productivity of wellbores completed in unconsolidated Earth formations. A principal reason for the use of expandable sand screens is to mechanically support the unconsolidated formation prior to initiating fluid production. By supporting the formation prior to initiating production, it is possible to reduce loss of formation permeability due to movement of solid materials against the screen during fluid production. A conventional (non-expandable) sand screen must necessarily have an external diameter smaller than the drilled out diameter of the wellbore (“open hole”) prior to insertion of the sand screen, in order for the screen to fit in the wellbore. The smaller screen diameter results in an annular space between the outer surface of the screen and the wall of the wellbore, which may become filled with formation solids moved from the formation during fluid production. Expandable sand screens are intended to provide a way to close the annular space prior to beginning fluid production, and thus prevent movement of formation solids. Expandable sand screens are run into the wellbore in an unexpanded state, wherein the external diameter of the screen is less than the drilled out diameter of the wellbore. After insertion, the screen is expanded using one or more types of expansion tools, preferably to cause the screen to be placed into firm contact with the wellbore wall.
[0005] During the expansion of expandable sand screens, it is advantageous to push the sand screen outward to an extent so that it “conforms” to, and applies pressure to, the wellbore wall in order to hold the sand in place and increase oil and/or gas flow into the wellbore. Many wellbores may include sections where the actual diameter of the wellbore exceeds the drilled out diameter (drill bit diameter) due to washout or other cause. In such sections, it maybe necessary to expand a screen to 35 or 40 percent greater than its unexpended diameter in order to place the screen in form contact with the wall of the wellbore.
[0006] One problem with expandable screens known in the art is that they are difficult to expand more than about 30 to 35 percent because the base pipes made out of carbon steel or stainless steel begin to fail. As a result, these screens may often not be expanded enough to apply the high contact pressures needed to hold the sand in place in enlarged wellbores, thus resulting in failure of the sand screen or inadequate production. Conversely, if expanded to the degree necessary to provide a suitable amount of contact pressure, the base pipe may be weakened to an extent so as to have very little resistance to crushing under external pressure, thus leaving the wellbore susceptible to failure.
SUMMARY OF THE INVENTION
[0007] It is desirable to have an expandable sand screen that can be made to conform to the wall of a wellbore, even if it is necessary to expand the screen to 35 percent or more beyond the unexpanded diameter of the screen, while maintaining sufficient mechanical integrity to resist failure of the screen and consequent loss of the wellbore.
[0008] In one embodiment, a wellbore completion method includes disposing an expandable screen into a wellbore and disposing a fluid into an annular space between a wall of the wellbore and the expandable screen. The fluid contains a plurality of near neutrally-buoyant particles. The method further includes radially expanding the screen, whereby the near neutrally-buoyant particles exert a force against the wall of the wellbore.
[0009] Embodiments of the invention may provide a number of technical advantages. In one embodiment, placement of neutrally-buoyant or near-neutrally-buoyant particles in the annular space outside of the screens makes the screens compliant and allows them to exert a force against the wall of a wellbore and hold the sand particles in place. This facilitates the use of strong base pipe with high torsional, axial, and collapse strength.
[0010] Other technical advantages are readily apparent to one skilled in the art from the following figures, descriptions, and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIGS. 1 and 2 are cross-sectional elevation views illustrating a wellbore completion method in accordance with one embodiment of the present invention.
DETAILED DESCRIPTION
[0012] FIGS. 1 and 2 are cross-sectional elevation views illustrating a wellbore completion method in accordance with one embodiment of the present invention. Referring first to FIG. 1 , a wellbore completion system 100 is utilized in completing a wellbore 101 drilled within a formation 102 . Wellbore 101 may be drilled using any suitable drilling techniques and may have any suitable diameter, length, and direction. Formation 102 may be any suitable geological formation; however, the present invention is particularly suitable for unconsolidated formations, such as sandstone.
[0013] Holding the sand or other particles from formation 102 in place during the completion process is important for effective oil and/or gas flow into wellbore 101 . Thus, expandable sand screens are sometimes utilized to hold the sand in place. A major problem with prior expandable sand screens is that they are difficult to expand more than about 30-35% before the base pipes from which they are made begin to fail. Thus, these prior screens may often not be expanded enough to apply high contact pressures to hold the sand in place.
[0014] Therefore, according to the teachings of one embodiment of the invention, a plurality of near neutrally-buoyant particles 106 are disposed within an annular space 108 between a wall 109 of wellbore 101 and an expandable screen 104 prior to expanding expandable screen 104 . Near neutrally-buoyant particles 106 reduce the amount of expansion required by expandable screen 104 and increases the contact force between expandable screen 104 and wall 109 . In the illustrated embodiment, near neutrally-buoyant particles 106 are disposed within a fluid 115 .
[0015] Expandable screen 104 may be any suitable screen of any suitable size and configuration, and may be formed from any suitable material. For example, expandable screen 104 may be formed from a suitable carbon steel and include a fine screen or coarse screen (or both) inside of a suitable sleeve (sometimes referred to as a “shroud”) having suitable apertures formed therein. Expandable screen 104 may also have any suitable length and may be formed from one or more sections. If expandable screen 104 is formed from more than one section, then expandable threads 112 may be utilized to couple the sections together. Expandable screen 104 may be disposed in wellbore 101 by any suitable method, such as the utilization of a suitable work string 110 . Any suitable method may be utilized to expand expandable screen 104 , such as a cone expander 114 or other suitable expander element.
[0016] Near neutrally-buoyant particles 106 may be any suitable particles formed from any suitable material. As used herein, the term “near neutrally-buoyant” means that particles 106 each have a density that is equal to or very near the density of fluid 115 in which they are suspended. As examples, near neutrally-buoyant particles 106 may be hollow or low density particles. Although near neutrally-buoyant particles 106 may have any suitable size and shape, in one embodiment, near neutrally-buoyant particles 106 are generally spherical in shape having any suitable diameters. In a particular embodiment of the invention, the near neutrally-buoyant particles 106 are generally spherical in shape and have diameters larger than the diameters of the pores existing within formation 102 adjacent wall 109 in order to prevent them from flowing into and plugging the pores in formation 102 . With respect to expandable screen 104 , in one embodiment, near neutrally-buoyant particles 106 may be generally spherical in shape and have diameters larger than the diameters of the holes formed within the outermost member of expandable screen 104 , such as a shroud. In one embodiment, this prevents the near neutrally-buoyant particles from damaging the fine screen inside of the shroud.
[0017] Fluid 115 may be any suitable fluid. For example, in one embodiment, fluid 115 is a suitable completion fluid. In addition, fluid 115 may be disposed within annular space 108 between wall 109 and expandable screen 104 in any suitable manner using any suitable equipment, such as a pump.
[0018] In some embodiments, fluid 115 develops “gel” strength when it is not being circulated. This gel strength allows near neutrally-buoyant particles 106 to be suspended in fluid 115 even though their densities are slightly different than fluid 115 . Therefore, in some embodiments, the densities of near neutrally-buoyant particles 106 do not have to equal the density of fluid 115 to be suspended therein.
[0019] In one embodiment, some of the near neutrally-buoyant particles 106 each have a density slightly greater than fluid 115 such that they tend to fall within fluid 115 prior to expansion of expandable screen 104 , and some of the near neutrally-buoyant particles 106 each have a density slightly less than fluid 115 such that they will tend to rise within fluid 115 prior to expansion of expandable screen 104 . This may improve the placement of particles 106 in annular space 108 around screen 104 . In another embodiment, near neutrally-buoyant particles 106 each have a density equal to fluid 115 such that particles 106 substantially remain in place around expandable screen 104 prior to expansion thereof with no tendency to rise or fall within fluid 115 . Other methods for moving and/or locating particles 106 within fluid 115 are contemplated by the present invention. It should be noted that larger near neutrally-buoyant particles 106 may tend to sink or float faster than smaller particles. Thus, as near neutrally-buoyant particles 106 get larger, the difference in density between near neutrally-buoyant particles 106 and fluid 115 may be smaller in order to suspend them in fluid 115 .
[0020] System 100 may also include a first barrier 118 coupled near a top of expandable screen 104 and a second barrier 120 coupled near a bottom of expandable screen 104 . Barriers 118 , 120 may be utilized to confine the near neutrally-buoyant particles 106 to a particular vertical space within annular space 108 of wellbore 101 . Barrier 118 and barrier 120 may be any suitable barriers formed from any suitable material, such as an elastomer. Barriers 118 , 120 are typically coupled to the outside of expandable screen 104 before expandable screen 104 is disposed within wellbore 101 .
[0021] A bottom sub 122 may also be coupled to a bottom of expandable screen 104 to prevent any fluid 115 from exiting expandable screen 104 . Bottom sub 122 may be any suitable plug formed from any suitable material and may coupled to expandable screen 104 in any suitable manner.
[0022] Also illustrated in FIG. 1 is a casing 124 , which may case any suitable portion of wellbore 101 , and an expandable liner hanger 126 that functions to hang any suitable lining within casing 124 . The present invention contemplates more, fewer, or different components than those illustrated in FIG. 1 .
[0023] In operation of one embodiment of the invention, and with reference to FIGS. 1 and 2 , wellbore 101 is first drilled by any suitable method within formation 102 and the upper portion thereof cased with casing 124 . Expandable liner hanger 126 is utilized to position expandable screen 104 within wellbore 101 . Work string 110 with cone expander 114 coupled thereto is then run-in-hole and fluid 115 is circulated down into wellbore 101 . Fluid 115 , with near neutrally-buoyant particles 106 suspended therein, fills annular space 108 .
[0024] Work string 110 then is utilized to apply weight to cone expander 114 , which translates downward and starts radially expanding expandable screen 104 , as illustrated best in FIG. 1 . Cone expander 114 plastically deforms expandable screen 104 . As expandable screen 104 is radially expanded out towards wall 109 , near neutrally-buoyant particles 106 exert a force against wall 109 in order to hold the sand associated with formation 102 in place. In the illustrated embodiment, the near neutrally-buoyant particles 106 have diameters larger than the pores existing in formation 102 in order to prevent them from flowing into and plugging the pores. Once cone expander 114 reaches the end of its desired travel, then work string 110 and cone expander 114 are pulled out of wellbore 101 , thereby leaving the arrangement illustrated in FIG. 2 .
[0025] As shown in FIG. 2 , expandable screen 104 is radially expanded outward towards wall 109 and applies a force to near neutrally-buoyant particles 106 so that they may exert a force on wall 109 of wellbore 101 . Expandable screen 104 is thus plastically deformed from a smaller diameter to a larger diameter. Any suitable expansion is contemplated by the present invention.
[0026] Thus, near neutrally-buoyant particles 106 within annular space 108 facilitate expandable screen 104 being compliant and holds sand particles associated with formation 102 in place by exerting a force against wall 109 . This may allow the use of a strong base pipe with expandable screen 104 with high torsional, axial and collapse strength. Efficient production from wellbore 101 may then be realized.
[0027] Although embodiments of the invention and their advantages are described in detail, a person of ordinary skill in the art could make various alterations, additions, and omissions without departing from the spirit and scope of the present invention as defined by the appended claims.
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In one embodiment, a wellbore completion method includes disposing an expandable screen into a well bore and disposing a fluid into an annular space between a wall of the wellbore and the expandable screen. The fluid contains a plurality of near neutrally-buoyant particles. The method further includes radially expanding the screen, whereby the near neutrally-buoyant particles exert a force against the wall of the wellbore.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a divisional application of U.S. Ser. No. 14/177,097, filed on Feb. 10, 2014, now U.S. Pat. No. 9,273,437, which is a divisional application of U.S. patent application Ser. No. 13/686,756, filed on Nov. 27, 2012, now U.S. Pat. No. 8,657,525, which is a divisional application of U.S. patent application Ser. No. 12/347,467, filed on Dec. 31, 2008, now U.S. Pat. No. 8,322,945. The present application claims the benefits of U.S. Provisional Application Ser. No. 61/061,567, filed Jun. 13, 2008, entitled “MOBILE BARRIER”, and 61/091,246, filed Aug. 22, 2008, entitled “MOBILE BARRIER”, and 61/122,941, filed Dec. 16, 2008, entitled “MOBILE BARRIER” each of which is incorporated herein by this reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates generally to the field of trailers and other types of barriers used to shield road construction workers from traffic. More specifically, the present invention discloses a safety and construction trailer having a fixed safety wall and semi tractor hookups at both ends.
BACKGROUND
[0003] Various types of barriers have long been used to protect road construction workers from passing vehicles. For example, cones, barrels and flashing lights have been widely used to warn drivers of construction zones, but provide only limited protection to road construction workers in the event a driver fails to take heed. Some construction projects routinely park a truck or other heavy construction equipment in the lane between the construction zone and on-coming traffic. This reduces the risk of worker injury from traffic in that lane, but does little with regard to errant traffic drifting laterally across lanes into the construction zone. In addition, conventional barriers require significant time and effort to transport to the work site, and expose workers to significant risk of accident while deploying the barrier at the work site. Therefore, a need exists for a safety barrier that can be readily transported to, and deployed at the work site. In addition, the safety barrier should protect against lateral incursions by traffic from adjacent lanes, as well as traffic in the same lane.
SUMMARY
[0004] These and other needs are addressed by the various embodiments and configurations of the present invention. In contrast to the prior art in the field, the present invention can provide a safety trailer with a fixed safety wall and semi tractor hookups at one or both ends.
[0005] In a first embodiment, a safety trailer includes:
[0006] (a) first and second removably interconnected platforms, at least one of the first and second platforms being engaged with an axle and wheels, the first and second platforms defining a trailer; and
[0007] (b) a plurality of wall sections supported by the trailer, the wall sections, when deployed to form a barrier wall, are positioned between the first and second interconnected platforms
[0008] (c) wherein at least one of the following is true:
[0009] (c1) the trailer supports a ballast member, the ballast member being positioned near a first side of the trailer and the ballast member near a second, opposing side of the trailer, the ballast member offsetting, at least partially, a weight of the plurality of wall sections, and
[0010] (c2) the axle of the trailer is engaged with a vertical adjustment member, the vertical adjustment member selectively adjusting a vertical position of a surface of the trailer.
[0011] In a second embodiment, a safety trailer includes:
[0012] (a) first and second platforms;
[0013] (b) a plurality of interconnected wall sections positioned between and connected to the first and second platforms, the plurality of wall sections defining a protected work area on a side of the trailer;
[0014] (c) wherein each wall section has at least one of the following features:
[0015] (c1) a plurality of interconnected levels, each level comprising first and second longitudinal members, a plurality of truss members interconnecting the first and second longitudinal members, and being connected to an end member;
[0016] (c2) a longitudinal member extending a length of the wall section, the longitudinal member being positioned at the approximate position of a bumper of a vehicle colliding with the wall section;
[0017] (c3) a plurality of full height and partial height wall members, the full height wall members extending substantially the height and width of the wall section and the partial height wall members extending substantially the width but less than the height of the wall section, the full height and partial height members alternating along a length of the wall section; and
[0018] (c4) first and second end members, each of the first and second end members comprising an outwardly projecting alignment member and an alignment-receiving member, the first and second end members having the alignment and alignment-receiving members positioned in opposing configurations.
[0019] In a third embodiment, a trailer includes:
[0020] (a) a trailer body;
[0021] (b) a removable caboose engageable with the trailer body, the caboose having a nose portion and at least one axle and wheels; and
[0022] (c) a caboose receiving member, the caboose receiving member comprising an alignment device, wherein, in a first mode when the caboose is moved into engagement with the trailer body, the alignment device orients the caboose with a king pin mounted on the trailer body and, in a second mode when the caboose is engaged with the trailer body, the alignment device maintains a desired orientation of the caboose with the trailer.
[0023] In a fourth embodiment, a safety system includes:
[0024] (a) a vehicle;
[0025] (b) first and second platforms;
[0026] (c) a barrier engaged with the first and second platforms, the barrier and first and second platforms forming a protected work space; and
[0027] (d) a caboose, wherein the vehicle and caboose are engaged with the first and second platforms, respectively, wherein the vehicle has a movable king pin plate engaged with a first king pin on the first platform, and wherein the caboose has a fixed king pin plate engaged with a second king pin on the second platform.
[0028] In a fifth embodiment, a safety system includes:
[0029] (a) a vehicle;
[0030] (b) first and second platforms;
[0031] (c) a barrier engaged with the first and second platforms, the barrier and first and second platforms forming a protected work space; and
[0032] (d) a caboose, wherein the vehicle and caboose are engaged with the first and second platforms, respectively, wherein the vehicle and caboose have braking systems that operate independently.
[0033] In a sixth embodiment, a trailer includes:
[0034] (a) first and second platforms;
[0035] (b) a barrier engaged with the first and second platforms, the barrier and first and second platforms forming a protected work space, wherein the barrier is formed by a plurality of interconnected wall sections and wherein the interconnected wall sections slidably engage one another.
[0036] In a seventh embodiment, a trailer includes:
[0037] (a) first and second platforms;
[0038] (b) a barrier engaged with the first and second platforms, the barrier and first and second platforms forming a protected work space, wherein the barrier is formed by a plurality of interconnected wall sections and wherein the interconnected wall sections telescopically engage one another.
[0039] In an eighth embodiment, a trailer includes:
[0040] (a) first and second platforms;
[0041] (b) a barrier engaged with the first and second platforms, the barrier and first and second platforms forming a protected area, wherein the barrier is formed by a plurality of interconnected wall sections, and wherein at least one of the following is true:
[0042] (b1) a bottom of the barrier is positioned at a distance above a surface upon which the trailer is parked and wherein the distance ranges from about 10 to about 14 inches;
[0043] (b2) a height of the barrier above the surface is at least about 3.5 feet; and
[0044] (b3) a height of the barrier from a bottom of the barrier to the top of the barrier is at least about 2.5 feet.
[0045] The present invention can provide a number of advantages depending on the particular configuration.
[0046] In one aspect, the barrier (and thus the entire trailer) is of any selected length or extendable, but the wall is “fixed” to the platforms on one side of the trailer. That side, however, can be changed to the right or left side of the road, depending on the end to which the semi tractor attaches. This dual-ended, fixed-wall design thus can eliminate the need for complex shifting or rotating designs, which are inherently weaker and more expensive, and which cannot support the visual barriers, lighting, ventilation and other amenities necessary for providing a comprehensive safety solution. The directional lighting and impact-absorbing features incorporated at each end of the trailer and in the caboose can combine with the fixed wall and improved lighting to provide increased protection for both work crews and the public, especially with ever-increasing amounts of night-time construction. End platforms integral to the trailer's design can minimize the need for workers to leave the protected zone and eliminate the need for separate maintenance vehicles by providing onboard hydraulics, compressors, generators and related power, fuel, water, storage and portable restroom facilities. Optional overhead protection can be extended out over the work area for even greater environmental relief (rain or shine). The fixed wall itself can be made of any rigid material, such as steel. Lighter weight materials having high strength are typically disfavored as their reduced weight is less able to withstand, without significant displacement, the force of a vehicular collision. The trailer can carry independent directional and safety lighting at both ends and will work with any standard semi tractor. Optionally, an impact-absorbing caboose can be attached at the end of the trailer opposite the tractor to provide additional safety lighting and impact protection.
[0047] In one aspect, the trailer is designed to provide road maintenance personnel with improved protection from ongoing, oncoming and passing traffic, to reduce the ability of passing traffic to see inside the work area (to mitigate rubber-necking and secondary incidents), and to provide a fully-contained, mobile, enhanced environment within which the work crews can function day or night, complete with optional power, lighting, ventilation, heating, cooling, and overhead protection including extendable mesh shading for sun protection, or tarp covering for protection from rain, snow or other inclement weather.
[0048] Platforms can be provided at both ends of the trailer for hydraulics, compressors, generators and other equipment and supplies, including portable restroom facilities. The trailer can be fully rigged with direction and safety lighting, as well as lighting for the work area and platforms. Power outlets can be provided in the interior of the work area for use with construction tools and equipment, with minimal need for separate power trailers or extended cords. Both the caboose and the center underside of both end platforms can provide areas for fuel, water and storage. Additional fuel, water and miscellaneous storage space can be provided in an optional extended caboose of like but lengthened design.
[0049] In one aspect, the trailer is designed to eliminate the need for separate lighting trucks or trailers, to reduce glare to traffic, to eliminate the need for separate vehicles pulling portable restroom facilities, to provide better a brighter, more controlled work environment and enhanced safety, and to, among other things, better facilitate 24-hour construction along our nation's roadways. Other applications include but are not limited to public safety, portable shielding and shelter, communications and public works. Two or more trailers can be used together to provide a fully enclosed inner area, such as may be necessary in multi-lane freeway environments.
[0050] With significant shifts to night construction and maintenance, the trailer, in one aspect, can provide a well-lit, self-contained, and mobile safety enclosure. Historical cones can still be used to block lanes, and detection systems or personnel can be used to provide notice of an errant driver, but neither offers physical protection or more than split second warning for drivers who may be under the influence of alcohol or intoxicants, or who, for whatever reason, become fixated on the construction/maintenance equipment or lights and veer into or careen along the same.
[0051] The trailer can provide an increased level of physical protection both day and night and workers with a self-contained and enhanced work environment that provides them with basic amenities such as restrooms, water, power, lighting, ventilation and even some possible heating/cooling and shelter. The trailer can also be designed to keep passing motorists from seeing what is going on within the work area and hopefully facilitate better attention to what is going on in front of them. Hopefully, this will reduce both direct and secondary incidents along such construction and maintenance sites.
[0052] Embodiments of this invention can provide a safety trailer with semi-tractor hookups at both ends and a safety wall that is fixed to one side of the trailer. That side, however, can be changed to the right or left side of the road, depending on the end to which the semi-tractor attaches. A caboose can be attached at the end of the trailer opposite the tractor to provide additional lighting and impact protection. Optionally, the trailer can be equipped with overhead protection, lighting, ventilation, onboard hydraulics, compressors, generators and other equipment, as well as related fuel, water, storage and restroom facilities and other amenities.
[0053] These and other advantages will be apparent from the disclosure of the invention(s) contained herein.
[0054] As used herein, “at least one”, “one or more”, and “and/or” are open-ended expressions that are both conjunctive and disjunctive in operation. For example, each of the expressions “at least one of A, B and C”, “at least one of A, B, or C”, “one or more of A, B, and C”, “one or more of A, B, or C” and “A, B, and/or C” means A alone, B alone, C alone, A and B together, A and C together, B and C together, or A, B and C together.
[0055] It is to be noted that the term “a” or “an” entity refers to one or more of that entity. As such, the terms “a” (or “an”), “one or more” and “at least one” can be used interchangeably herein. It is also to be noted that the terms “comprising”, “including”, and “having” can be used interchangeably.
[0056] The preceding is a simplified summary of the invention to provide an understanding of some aspects of the invention. This summary is neither an extensive nor exhaustive overview of the invention and its various embodiments. It is intended neither to identify key or critical elements of the invention nor to delineate the scope of the invention but to present selected concepts of the invention in a simplified form as an introduction to the more detailed description presented below. As will be appreciated, other embodiments of the invention are possible utilizing, alone or in combination, one or more of the features set forth above or described in detail below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0057] FIGS. 1A-1E show a loaded trailer, in accordance with embodiments of the present invention;
[0058] FIGS. 2A-2C show a deployed protective wall, in accordance with embodiments of the present invention;
[0059] FIGS. 3A-3C show a wall section in accordance with embodiments of the present invention;
[0060] FIGS. 4A-4H show a platform and its components in accordance with embodiments of the present invention;
[0061] FIGS. 5A-5B show a caboose, in accordance with embodiments of the present invention;
[0062] FIGS. 6A-6G show a truck mounted attenuator attached to the caboose shown in FIGS. 5A-5B ;
[0063] FIG. 7 shows an interconnection member between a platform and a truck mounted attenuator;
[0064] FIG. 8 shows a forced air system, in accordance with embodiments of the present invention;
[0065] FIG. 9 shows the loaded trailer, including a storage compartment;
[0066] FIG. 10 is a flow chart illustrating a method of deploying a protective barrier;
[0067] FIG. 11 is a flow chart illustrating a method of balancing the weight of a protective barrier;
[0068] FIG. 12 is a flow chart illustrating a method of changing the orientation of a protective barrier/trailer;
[0069] FIG. 13 is a flow chart illustrating a method of disassembling a protective barrier and loading the component parts for transport;
[0070] FIGS. 14A-C are illustrations of a fixed wall protective barrier in accordance with alternative embodiments of the present invention;
[0071] FIG. 15A-C are illustrations of a fixed wall protective barrier in accordance with another alternative embodiment of the present invention;
[0072] FIG. 16 shows a configuration of the caboose according to an embodiment;
[0073] FIG. 17 shows a configuration of the caboose according to an embodiment; and
[0074] FIG. 18 shows a configuration of the caboose according to an embodiment.
DETAILED DESCRIPTION
[0075] Embodiments of the present invention are directed to a mobile traffic barrier. In one embodiment, the mobile traffic barrier includes a number of inter-connectable wall sections that can be loaded onto a truck bed. The truck bed itself includes two (first and second) platforms. Each platform includes a king pin (not shown); the king pin providing a connection between the selected platform and either a caboose or a tractor. By enabling the tractor to hook at either end, the trailer can incorporate a rigid fixed wall that is open to the right or left side of the road, depending on the end to which the tractor is connected. The side wall and the ends of the trailer define a protected work area for road maintenance and other operations. The tractor and caboose may exchange trailer ends to change the side to which the wall faces. The dual-hookup, fixed-wall design can enable and incorporate compartments (in the platforms) for equipment and storage, onboard power for lighting, ventilation, and heating and/or cooling devices and power tools, and on-board hydraulics for hydraulic tools. The design can also provide for relatively high shielding from driver views, and in general, a larger and better work environment, day or night.
[0076] Referring initially to FIG. 1A , a trailer in accordance with an embodiment is generally identified with reference numeral 100 . The trailer 100 includes two (first and second) platforms 104 a,b and a number of wall sections 108 a - c . As described in greater detail below, the wall sections 108 a - c are adapted to interconnect to each other and to the platforms 104 a,b to form a protective wall. In FIG. 1A , the wall sections 108 a,b are disconnected from each other and secured in a stored position on top of the interconnected platforms 104 a,b . In this position, the trailer 100 is configured so that it may be transported to a work site. In the transport configuration illustrated in FIG. 1A , the platforms 104 are bolted to each other to form a truck bed that is operable to carry the wall sections 108 and other components.
[0077] In addition to the wall sections 108 a - c , the platforms 104 a,b carry two rectangular shaped ballast members 112 a,b , which are shown as boxes of sand. As will be appreciated, the ballast members can be any other heavy material. The weights of ballast boxes 112 a,b counter balance the weights of the wall sections 108 a - c , when the wall sections 108 a - c are deployed to form a protective barrier and when being transported atop the platforms. The ballast boxes 112 a,b hold between about 5,000 and 8,000 lbs. of weight, particularly sand. At 8,000 lbs., the ballast boxes 112 a,b counter balance three wall sections 108 a - c , when the wall sections are deployed or being transported. In one configuration, the wall sections 108 a - c weigh approximately 5,000 lbs. each.
[0078] The truck bed formed by the interconnected platforms 108 a,b is connected at one end to a standard semi-tractor 116 and at the other end to an impact-absorbing caboose 120 . Both of the platforms 108 a,b include a standard king pin connection to the tractor 116 or caboose 120 , as the case may be. The caboose 120 may include an impact absorbing Track Mounted Attenuator (“TMA”) 136 , such as the SCORPION™ manufactured by TrafFix Devices, Inc. In accordance with alternative embodiments, the caboose 120 and/or tractor 116 may include a rigid connection to the rear platform 104 .
[0079] FIG. 1B shows a reverse side of the trailer 100 shown in FIG. 1A . Each platform 104 a,b includes at least one storage compartment 124 . The doors 128 to the storage compartment 124 are shown in FIG. 1A . The reverse perspective of FIG. 1B shows a rigid wall 132 forming the rear of the storage compartment 124 .
[0080] FIG. 1C shows a rear view of the trailer 100 . In FIG. 1C , the TMA 136 is shown in its retracted position. FIG. 1D shows a rear view of the trailer 100 with the TMA 136 in a deployed position.
[0081] FIG. 1E shows a top plan view of the trailer 100 . As can also be seen in FIGS. 1D and 1E , the trailer 100 includes three wall sections 108 stored on top of the platforms 104 a,b . Two of the wall sections 108 a,b nearest the right side of the trailer are positioned end-to-end, with one being positioned on top of each platform. The third wall section 108 c is positioned between the wall sections 108 a,b and the ballast boxes 112 and is approximately bisected by the longitudinal axis A of the trailer (or the first and second platforms). Effectively, by substantially co-locating the longitudinal axis of the third wall section 108 c with the longitudinal axis A of the trailer, the weight of the third wall section 108 c is effectively counter-balanced. The weight of ballast box 112 a therefore counterbalances effectively the first wall section 104 a and ballast box 112 b counterbalances effectively the second wall section 104 b . The platforms 104 a,b are asymmetrical with respect to the longitudinal axis A. Accordingly, the weights of the ballast boxes can be greater than the weights of the wall sections to counter balanced the asymmetrical portion of the platforms. The loading of the trailer shown in FIG. 1E thus serves to balance the weight of the various trailer components with respect to the longitudinal axis A.
[0082] Referring now to FIG. 2A , the trailer 100 is shown in its unloaded or deployed configuration. As can be seen in FIG. 2A , the wall sections 108 a - c have been removed from their loaded positions on top of the platforms 104 a,b and connected between the platforms 104 a,b to form a protective barrier 200 . This is accomplished by removing the wall sections 108 a - c , such as for example through the use of cranes or a forklift, and then disconnecting the two platforms 104 a,b from each other. After the platforms 104 a,b have been disconnected, the platforms 104 a,b are spatially separated and the wall sections 108 a - c are then inserted there-between. As can be seen in FIG. 2A , the two ballast boxes 112 a,b remain in place on top of the platforms 104 a,b . The ballast boxes provide a counter-balance to the weight of the wall sections 108 a - c , which are disposed on the opposite side of the platforms 104 a,b.
[0083] FIG. 2A shows a view of the protective barrier 200 from the perspective of the protected work zone area. From the protected work zone, the storage compartment doors 128 and other equipment are accessible. The protected work zone area 204 can seen in FIG. 2B , which shows a top plan view of the protective barrier 200 shown in FIG. 2A . As can be seen, the protective barrier creates a protected work area 204 , which includes a space adjacent to the wall sections 108 a - c and between the platforms 104 a,b . The road or other work surface is exposed within the work zone area 204 . The work zone area 204 is sufficiently large for heavy equipment to access the work surface.
[0084] FIG. 2C shows the traffic-facing side of the protective barrier 200 . As can be seen in FIG. 2C , the protective barrier 200 presents a protective wall 208 proximate to the traffic zone. The protective wall 208 includes the rigid wall 132 and number of wall sections 108 a - c , which are interconnected to the two platforms 104 a,b . The bottoms of the wall sections 108 a - c are elevated a distance 280 above the roadway 284 . FIGS. 5A-B additionally show a portion of the caboose 120 , which interconnects to and is disposed underneath a selected one of the platforms 104 a,b . The wheels of the caboose 120 , in the deployed position of the trailer 100 shown in FIG. 2C , are covered with a piece of sheet metal 212 . During transport, this piece of sheet metal 212 can be disconnected from the platform 104 and positioned in a stowed manner on top of one of the platforms 104 .
[0085] Although stands 290 are shown in place at either end of the protective barrier 200 and may be used to support individual wall sections 108 of the barrier 200 , it is to be understood that no stands are required to support the barrier 200 . The barrier 200 has sufficient structural rigidity to act as a self-supporting elongated beam when supported on either end by the tractor 116 and caboose 120 . This ability permits the barrier 200 to be located simply by locking the tractor and caboose brakes and relocated simply by unlocking the brakes, moving the barrier 200 to the desired location, and relocking the brakes of the tractor and caboose. Requiring additional supports or stands to be lowered as part of barrier 200 deployment can not only immobilize the barrier 200 but also increase barrier rigidity to the point where it may cause excess damage and deflection to a colliding vehicle and excess ride down and lateral G forces to the occupant of the vehicle.
[0086] The wall section height is preferably sufficient to prevent a vehicle colliding with the barrier 200 from flipping over the wall section into the work area and/or the barrier 200 from cutting into the colliding vehicle, thereby increasing vehicle damage and lateral and ride-down G forces to vehicular occupants. Preferably, the height of each of the wall sections is at least about 2.5 feet, more preferably at least about 3.0 feet, even more preferably at least about 3.5 feet, and even more preferably at least about 4.0 feet. Preferably, the height of the top of each wall section above the surface of the ground or pavement 284 is at least about 3.5 feet, more preferably at least about 4 feet, even more preferably at least about 4.5 feet, and even more preferably at least about 5 feet.
[0087] The protective wall or barrier 200 may additionally include attachment members 216 operable to interconnect a visual barrier 220 to the protective wall 200 . A visual barrier 220 in accordance with embodiments is mounted to the protective wall 200 and extends from the top of the protective wall 200 to approximately four feet above the wall 200 . The visual barrier 220 is interconnected to attachment members 216 , such as poles, which are interconnected to the wall 200 . In accordance with an embodiment, the attachment members 216 comprise poles which extend 10 feet upwardly from the wall section 200 . Each pole may support a 6 lb. light head at the top which generates over 3,000 alums of light. The poles may additionally provide an attachment means for the visual barrier 220 . While attached to the poles, the visual barrier 220 extends approximately 4 feet upwardly from the protective wall 200 .
[0088] The visual barrier 220 provides an additional safety factor for the work zone 204 . Studies have shown that a major cause of highway traffic accidents in and around work zone areas is the tendency for drivers to “rubber-neck” or look into the work zone from a moving vehicle. In this regard, it is found that such behavior can lead to traffic accidents. In particular, the “rubber-necking” driver may veer out of his or her traffic lane and into the work zone, resulting in a work zone incursion. The present invention can provide a structurally rigid wall 200 that prevents incursion into the work zone 204 , as well as a visual barrier 220 which discourages this, so called, “rubber necking” behavior.
[0089] Studies have indicated that people are drawn to lights and distractions, and that they tend to steer and drive into what they are looking at. This is particularly hazardous for construction workers, especially where cones and other temporary barriers are being deployed on maintenance projects. Studies also indicate that lighting and equipment movement within a work zone are important factors in work site safety. Significant numbers of people are injured not only from errant vehicles entering the work zone, but also simply by movement of equipment within the work area. The trailer can be designed not only to keep passing traffic out of the work area, but also to reduce the amount of vehicles and equipment otherwise moving around within the work area.
[0090] In terms of lighting, research indicates more is better. Current lighting is often somewhat removed from the location where the work is actually taking place. Often, the lighting banks are on separate carts which themselves contribute to equipment traffic, congestion and accidents within the job site.
[0091] These competing considerations of motorists, at night, steering towards lights and roadside workmen being safer at night with more lighting can be satisfied by the trailer. The trailer can use the light heads 270 to provide substantial lighting where it is needed. If the work moves, the lighting moves with the work area, rather than the work area moving away from the lighting. Most importantly, the safety barrier—front, back and side—can move along too, providing simple but effective physical and visual barriers to passing traffic. Referring to FIGS. 2B and 2C , the light heads 270 positioned along the barrier 200 have a direction of illumination that is approximately perpendicular or normal to the direction of oncoming traffic. This configuration provides not only less glare to oncoming motorists but also less temptation for motorists to steer towards and into the barrier 200 .
[0092] FIGS. 2A-2C show the protective barrier 200 deployed for use in connection with a work-zone area. The design of the support members and the traffic facing portion of the protective barrier 200 , serve to provide a safe means for mitigating the effects of such a collision. In particular, the barrier 200 can re-direct the impacted moving car down the length of the protective wall 208 . Here, the moving car is not reflected back into traffic. Further incidents are prevented by not reflecting the moving car back from the mobile barrier into other cars, thereby enhancing safety not only of the driver of the vehicle colliding with the barrier but also of other drivers in the vicinity of the incident. The inherent rock/roll movement in the tractor 116 and trailer (caboose) springs and shocks assist dissipation of shock from vehicular impact. In addition, by deflecting the moving vehicle down the length of the protective wall 208 , the work zone 200 is prevented from sustaining an incursion by the moving vehicle, thereby enhancing safety of workers.
[0093] A number of factors are potentially important in maintaining this desirable effect. Firstly, the protective barrier 204 is maintained in a substantially vertical position. This is accomplished through a ballasting system and method in accordance with an embodiment. In particular, the wall sections 108 are balanced in a first step with the ballast boxes 112 . In a following step, a more precise balancing of the protective barrier 200 position is achieved through a system of movable pistons associated with the caboose 120 . This aspect of the invention is described in greater detail below. Second, the structural design of the wall sections 108 serve to provide optimal deflection of an incoming car. Finally as shown in FIG. 2B , the protective wall or barrier 200 is substantially planar and smooth (and substantially free of projections) along its length to provide a relatively low coefficient of friction to an oncoming vehicle. As will be appreciated, projections can redirect the vehicle into the wall and interfere with the wall's ability to direct the vehicle in a direction substantially parallel to the wall.
[0094] Turning now to FIG. 3A , an individual wall section 108 is shown in perspective view from the traffic side of the wall section 108 . As can be seen in FIG. 3A , the wall section 108 includes a wall skin portion 300 , which faces the traffic side of the protective barrier 200 and is smooth to provide a relatively low coefficient of friction to a colliding vehicle. The wall skin 300 is adapted to distribute the force of the impact along a broad surface, thereby absorbing substantially the impact. As additionally can be seen in FIG. 3A , the wall section 108 includes a first end portion or wall end member 304 a . The first end portion 304 a includes a conduit box 308 , a number of bolt holes 312 , a protruding alignment member, which is shown as a large dowel 316 a , and an alignment receiving member, which is shown as a small dowel receiver hole 320 a . As will be appreciated, the alignment member can have any shape or length, depending on the application. The first end portion 304 a of the wall section 108 is adapted to be interconnected to a second end portion 304 b of an adjacent wall section 108 or platform 104 . A second end portion 304 b can be seen in FIG. 3B , which shows the opposite end 304 b of the wall section 108 shown in FIG. 3A , including a protruding small dowel 316 b and a large dowel receiver hole 320 b . For each wall section 108 , the large dowel 316 a disposed on the top of the first end portion 304 a is operatively associated with a large dowel receiver hole 320 b in the second end portion 304 b of an adjacent wall section 108 or platform 104 . Similarly, the small dowel 316 b on the second end portion 304 b is operatively associated with the small dowel receiver hole 320 a in the first end portion 304 a of an adjacent wall section 108 or platform 104 . Additionally, the wall sections 108 are interconnected through a screw-and-bolt connection using the bolt holes 312 associated with the wall ends 304 . The conduit box 308 is additionally aligned with an adjacent conduit box 308 , providing a means for allowing entry and pass-through of such components as electrical lines, air hoses, hydraulic lines, and the like.
[0095] In FIG. 3B , a portion of the wall skin 300 is not shown in order to reveal the interior of the wall section 108 . As can be appreciated, such a partial wall skin 300 is shown here for illustrative purposes. As can be seen in FIGS. 3B and 3C , the wall section 108 includes three bracing sections 324 a - c vertically spaced equidistant from one another. Each of the bracing sections 324 includes two opposing horizontal beams 328 a - b , with the free ends being connected to the adjacent wall end member 304 a,b . The two horizontal beams 328 a - b are interconnected with angled steel members 332 to form a truss-like structure. The wall section 108 includes three bracing sections: the first bracing section 324 a being at the top, the second bracing section 324 b being at the middle and the third bracing section 324 c being at the bottom. Additionally, the wall section 108 includes a number of full-height vertical wall sections 336 a,b , the wall end members 304 a,b , and a number of partial-height vertical wall sections 340 a - c . As shown in FIG. 3A , the full-height wall sections 336 a,b and partial-height wall sections 340 a - c alternate. Additionally, it can be seen that the angled steel members 332 intersect at points where the partial-height wall 340 or full height wall 336 section, as the case may be, meets the horizontal beam 328 a,b , which, on one side, faces the traffic side of the wall section 108 . Additionally, the wall section includes a fourth horizontal member 344 . Unlike the structural members 328 and 336 which are preferably configured as rectangular steel beams, this fourth horizontal member 344 is configured as a steel C-channel beam. The C-channel is preferably positioned substantially at the height of a car or SUV bumper. In use, the bottom of the wall section 108 sits approximately eleven inches off of the ground, and the fourth horizontal member 344 sits approximately twenty inches off of the ground.
[0096] The wall sections 108 constructed as described and shown herein are specifically adapted to prevent gouging of the wall as a result of an impact from a moving car. In particular, gouging as used herein refers to piercing or tearing or otherwise drastic deformation of the wall section, which results in transfer of energy from a moving car into the mobile barrier 200 . As described herein, by deflecting the car down the length of the protective wall 200 , a desirable amount of energy is absorbed by the wall and therefore not transferred to other portions of the protective wall 200 . It is additionally noted that the floating king pin plate of the standard trailer 116 provides a shock absorbing effect for impacts which are received by the protective wall 200 . The shock absorbing effect of the trailer's 116 floating king pin plate 500 is complemented by fixed king pin plate associated with the caboose 120 (which is discussed below).
[0097] In accordance with an embodiment, the dimensions of the various trailer and wall components vary. By way of example, the length of each wall section 108 preferably ranges from about 10 to 30 feet in length, more preferably from about 15 to 25 feet in length, and more preferably from about 18 to 22 feet in length. The width of each of the wall sections preferably ranges from about 18 to 30 inches, more preferably from about 22 to 28 inches, and more preferably from about 23 to 25 inches. The height of each of the wall sections 108 preferably ranges from about 3 to 4.5 feet, more preferably from about 3.75 to 4.25 feet, and more preferably from about 3.9 to 4.1 feet. It should be noted that these height ranges and distances measure from the base of a wall section 108 to the top of the wall section 108 and do not include the wall section's height when it is displaced with respect to the ground. In use, the wall section 108 typically is disposed at a predetermined distance from the ground. In particular, this distance preferably ranges from about 10 to 14 inches, more preferably from about 11 to 13 inches, and more preferably from about 11.5 to 12.5 inches. In accordance with an embodiment, a wall section is approximately 20 feet long, 24 inches wide, 4 feet high as measured from the base of the wall section to the top of the wall section and, when deployed, disposed at a distance of 12 inches from the ground.
[0098] The beams 328 a and 328 b span the length of the entire wall section. In accordance with an embodiment, the horizontal beams 328 a and 328 b measure from about 3-5 inches by about 5-7 inches, more preferably from about 3.5 inches to 4.5 inches by 5.5 inches to 6.5 inches, and even more preferably are about 4 inches by 6 inches. In accordance with an embodiment, the longer dimension of the beam is disposed in the horizontal direction. For example, with 4.times.6 beams, the 4-inch dimension is disposed in the vertical direction and the 6-inch dimension in the horizontal direction. In this embodiment with three sets of horizontal beams, the bottom and middle beams are separated by about 18 inches and the middle and the top beams also by about 18 inches. In this configuration, the total height of the wall section is 4 feet. In other portions of the mobile barrier 200 , the orientations of the horizontal beams may differ. In particular, the longer 6 inch dimension may be in the vertical direction, and the shorter 4 inch dimension may be in the horizontal direction. In accordance with an embodiment, this orientation for the horizontal beams is implemented in connection with the platforms 104 .
[0099] The wall skin 300 may be comprised of a single homogeneous piece of steel that is welded to the wall section 108 . The wall skin 300 is preferably between about 0.1 and 0.5 inch thick, more preferably between about 0.2 and 0.4 inch, and even more preferably approximately 0.25 inches thick. These dimensions are also applicable to the partial-height and full height wall members 340 , 336 . The wall end portions or plates 304 b and 304 a are preferably between about 0.25 and 1.25 inch thick, more preferably between about 0.5 and 1 inch thick, and even more preferably are about 0.75 inch thick.
[0100] In accordance with a preferred embodiment where the wall sections 108 are approximately 20 feet in length, a work space area 204 is defined when these wall sections are deployed that measures approximately 80 feet in length. In particular, the three wall sections total 60 feet in addition to 10 feet on each side of additional space provided by the interior portions of the platforms 104 .
[0101] Referring again to FIG. 3C , a wall section 108 may include a number of attaching devices, which provide a means for interconnecting various auxiliary components to the wall section 108 . In particular, a wall section 108 may include an attachment member mounting 348 , operable to mount an attachment member 216 , such as a pole. The attachment member mounting shown in FIG. 3C includes a lever which, through a quarter turn, is operable to lock the light pole in place. A pole may be used to mount a light in connection with using the wall barrier during night-time hours. As can be appreciated in such conditions, the work area will be required to be illuminated. Such illumination can be accomplished by light poles and corresponding lights which are mounted to the wall section. The light poles, lights and other auxiliary components may be stored in the storage compartments 124 .
[0102] The wall section 108 additionally may include attachments for jack stands 352 . The jack stands 352 provide a means for supporting the wall section 108 at the above-mentioned height of approximately eleven inches from the ground.
[0103] The wall section 108 may additionally include, so called, “glad hand boxes” (not shown), which provide means for accessing 12, 110, 120, 220, and/or 240 volt electricity. In accordance with the embodiments, the protective barrier 200 includes an electric generator and/or one or more batteries (which may be recharged by on-board solar panels) providing electricity which is accessible through the glad hand box and is additionally used in connection with other components of the protective barrier 200 described herein. The generator and/or the batteries may additionally be stored the storage compartments 124 , and the batteries used to start the generator and support electronics when the generator is turned off or is not operational.
[0104] The wall section 108 may be comprised of, or formed from, any suitable material which provides strength and rigidity to the wall section 108 . In accordance with embodiments, the beams of the wall section are made of steel and the outer skin of the wall section is made from sheets of steel. In accordance with alternative embodiments, the wall section 108 is made from carbon fiber composite material.
[0105] Referring now to FIG. 4A , a side perspective view of a platform 104 is shown. In FIG. 4A the platform is resting on a jack stand 352 . Additionally, the outline of the caboose 120 is shown in FIG. 4A . With the caboose 120 attached, the platform 104 shown in FIG. 4A would correspond to the rear of the protective barrier 200 and/or the rear of the loaded trailer 100 . As can be seen in FIG. 4A , the platform includes a king pin 400 . The king pin 400 provides an interconnection between the platform 104 and the caboose 120 . The king pin 400 is disposed on the underside of the platform 104 in a position that allows the king pin 400 to connect with a standard floating king pin plate associated with a semi-tractor 116 or a fixed king pin plate associated with the caboose 120 . In this way, either the caboose 120 or the semi-tractor 116 may be connected to the platform 104 using the king pin 400 . A nose receiver 404 portion of the platform 104 provides a means for receiving the end, or nose portion of the caboose 120 . This aspect of the invention is described in greater detail below.
[0106] In FIG. 4B and FIG. 4C , two opposed platforms 104 are shown with a central external cover plate of the central portions of the platforms being removed to show the structural members while the ballast box external support plates are in position, in FIG. 4D , a platform is shown with all exterior cover plates removed, and in FIG. 4G a platform is shown with all external cover plates in position. As can be seen, the first end 408 of the platform 104 is wider than the second end 412 of the platform 104 . Here, the platform 104 includes support members 421 for supporting the king pin (not shown), a sloping plate 428 for receiving the nose portion of the caboose, a flat plate assembly 422 positioned above and supporting the jack stands 423 , and a sloped or narrowing section 416 , which slopes from the larger, first-end 408 width, to the smaller, second-end 412 width. This sloped portion 416 of the platforms 104 includes the storage compartment 124 . The two second-ends 412 of the platform 104 are adapted to be interconnected to each other. The two first-ends 408 of the platform 104 are adapted to interconnect to either the tractor 116 or the caboose 120 , as described above. As can be seen in FIG. 4D , the platform 104 includes two side channels 420 a - b . Typically, the channel 420 a proximate to the work zone is adapted to receive a ballast box 112 , both in the mobile and the deployed positions.
[0107] FIGS. 4D, 4E, and 4F further show the structural members of each of the platforms. The platforms are identically constructed but are mirror images of one another. The traffic-facing, or elongated, side 460 of the platform 104 includes upper, middle, and lower horizontal structural members 464 , 468 , and 472 . The upper, middle, and lower horizontal structural members are at the same heights as and similar dimensions to the upper, middle, and lower horizontal beams 328 , respectively. The members 464 , 468 , and 472 , unlike the beams 328 , are oriented with the long dimension vertical and the shorter dimension horizontal. By orienting the members differently from the beams, the need for a member similar to the fourth horizontal member 344 is obviated. The upper structural member 464 is part of an interconnected framework of interconnected members 476 , 480 , 484 , 488 , 490 , and 492 defining the upper level of the platform. Lateral structural members 494 provide structural support for the ballast boxes, depending on where they are positioned, and lateral members 496 provide further structural support for the upper level and for the king pin and other caboose interconnecting features discussed below. The first end of the lower structural member attaches to a corner member 497 and second ends of the upper and lower structural members to the second end member 498 . At the level of the lower structural member 472 , lower structural members 473 , 474 , 475 , and 477 define the lower level of the platform. Additional vertical and corner members 478 , 479 , and 481 attach the lower and upper levels of the platform and horizontal support member 483 interconnects corner members 497 and 481 and vertical members 478 and 479 . The lower level further includes lateral members 475 and elongated member 477 to provide further structural support for the lower level and provide support for the bottom of the storage compartment.
[0108] In FIGS. 4G and 4H , portions of the platform 104 are shown, which include the underside of a platform 104 . As can be seen in FIG. 4E , the platform 104 includes a king pin 400 disposed substantially in alignment with a longitudinal axis 405 bisecting a space 407 defined by the nose receiver portion 404 . The nose receiver portion 404 includes two angled components 424 a,b as well as a downwardly facing deflection plate 428 . FIG. 4H shows, in plan view, the components 424 a,b , each of which includes a straight portion 409 a,b and angled portion 411 a,b . The space 407 between the angled portions is in substantial alignment with the king pin 400 .
[0109] As the caboose 120 is backed into the space underneath the platform 104 , the king pin 400 is received in a king pin receiver channel 524 ( FIG. 5 ) in a fixed king pin plate on the caboose 120 , and the nose of the caboose is received in the nose receiver 404 portion of the platform 104 . The nose receiver portion 404 , namely the angled portions of the components 424 a,b and sloped deflection plate 428 , guide the an angled front-nose portion 520 ( FIG. 5 ) of the caboose as the caboose is brought into position underneath the platform 104 to align the king pin with the king pin receiver channel 524 ( FIG. 5 ). In particular, the two angled components 424 operate to provide lateral guidance for the position of the caboose 120 . Here, the two angled components 424 ensure that the king pin 400 is received in the king pin receiver channel 524 associated with the caboose 120 . The downwardly facing deflection plate 428 exerts a downward force on the nose 520 of the caboose that results in the rear of the caboose 120 raising up to engage the rear of the platform 104 . The interconnection between the caboose 120 and the rear of the platform 104 is described in greater detail below.
[0110] In FIG. 5A , a side perspective view of the caboose 120 is shown. As shown in FIG. 5A , the caboose 120 includes the fixed king pin plate 500 . The king pin plate 500 includes a king pin receiver channel 524 provided at the end of the plate 500 . This pin receiver channel 524 is adapted to receive the king pin 400 and provides a locking mechanism for locking the caboose 120 to the end of the platform 104 . In addition, the caboose 104 includes a vertical adjustment member, which is shown as movable pneumatically or hydraulically actuated piston 508 (as can be seen in FIG. 4A ), disposed on each side between the two wheels of the caboose 120 . Although a piston is shown, it is to be understood that any suitable adjustment member may be used, such as a mechanical lifting device (e.g., a jack or crank). The movable piston 508 is associated with a piston cylinder and is interconnected to a top 512 portion and a bottom portion 516 of the caboose 120 . The bottom portion 516 provides a mounting for the wheel axles as well as the wheel suspension. The movable piston 508 , as described in greater detail below, is operable to be inflated, thereby adjusting the height of the selected, adjacent side of mobile barrier 200 . More specifically, the movable piston 508 moves the caboose 120 off of its suspension or leaf springs.
[0111] In FIG. 5A , a side perspective view of the caboose 120 is shown. As can be seen in FIG. 5B , the fixed king pin plate 500 includes the king pin receiver channel 524 . The king pin receiver channel 524 includes a front, wide portion 528 , which leads into a rear, narrow portion 532 , as this king pin receiver channel 524 allows the caboose 120 to be positioned properly while the caboose is being backed into and underneath the platform 104 . In this regard, the nose 520 of the caboose 120 is additionally received in the nose receiver portion 404 , disposed on the underside of the platform 104 . This aspect of the present invention is described in greater detail below.
[0112] Referring now to FIG. 58B , an additional side perspective view of the caboose 120 is shown. In FIG. 5B , the king pin plate 500 is shown removed from the caboose 120 . As can be seen in FIG. 5B , underneath the king pin plate 500 , the caboose 120 includes a number of air cylinders 536 . These air cylinders 536 are associated with a standard ABS braking system and operate independently of the braking system of the tractor 116 . As described in greater detail below, the air cylinders 536 can be locked by an auxiliary mechanism associated with the caboose 120 to hold the caboose 120 in place. The auxiliary mechanism may be adjusted to allow the brakes to be engaged and the caboose 120 held in place even if the caboose 120 is disconnected from the platform 104 . This mechanism additionally provides a means for inflating and deflating the movable piston 508 disposed on either side of the caboose 120 .
[0113] FIGS. 5A, 5B, and 8 depict the removable attachment mechanism between the caboose and the platform. The caboose includes permanently attached first and second pairs 580 a,b of opposing attachment members 584 a,b . Each attachment member 584 a,b in the pair 580 a,b has matching and aligned holes extending through each attachment member. In FIG. 8 , first and second pairs 804 a,b of attachment members 808 a,b are permanently attached to the platform. Each attachment member 808 a,b in the pair includes matching and aligned holes extending through the attachment member 808 . When the caboose is in proper position relative to the platform, the holes in the attachment members 584 a,b and 808 a,b are aligned and removably receive a pin 802 having a cotter pin or key 810 to lock the dowell 802 in position in the aligned holes of each set of engaged pairs of attachment members 580 and 804 .
[0114] An embodiment includes a truck mounted crash attenuator, or equivalently, a Truck Mounted Attenuator (TMA). Referring again to FIG. 1A , a truck mounted attenuator 136 is shown interconnected to the trailer 100 at the caboose 120 . In FIG. 1A , the truck mounted attenuator 136 is shown in a retracted position. The truck mounted attenuator 136 includes a first portion 140 and a second portion 144 . In the retracted position, the first portion 140 is positioned substantially vertically and supports the weight of the second portion 144 , which is held in a substantially horizontal position over the caboose 120 . A movable electronic billboard 148 and light bar 150 (which can provide a selected message to oncoming traffic) is located underneath the second portion 144 of the truck mounted attenuator 136 .
[0115] The deployment of the truck mounted attenuator 136 and the electronic billboard and light bar 148 is illustrated in FIGS. 6A-6G . As shown in FIG. 6A through FIG. 6F , the truck mounted attenuator 136 is extended and lowered into a position wherein both the first portion 140 and the second portion 144 are substantially horizontal and proximate to the ground. As shown in FIG. 6G , the electronic billboard 148 and light bar 150 are then raised. Referring to FIG. 7 , the TMA 136 is typically bolted by a bracket 700 to the caboose 120 . The TMA is thus readily removable simply by unbolting the TMA from the vertical plate of the bracket 700 . Additionally, the bracket 700 and associated components provide a means for attaching the electronic billboard 148 and light bar 150 to the caboose 120 . The bracket 700 is mounted to provide a desirable height for the truck mounted attenuator in its deployed position, more specifically, approximately ten to eleven inches off of the ground. The bracket 700 is additionally mounted to provide visibility of the caboose brake lights and other warning lights associated with the trailer 100 . In FIG. 1C , a rear view of the loaded trailer 100 is illustrated. As shown herein, the truck mounted attenuator 136 is raised into its tracked position. As can be seen, the brake lights 152 of the caboose 120 are visible underneath the truck mounted attenuator 136 . A beacon 156 is also visible, despite the presence of the truck mounted attenuator 136 . The beacon 156 provides a visual indication of an end portion of the trailer 100 . As with the caboose 120 , the truck mounted attenuator 136 may be associated with either of the two platforms 104 and thereafter either end of the trailer.
[0116] Turning now to FIG. 8 , a forced air system 800 in accordance with an embodiment is shown. The forced air system 800 includes two lever attenuators 804 operable to lock the brakes of the caboose 120 independently of the brakes of the tractor 116 . As used herein, locking the brakes includes disconnecting or disabling the automatic brake system, typically associated with the caboose 120 . Here, the brakes are forced into a locked position, thereby locking or preventing movement of the caboose 120 . Also shown in FIG. 8 is a knob 808 operable to control the inflation and/or deflation of the moveable pistons 508 . As described above, the pistons 508 are used to provide a finer grade vertical adjustment of the balancing of the protective barrier 200 by vertically lifting or lowering a selected side of the caboose and interconnected platform. In other words, inflating the piston on a first side of the caboose lifts the first side of the platform relative to the second side of the platform and vice versa. In accordance with embodiments, the air provided to the pistons 508 is delivered from an air supply associated with the trailer 116 and not from an air compressor.
[0117] The interconnection between the platform 104 and the king pin plate 500 is illustrated in FIG. 8 . A removable pin interconnects the platform to the caboose. The pin is removable, and may be locked in place with attachment member 802 .
[0118] Turning now to FIG. 9 , a loaded trailer 100 is shown from the work area-side of the trailer 100 . As shown herein, the wall sections 108 are loaded on top of the platforms 104 and the platforms 104 are interconnected. As described above, this loaded position corresponds to an arrangement of the various components, which can be used to transport the entire system. As shown in FIG. 9 , the platform includes a storage compartment. Various auxiliary components described herein are stored in this storage compartment 124 . As can be seen in FIG. 9 , such components, as the light poles 900 , the corresponding lights themselves 904 , the visual barrier 220 , as well as various electrical components, are shown inside of the compartment. For example, FIG. 9 includes an onboard computer 908 and a generator 912 . In this configuration or in the deployed configuration, various lines 916 , such as electrical lines or air lines, may run along the length of a wall section 108 through the various adjacent conduit boxes 308 .
[0119] Referring now to FIG. 10 , a flow chart is shown which illustrates the steps in a method of deploying a mobile barrier in accordance with an embodiment. Initially at step 1004 , the trailer arrives at a worksite. At step 1008 , the wall sections 108 are unloaded from the trailer bed. This may be done with the use of cranes, a fork lift, and/or other heavy equipment operable to remove and manipulate the weight associated with the wall sections 108 . At step 1012 , the platforms 104 are disconnected from each other. More particularly, the bolt connections that interconnect the platforms 104 are removed. At step 1016 , the platforms 104 are separated. Here, the brakes of the caboose 120 may be locked and the disconnected platform portion of the trailer 116 attached to the tractor 116 may be driven away from the location of the caboose 120 and its attached platform. A dolly or castor wheel may be connected to the end of the platform 104 to provide mobility for the portion of the platform 104 attached to the tractor 116 , thereby allowing the platform to move into position to be engaged with the end wall section. Alternatively, a first platform connected to the tractor 116 is positioned at the desired location before disconnection of the platforms. Jacks attached to the first platform are lowered into position with the roadway. The platforms are then disconnected, with the second platform being supported by the caboose. A forklift or other vehicle is used to move the second platform into position for connection with the wall sections. In any event at step 1020 , the platforms 104 and wall sections 108 are interconnected to form a protective barrier 200 . At this point a continuous protective barrier 200 is formed from the various components of the trailer. Next, a number of steps or operations may be employed. At step 1024 , it may be determined that the protective barrier 200 must be balanced. More particularly, the weight of the protective barrier 200 must be adjusted such that the protective barrier 200 wall comes into a substantially vertical alignment. If no balancing of the protective barrier 200 is needed, work may be commenced within the protected area 204 of the protective wall 200 . At step 1028 , it may be determined that the direction or orientation of the protective barrier 200 may need to be changed. This may be done by jacking the second platform, disconnecting the caboose, and reversing the positions of the tractor 116 and caboose 120 . Alternatively, the jack stands may be retracted and the truck, while the wall sections are deployed, driven, while attached to the barrier, to a new location. At step 1032 , work may be completed and the protective barrier 200 may then be disassembled for transport.
[0120] Turning now to FIG. 11 , a method of balancing a protective barrier 200 (step 1024 ) is illustrated. This method assumes that the ballast boxes are not adequate to counter-balance completely the deployed barrier. At step 1104 , the protective barrier 200 or wall is inspected to determine whether or not the wall is disposed at a substantially vertical orientation. This can be done using a manual or automatic level detection device. If at decision 1108 the wall is substantially vertical, step 1112 follows. At step 1112 the process may end. If at decision 1108 , it is determined that the wall is not substantially vertical, step 1116 follows. At step 1116 , one or more of the piston cylinders 508 are inflated or deflated to provide a counter balance to the weight of the protective barrier 200 and desired barrier 200 orientation.
[0121] FIG. 12 illustrates a method of changing directions for the protective barrier 200 . Initially, at step 1204 , the caboose-engaging platform is placed on jack stands and thereafter the caboose is disconnected from the platform to which it is attached. At step 1208 , the caboose is towed out from underneath the platform 104 . Here, the caboose 120 may be connected to or otherwise attached to a tractor, forklift, or pickup truck, which is operable to tow the caboose 120 . At step 1220 , the tractor-engaging platform is placed on jack stands and the tractor 116 is disconnected from the platform 104 to which it is attached. At step 1216 , the tractor 116 is driven out from underneath the platform 104 . At step 1220 , the positions of the caboose 120 and tractor 116 are interchanged. At 1224 , the caboose 120 is positioned underneath and connected to the platform 104 to which the tractor 104 was formally attached. As described above, this includes a nose receiver portion 404 , providing guidance to the caboose 120 in order to guide the king pin 400 into the king pin receiver channel 532 associated with the king pin plate. At step 1228 , the tractor 116 is positioned with respect to and connected to the platform 104 to which the caboose 120 was formally attached.
[0122] Referring now to FIG. 13 , a method of loading a trailer in accordance with embodiments is illustrated. Initially at step 1304 , the platforms 104 and wall sections 108 are placed on jack stands and disconnected from one another. This includes removing the bolt connections which interconnect the opposing faces of the platforms 104 and/or wall sections 108 . At step 1308 , the platforms 104 are brought together. As described above, this includes interconnecting a castor or dolly wheel to at least one platform end and driving the platform 104 in the direction of the opposing platform. Alternatively, the platform engaging the caboose is taken off of its jack stands and maneuvered by a vehicle to mate with the other, stationary platform. At step 1312 , the platforms 104 are interconnected by such means as bolting the platforms together. At step 1316 , the wall sections 108 are loaded onto the truck bed. Because the ballast boxes typically do not counter-balance precisely the loaded wall sections and vice versa, the piston cylinders 508 are inflated or deflated, as desired, to provide a level ride of the trailer. Finally, at step 1320 , the trailer 100 departs from the worksite. In one configuration, castor or dolly wheels may be put on each of the two platforms so that, when they are disconnected from end wall sections of the barrier, the first and second platforms may be moved into engagement with and connected to one another. The wall sections may then be disconnected from one another and loaded onto the connected platforms.
[0123] The above discussion relates to a mobile barrier in accordance with an embodiment that includes a number of interconnectable wall sections, which are, in one configuration placed on the surface of a truck bed. In a second configuration, these wall sections are removed from the truck bed and interconnected with portions of the trailer to form a protective barrier. In this way, a fixed wall is formed that provides protection for a work area. The present invention can provide a non-rotating wall that is deployed to form the protective barrier. Alternative embodiments of a fixed wall mobile barrier are illustrated in FIGS. 14A-C and FIGS. 15A-C .
[0124] FIGS. 14A-C illustrate a “sandwich” type extendable protective wall. As shown in FIG. 14A , the mobile barrier 1400 includes two platforms 104 and three interconnected wall sections 1404 a , 1404 b and 1404 c . FIG. 14A illustrates a contracted or retracted position wherein the wall sections 1404 a - c are disposed adjacent to one another in a “sandwich position”. FIG. 14B illustrates an intermediate step in the deployment of the mobile barrier 1400 . Here, the platforms 104 are moved away from each other and the sandwiched wall sections extended. From this intermediate position, the sections 1404 a and 1404 c move forward to a position adjacent to the forward position of the wall section 1404 a . In accordance with embodiments, the wall sections 1404 a - c are disposed on sliding rails which allow the displacement shown in FIG. 14B-C . Additionally between wall sections 1404 a and 1404 a (similarly 1404 b and 1404 c ) an articulating mechanism is provided, which allows motion between the adjacent wall sections. FIG. 14C shows the final position of the mobile barrier 1400 . Here, the various wall sections 1404 a - c and the platforms 104 provide a continuous mobile barrier included a protected work space.
[0125] FIGS. 15A-15C illustrate a telescoping type protective wall system 1500 . FIG. 15A shows a retracted, or closed, position of the protective barrier 1500 . The protective barrier includes opposing platforms 104 . The protective barrier in this embodiment includes two wall sections, the first wall section 1504 encloses the second wall section 1508 in the contracted position shown in FIG. 15A . In the intermediate position shown in FIG. 15B , the second wall section 1508 is extended outward from the first wall section 1504 in a telescopic manner. In the final position shown in FIG. 15C , the second wall section 1508 moves forward to a position adjacent to the first wall section 1504 . In the final position shown in FIG. 15C , the first wall section 1504 , second wall section 1508 and portions of the two platforms 104 form a continuous protective barrier including protective interior space.
[0126] A number of alternative caboose embodiments will now be discussed.
[0127] Referring to FIG. 16 , the caboose 1600 has one or more steerable or articulating axles 1604 a,b or wheels 1608 a - d to avoid a selected area 1612 , such as a work area containing wet concrete. The wheels 1608 a - d are turned to a desired orientation, which is out of alignment with the tractor 116 tires, so that, when the trailer is pulled forward by the tractor 116 , the trailer moves both forward and laterally out of alignment with the path of movement of the tractor 116 . This may be effected in many ways. In one configuration, steering arms (not shown) are attached to the axles 1604 , and the arms are controlled by electrically operated hydraulic cylinders incorporated into the caboose frame assembly. The caboose axles are turned out when pulling ahead to more quickly move the rear of the trailer out and away from the area 1612 . Once the tractor and trailer are out of alignment with the area 1612 , the axles are returned, such as by the hydraulics, to their original positions in alignment with the tractor wheels. The electronics controlling the hydraulics are controlled from the tractor cab or a special switch assembly located in the caboose or on the trailer near the caboose. Alternatively, the axles or wheels may be steered manually, such as by a steering wheel mounted on the platform or caboose. The nose portion of the caboose remains stationary in the members 404 a,b , or the caboose does not rotate about the kingpin but remains aligned with the longitudinal axis of the trailer throughout the above sequence.
[0128] Referring to FIG. 17 , the caboose 1700 articulates or rotates about the king pin 400 . One or more electrically driven hydraulic cylinders at the front of the caboose laterally displaces the nose 1704 in a desired orientation relative to the longitudinal axis of the trailer. When the caboose is rotated to place the wheels 1708 a - d in a desired orientation, which is out of alignment with the tractor 116 tires, the tractor pulls the trailer forward. The trailer moves both forward and laterally out of alignment with the path of movement of the tractor 116 . The hydraulics then push the nose of the caboose to the aligned, or normal, orientation in which the wheels of the caboose are in alignment with the wheels of the tractor. The hydraulic cylinder(s) can be connected directly to a front pivot (not shown) or incorporated into the nose portion or the current “V” wedge assembly, which includes the members 404 a,b . In the latter design, the members 404 a,b are mounted on a movable plate, and the hydraulic cylinder(s) move the plate to a desired position while the nose portion 1704 is engaged by, or sandwiched between, the members 404 a,b . Unlike the prior caboose embodiment, the caboose rotates about the kingpin and does not remain aligned with the longitudinal axis of the trailer throughout the above sequence.
[0129] Referring to FIG. 18 , the caboose 1800 has an elongated frame with articulated steering on one or more axles 1804 a - c , with the rear axle 1804 a being preferred. When only the rear axle is steerable, the axle 1804 a is steered, as noted above, to place the wheels 1808 a,b in the desired orientation. After the caboose is rotated to place the wheels 1808 a,b in a desired orientation, which is out of alignment with the tractor 116 tires, the tractor pulls the trailer forward. The trailer rotates about the king pin 400 and moves both forward and laterally out of alignment with the path of movement of the tractor 116 . The wheels 1808 are then moved back into alignment with the wheels of the tractor. Like the prior embodiment, the caboose rotates about the kingpin and does not remain aligned with the longitudinal axis of the trailer throughout the above sequence. To make this possible, the nose portion of the caboose may need to be removed from engagement with the members 404 a,b , such as by moving a movable plate, to which the members are attached, away from the nose portion.
[0130] In another embodiment, the caboose is motorized independently of the tractor. An engine is incorporated directly into the caboose to provide self-movement and power. In one configuration made possible by this embodiment, the platforms could engage simultaneously two cabooses with a TMA positioned on each caboose to provide crash attenuation at both ends of the trailer. One or both of the cabooses is motorized. This is particularly useful where the trailer may be on site for longer periods and needs only nominal movement from time-to-time, such as at gates, for spot inspection stations, or for security and/or military applications where unmanned and/or more protected movement is desired.
[0131] In other embodiments, the caboose is attached permanently to the platform. In this embodiment, different tractor/trailers, that are mirror images of one another, are used to handle roadside work areas at either side of a roadway.
[0132] The present invention, in various embodiments, includes components, methods, processes, systems and/or apparatus substantially as depicted and described herein, including various embodiments, sub combinations, and subsets thereof. Those of skill in the art will understand how to make and use the present invention after understanding the present disclosure. The present invention, in various embodiments, includes providing devices and processes in the absence of items not depicted and/or described herein or in various embodiments hereof, including in the absence of such items as may have been used in previous devices or processes, e.g., for improving performance, achieving ease and/or reducing cost of implementation.
[0133] The foregoing discussion of the invention has been presented for purposes of illustration and description. The foregoing is not intended to limit the invention to the form or forms disclosed herein. In the foregoing Detailed Description for example, various features of the invention are grouped together in one or more embodiments for the purpose of streamlining the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that the claimed invention requires more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive aspects lie in less than all features of a single foregoing disclosed embodiment. Thus, the following claims are hereby incorporated into this Detailed Description, with each claim standing on its own as a separate preferred embodiment of the invention.
[0134] Moreover, though the description of the invention has included description of one or more embodiments and certain variations and modifications, other variations and modifications are within the scope of the invention, e.g., as may be within the skill and knowledge of those in the art, after understanding the present disclosure. It is intended to obtain rights which include alternative embodiments to the extent permitted, including alternate, interchangeable and/or equivalent structures, functions, ranges or steps to those claimed, whether or not such alternate, interchangeable and/or equivalent structures, functions, ranges or steps are disclosed herein, and without intending to publicly dedicate any patentable subject matter.
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In one embodiment, a safety trailer has semi-tractor hitches at both ends and a safety wall that is fixed to one side of the trailer. That side, however, can be changed to the right or left side of the road, depending on the end to which the truck attaches. A caboose can be attached at the end of the trailer opposite the tractor to provide additional lighting and impact protection. Optionally, the trailer can be equipped with overhead protection, lighting, ventilation, onboard hydraulics, compressors, generators and other equipment, as well as related fuel, water, storage and restroom facilities and other amenities.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This Application claims priority from U.S. Application No. 61/646,982 filed on May 15, 2012, by Anthony L. Wood, Sr., which is incorporated herein in its entirety by reference.
FIELD OF THE INVENTION
[0002] The invention relates to construction equipment and, more particularly, to equipment for terrain conditioning for seeding to mitigate erosion.
BACKGROUND
[0003] It is often desirable to track slopes with a bulldozer to prepare terrain for grass seeding. For example, sloped terrain at a construction site may be conditioned for grass seeding in accordance with various design requirements, construction codes, or erosion prevention plans. The conditioning process typically includes tracking the soil and creating a plurality drainage trenches perpendicular to the direction of slope to prevent seed runoff. A prior art method of conditioning soil required traversing the terrain with a tracked bulldozer so that its raised treads make depressions in the ground to form seed bed trenches.
[0004] While this prior art method is acceptable for its intended purpose on generally flat terrain, it has several drawbacks, particularly when used in sloped environments. First, it requires bulldozer movement over the terrain, leading to high fuel usage, wear and tear on the undercarriage, and additional operator labor. Because the prior art method requires placement of the bulldozer tracks (and therefore placement of the bulldozer) at the area to be conditioned, it raises safety concerns, particularly when the terrain is steep, unstable, uneven, or near drop offs. Furthermore, the spaced-apart bulldozer tracks of the bulldozer form spaced-apart conditioned areas. Consequently, it can be difficult to provide a particular arrangement of drainage trenches, or to condition small or confined areas, such as those at a corner between two meeting slopes where bulldozer maneuverability can be challenging. In addition, the use of skid steering can disturb previously conditioned areas. Finally, it is difficult to adjust the degree of compaction provided by the bulldozer tracks.
OVERVIEW
[0005] In an example embodiment, a conditioner is configured to condition the ground for seeding, such as grass seeding. In one example embodiment, the conditioner includes a roller, and a mounting assembly to rotatably support the roller and releasably couple the roller to a support member of a construction vehicle. In an example embodiment, the roller may be cylindrically-shaped with a plurality of spaced-apart elongated cleats along its circumferential surface to engage and compact the ground and provide a plurality of drainage trenches therein. The cleats may be arranged in a series of overlapping offset columns to provide a spaced-apart staggered drainage trench pattern. In one example embodiment, the cleats are arranged with a center column of cleats offset vertically from two outer aligned columns of cleats. The center cleats may overlap the offset outer cleats. For example, the outer portions of the center cleats may overlap the inner portions of the outer cleats. This arrangement provides a misaligned pattern of drainage trenches in the ground. The roller may also include one or more ports for the addition or removal of fluid to alter the weight of the roller and the degree of compaction it provides. This feature allows the roller to be easily adapted for different soil conditions.
[0006] The mounting assembly may include a frame to rotatably support the roller, and a bracket assembly for coupling the frame to a support member of a construction vehicle. The frame may include a cross support member arranged to extend above and along the axis of the roller, and can include downwardly extending support arms at each end. The support arms may include bearing assemblies for rotatably supporting opposing ends of a shaft extending through the roller so that the roller is rotatably supported by the frame.
[0007] The bracket assembly may be attached to the frame and configured to removably couple the frame (and the roller supported by the frame) to a support member of a construction vehicle. For example, the bracket assembly may include a bracket having receiving holes and bosses arranged to releasably couple the bracket to a dipper arm of an excavator. In an example embodiment, the bracket assembly includes a first bracket having bosses arranged to receive a pin of an excavator pin coupler, and a second bracket having bosses for receiving a pin associated with an excavator dipper arm. In another example embodiment only a single bracket is provided.
[0008] With the roller rotatably supported by the frame, and the bracket coupled to the dipper arm of the construction vehicle, the roller may be moved by the dipper arm to contact and roll across a sloped surface. The outer surface of the roller compacts the soil, and the cleats of the roller engage the ground to provide a plurality of spaced apart drainage trenches. This arrangement, in which the movement of the roller is controlled by the articulating movement of the dipper arm, allows the construction vehicle to be located apart from the area being conditioned. Thus, rather than moving the entire machine over a sloped area, a roller can be moved by a construction vehicle's support arm and hydraulics system. The construction vehicle cab can remain stationary at a remote location, conserving fuel as well as reducing wear and tear on the vehicle.
[0009] The safety of both operator and vehicle during conditioning operations is improved since the construction vehicle can be positioned at a stable location away from drop-offs. The roller can be used in tight, unstable, and steep areas where it may be dangerous and/or difficult to move the vehicle's base. By coupling the conditioner to a dipper arm of an excavator, the hydraulic cylinder piston of the excavator or “bucket cylinder” can be used to manipulate the angle of the frame relative to the arm to allow for added maneuverability, similar to the movement of a bucket.
[0010] In addition, compaction provided by the conditioner can be easily changed. For example, the downward force of the roller can be changed by controlled management of the boom hydraulics and dipper stick. In addition, fluid can be added or removed from the interior of the roller through the roller's port.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 shows a prior art method of conditioning a sloped surface for seeding using the tracks of a bulldozer.
[0012] FIG. 2 shows an excavator having a conditioner for preparing a surface for seeding in accordance with an example embodiment of the invention.
[0013] FIG. 3 shows an example embodiment of a conditioner in which a bucket cylinder of the excavator dipper arm is extended.
[0014] FIG. 4 shows an example embodiment of the conditioner of FIG. 3 in which a bucket cylinder of a dipper arm of the excavator is retracted.
[0015] FIG. 5 shows an example embodiment of the conditioner of FIG. 3 in which the dipper arm is further extended.
[0016] FIG. 6 shows an example embodiment of the conditioner.
[0017] FIG. 7 shows a front view of an example embodiment the roller.
[0018] FIG. 8 shows a boss for supporting a shaft extending through the roller.
[0019] FIG. 9 shows sidewall of the roller.
[0020] FIG. 10 shows a front view of an example support assembly.
[0021] FIG. 11 shows a side view of an example embodiment the conditioner showing a port for adding or removing fluid.
[0022] FIG. 12 shows a side view of the support assembly.
[0023] FIG. 13A shows a boss of a support bracket for receiving a coupler pin.
[0024] FIG. 13B shows a boss of a support bracket for receiving a coupler pin.
[0025] FIG. 14 shows an example embodiment of a support member of a support bracket for coupling a frame of the conditioner to a coupler of a construction vehicle.
[0026] FIG. 15A shows a support arm having a bore for flange bearings.
[0027] FIG. 15B shows a side view of the support arm of FIG. 15A .
[0028] FIG. 16 shows an example embodiment of a cover plate for use with the support arms of the frame.
[0029] FIG. 17 shows an alternative embodiment of a conditioner in which a single bracket is provided.
DETAILED DESCRIPTION
[0030] As required, example embodiments of the present invention are disclosed herein. These embodiments are meant to be examples of various ways of implementing the invention, and it will be understood that the invention may be embodied in alternative forms. The figures are not necessarily to scale and some features may be exaggerated or minimized to show details of particular elements, while related elements may have been eliminated to prevent obscuring novel aspects. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention. In addition, it should be understood that any directional terms, such as “left”, “right”, “upward”, “downward”, etc. are for use in describing in reference to the particular arrangements shown in the example embodiments of the particular drawings and are not intended to be limiting in terms of subject matter. In addition, while in the exemplary embodiments the apparatus is discussed in conjunction with the use of an excavator, the apparatus could be used in conjunction with other type construction equipment such as a backhoe or the like.
[0031] Turning to the figures, wherein like characters represent like items throughout the several views, FIG. 1 shows an example embodiment of a prior art method of conditioning soil in which a bulldozer 2 is moved over a sloped terrain 4 so that its tracks 6 compact the soil and the tracks' treads 10 engage the terrain 4 to produce a plurality of drainage trenches 12 .
[0032] FIGS. 2-5 show an example embodiment of the invention in which a conditioner 20 is coupled to an excavator 22 . The conditioner 20 includes a roller 24 and a mounting assembly 25 that rotatably supports the roller and releasably couples the roller to the excavator 22 . The roller 24 may have a plurality of cleats 26 that extend parallel to the cylindrical axis of the roller 24 to engage and roll along the ground to provide a plurality of drainage trenches. As shown in FIGS. 3-5 the roller 24 can be positioned to contact and roll along the ground 32 . For example, the roller 24 may be moved along the terrain by movement of the dipper arm 34 and boom 36 of an excavator 22 or other equipment. This allows movement of the roller 24 through the use of the hydraulics of the excavator arm 34 . This allows the terrain to be conditioned while the cab 40 of the construction vehicle remains at a remote location. Terrain conditioning through controlled manipulation of the roller 24 while the excavator 22 remains stationary avoids the safety issues, fuel consumption, and wear and tear associated with prior art bulldozer methods that required movement of the entire vehicle. The bucket cylinder piston 42 can be used to position the roller 24 relative to the dipper arm to assist movement of the roller 24 on the slope. For example, FIG. 3 shows the piston 42 in an extended condition, and FIG. 4 shows the piston 42 in a more retracted position.
[0033] FIG. 6 shows the conditioner 20 having the roller 24 rotatably coupled to the mounting assembly 25 . The mounting assembly 25 includes a frame 80 for rotatably supporting the roller 24 , and a bracket assembly 28 for releasably coupling the frame 80 to a support member of a construction vehicle. This allows the roller 24 to condition terrain as it is moved by a support member 34 of a construction vehicle
[0034] FIGS. 7-9 show an example embodiment of the roller 24 and its various components. Referring to FIGS. 6-9 , the roller 24 may be generally cylindrical in shape and include a cylinder 48 with an outer cylindrical surface 50 and sidewalls 52 . In an example embodiment, the roller 24 (cylinder) may have a width w of about 6 feet, a circumference of about 117 1/32″, and an inner radius of about 18⅜″. The cylindrical surface 50 may extend beyond the sidewalls 52 .
[0035] A plurality of cleats 26 may be arranged about the circumferential surface 50 of the cylinder 48 and arranged extending parallel to the axis of the roller 24 . This allows the cleats 26 to make drainage trenches perpendicular to the direction that the roller 24 is rolled. In the example embodiment, the cleats 26 have a length of about 26 inches and a height of 2 inches and a thickness of ½″ so as to make an elongated drainage trench in the ground. The cleats 26 may be arranged about the surface 50 of the roller 24 in a spaced apart arrangement to provide a pattern of misaligned adjacent drainage trenches. In this example embodiment, two outer sets or columns 54 of cleats have aligned cleats, and a center set or column 56 of cleats 26 are misaligned with the outer cleats 26 . For example, the center cleats 26 can be arranged around a center portion of the roller 24 so that each cleat 26 is positioned between the cleats 26 on the outer portions of the roller 24 . In an example embodiment, the cleats 26 in each grouping may be spaced about 8 5/32″ apart. One or more ports 38 may be provided in the sidewall 52 to allow for the additional or removal of fluid from the interior of the cylinder 48 . An operator can increase or decrease the weight of the roller 24 by adding or removing fluid via the ports 38 . This allows the roller to be readily adapted for different terrains on site, and also allows for the weight of the roller to be lightened during transport to and from the work site.
[0036] The outer cleats 26 may be positioned to overlap the cleats 26 of the center column 56 . In the example embodiment, the overlap is about 3 inches. The cleats 26 may be positioned around the circumferential surface 50 of the roller so that the spaces between the cleats 26 serve as compaction surfaces 50 for compacting the ground they contact. The sidewalls 52 define the sides of the cylinder 48 and include an aperture 53 for a shaft and an aperture 55 for a port 38 . A boss 60 may be provided at the sidewalls 52 with an aperture 62 of similar size of the aperture 53 of the sidewall 52 to receive the shaft 64 therethrough. The shaft 64 may have a diameter of 3 15/16″ to fit through 4″ apertures 53 , 62 and a length sufficient to extend through the cylinder 48 and extend from the sidewalls 52 . In the example embodiment, the shaft 64 may have a length of 81″.
[0037] FIGS. 6 and 10 - 16 show various components of the mounting assembly 25 that includes the bracket assembly 28 and the frame 80 . As perhaps best shown in FIGS. 11 and 12 , the bracket assembly 28 can include a dipper arm bracket 66 for connecting to a dipper arm 34 of an excavator or similar equipment. It can also include a coupler bracket 70 configured to releasably couple with a standard pinhole coupler commonly used in conjunction with construction equipment. The brackets 66 , 70 may include support members 71 and 104 with apertures 106 ( FIGS. 13-14 ) for receiving bosses 68 and coupled to triangular gusset plates 73 connected to the frame 80 . The bosses 68 have aligned pinholes 74 for receiving pins 76 extending through the dipper arm 34 and coupler 78 and of the excavator. (See FIGS. 3 and 11 ) As perhaps best seen in FIGS. 3 - 5 , movement of a bucket cylinder piston 42 of the excavator 22 can be used to change the angle of the bracket assembly 28 to assist in the positioning of the roller 24 . In the depicted example, the excavator cab 40 is positioned at a stable location above the slope being conditioned as the excavator arm 34 reaches downward to the sloped terrain 32 , but it is contemplated that the excavator 22 can be positioned at a lower point and reach upward, or some other position. This allows the excavator 22 to condition large areas while the cab 40 remains in a stable remote location.
[0038] The frame 80 is connected to the bracket assembly 28 , and may include a cross support assembly 82 that can extend above and along the axis of the cylinder 48 with a length that can extend beyond the roller 24 . The cross support 82 may include various support members that may be welded together, such as vertical support plates 84 ( FIGS. 6 , 10 ), main support member 88 , and upright support member 86 . The outer ends of the support plates 86 , 88 may extend to and be coupled with support arms 90 . The support arms 90 may extend downward from the cross support assembly 82 and have bores 92 for supporting flange bearings 94 ( FIGS. 10 , 15 A-B). The ends of the shaft 64 extending through the cylinder 48 may be journaled in the flange bearings 94 . The support arms 90 extend downward a length such that when roller 24 is journaled in the bearings 94 with bushing 98 there is a sufficient gap between the cross support assembly 82 and the cleats 26 that the roller 24 may freely roll. A cover plate 96 ( FIG. 16 ) with screw holes 97 arranged to align with holes 99 in the support arms 90 can be screwed to the support arm 90 to cover the bore 92 and flange bearings 94 .
[0039] FIGS. 12 and 14 show an example embodiment of the bracket support plate 104 that forms part of the coupler bracket 70 . The bracket support plate 104 includes an aperture 106 for receiving a boss 68 , and a flange 108 for coupling to the cross support 82 . In the example embodiment shown in FIG. 10 , the flange 108 may be welded to the support members 86 , 88 . As shown in FIG. 11 the position of the bushing 68 in the coupler bracket 70 is angled about 5 degrees from the boss 68 of the dipper arm bracket 66 .
[0040] FIG. 17 shows an example embodiment of a conditioner 100 having a single bracket 110 for releasably coupling to the dipper stick of a construction vehicle.
[0041] In light of the foregoing disclosure of the invention and description of certain preferred embodiments, those skilled in the art will readily understand that various modifications and adaptations can be made without departing from the true scope and spirit of the invention. All such modifications and adaptations are intended to be covered by the following claims. Thus, the foregoing has broadly outlined some of the more pertinent aspects and features of the present invention. These should be construed to be merely illustrative of some of the more prominent features and applications of the invention. Other beneficial results can be obtained by applying the disclosed information in a different manner or by modifying the disclosed embodiments. Accordingly, other aspects and a more comprehensive understanding of the invention may be obtained by referring to the detailed description of the exemplary embodiments taken in conjunction with the accompanying drawings, in addition to the scope of the invention defined by the claims.
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A conditioner is configured to couple to a support member of a construction vehicle and condition the ground while the vehicle remains stationary. A conditioner can include a mounting assembly for releasably coupling to the vehicle and rotatably supporting a roller configured to provide a plurality of seed beds. A cylindrically shaped roller can have a plurality of cleats disposed along a circumferential surface. The cleats may be arranged to provide a spaced-apart staggered pattern of seed beds. Through operation of the vehicle's support member and hydraulic system, the roller can be manipulated to move along steep slopes within confined areas while the construction vehicle remains stationary at a stable location. The roller can be configured for adjustable ground compaction through addition and/or withdrawal of fluids through a port.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation of application Ser. No. 325,666, filed on Mar. 20, 1990, entitled "Continuous Miner With Duct Assembly", now U.S. Pat. No. 4,936,632, a continuation in part of application Ser. No. 076,155 filed on June 20, 1989 entitled "Continuous Miner With Duct Assembly", now U.S. Pat. No. 4,840,432.
BACKGROUND OF THE INVENTION
1. Field Of The Invention
This invention relates to a mining machine, and more particularly, to a continuous miner which includes a mobile frame assembly and a boom assembly pivotally secured to the mobile frame assembly by a plurality of connectors which distribute the load placed on the boom assembly as the boom assembly is pivoted upwardly from the mobile frame assembly evenly throughout the boom structure, and to a dust collecting system for collecting airborne particles produced as a material dislodging head mounted on the end of the boom assembly dislodges material from a mine face.
2. Description Of The Prior Art
In underground mining, it is well known to provide a continuous mining machine which includes a material dislodging head positioned on the front end of the mining machine for dislodging material from a mine face. The dislodged material is conveyed rearwardly of the mining machine by a conveying system positioned on the continuous mining machine. The continuous mining is designed to continuously advance and dislodge material being mined to form an entry or tunnel in the material seam.
Various types of continuous mining machines having different types of tilting of pivoting mining heads are known. U.S. Pat. No. 2,986,384 discloses a mining machine having tiltable, dual mining heads. U.S. Pat. Nos. 3,479,090 and 3,495,876 disclose continuous mining machines each having a pivoting structure for supporting a mining head.
U.S. Pat. No. 3,498,676 discloses a continuous mining machine having a mining head that is positioned at the top of the mine face. The mining head is advanced into the mine face and traversed downwardly through the mine face to cut and break the material out of the mine face. The mining machine is supported on traction treads by which the machine is propelled forwardly to advance the mining head into the mine face.
U.S. Pat. No. 3,499,684 discloses a mining machine with a mining head positioned at the forward end of the machine. Traction means propels the mining machine, and gathering means collects the mined material and transfers the material to a conveyor for moving the mined material to the rear of the machine. The mining head is positioned on a boom that is movable upwardly and downwardly about the transverse axis of a pivot support on the machine main frame.
U.S. Pat. No. 3,516,712 discloses a continuous mining machine with a transverse rotary mining head for mining material from the entire area of the mine face by traversing the mining head through the mine face.
U.S. Pat. No. 3,874,735 discloses a continuous mining machine adapted for low overhead coal seams having a relatively small diameter cutter head of the non-oscillating or fixed head type driven by chains that also cut coal and convey it rearwardly to a gathering head mounted on the front of the machine. The gathering head carries a pair of counter-rotating discs having veins cooperating with conveyor fences for sweeping and discharging coal to a conventional conveyor mounted on the machine chassis.
U.S. Pat. No. 3,966,258 discloses a mining machine having a disintegrating head carried on the front end of the machine by a pivotal link arrangement.
In continuous underground mining, it is also known to provide a mining machine which includes a dust collecting system mounted thereon for collecting airborne dust particles produced as the mining machine cutting or dislodging head operates. The dust collecting system provides a relatively clean environment for the mining machine operator.
U.S. Pat. No. 3,712,678 discloses a continuous miner which is provided with a dust collecting system comprising boom-carried ducting adapted to receive dust-entrained air adjacent and rearwardly of the mining head. The mining machine chassis carries ducting which is operable to alternatively discharge the air to opposite sides of the machine. Counter-rotating centrifugal fans mounted in the boom-carried ducting draw dust-entrained air to such ducting whereby the air flows therethrough to the chassis-carried ducting. Scrubbers or cleaners are operatively associated with the boom-carried ducting for removing larger dust particles from the air.
U.S. Pat. No. 3,810,677 discloses a mining machine having a boom enclosed dust collector assembly for use in a coal mining operation wherein the dusty air from a mining operation is gathered directly from the operation, collected in the mining machine boom and selectively wetted and separated by centrifugal processing into a coal slurry for disposal. The clean air is exhausted to atmosphere. The coal slurry is discharged from the mining machine boom through a flexible hose which lies on the ground along a side of the machine.
U.S. Pat. No. 4,380,353 discloses a dust control system for a mining machine comprising a ductwork system having intakes adjacent the cutter head of the mining machine. A fan draws air through the ductwork system, and a flooded bed scrubber in the ductwork system upstream from the fan entrains the dust in droplets of water. The dust laden water is pumped to a point adjacent the cutting head.
U.S. Pat. No. 4,557,524 discloses a continuous mining machine having a dust control system which includes a generally rectangular intake duct section associated with the boom and a generally rectangular fixed duct section mounted on the vehicle. A transition section is connected to the intake of the fixed duct section. The transition section consists of a two piece arrangement wherein each piece is hinged to the intake duct section and is capable of slidingly engaging the fixed duct section at the end thereof adjacent the boom to sealingly couple the intake duct section to the fixed duct section as the boom swings upwardly and downwardly.
Although the prior art continuous mining machines include various types of cutting heads pivotally mounted on the mining machine, there is a need for an improved mining machine having a boom assembly pivotally connected to the mining machine frame assembly by a plurality of connectors which distribute the load on the mining machine boom assembly as it is pivoted upwardly from the mining machine frame assembly evenly throughout the boom assembly structure. Further, there is a need for a simple, efficient dust collecting system whereby dust produced as a dislodging head dislodges material from a mine face is passed through a boom assembly hollow interior portion to a dust collecting system mounted on the mining machine frame. A portion of the boom assembly forms a pivoting joint with a portion of the dust collecting system positioned on the mobile frame assembly to allow airborne dust particles to be withdrawn from the mine face as the boom assembly pivots upwardly and downwardly relative to the mobile frame assembly.
In another embodiment of the invention, two portions of the boom assembly form pivoting joints with portions of the dust collecting system positioned on each side of the mobile frame assembly to allow airborne dust particles to be withdrawn from the mine face as the boom assembly pivots upwardly and downwardly relative to the mobile frame assembly.
Twin ducts of the collecting system meet the boom on each side of the mining machine and extend rearwardly along each side of the mobile frame assembly. One of the twin ducts passes between the conveying reach and the return reach of the conveying system to join with the other duct to allow a single fan to withdraw airborne dust particles from the mine face.
SUMMARY OF THE INVENTION
In accordance with the present invention, there is provided a continuous mining machine for use in an underground mine which includes a mobile frame assembly and a boom assembly extending from the mobile frame assembly. The boom assembly has a first end portion pivotally connected to the mobile frame assembly by a plurality of connecting means and a second end portion spaced from the first end portion. The boom assembly first end portion is pivotally connected to the mobile frame assembly to permit upward and downward pivotal movement of the boom assembly relative to the mobile frame assembly. A material dislodging head is connected to the boom assembly second end portion. The plurality of connecting means are positioned on the boom assembly to distribute the load placed on the boom assembly as it is pivoted upwardly from the mobile frame assembly evenly through the boom assembly structure.
In one embodiment of the invention, the boom assembly has a hollow interior portion with an air inlet portion connected to the hollow interior portion at each boom assembly second end portion and an air outlet portion at the boom assembly first end portion. A collecting means is positioned on the mobile frame assembly. The collecting means induces a flow of air through the boom assembly hollow interior portion. As the dislodging head operates to dislodge material from a mine face, the collecting means draws airborne dust produced by the dislodging head through the hollow interior portion of the boom assembly into the collecting means positioned on the mobile frame assembly. A portion of the boom assembly air outlet portion is pivotally connected to a portion of the mobile frame assembly collecting means to allow the collecting means to continually draw airborne dust from the mine face as the boom assembly pivots upwardly and downwardly relative to the mobile frame assembly.
In another embodiment of the invention, the boom assembly has a hollow interior portion with inlet portions connected to the hollow interior portion at each boom assembly second end portion and air outlet portion at the boom assembly first end portion. A collecting means is positioned on the mobile frame assembly. The collecting means induces a flow of air through the boom assembly hollow interior portion. As the dislodging head operates to dislodge material from a mine face, the collecting means draws airborne dust produced by the dislodging head through the hollow interior portion of the boom assembly into the collecting means positioned on the mobile frame assembly. Two portions of the boom assembly air outlet portions are pivotally connected to portions of the mobile frame assembly collecting means to allow the collecting means to continually draw airborne dust from the mine face as the boom assembly pivots upwardly and downwardly relative to the mobile frame assembly. Twin ducts of the collecting system meet the boom assembly on each side of the mining machine and the ducts of the collecting system extend rearwardly along each side of the mobile frame assembly. The first duct assembly extends longitudinally along the first side of the mobile frame assembly. The second duct assembly extends longitudinally along part of the second side of the mobile frame. The second duct assembly then traverses the mobile frame by means of a cross-over portion that passes between the conveying reach and the return reach of a conveying means to join with the first duct assembly. Each duct assembly opposite end portion is in fluid communication with the boom assembly hollow interior portions in all positions that the boom assembly pivots upwardly and downwardly so that a single fan may be used to draw airborne dust through the system.
The continuous mining machine further includes the conveying system which extends longitudinally through the center of the mining machine. The conveying system includes a longitudinal first section which extends from the front end of the mobile frame assembly to the rear end of the mobile frame assembly. The conveying system also includes a conveyor second section pivotally connected to the conveyor first section which extends rearwardly from the rear end of the mobile frame assembly. The conveyor second section is pivotally connected to the conveyor first section for selected lateral and vertical movement relative to the conveyor first section. Material removed from the mine face by the dislodging head is transferred rearwardly of the mining machine along the conveyor system first and second sections by a plurality of spaced flights. The conveyor second section is pivoted relative to the conveyor first section to deposit dislodged material at predetermined locations rearwardly of the mining machine.
Accordingly, the principal object of the present invention is to provide a continuous mining machine which includes a boom assembly pivotally connected to the mining machine mobile frame assembly by a plurality of connecting means.
Another object of the present invention is to provide a continuous mining machine having a boom assembly pivotally connected to a mobile frame assembly by a plurality of connecting means suitably positioned on the boom assembly to distribute the loading created on the boom assembly as the boom assembly is pivoted upwardly relative to the mobile frame assembly evenly throughout the boom assembly structure.
A further object of the present invention is to provide a continuous mining machine which includes a dust collecting system positioned on the mobile frame assembly for inducing a flow of air through a hollow interior portion of the boom assembly as the boom assembly pivots upwardly and downwardly relative to the mobile frame assembly.
A further object of the present invention in one of its embodiments is to provide a continuous mining machine which includes a dust collecting system with one fan and twin ducts positioned on the mobile frame assembly for inducing a flow of air through two hollow interior portions of the boom assembly as the boom assembly pivots upwardly and downwardly relative to the mobile frame assembly.
Still another object of the present invention is to provide a continuous mining machine which includes a conveying system longitudinally positioned on the mobile frame assembly to receive material dislodged from a mine face by a dislodging head and transfer the dislodged material rearwardly from the mine face.
These and other objects of the present invention will be more completely disclosed and described in the following specification, the accompanying drawings and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top plan view of one embodiment of a self-propelled continuous mining machine which is the subject of this invention.
FIG. 2 is a view in side elevation of the continuous mining machine shown in FIG. 1, illustrating a boom assembly having a dislodging head secured thereto resting on a mine floor, and illustrating in phantom the boom assembly pivoted upwardly relative to the mining machine to show the extent of travel of the boom assembly.
FIG. 3 is a top plan view of one embodiment of a boom assembly, illustrating in phantom the boom assembly connections to the mining machine.
FIG. 4 is a partial fragmentary view in side elevation of the boom assembly shown in FIG. 3, illustrating a pivoting joint connection which is the subject of this invention.
FIG. 5 is a top plan view of a second embodiment of a self-propelled continuous mining machine which is the subject of this invention.
FIG. 6 is a view in side elevation of the continuous mining machine shown in FIG. 5, illustrating a boom assembly having a dislodging head secured thereto adjacent the mine floor, and illustrating in phantom the boom assembly pivoted upwardly relative to the mining machine to show the extent of travel of the boom assembly.
FIG. 7 is a top plan view of a second embodiment of a boom assembly, illustrating in phantom the boom assembly connections to each side of the mobile frame assembly of the mining machine.
FIG. 8 is a partial fragmentary view in side elevation of the boom assembly shown in FIG. 7, illustrating a pivoting joint connection which is the subject of this invention, and illustrating in phantom the boom assembly pivoted upwardly relative to the mining machine to show the operation of the pivoting joint connection.
FIG. 9 is a fragmentary cross section of the conveying system showing the cross-over portion of the second duct assembly passing between the conveying reach and the return reach of the conveying system.
FIG. 10 is a fragmentary sectional view taken along line X--X of FIG. 9 showing a portion of the cross-over duct.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the drawings, and particularly to FIGS. 1, 2, 5, and 6, there is illustrated a continuous mining machine generally designated by the numeral 10 for use in an underground mine to dislodge material from a mine face. Continuous mining machine 10 includes a mobile frame assembly 12 and a pair of ground engaging traction means 14 (one shown in FIGS. 2 and 6) positioned at each side of mobile frame assembly 12 for propelling mining machine 10 within a mine 16 along the floor 18 thereof.
Continuous mining machine 10 is capable of being operated from an operating station 20 in a manner similar to other such machines to dislodge material from a mine face 36 and transport it rearwardly of the rear end 46 of mining machine 10. Accordingly, mining machine 10 includes operating controls and sources of power for operating ground engaging traction means 14 and other equipment included thereon.
Mining machine 10 includes a boom assembly 22 having a first end section 24 pivotally secured to the front end 26 of mobile frame assembly 12. Boom assembly 22 also includes a second end section 28. As seen in FIGS. 1, 2, 5, and 6, a material dislodging head generally designated by the numeral 30 is connected to boom assembly 22 second end section 28. Although a material dislodging head such as dislodging head 30 is illustrated in the figures, it should be understood that any desired dislodging head 30 known in the art may be secured to boom assembly 22 second end section 28.
Boom assembly 22 also includes four longitudinally extending engaging plates 32 which extend rearwardly from boom assembly 22 first end section 24 to engage four generally U-shaped retainers 34 secured to the front end 26 of mobile frame assembly 12. Boom assembly 22 engaging plates 32 are pivotally secured to the mobile frame assembly 12 generally U-shaped retainers 34 to allow boom assembly 22 to be pivoted upwardly and downwardly relative to mobile frame assembly 12. In this manner, as boom assembly 22 is pivoted upwardly and downwardly relative to mobile frame assembly 12, dislodging head 30 may be operated to dislodge material from a face 36 of the mine 16.
Although not specifically illustrated in the figures, actuating cylinders, preferably hydraulic cylinders, are connected at one end to front end 26 of mobile frame assembly 12. The other ends of the actuating cylinders are connected to retainers 38 (one shown in FIGS. 4 and 8) on boom assembly 22. As the actuating cylinders extensible rod portions are extended outwardly from their respective cylinder bodies, boom assembly 22 pivots vertically relative to mobile frame assembly 12 to allow dislodging head 30 to dislodge material from the full vertical surface of mine face 36. As seen in FIGS. 2 and 6, since boom assembly 22 is pivotally connected to mobile frame assembly 12, boom assembly 22 travels in an arcuate path between mine floor 18 and mine roof 40 as dislodging head 30 dislodges material from mine face 36. As also seen in FIGS. 2 and 6, boom assembly 22 is capable of downward arcuate movement to allow dislodging head 30 to travel below the surface of mine floor 18.
As illustrated in phantom in FIGS. 2 and 6, since boom assembly 22 is pivotally secured to mobile frame assembly 12, boom assembly 22 travels in an arcuate path from a point beneath mine floor 18 to mine roof 40. As boom assembly 22 pivots upwardly towards mine roof 40, the weight of boom assembly 22 and dislodging head 30 creates torsional loading on the four pivot pins (shown in FIGS. 3 and 7) which secure boom assembly 22 engaging plates 32 to mobile frame assembly 12 generally U-shaped retainers 34. However, since boom assembly 22 is pivotally connected to mobile frame assembly 12 by four engaging plates 32, this four point connection allows the torsional loading created as boom assembly 22 and dislodging head 30 are pivoted upwardly towards mine roof 40 to be evenly spread through boom assembly 22. This four point connection reduces the wear on the pivot pins and provides a sturdy connection between boom assembly 22 and mobile frame assembly 12.
In the embodiment of FIGS. 1-4, mining machine 10 also includes a dust collecting system generally designated by the numeral 42. Dust collecting system 42 is operable to remove airborne particles produced as dislodging head 30 dislodges material from mine face 36 to provide a clean working environment for the mining machine 10 operator. Dust collecting system 42 includes a fan assembly 44 mounted on mobile frame assembly 12 at the rear end 46 of mining machine 10. Dust collector 50 is also positioned on mobile frame assembly 12 and is connected to fan assembly 44. Duct assembly 48, which runs longitudinally along mobile frame assembly 12, has an end portion connected to a dust collector 50 and an opposite end portion which extends between a pair of generally U-shaped retainers 34 on mobile frame assembly 12. As will be explained later, duct assembly 48 includes a top wall 49 and a bottom wall 51 each having formed, arcuate end sections. As will also be explained later and illustrated in FIG. 4, boom assembly 22 includes a hollow interior portion 78 and an air inlet 52 which form part of dust collecting system 42. A portion of boom assembly 22 forms a pivoting joint with the formed, arcuate end sections of duct assembly 48 top wall 49 and bottom wall 51.
As dislodging head 30 operates to dislodge material from mine face 36, fan assembly 44 draws airborne dust produced by dislodging head 30 into boom assembly 22 air inlet portion 52 and through the hollow interior 78 of boom assembly 22 into duct assembly 48 positioned on mobile frame assembly 12. The dust which passes through duct assembly 48 is collected in dust collector 50. Dust collecting system 42 withdraws airborne dust from the area adjacent mine face 36 for the safety of the mining machine 10 operator. The pivoting point formed duct assembly 48 and boom assembly 22 allows collecting system 42 to draw airborne dust away from mine face 36 as boom assembly 22 is pivoted upwardly and downwardly on mobile frame assembly 12.
In the embodiment of FIGS. 5-10, mining machine 10 includes a dust collecting system also generally designated by the numeral 42. Dust collecting system 42 is operable to remove airborne particles produced as dislodging head 30 dislodges material from mine face 36 to provide a clean working environment for the mining machine 10 operator. Dust collecting system 42 includes a fan assembly 44 mounted on mobile frame 12 at the rear end 46 of mine machine 10. A dust collector 50 is also positioned on mobile frame assembly 12 and is connected to fan assembly 44. A duct assembly generally designated by the numeral 48 includes first duct assembly 47, which runs longitudinally along mobile frame assembly 12, has an end portion connected to a dust collector 50 and an opposite end portion which extends between a pair of generally U-shaped retainers 34 on mobile frame assembly 12 and includes second duct assembly 90. On the opposite side of mobile frame 12 from first duct assembly 47 the second duct assembly 90 runs longitudinally partially along mobile frame assembly 12 to a traverse cross-over portion 92 extending between the conveying reach 59 and the return reach 61 (shown in FIG. 10) of conveyor deck 60 where the end portion 94 of second duct assembly 90 interconnects with first duct assembly 48.
As will be explained later in greater detail, first duct assembly 48 and second duct assembly 90 each include a top wall 49 having formed, arcuate end section 85 and a bottom wall 51 having a formed, arcuate end section 87 that are connected to a pair of vertically extending side walls 91 (shown in FIG. 9). As will be explained later in greater detail and illustrated in FIG. 8, boom assembly 22 includes a hollow interior portion 78 and an air inlet 52 which forms a part of dust collecting system 42. Two portions of boom assembly 22 form sliding joints 41 with the formed, arcuate end sections 85, 87 of first duct assembly 48 top wall 49 and bottom wall 51 and with the formed, arcuate end sections 85, 87 of second duct assembly 90 top wall 49 and bottom wall 51. This allows airborne dust to pass between joint space 89 located between the ends of formed, arcuate end section 85 and the formed, arcuate end section 87.
As dislodging head 30 operates to dislodge material from mine face 36, fan assembly 44 draws airborne dust produced by dislodging head 30 into boom assembly 22 air inlet portion 52 and through the hollow interior 78 of boom assembly 22 into first duct assembly 47 and second duct assembly 90 positioned on opposite ends of mobile frame assembly 12. The dust which passes through first duct assembly 47 is collected in dust collector 50. The dust which passes through second duct assembly 90 then passes through cross-over portion 92 to end portion 94 and therethrough to first duct assembly 48 where the duct is collected in dust collector 50. As described, dust collecting system 42 withdraws airborne dust from the area adjacent mine face 36 for the safety of the mining machine 10 operator. Sliding joints 41 formed from first duct assembly 47 and boom assembly 22 and from second duct assembly 90 and boom assembly 22 allow collecting system 42 to draw airborne dust away from mine face 36 as boom assembly 22 is pivoted upwardly and downwardly on mobile frame assembly 12.
In both embodiments of the invention, mining machine 10 also includes a conveyor system generally designated by the numeral 54. Conveyor system 54 extends longitudinally from the front end 26 of mobile frame assembly 12 to a location rearwardly of the rear end 46 of mobile frame assembly 12. Conveyor system 54 includes a conveyor first section 56 which extends longitudinally through the center of mobile frame assembly 12. Conveyor system 54 also includes a conveyor second section 58 which extends rearwardly to the rear end 46 of the mobile frame assembly 12 and is pivotally connected to the conveyor first section 56 for lateral movement relative to conveyor first section 56. In this manner, conveyor second section 58 can be suitably positioned to deposit material provided to conveyor system 54 by dislodging head 30 at a preselected location rearwardly of rear end 46 of mining machine 10. Further, as illustrated in phantom in FIGS. 2 and 6, conveyor second section 58 may be inclined to conveyor first section 56 if it is desired to deposit the dislodged material into a receiver. Conveyor first and second sections 56, 58 include a common conveyor deck 60 having track 107 which rotates by conventional means over a conveying reach 59 above and a return reach 61 below common conveyor deck 60. A plurality of spaced flights 62 transports material dislodged by dislodging head 30 over conveying reach 59 rearwardly of the rear end 46 of mining machine 10 along the common conveyor deck 60 of conveyor first section 56 and conveyor second section 58.
As seen in FIGS. 2 and 6, mining machine 10 also includes a stabilizer 64 which is pivotally connected to mobile frame assembly 12. Before mining machine 10 commences operation to dislodge material for mine face 36, stabilizer 64 is extended downwardly to contact mine floor 18. As boom assembly 22 and dislodging head 30 are pivoted vertically relative to mobile frame assembly 12 to dislodge material from mine face 36, stabilizer 64 operates to stabilize the rear end 46 of mining machine 10 to prevent vertical movement of the rear end 46 of mining machine 10.
Referring to FIGS. 3, 4, 7, and 8, there is illustrated boom assembly 22 previously described. Boom assembly 22 includes a generally transverse front wall 66 and a pair of generally longitudinally extending outer side walls 68 connected to a transverse front wall 66. Generally longitudinally extending outer side walls 68 each include a bent portion 69 which provides clearance for dislodging head 30 drive motors 71.
Boom assembly 22 also includes a horizontally extending top wall 72 and a horizontally extending bottom wall 74. Horizontally extending top wall 72 and horizontally extending bottom wall 74 are connected between the generally longitudinally extending outer side walls 68. Horizontally extending top and bottom wall 72, 74 are also connected to transverse front wall 66.
As seen in FIGS. 3 and 7, horizontally extending top wall 72 and horizontally extending bottom wall 74 each include a generally U-shaped cutout 76. The generally U-shaped cutouts 76 and horizontally extending top wall 72 and horizontally extending bottom wall 74 provide clearance for conveyor first section 56 which passes longitudinally through the center of mobile frame assembly 12.
A pair of longitudinally extending inner side walls 70 are connected between horizontally extending top wall 72 and horizontally extending bottom wall 74 as shown in FIGS. 3 and 7. As seen, the arrangement of generally longitudinally extending outer side walls 68, longitudinally extending inner side walls 70, transverse front wall 66 and horizontally extending top and bottom walls 72, 74 provide boom assembly 22 with the hollow interior 78 previously described.
As seen in FIGS. 3 and 7, the pair of generally longitudinally extending outer side walls 68 include a pair of outer side wall plates 32 arranged to be received by a pair of generally U-shaped retainers 34 secured on mobile frame assembly 12 and illustrated in phantom. Similarly, the pair of longitudinally extending inner side walls 70 include a pair of inner side wall plates 32 arranged to be received by another pair of generally U-shaped retainers 34 secured on mobile frame assembly 12 and illustrated in phantom. Outer side wall plates 32 and inner side wall plates 32 represent the engaging plates 32 previously described.
Outer side wall plates of engaging plates 32, inner side wall plates of engaging plates 32 and the four generally U-shaped retainers 34 each include aligned holes to receive four pivot pins 84. As earlier described, boom assembly 22 pivots upwardly and downwardly about pivot pins 84 as the actuating means (not shown) operates to raise and lower boom assembly 22 relative to mobile frame assembly 12. This four pivot pin arrangement evenly distributes the torsional loading placed on boom assembly 22 as boom assembly 22 and dislodging head 30 are pivoted upwardly relative to mobile frame assembly 12. Since the torsional loading is evenly distributed throughout the four pivot pins 84, frictional wearing on each pivot pin 84 is reduced, and the frictional wearing on the pivot pin receiving holes in outer side wall plates of engaging plates 32 and inner side wall plates of engaging plates 32 is also reduced.
In one embodiment of the invention, referring to FIG. 4, there is illustrated the pivoting joint previously described. The pivoting joint is generally designated by the numeral 57. Horizontally extending top wall 72 and horizontally extending bottom wall 74 include formed, arcuate ends 86, 88, respectively, positioned between a pair of generally U-shaped retainers 34 illustrated in FIG. 3.
As earlier described, collecting system 42 duct assembly 48 includes duct top wall 49 and duct bottom wall 51 having formed, arcuate ends 53, 55, respectively. As seen in FIG. 4, horizontally extending top wall 72 and horizontally extending bottom wall 74 arcuate ends 86, 88 contact the inner surfaces of arcuate ends 53, 55 of each duct top wall 49 and each duct bottom wall 51, respectively, to form pivoting joint 57 between boom assembly 22 and duct assembly 48.
As boom assembly 22 is pivoted upwardly or downwardly relative to mobile frame assembly 12, arcuate ends 86, 88 pivotally contact the inner surfaces of duct assembly 48 arcuate ends 53, 55 to provide pivoting joint 57. In this manner, as fan assembly 44 operates to draw airborne dust produced by dislodging head 30 through air inlet 52 and boom assembly 22 hollow interior 78, the dust passes through pivoting joint 57 formed by arcuate ends 86, 88 and arcuate ends 53, 55 into duct assembly 48. As boom assembly 22 is raised and lowered relative to mobile frame assembly 12 to allow dislodging head 30 to remove material from the full vertical surface of mine face 36, the dust produced by dislodging head 30 is passed through the hollow interior 78 of boom assembly 22 into duct assembly 48 by means of pivoting joint 57. As seen, collecting system 42 can operate to withdraw airborne dust from mine face 36 regardless of the position of boom assembly 22 relative to mobile frame assembly 12. As described, the pivoting joint 57 formed by arcuate ends 86, 88 and arcuate ends 53, 55 eliminates the need for flexible or telescoping duct connections between duct assembly 48 and boom assembly 22.
In a second embodiment of the invention, referring to FIG. 8, there is illustrated the sliding joint previously described. The sliding joint is generally designated by the numeral 41. Horizontally extending top wall 72 and horizontally extending bottom wall 74 include formed, arcuate ends 73, 75, respectively, positioned between a pair of generally U-shaped retainers 34 illustrated in FIG. 7.
As earlier described, collecting system 42 first duct assembly 47 and second duct assembly 90 each include duct top wall 49 and duct bottom wall 51 having formed, arcuate ends 85, 87, respectively. As seen in FIG. 8, horizontally extending top wall 72 and horizontally extending bottom wall 74 arcuate ends 73, 75 contact the inner surfaces of arcuate ends 85, 87 of each duct top wall 49 in each duct bottom wall 51, respectively, to form sliding joint 41 between boom assembly 22 and first duct assembly 47 and between boom assembly 22 and second duct assembly 90. As shown, arcuate ends 85, 87 do not interconnect leaving joint space 89 to allow for the passage of airborne dust between the hollow interior 78 of boom assembly 22 and mobile frame assembly 12 first duct assembly 47 and second duct assembly 90.
As boom assembly 22 is pivoted upwardly or downwardly relative to the mobile frame assembly 12, arcuate ends 73, 75 slidingly contact the inner surfaces of first duct assembly 47 and second duct assembly 90 arcuate ends 85, 87 to provide sliding joint 41. In this manner, as fan assembly 44 operates to draw airborne dust produced by dislodging head 30 through air inlet 52 and boom assembly 22 hollow interior 78, the dust passes through joint space 89 of sliding joint 41 formed by arcuate ends 73, 75 and arcuate ends 85, 87 into first duct assembly 47 and second duct assembly 90. As boom assembly 22 is raised and lowered relative to mobile frame assembly 12 to another dislodging head 30 to remove material from the full vertical surface of mine face 36, the dust produced by dislodging head 30 is passed through the hollow interior 78 of boom assembly 22 into first duct assembly 47 and second duct assembly 90 through joint space 89 by means of sliding joint 41. As seen, collecting face 42 can operate to withdraw airborne dust from mine face 36 regardless of the position of boom assembly 22 relative to mobile frame assembly 12. As described, the sliding joint 41 formed by arcuate ends 73, 75 and arcuate ends 85, 87 eliminate the need for flexible or telescoping duct connections between boom assembly 22 and between first duct assembly 47 and second duct assembly 90, respectively.
There is also retaining wall 97 which is pivotally fastened by conventional means to mobile frame assembly 12 by mobile frame assembly fastener 96 and to boom assembly 22 by boom assembly fastener 98. Retaining wall 97 pivotally moves in an arcuate direction as boom assembly 22 is moved upwardly and downwardly and provides extra support to the connection between boom assembly 22 and mobile frame assembly 12.
As described previously, second duct assembly 90 traverse cross-over portion 92 passes between conveying reach 59 and return reach 61 of conveyor first section 56 to end portion 94 where it connects with first duct assembly 47. Portions of both interior walls of mobile frame assembly 12 are cut open (as shown in FIG. 5) to receive cross-over portion 92 of second duct assembly 90.
Referring to FIG. 9, there is illustrated a fragmentary cross section of conveyor first section 56 and traverse cross-over portion 92 of second duct assembly 90. Conveyor first section 56 includes conveying reach 59 with bottom portion 100 positioned above return reach 61 with top portion 102 with hollow conveyor interior of first section 104 positioned therebetween. Cross-over portion 92 of second duct assembly 90 is positioned in hollow conveyor interior 104 between bottom portion 100 of conveying reach 59 and top portion 102 of return reach 61. Cross-over portion 92 of second duct assembly 90 includes a horizontal top wall 49 and a horizontal bottom wall 51. Horizontally extending top wall 49 and horizontally extending bottom wall 51 are connected between the vertically extending side walls 91 to provide for a hollow cavity 93 surrounded by top wall 49, bottom wall 51 and side walls 91. This hollow cavity facilitates the withdrawal of airborne dust from mine face 36 to dust collector 50.
Referring to FIG. 10, a transverse cross section of cross-over portion 92 of second duct assembly 90 and conveyor first section 56 is taken along line X--X of FIG. 9. Return reach 61 includes horizontal top portion 102 and horizontal bottom portion 108 which encloses the track 107 and spaced flights 62 of return reach 61. Horizontal top portion 102 and horizontal bottom portion 108 of return reach 61 are connected to vertically extending side walls 106 which extend beyond the top portion 102 of return reach 61 to bottom wall 51 of crossover portion 92. Conveying reach 59 includes horizontal bottom portion 100 extending below track 107 and spaced flights 62 connecting to vertically extending side walls 110. Vertical side walls 110 extend below bottom portion 100 of conveying reach 59 to top wall 49 of cross-over portion 92. Vertical side walls 110 and vertical side walls 106 wedge in top wall 49 and bottom wall 51 of cross-over portion 92 of second duct assembly 90, respectively, to provide stability for cross-over portion 92 of second duct assembly 90 while mobile frame assembly 12 is in all modes of operation.
According to the provisions of the Patent Statutes, we have explained the principle, preferred construction and mode of operation of our invention and have illustrated and described what we now consider to represent its best embodiments. However, it should be understood that, within the scope of the appended claims, the invention may be practiced otherwise than as specifically illustrated and described.
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A self-propelled continuous mining machine includes a mobile frame assembly having a front end portion with a boom assembly pivotally retained thereon. A dust collecting system is positioned on the mobile frame assembly for inducing a flow of air through a hollow interior portion of the boom assembly. As a dislodging head removes material from a mine face, the dust collecting system draws airborne dust created by the dislodging head through a hollow interior of the boom assembly and into the collecting system mounted on the mobile frame assembly. Two portions of the boom assembly are pivotally connected to portions of the collecting system mounted on the mobile frame assembly to provide pivoting joints to allow the collecting system to draw airborne dust through the boom assembly with the boom assembly in any preselected position relative to the mobile frame assembly. Twin ducts of the collecting system meet the boom on each side of the mining machine and the ducts of the collecting system extend rearwardly along each side of the mobile frame assembly. A conveying system mounted on the mobile frame assembly receives material from the dislodging head and transports the material rearwardly of the machine. One of the twin ducts crosses to the other side of the mobile frame by passing between the conveying reach and the return reach of the conveying system and joins with the other duct so that a single fan may be used to draw airborne dust through the system.
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TECHNICAL FIELD OF INVENTION
[0001] The present invention relates to a safety device for emergency disconnect of a riser or hose, typically in relation with well intervention riser systems, completion/work over (C/WO) riser systems etc. The technology/concept may also be applicable for production risers including flexible risers and also offshore offloading systems and other riser or hose systems in use offshore today.
BACKGROUND
[0002] The conventional riser disconnect systems are based on either an operator initiated emergency disconnect system requiring the active intervention of an operator (by the push of a button) and automatic disconnect systems based on a weak link placed in the riser system which is designed to fail mechanically in an emergency scenario before any other critical components fail. Such disconnect systems are typically referred to as “weak links”.
[0003] The key purpose of a weak link is to protect the well barrier(s) or other critical structure(s) interfacing the riser in accidental scenarios, such as heave compensator lock-up or loss of rig position which may be caused by loss of an anchor (dragged anchor), drift-off, where the rig or ship drifts off location because the rig or ship loses power, or drive-off, which is a scenario where the dynamic positioning system on the rig or ship fails for any reason causing the ship to drive off location in any arbitrary direction. In such accidental scenarios operators will have very limited time to recognize that an accident is happening and to trigger a release of the riser from the well or other critical structure(s) attached to the riser. In such accidental scenarios where the operators do not have reasonable time to react to an accident the weak link shall ensure that the integrity of the well barrier(s) or other critical interfacing structure(s) is/are protected.
[0004] When a riser is connected to a wellhead, a X-mas tree (or a lower riser package with a X-mas tree) is landed and locked onto the wellhead. The riser system is then fixed to the well on the seabed in the lower end. The upper end of the riser is typically suspended from a so-called heave compensator 1 and/or riser tensioning system in the upper end as illustrated in FIG. 1 . The riser tensioning system applies top tension to the riser 2 and is connected to a heave compensator 1 which compensates for the relative heave motion between the vessel 3 (e.g. a rig or a ship) moving in the waves and the riser fixed to the seabed 4 . The heave compensator system 1 is typically based on a combination of hydraulic pistons and pressurized air accumulators (not shown). The hydraulic pistons are driven actively up and down by a hydraulic power unit in order to compensate for the vertical motion of the vessel 3 in the waves. The air accumulators are connected to the same system and are used to maintain a relatively constant tension in the system. This is done by suspending the risers from cylinders resting on a pressurized air column, where the pressure is set according to the load in the system. The volume of the air accumulators and the stroke of the cylinders will then define the motion hysteresis and therefore the tension in the system as the vessel 3 moves vertically in the waves.
[0005] A compensator lock-up refers to a scenario where the heave compensation system fails, causing the heave compensator cylinders to lock and thereby failing to compensate for the heave motion between riser 2 and vessel 3 , ref. FIG. 2 . This may result in snag loads and excessive tension forces on the riser 2 . Such snag loads may cause damage to well barrier(s) 5 or other interfacing structure(s). A weak link in the riser 2 will, when properly designed, protect the well barrier(s) 5 from damage in case of a compensator lock-up occurring. However, one challenge is that during normal operation the vessel 3 may be positioned within a certain operational window above the well on the seabed 4 . This gives a relative angle α between the vessel 3 and the well on the seabed 4 . This angle α means that any tension load in the riser 2 will also cause bending moments in the well barrier(s) 5 . To properly protect the well barrier(s) 5 in case of heave compensator lock-up, a weak link will need to release before the combined load from riser tension and bending moment due to vessel 3 offset damages the well barrier(s) 5 .
[0006] Loss of position occurs when the vessel 3 fails to maintain its position within defined boundaries above the wellhead. Anchored vessels 3 usually experience loss of position caused by loss of one or more anchors. For dynamically positioned (DP) vessels, loss of position is normally caused by DP failure or by operator error causing the vessel 3 to drive-off from its intended position. In a drift-off scenario the vessel either does not have sufficient power to stay in its position given the current weather conditions, or vessel power is lost and the vessel will drift off in the direction of the wind, waves and currents. All such accidental scenarios result in excessive vessel 3 offset relative to well barrier(s) 5 , ref. FIG. 3 . When the position of the vessel moves outside the allowable boundaries, the resulting riser angle α in combination with riser tension will induce high bending moments in the lower and upper part of the riser 2 . Furthermore as the relative distance between the vessel 3 and the well barrier(s) 5 on the seabed increases, the heave compensator cylinder will stroke out to compensate an otherwise increase in tension. Subsequently the heave compensator 1 will stroke out, leading to a rapid increase in the riser tension. When this occurs the relative angle α between the well barrier(s) 5 on the seabed 4 and the vessel 3 will have increased significantly and the rapid tension increase will cause high bending moments in the well barrier(s) 5 , ref. FIG. 3 .
[0007] To protect the well barrier(s) 5 in the mentioned accidental scenarios, a weak link needs to disconnect the riser 2 from the well barrier(s) 5 prior to exceeding the combined load capacity of the well barrier(s) 5 in tension and bending, see FIG. 6 .
[0008] Exceeding the load capacity of the well barrier(s) 5 may involve damage of the well head, damage inside the well, damage on the riser 2 etc., all of which are considered to be serious accidental scenarios with high risk towards personnel and the environment.
[0009] Damage of the well barrier(s) 5 may result in costly and time consuming repair work, costly delays due to lack of progress in the operation, and last, but not least, environmental and human risks in the form of pollution, blow-outs, explosions, fires, etc. The ultimate consequence of well barrier damage is a full scale subsea blow-out, with oil and gas from the reservoir being released directly and uncontrollably into the ocean. If the down-hole safety valve should fail or be damaged in the accident, there are no more means of shutting down the well without drilling a new side well for getting into and plugging the damaged well.
[0010] The challenges with existing weak link designs are related to the combination of fulfilling all design requirements (safety factors, etc.) during normal operation of the system, and at the same time ensuring reliable disconnect of the system in an accidental scenario.
[0011] The most common weak link concepts today rely on structural failure in a component or components. Typical designs involve a flange with bolts that are designed to break at a certain load, or a pipe section that is machined down over a short length to cause a controlled break of the riser in that location.
[0012] Most conventional weak links that are in use today only rely on tension forces, i.e. a given weak link is designed to break at a certain, pre-defined tension load. However, the emergency situations that arise do not involve tension forces alone. In the case of e.g. a drift-off, there will be significant bending moments introduced into the well barrier(s) 5 in addition to the tension forces. Even in a heave compensator lock-up scenario, bending moments acting on the well barrier(s) 5 may be significant due to the rig/vessel offset within the allowable operation window. It is not uncommon that the weather window for an operation is limited because the weak link can only accommodate a certain vessel offset in normal operation as illustrated by a typical operational diagram shown in FIG. 4 . Vessel station keeping ability above the well will be reduced with increasing winds and waves and normal variations in the position of the rig above the well will increase. If the offset exceeded a certain limit the weak link will not protect the well barrier(s) 5 in case of a heave compensator lock-up. Therefore, the ability of the weak link to fail due to bending may affect the weather window of the operation.
[0013] Furthermore, the internal pressure in a riser, which may vary from atmospheric up to 10,000 psi or higher, has a significant impact on the loads experienced by the riser 2 , the well barrier(s) 5 and on the weak link.
[0014] When the internal pressure is greater than the external pressure the riser component will experience increased axial tension and hoop tension. The axial tension caused by internal overpressure is often referred to as the end cap load [N] (=internal area·internal overpressure). Internal pressure causing the pipe to fail in hoop tension is referred to as the burst pressure.
[0015] The effect of internal pressure causes a dilemma in weak link designs based on structural failure:
1. The weak link needs to be dimensioned for operation under full pressure with normal safety margins. 2. The tension and bending capacity of the well barrier(s) are reduced by internal pressure. 3. In some operations the well barrier(s) will be pressurized, but the riser with the weak link will be unpressurised. 4. In an accidental scenario the weak link must release before the well barrier(s) is(are) damaged, even when the well barrier(s) is(are) pressurized and the weak link is not pressurized.
[0020] Point 4 above is often challenging to achieve in the design of a weak link based on structural failure because the band between minimum capacity in normal operation and maximum break load in an accidental scenario becomes too wide. In some cases with high pressure system it may not be practically achievable to design a weak link based on structural failure.
[0021] FIG. 5 illustrates the challenges linked to designing a weak link which is based on structural failure, e.g. the conventional breaking of weakened flange bolts or the like. The illustration shows a system where the nominal system tension in the weak link is 100 T (1 T=1 ton=1000 kg). The system shall work under pressure and the end cap effect of the pressure increases the tension to more than 200 T which the weak link needs to be designed for. In the design of the weak link, safety factors and spread in material properties has to be allowed for thus increasing the actual capacity of the part to more than 400 T. The weak link will normally also have to accommodate a certain bending moment in normal operation, which in the illustration mentioned above, has increased the structural capacity of the weak link to around 500 T. This means that in the example above, a weak link designed for a maximum operational tension of 100 T and a given bending moment, cannot be designed with a breaking load less than 500 T. In some cases the gap between design load and the minimum possible breaking load is greater than the allowable capacity in the well barrier(s), thus requiring a reduction in the operational capacities, which again reduces the operational envelopes. As the examples shows, the fact that the weak link shall be designed for full pressure, but at the same time shall work as a weak link when there is no pressure in the system, will for a high pressure system contribute significantly to the gap between the operational design load and the minimum breaking load in a weak link based on structural failure.
[0022] In additional, to the technical challenges related to existing weak link solutions based on structural failure, there are also schedule and cost challenges related to the conventional systems. A weak link based on structural failure requires a comprehensive qualification program for each project and typically imposes stringent requirements on material deliveries to control material properties of the parts designed to fail. These qualification programs and the additional requirements for particular material properties are often a challenge with respect to project schedules.
[0023] FIG. 6 shows a typical capacity curve for combined loading for well barrier(s) 5 being defined by a straight line along which all safety factors in the well barrier design have been fully utilized. This line does not represent the structural failure of the well barrier(s), but indicates the calculated allowable capacity of the well barrier(s) 5 . If the combined loads exceed this line there is no guarantee for the integrity of the well barrier(s), and it is likely that the barrier(s) is(are) damaged and possible leaks may occur.
[0024] FIG. 7 illustrates how the loads in the riser 2 and in the well barrier(s) 5 develop in a heave compensator lock-up, and how this relates to the capacity of the riser weak link and the capacity of the well barrier(s). The actual capacity of a weak link defined by structural failure is shown as the curved capacity curve for the riser pipe.
[0025] When the heave compensator lock-up occurs, the riser 2 will see a rapid increase in axial loading, as shown in the upper load diagram. At the same time the well barrier(s) 5 will see an increase in axial load but also in bending moment due to the rigs offset relative to the position of the well as shown in the lower load diagram by the angle α. The challenge with current weak link design is then that with a certain rig offset the load capacity of the well barrier(s) 5 will be exceeded before the load in the riser 2 reaches the structural capacity of the weak link.
[0026] FIG. 8 shows the same type of illustration for a loss of position scenario. When the rig 3 loses its position the load in the riser 2 will initially remain constant, because the heave compensator will stroke out to maintain a constant load in the riser. Once the heave compensator 1 strokes out, the tension in the riser 2 will increase rapidly as shown in the upper load diagram. The load in the well barrier(s) 5 will also remain close to constant while the heave compensator 1 strokes out (there will be some increase in the bending loads in the barrier(s)) and when the heave compensator 1 stops the axial load in the riser 2 will increase rapidly causing very high bending loads in the well barrier(s) 5 . In such accidental scenarios existing weak links relying on structural failure in a riser component will typically reach its structural capacity curve long after having exceeded the design load capacity curve of the well barrier(s).
OBJECTS OF THE INVENTION
[0027] It is an object of the present invention to provide a reliable, autonomous device which will protect the integrity of the well barrier(s) in any accidental scenario which could impose excessive tension, excessive bending or any excessive combination of tension and bending which could otherwise damage the well barrier(s).
[0028] It is an object of the present invention to provide a device and method for safe, reliable and predictable disconnect in various kinds of riser applications, e.g. drilling riser systems, well intervention risers systems, completion/work over (C/WO) riser systems, flexible production risers and offloading hoses, etc.
[0029] It is a further object of the present invention to provide a device and method for safe, reliable and predictable disconnect in various kinds of riser and hose applications, wherein the device and method provide an increased operating envelope for the riser.
[0030] It is yet a further object of the present invention to provide a device and method that fulfills all design requirements (safety factors, etc.) during normal operation, while at the same time ensuring reliable disconnect of the riser system in an accidental scenario.
[0031] Another object of the present invention is to provide a weak link that operates at maximum internal pressure and ensures release at minimum internal pressure, as well as providing a pressure balanced weak link allowing the tension, bending and failure load not to be affected by the internal pressure, thereby significantly increasing the window of operation of the riser system.
[0032] Yet another object of the invention is to provide a weak link where the release is not linked to any type of mechanical failure in the weak link, thus significantly reducing the need for project specific qualification programs to document release load.
[0033] Another object of the invention is to provide a weak link where the release limit is defined as a combined loading limit curve that can easily be adjusted on a project basis without requiring a new qualification program. This will significantly reduce lead times for preparing a weak link for a project, compared to lead times required for weak links relying on mechanical failure.
SUMMARY OF THE INVENTION
[0034] These and other objects are achieved by a safety device according to the independent claim 1 , and a method according to the independent claim 17 . Further advantageous features and embodiments are set out in the dependent claims.
SHORT DESCRIPTION OF THE DRAWINGS
[0035] The following is a detailed description of advantageous embodiments, with reference to the figures, where:
[0036] FIG. 1 shows a vessel 3 during a workover operation, where a rigid riser 2 is suspended from a heave compensator 1 on the rig and is rigidly attached to a wellhead (well barrier(s) 5 ) on the seabed. The heave compensator 1 strokes up and down to compensate for the heave motion of the vessel 3 in the waves.
[0037] FIG. 2 illustrates the accidental scenario referred to as “heave compensator lock-up”, causing a tension increase in the riser 2 when the waves lifts the vessel upward. The rapid increase in riser tension will typically result in excessive combined loading of the well barrier(s) 5 .
[0038] FIG. 3 illustrates the accidental scenario referred to as loss of position (due to loss of an anchor, drive-off or drift off) and how this will cause excessive bending in the well barrier(s) once the heave compensator 1 has stroked out.
[0039] FIG. 4 shows a typical operational envelope of a vessel for a workover operation. The figure further illustrates how allowable vessel offset needs to be limited to protect the well barrier(s) from heave compensator lock-up when the weak link being used relies on failure of a riser component in tension. The figure shows how much the operational envelopes can be increased if there is a weak link that protects the well barrier(s) against any type of combined loading without regard for vessel position of system pressure.
[0040] FIG. 5 illustrates the challenge of designing a weak link that fulfils all safety criteria in normal operation, but at the same time ensures a reliable release in an accidental scenario before the well barrier(s) is(are) damaged. The figure illustrates the problem related to the width of the band between the weak link fulfilling all design requirements and the structural failure capacity of the same weak link.
[0041] FIG. 6 illustrates a typical defined combined loading capacity curve for well barrier(s) 5 . The load capacity curve does not represent an actual break of the well barrier(s), but indicates the design curve that has been used for accidental scenarios where all safety factors have been removed. When the combined load in the well barrier(s) 5 exceeds this curve there is no guarantee for the integrity of the well barrier(s), and there is a significant risk of having damaged the seals or having caused some form of permanent damage to the well barrier(s) 5 .
[0042] FIG. 7 illustrates the problem of using a weak link based on structural failure in a riser component to protect the well barrier(s) in case of a heave compensator lock-up. The figure shows how the combined load in the well barrier(s) 5 will exceed its capacity curve before the structural capacity of the weak link is reaches typically due to the vessel 3 offset causing the angle α which increases the bending loads on the well barrier(s) 5 .
[0043] FIG. 8 illustrates the problem of using a weak link based on structural failure in a riser component to protect the well barrier(s) in case of a loss of position accidental scenario. The figure shows how the riser 2 tension remains constant until the heave compensator 1 stroke out. At this point the tension will increase rapidly and the angle α will cause high bending loads in the well barrier(s) 5 , causing the load capacity of the well barrier(s) 5 to be exceeded long before reaching the structural failure of the riser weak link designed to fail in tension.
[0044] FIG. 9 shows how the present invention would work to protect the well barrier(s) 5 in case of a heave compensator 1 lock-up. The figure shows how the combined load capacity of the weak link is defined to be just within the capacity of the well barrier(s) 5 . Hence for any load combination induced on the well barrier(s) 5 the invention will ensure a controlled disconnect of the riser before exceeding the capacity curve of the well barrier(s) 5 .
[0045] FIG. 10 shows how the present invention would work to protect the well barrier(s) 5 in case of the vessel loosing its position due to a drive-off or drift-off scenario. The figure shows how the combined load capacity of the weak link is defined to be just within the capacity of the well barrier(s) 5 . Hence for any load combination induced on the well barrier(s) 5 the invention will ensure a controlled disconnect of the riser before exceeding the capacity curve of the well barrier(s) 5 .
[0046] FIG. 11 shows a cross section of an embodiment of the present invention with a disconnectable connector 6 , a sensor package 19 to measure combined loading in the riser 2 , an electronic unit which interprets the information from the sensors and checks if the combined load in the riser is within the allowable limits and if not trigger a disconnect sequence.
[0047] FIG. 12 illustrates the actuation sequence when releasing the locking pin 8 that holds the cam ring 7 of the connector 6 in place.
[0048] FIG. 13 shows one possible embodiment of the actuator mechanism 20 for disconnecting the releasable connector 6 and some alternative release mechanisms that may be applied. In this possible embodiment of the actuator 15 a , a spring 10 loaded locking pin 8 , which locks the connector, is supported by an over-center mechanism which is balanced by a magnet or an electrical switch. When the electronic unit 20 recognizes that the measured combined load reaches the defined combined load limit curve the switch or magnet will release the over-center mechanism. The rotation of the over-center mechanism will release the spring 10 , thereby releasing the locking pin 8 to trigger a disconnect of the releasable connector 6 . Alternative configurations of the actuator is shown in 15 b with an electric motor for releasing the locking pin 8 and in 15 c where the locking pin 8 is removed hydraulically by opening an electric valve connected to a charged accumulator.
[0049] FIG. 14 shows a disconnect sequence of the preferred embodiment of the present invention from the point where the spring loaded locking pin 8 is released. The spring loaded locking pin is pulled out from the connectors cam ring 7 by the force of the preloaded spring. When the locking pin 8 is removed, the cam ring 7 will open due to the tension forces in the system or by using a leaf spring in the cam ring 7 . When the cam ring opens the upper and lower part of the pipe hubs in the connector will pull apart as the connector dogs 9 are free to rotate.
[0050] FIG. 15 shows a 3D illustration of a disconnect sequence of the preferred embodiment of the present invention.
[0051] FIG. 16 illustrates alternatives for disconnecting the control umbilical when the connector disengages in an accidental scenario. In the preferred embodiment of the invention the umbilical is clamped tightly to the workover riser on either side of the electronic combined loading weak link. This method relies on the tension forces in the system to ensure that the umbilical is torn off when the connector 6 is released. An alternative solution to cut the control umbilical is illustrated in 14 a using an over center mechanism which is triggered electronically to release a cutting ram which is charged by a mechanical spring held in place by the over center mechanism. 14 b is a similar solution where the cutting ram is released by an electric motor rotating a disk that holds the ram in place during normal operation. 14 c uses a hydraulic principle to move the shear ram to cut the umbilical. In this case a valve to a charged accumulator is opened electrically to push to cutting ram towards the umbilical.
DETAILED DESCRIPTION OF THE INVENTION
[0052] The safety device according to the present invention responds to bending forces in the riser system in addition to tension forces. Furthermore, the device according to the present invention preferably monitors the total combined load including tension, bending, internal pressure and/or temperature effects. All these parameters may continuously be monitored by an autonomous electronic unit 20 which evaluates the combined load on the system and ensures that the combined load is kept within pre-defined allowable limits. The electronic unit 20 compares the evaluated combined load with a pre-defined, limiting combined loading curve developed to protect the well barrier(s) 5 and which will be defined by the calculated relationship between the combined load at the position of the weak link and the combined load capacity curve for the well barrier(s). If the combined load measured exceeds the defined limit curve for the well barrier(s) 5 on the well in question the electronic unit 20 will trigger a disconnect of a releasable connector in the riser.
[0053] One embodiment of the electronic combined loading weak link according to the present invention comprises a sensor 18 pipe with an electronic processing unit 20 which interprets the combined loading condition in the sensor pipe 18 . The limiting combined load in the sensor pipe is developed to ensure the integrity of the well barrier(s) (ref. FIG. 9 and FIG. 10 ) and is given as input to the electronic processing unit. If the combined load in the sensor pipe 18 exceeds the defined allowable limit, the unit will activate a mechanical, electric or hydraulic trigger which will disengage a releasable connector 6 in the riser 2 .
[0054] A standard connector principle may be modified with a release mechanism 11 using a hinged and split cam ring 7 and a spring loaded locking pin 8 as illustrated in FIG. 11-FIG . 16 . The locking pin 8 may also be energized using any sort of hydraulic arrangement. The split cam ring 7 is pre-tensioned to engage connector dogs 9 with sufficient force as for a normal connector design. In order to accommodate a disconnect function the split cam ring 7 is hinged in two or more locations. It is understood that the number of hinges may be higher or lower, for example 3, 4, 5, 6, or any other suitable number. At least one of the hinges is connected by an energized locking pin 8 . The locking pin 8 is energized with sufficient force to ensure that the locking pin can be retracted from the split cam ring 7 when the split cam ring 7 is pre-tensioned up to it's maximum design load. According to one embodiment the locking pin 8 is energized by a loaded mechanical spring 10 . Alternatively a pressurized hydraulic system with electronically actuated valves may equally well be used. Pure electric retraction of the locking pin 10 may be another option. Several alternative principles for retracting the locking pin are illustrated in FIG. 12 . The locking pin 8 holds the split cam ring 7 together as long as the locking pin 8 is in place. In order to disconnect the riser 2 , the locking pin 8 in the split cam ring 7 is released by releasing the mechanical spring 10 , alternatively by opening a hydraulic valve, or any other suitable method for retracting the locking pin 8 . The locking pin 8 is then pulled out and cleared from the split cam ring 7 , which will then open up due to the tension forces in the system. The connector dogs 9 , which hold the flanges of two riser sections together, are then free to rotate, and the tension in the riser 2 will ensure that the flange faces 11 of the riser sections are pulled apart, and the riser 2 is disconnected from the well. Radial springs (not shown) may be incorporated into the split cam ring 7 in order to ensure that the split cam ring 7 opens up when the locking pin 8 is retracted. It is understood that a releasable latching mechanism (not shown) may be used instead of locking pin 8 .
[0055] The disconnect sequence is illustrated in FIG. 14 and FIG. 15 .
[0056] In the case that an umbilical line 12 is deployed along the riser, for example during work over applications using a work over riser (WOR), umbilical release is ensured by applying tight umbilical clamps 13 in the region immediately above and below the electronic combined loading weak link connector, as shown in FIG. 16 . This will ensure a concentrated load/strain in the umbilical 12 at the location of the connector. The strain concentration will cause the umbilical 12 to tear off when the electronic combined loading weak link connector is released. Tearing off the umbilical 12 will initiate a shut down sequence, securing the well barrier(s) 5 . For umbilical designs not suitable for being torn off by axial loads, a spring loaded shear ram mechanism may be used to cut the umbilical. The shear ram may be triggered by an actuator similar to the one used to release the locking pin 8 . Alternative configurations of such a shear ram for umbilical cutting are illustrated in FIG. 16 .
[0057] According to one embodiment of the present invention, again with reference to FIG. 11 a sensor pipe 18 may comprise a machined pipe section which is provided with for example three separate and complete instrument packages 19 . The instrument packages 19 may for example comprise a number of strain gauges, a number of temperature gauges and/or a number of pressure gauges or strain gauges set to measure hoop stress used to deduct internal over pressure. Each instrumentation package 19 will primarily be fitted around the circumference of the sensor pipe 18 , but may also be fitted in alternative configurations. An electronic processing unit 20 will continuously monitor signals from the sensors in each of the (e.g. three or more) instrumentation packages 19 on the sensor pipe 18 .
[0058] According to one embodiment, the signals may be processed by a voting system in order to ensure that only functioning sensors are interpreted by the system. The signals will further be used in an algorithm developed to monitor the combined loading in the pipe. Pressure measurements will be used in an algorithm to ensure that the device works equally well if the riser is un-pressurized or if the riser is fully pressurized to its design pressure. The electronic processing unit 20 may be designed according to the appropriate Safety Integrity Level (SIL) as required by the relevant authorities to ensure sufficient system reliability. According to one embodiment of the present invention, the electronic unit may be designed according to SIL2 requirements to ensure sufficient reliability of the system, but higher or lower levels of safety performance may be chosen according to need, requirement and/or preference.
[0059] According to the present invention, the measurement of the measurement data relating to at least one of tension loads, bending loads, internal pressure loads and temperature, may be continuously or discontinuously received and processed by the electronic processing unit ( 20 ). Furthermore, the electronic processing unit ( 20 ) may continuously or discontinuously determine the combined load in the riser string or hose ( 2 ), and compares the determined combined load with the pre-defined allowable combined load capacity of the well barrier(s) ( 5 ) or other interfacing structure(s).
[0060] A release curve, of which two examples are given in FIG. 9 and FIG. 10 , can be given as an input to the electronic unit 20 for each specific field or project. Thus the Safety Device according to the present invention is suitable for operation on any field, as the release curve may be tailored for each individual location and application.
[0061] The purpose of the instrumentation packages 19 on the sensor pipe 18 is to capture the internal pressure, the bending moment and the axial tension of the weak link detector pipe. To do this, the following sensors would, according to one possible embodiment, be needed:
For redundancy, 3 independent measuring sections are recommended. Each measuring section may contain:
4 strain measuring points including strain gauge rosettes located at for example 0°, 90°, 180° and 270° around the circumference of the sensor pipe 18 . Each point must contain strain gauges in both the axial and the hoop direction. Temperature sensor(s).
An electronic processing unit containing:
Logics to process the strain and temperature measurements from each measuring section mentioned above; A voting system for selecting between the measuring sections.
[0068] An example of each step necessary to carry out one embodiment of the present invention is outlined in the following. It is understood that the specific steps and methods to deduce the various results may vary and that the person skilled in the art with the benefit of the present teachings may chose to simplify, rewrite, add, or exclude certain terms and/or parameters in the following exemplary equations and steps.
1. Conversion of Measured Strain to Stress:
[0069] The surface of the pipe where the strain gages are located is in a plane stress condition. The following equations apply for converting the local strain and temperature at the pipe outer surface to local stress:
[0000]
σ
z
=
E
1
-
v
2
(
ɛ
z
+
v
ɛ
θ
)
-
E
α
Δ
T
1
-
v
(
Axial
stress
)
σ
θ
=
E
1
-
v
2
(
ɛ
θ
+
v
ɛ
z
)
-
E
α
Δ
T
1
-
v
(
Hoop
stress
)
[0070] Where:
σ ε —Axial stress σ θ —Hoop stress ε ε —Axial strain ε θ —Hoop strain E—Young's modulus ν—Passion's ratio α—Thermal expansion coefficient ΔT—Temperature difference relative to reference temperature
[0079] These equations will cover the situation with constant temperature over the cross section. The strain contribution from temperature changes will be compensated for in the algorithm based on the temperature measured by the temperature sensor(s).
2. Convert Surface Stress to Pressure, Tension and Bending Moment
[0080] The following equations may be used to convert from stress at pipe surface to effective tension, internal pressure and bending moment (index 0°, 90°, 180° and 270° indicates position around circumference):
[0000]
M
x
=
(
σ
z
,
90
°
-
σ
z
,
270
°
)
2
×
π
32
D
o
×
(
D
o
4
-
D
i
4
)
(
Bending
about
local
x
-
axis
)
M
y
=
(
σ
z
,
0
°
-
σ
z
,
180
°
)
2
×
π
32
D
o
×
(
D
o
4
-
D
i
4
)
(
Bending
about
local
y
-
axis
)
M
Tot
=
M
x
2
+
M
y
2
(
Combined
bending
moment
)
T
=
(
σ
z
,
0
°
+
σ
z
,
90
°
+
σ
z
,
180
°
+
σ
z
,
270
°
)
4
×
π
4
(
D
o
2
-
D
i
2
)
(
True
wall
tension
)
T
e
=
T
-
p
i
×
π
4
D
i
2
(
Effective
tension
)
p
i
=
(
σ
θ
,
0
°
+
σ
θ
,
90
°
+
σ
θ
,
180
°
+
σ
θ
,
270
°
)
4
×
1
-
(
D
i
D
o
)
2
2
(
D
i
D
o
)
2
(
Internal
pressure
)
3. Failure Functions and Weak Link Release Criteria
[0081] To establish a logical signal giving failure/no failure, a range of failure functions may be used. These failure functions may trigger on single loads or a combination of different loads depending on existing limitations in the equipment. The following combined failure function may be used:
[0000]
f
=
T
e
F
s
×
T
max
+
M
tot
F
s
×
M
max
+
p
i
F
s
×
p
max
[0082] Where:
F s —An overall safety factor (defined by operator or regulations T max —Is the maximum allowable tension in the weak link (typically set to the tension capacity of the limiting barrier component) M max —Is the maximum allowable bending moment in the weak link (typically set to the bending capacity of the limiting barrier component)
[0086] Release should be triggered when the failure function exceeds 1. Typically T max and M max will be project specific and will be given as input to the weak link algorithm for a specific wellhead system to define the appropriate release limit for that well.
[0087] The instrumentation of the riser can be performed with any type of commercially available measuring device. The measurement can be based either on systems measuring local strain on the riser surface or it can be a system measuring displacement/deformation of the riser structure over a defined length.
[0088] Tension in the system is typically measured with strain gauges which are fixed to the riser surface and measures strain on the riser surface. Strain gauges are typically based on measuring changes in the electrical resistance in the material as the length and/or shape of the spools shown on the figure changes with material deformation.
[0089] Tension can also be measured by measuring the global elongation of the riser of a pre-defined length segment. This can be done by measuring change in conductivity in a pre-tensioned electrical wire, optically with laser systems, or with other commercial systems that also are available.
[0090] Bending moment in the riser can be done by combining strain measurements around the cross section of the riser to separate the bending strains from the axial strains in the pipe. Alternatively, the curvature in the riser of a pre-defined length segment can be measured directly by measuring changes in the electrical conductivity of specially developed curvature measurement bars.
[0091] The pressure in the pipe can be measured through a conventional pressure gauge measuring the internal pressure in the riser. Alternatively, the pressure can be extracted by measuring the hoop strain in the pipe using strain gauges.
[0092] According to one embodiment of the present invention, traditional strain gauges are used for all measurements as these currently are the most reliable over time. If or when other strain gauging devices prove to be as reliable or more reliable over time, these may equally be used to make the necessary measurements.
[0093] When it comes to details around the arrangement of the split cam ring 7 , the connector dogs 9 and the release mechanism 10 , there are several alternative solutions according to the present invention. As an example, the actuator may be designed to give an instant release of a force up to 80 T. It is envisioned that the force of 80 T will primarily come from a pre-tensioned spring mechanism. Alternatively this force could also be provided by a hydraulic actuator or even from an electrical motor. To release the locking pin 8 , one of the following principles may be utilized (as also illustrated in FIG. 12 ):
An electric switch or a magnet that releases an over-center mechanism which triggers the release of the 80 T force. An electric motor which frees the locking pin 8 . A hydraulic system that opens a hydraulic valve thereby applying hydraulic pressure from a pre-charged accumulator to release the locking pin 8 .
[0097] The electronic combined loading weak link according to the present invention may also find other applications. For a typical test production (extended well testing) through a drill pipe or a WOR riser the weak link may be directly applicable also for production risers. For offloading hoses the electronic combined loading weak link according to the present invention would need to be configured for relevant accidental scenarios for the particular application. However, the same principles for combining electronic measurements into a combined loading formula which is compared continuously against a defined limit, and for triggering a connector release when necessary, are generally applicable. It should be noted that in particular for offloading systems there is normally a focus on having valves on the connector to prevent pollution from the hose in a disconnect scenario. This is not required for a WOR riser as a weak link release would be the very last resort to prevent accidents at a much larger scale.
[0098] The present invention offers a number of possible advantages as compared to the conventional solutions that are in use today. Operational envelopes can be increased significantly during C/WO operations as static offset in operation does no longer affect the weak links ability to protect the well barrier(s), ref. FIG. 4 . Each supplier can in principle qualify one weak link which can be used on any C/WO system and the release settings can be set for each specific project. The increase in the operating envelope is particularly important for work over operations performed from a dynamically positioned vessel, but will also apply to anchored vessels.
[0099] In the case of a heave compensator 1 lock up, which creates excessive bending in the well barrier(s) 5 with rig offset, the allowable offset is usually limited. With a combined loading weak link according to the present invention, this limitation can be removed, and the weak link will protect the well barrier(s) against any combined load scenario. Hence, the combined loading weak link according to the present invention will also cover excessive vessel offset and thus will protect well barrier(s) for all accidental scenarios requiring a sudden disconnect of the workover riser.
[0100] The safety level during C/WO operations, in particular from DP operated vessels, will be improved considerably as the combined loading weak link according to the present invention monitors and considers the accurate combined load that arises in the riser 2 and well barrier(s) 5 . The combined loading weak link according to the present invention is able to protect the well barrier(s) 5 in case of compensator lock-up, vessel drift-off or vessel drive-off or any combination of these scenarios.
[0101] The combined loading weak link according to the present invention does not rely on structural failure in any component and is therefore not relying on specific material batches that need project specific qualification. Such project specific qualification schemes have proven to be expensive, time consuming and in some respects unreliable. With the combined loading weak link according to the present invention, stringent project qualification schemes can be carried out with only non-destructive testing.
[0102] The combined loading weak link according to the present invention considers tension loading and bending loads as well as any combination of these loads with better accuracy than existing weak link designs which are primarily suitable for pure tension or pure bending loads only.
[0103] The combined loading weak link according to the present invention uses the pressure in the system in the combined loading analysis. Thus, it is no longer a challenge to fulfill all design requirements when the system is pressurized and at the same time ensure safe release when the system is unpressurized.
[0104] The release settings of combined loading weak link according to the present invention can be adjusted with “push button” functionality and is not reliant on any structural design work or manufacturing of new components when being used on a new project with new design criteria.
[0105] The combined loading weak link according to the present invention can be electronically tested on deck to ensure full functionality on deck immediately before use.
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A safety device and method for protection of the integrity of well barrier(s) or other interfacing structure(s) at an end of a riser string or a hose includes a releasable connection in the riser string or hose, the releasable connection arranged to release or disconnect during given predefined conditions in order to protect the well barrier(s) or other interfacing structure(s). The safety device safety device includes at least one sensor to monitor at least one of tension loads, bending loads, internal pressure loads and temperature. The sensor provides measured data relating to at least one of tension loads, bending loads, internal pressure loads and temperature. An electronic processing unit receives and interprets the measured data from the sensor. An electronic, hydraulic or mechanical actuator or switch is arranged to receive a signal from the electronic processing unit and initiate a release or disconnect of the releasable connection.
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This is a continuation-in-part of Ser. No. 08/805,422 filed Feb. 25, 1997 now U.S. Pat. No. 5,911,796.
BACKGROUND OF INVENTION
The present invention relates to tools used in the in the oil and gas drilling industry to grip and rotate tubular members such as drill pipe. More particularly, the present invention relates to the jaw assembly, which is the component of such tools actually coming into contact with the tubular.
In the oil and gas drilling industry, a certain class of machines known as power tongs are employed to grip and rotate drill pipe and other tubular members in the process of making up or breaking apart the joints on a string of tubulars. Typically, when a tubular joint is be made up or broken apart, back-up power tongs will grip the tubular on one side of the joint and power tongs will grip the tubular on the opposite side of the joint. The power tongs are used to apply torque to one tubular while the back-up power tongs (hereinafter referred to simply as back-up tongs) are used to hold the other tubular stationary against rotation. Both the back-up tongs and the power tongs must have a means to securely grip the tubular when large torque loads are being applied. One such gripping means is a jaw member having a concave shaped die insert such as seen in U.S. Pat. No. 4,576,067 to Buck. The die insert may have a knurled surface in order to better grip the tubular. However, the die must be easily replaceable in the jaw member because the knurled surface is eventually worn smooth during use and loses its gripping characteristics. While being replaceable, the dies must also be able to transfer large torque loads between the jaw member and the tubular without the die breaking its mounting in the jaw member. One successful solution to this problem is disclosed in U.S. Pat. No. 4,576,067 to Buck where the jaw member and die have a plurality splines and grooves that interlock lock the jaw member and die together.
However, the torque load imparting a force transverse to the splines and grooves is not the only force acting on the die. In certain situations, a vertical force parallel to the spline and grooves is exerted on the dies. To resist this vertical force, the prior art typically employed some type of retaining screw. If the vertical force becomes great enough, the retaining screw fails and the die is displaced from the jaw. What is needed in the art is an improved method of making the die secure in the jaw member from vertical displacement.
SUMMARY OF INVENTION
The present invention provides a jaw assembly and die insert for use in conventional power tongs, back-up power tongs, and similar tools. The die insert has a rear surface having a plurality of splines extending outwardly from the rear surface and forming a plurality of grooves between the splines. The die also has a front surface adapted to grip a tubular member and a keyway formed on the rear surface. A mating jaw member is provided which also has a front face of splines and grooves with a keyway which aligns with the die's keyway when the die is inserted into the jaw member. A key is inserted into this combined keyway to prevent vertical forces from drawing the die out of the jaw member.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a prior art jaw assembly.
FIG. 2 is a top view of the same prior art jaw assembly.
FIG. 3 is a top view of the interior of a prior art power tong illustrating the placement of the jaw assemblies.
FIG. 4 is a top view of the interior of a prior art back-up power tong illustrating the placement of the jaw assemblies.
FIG. 5 is a side view illustrating the typical combined use of power tongs and back-up power tongs.
FIG. 6 is an exploded view of the jaw assembly of the present invention.
FIG. 7 is a rear perspective view of a die insert of the present invention.
FIG. 8 is an exploded view of an alternate jaw assembly of the present invention.
FIG. 9 is a perspective view of a jaw member which comprises a third embodiment of the present invention.
DETAILED DESCRIPTION
The prior art jaw assembly and die insert are depicted in FIGS. 1 and 2 and are explained thoroughly in U.S. Pat. No. 4,576,067 to Buck which is incorporated by reference herein. The jaw member 40 has a pin aperture 42 for pinning jaw member 40 into the power tongs 30 (seen in FIG. 3) or back-up tongs 34 (seen in FIG. 4 ). The jaw member 40 further has a concave surface with a plurality of splines 44 and grooves 45 which matingly engage corresponding splines 46 and grooves 47 in die 41 . Die 41 may slide into position in jaw member 40 and is retained in the downward direction by lip 48 which is formed at the bottom of the concave surface of jaw member 40 . To secure die 41 from sliding upward and out of jaw member 40 , retaining screw 43 is threaded into aperture 49 and the head of retaining screw 43 overlaps die 41 in order to prevent upward movement of die 41 .
Die 41 typically has a gripping surface 64 , which is shown in FIG. 1 as being formed from a pattern of raised metal teeth 65 . Each of the teeth 65 will include peak 66 which will be the first part of the teeth 65 to contact and bite into the tubular member being gripped. Between the peaks 66 of teeth 65 are depressions or valleys. The gripping surface 64 seen in FIG. 1 includes horizontal depressions 67 and vertical depressions 68 . However, the depressions need not be horizontal and vertical or run perpendicular to one another. It is only necessary that the depressions substantially surround teeth 65 in order to form peaks 66 . This allows the peaks 66 to bite into a tubular and for teeth 65 to resist slipping between die 41 and the tubular in the horizontal direction, the vertical direction, or any other direction.
Teeth 65 with peaks 66 should be distinguished from other prior art gripping surfaces such as that disclosed in U.S. Pat. No. 2,656,751 to Johnson, which is incorporated by reference herein. Johnson discloses a pipe wrench having jaws with ridges running parallel to the long axis of the pipe being gripped. The ridges will resist slippage between the wrench and pipe when torque is applied. However, if an axial force is applied to the wrench, the ridges will be prone to slipping along the surface of the pipe. This slipping will occur because the ridges are continuous along the axial direction in which the force is applied. Therefore, the ridges cannot bite into the pipe in a manner to prevent slippage in the axial direction.
Nor should only the gripping surface 64 as shown in FIG. 1 be considered teeth with peaks and depressions. Co-pending application Ser. No. 09/267,174 to Daniel Bangert, filed on Mar. 12, 1999, discloses a gripping surface formed of granular particles. The granular particles are also intended to be considered as teeth having peaks and depressions between adjacent particles.
The manner in which jaw members 40 are used in power tongs 30 and back-up tongs 34 , as well as the main components of a typical prior art power tongs 30 and back-up tongs 34 , are seen in FIGS. 3 and 4, respectively. FIG. 3 illustrates power tongs 30 which are intended to grasp a tubular 60 in jaw members 40 and rotate the jaw members 40 and tubular 60 by way of a ring gear 50 . The back-up tongs 34 seen in FIG. 4 illustrate how back-up tongs are not designed to rotate the tubular 60 , but rather to simply securely grasp the tubular 60 and hold it against rotation. FIG. 5 depicts how power tongs 30 are used in combination with back-up tongs 34 in order to make up or break apart a tubular joint 51 . The frames of power tongs 30 and back-up tongs 34 are joined and maintained in alignment by guide legs 38 . Typically the guide legs 38 are coupled with some type of resilient means, such as a heavy tension spring 55 , which allows some relative movement between back-up tongs 34 and power tongs 30 . However, because of the substantial weight of the back-up tongs 34 , these springs must have considerable rigidity and only large forces will induce relative movement between power tongs 30 and back-up tongs 34 .
In operation as shown in FIG. 5, the combination of tongs 30 and 34 will be positioned on the tubular string such that the joint 51 connecting the tubulars is between back-up tongs 34 and power tongs 30 . In this manner, back-up tongs 34 may hold the lower tubular 52 immobile while power tongs 30 apply torque to the upper tubular 53 in order to make up or break apart the joint 51 . It will be understood that as the joint is being made up, the distance between the tubulars decreases as the threaded portions of joint 51 come together. This causes an upward vertical force on the jaw members 40 in back-up tongs 34 and a downward vertical force on the jaw members 40 in power tongs 30 . Conversely, when joint 51 is being broken apart, tubulars 53 and 52 move apart causing a downward force on the jaw members 40 of back-up tongs 34 and an upward force on the jaw members 40 of power tongs 30 . Additionally, other circumstances may impart vertical forces to the power tongs 30 and back-up tongs 34 . For example, the drill string may inadvertently be slightly raised or lowered while the tongs are gripping a tubular. Because the dies 41 have gripping surfaces 64 formed from teeth 65 with peaks 66 , gripping surface 64 will be capable of preventing vertical slipping between the tubular member and the jaw members 40 .
However, these vertical forces on the jaw members 40 are often sufficient to over stress the retaining screw 43 securing die 41 , causing retaining screw 43 to fail and die 41 to be lifted from jaw member 40 . While the spring devices 55 on guide legs 38 will allow some displacement between the tongs, these spring devices are typically so rigid that retaining screw 43 will fail prior to the spring devices being displace any appreciable distance.
To overcome these disadvantages in the art, FIG. 6 illustrates a novel jaw assembly which retains a die insert securely against far higher vertical loads than the prior art jaw assembly described above. Jaw assembly 1 will include jaw member 2 and removably insertable die 3 . Jaw member 2 will have pinning aperture 15 through which pin 17 will be inserted to secure jaw assembly 1 in power tongs 30 , back-up tongs 34 or other tools where jaw assemblies are employed. Jaw member 2 has a front surface 18 with splines 13 and grooves 14 formed thereon. As best seen in FIG. 7, rear surface 20 of die 3 also has splines 4 and grooves 5 . When die 3 is inserted in jaw member 2 , jaw member splines 13 and grooves 14 will mesh with die grooves 5 and splines 4 and will prevent lateral movement between jaw member 2 and die 3 . Jaw assembly 1 further includes die retention clips 8 which have front edges 12 and retaining screw apertures 9 a . It will be understood that when die 3 is inserted into jaw member 2 , front edges 12 of retention clips 8 will engage die retaining channels 6 of die 3 . When screws are threaded through apertures 9 a in to apertures 9 in jaw member 2 , die 3 will be held against forward and vertical movement within jaw member 2 . It should be noted that there will be some variation in size and shape of the jaw assemblies 1 depending the size of pipe they are designed to grip and the type of tool in which they are to be used. Not all jaw assemblies 1 will require retention clips 8 if the size and amount of curvature in a particular jaw assembly is sufficient to prevent die 3 from moving forward out of jaw member 2 . However, the embodiments of jaw assembly 1 illustrated herein all require retention clips 8 .
Still viewing FIG. 6, it can be seen that jaw member 2 has a keyway 16 formed laterally across front surface 18 . As best seen if FIG. 7, die 3 has a corresponding keyway 7 formed across its back surface 20 . When die 3 is inserted into jaw member 2 , keyways 16 and 7 will be aligned such that key 11 (FIG. 6) may be inserted in keyways 16 and 7 . Key 11 may be formed of steel or any other material flexible enough to be inserted into the key yet hard enough to not seriously deform under the vertical forces encountered. By employing this key and keyway configuration, any vertical force tending to lift die 3 out of jaw member 2 will be resisted by the entire length of key 11 as opposed to merely the retaining screws found in the prior art. This key and keyway configuration allows die 3 to resist many times more vertical force than the prior art retaining screws were able to withstand. While key 11 in FIG. 6 is shown as a length of material having a square cross-section, any cross-sectional shape of key that will securely engage keyways 16 and 7 may be utilized. Furthermore, keyway 16 need not span the entire distance across the front surface 18 of jaw member 2 , but could span less than the entire distance as long as a suitable provision is made for pulling key 11 out of the keyway rather than driving key 11 out the side opposite insertion as envisioned in the embodiment of FIG. 6 .
An alternate embodiment of the present invention is shown in FIG. 8 . Here jaw member 2 has a keyway 16 beginning in a first side 21 of jaw member 2 and extending through jaw member 2 to a second side 22 (hidden from view in FIG. 8 ). As suggested by the straight key 11 , keyway 16 does not follow the concave shape of front surface 18 , but rather travels on a straight line through jaw member 2 . As seen in FIG. 8, this results in keyway 16 intersecting front surface 18 only along that portion of front surface 18 with the deepest concave curvature. While this embodiment illustrates a friction pin type key 11 , it will be understood that a threaded key 110 as shown in FIG. 8 could also be employed if keyway 16 was threaded. Still other types of keys 11 could be used in place of friction pin key 11 or threaded key 110 .
A third embodiment of the present invention is seen in FIG. 9 and illustrates an alternative method of forming a key 11 . In this embodiment, jaw member splines 13 have discrete key extensions 25 formed approximate to the midpoint of each spline 13 . Of course, less than all splines 13 could be provided with extensions 25 . Nor do the extensions need to be at the midpoint of the spline as long as the corresponding keyway 7 on die 3 is positioned at the same level as key extensions 25 . As best seen in FIG. 7, keyway 7 may be formed by cutting not just the splines 4 extending from rear surface 20 , but also cutting a short distance into rear surface 20 itself. This produces upper and lower keyway shoulders 10 between which key extensions 25 become engaged. To install this embodiment of die 3 in jaw member 2 , the retention clips 8 are removed and die 3 is placed against jaw member 2 such that key extensions 25 rest between keyway shoulders 10 . Retention clips 8 are then attached to jaw member 2 securing die 3 in jaw member 2 and thereby securing key extensions 25 between keyway shoulders 10 . It will be understood that a jaw member 2 having keyway extensions must be mated with dies 3 having keyway shoulders cut therein. Otherwise dies 3 will not fit closely enough against jaw members 2 in order that retention clips 8 may be properly attached between dies 3 and jaw members 2 .
Finally, while many parts of the present invention have been described in terms of specific embodiments, it is anticipated that still further alterations and modifications thereof will no doubt become apparent to those skilled in the art. For example, while not shown in the drawings, the term jaw member is intended to include slips, elevators or other holding devices used in the oil and gas industry for suspending and lifting tubular members. Conventional slips or elevators could be adapted to the present invention by being manufactured with a removable die as the gripping surface. The slip or elevator body would be formed with a concave surface having splines and grooves similar to the jaw member 2 seen in FIG. 9 . Dies 3 could then be removably inserted in the elevator or slip and later replaced when the die gripping surface became excessively worn. This example is just one possible modification of the present invention and it is intended that the following claims be interpreted as covering all such alterations and modifications as fall within the true spirit and scope of the invention.
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The present invention provides a jaw assembly and die insert for use in conventional power tongs, back-up power tongs, and similar tools. The die insert has a rear surface having a plurality of splines extending outwardly from the rear surface and forming a plurality of grooves between the splines. The die also has a front surface adapted to grip a tubular member and a keyway formed on the rear surface. A mating jaw member is provided which also has a front face of splines and grooves with a keyway which aligns with the die's keyway when the die is inserted into the jaw. A key is inserted into this combined keyway to prevent vertical forces from drawing the die out of the jaw member.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of U.S. patent application Ser. No. 11/533,679, filed on Sep. 20, 2006, which is a divisional of U.S. patent application Ser. No. 11/101,855, filed on Apr. 8, 2005, now issued as U.S. Pat. No. 7,124,831, which is a continuation of U.S. patent application Ser. No. 10/811,559, filed on Mar. 29, 2004, now abandoned, which is a continuation of U.S. patent application Ser. No. 09/893,505, filed on Jun. 27, 2001, now issued as U.S. Pat. No. 6,712,153, which are each incorporated by reference herein in their entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a downhole non-metallic sealing element system. More particularly, the present invention relates to downhole tools such as bridge plugs, frac-plugs, and packers having a non-metallic sealing element system.
[0004] 2. Background of the Related Art
[0005] An oil or gas well includes a wellbore extending into a well to some depth below the surface. Typically, the wellbore is lined with tubulars or casing to strengthen the walls of the borehole. To further strengthen the walls of the borehole, the annular area formed between the casing and the borehole is typically filled with cement to permanently set the casing in the wellbore. The casing is then perforated to allow production fluid to enter the wellbore and be retrieved at the surface of the well.
[0006] Downhole tools with sealing elements are placed within the wellbore to isolate the production fluid or to manage production fluid flow through the well. The tools, such as plugs or packers for example, are usually constructed of cast iron, aluminum, or other alloyed metals, but have a malleable, synthetic element system. An element system is typically made of a composite or synthetic rubber material which seals off an annulus within the wellbore to prevent the passage of fluids. The element system is compressed, thereby expanding radially outward from the tool to sealingly engage a surrounding tubular. For example, a bridge plug or frac-plug is placed within the wellbore to isolate upper and lower sections of production zones. By creating a pressure seal in the wellbore, bridge plugs and frac-plugs allow pressurized fluids or solids to treat an isolated formation.
[0007] FIG. 1 is a cross sectional view of a conventional bridge plug 50 . The bridge plug 50 generally includes a metallic body 80 , a synthetic sealing member 52 to seal an annular area between the bridge plug 50 and an inner wall of casing there-around (not shown), and one or more metallic slips 56 , 61 . The sealing member 52 is disposed between an upper metallic retaining portion 55 and a lower metallic retaining portion 60 . In operation, axial forces are applied to the slip 56 while the body 80 and slip 61 are held in a fixed position. As the slip 56 moves down in relation to the body 80 and slip 61 , the sealing member is actuated and the slips 56 , 61 are driven up cones 55 , 60 . The movement of the cones and slips axially compress and radially expand the sealing member 52 thereby forcing the sealing portion radially outward from the plug to contact the inner surface of the well bore casing. In this manner, the compressed sealing member 52 provides a fluid seal to prevent movement of fluids across the bridge plug 50 .
[0008] Like the bridge plug described above, conventional packers typically comprise a synthetic sealing element located between upper and lower metallic retaining rings. Packers are typically used to seal an annular area formed between two co-axially disposed tubulars within a wellbore. For example, packers may seal an annulus formed between production tubing disposed within wellbore casing. Alternatively, packers may seal an annulus between the outside of a tubular and an unlined borehole. Routine uses of packers include the protection of casing from pressure, both well and stimulation pressures, as well as the protection of the wellbore casing from corrosive fluids. Other common uses include the isolation of formations or leaks within a wellbore casing or multiple producing zones, thereby preventing the migration of fluid between zones. Packers may also be used to hold kill fluids or treating fluids within the casing annulus.
[0009] One problem associated with conventional element systems of downhole tools arises in high temperature and/or high pressure applications. High temperatures are generally defined as downhole temperatures above 200° F. and up to 450° F. High pressures are generally defined as downhole pressures above 7,500 psi and up to 15,000 psi. Another problem with conventional element systems occurs in both high and low pH environments. Low pH is generally defined as less than 6.0, and high pH is generally defined as more than 8.0. In these extreme downhole conditions, conventional sealing elements become ineffective. Most often, the physical properties of the sealing element suffer from degradation due to extreme downhole conditions. For example, the sealing element may melt, solidify, or otherwise loose elasticity.
[0010] Yet another problem associated with conventional element systems of downhole tools arises when the tool is no longer needed to seal an annulus and must be removed from the wellbore. For example, plugs and packers are sometimes intended to be temporary and must be removed to access the wellbore. Rather than de-actuate the tool and bring it to the surface of the well, the tool is typically destroyed with a rotating milling or drilling device. As the mill contacts the tool, the tool is “drilled up” or reduced to small pieces that are either washed out of the wellbore or simply left at the bottom of the wellbore. The more metal parts making up the tool, the longer the milling operation takes. Metallic components also typically require numerous trips in and out of the wellbore to replace worn out mills or drill bits.
[0011] There is a need, therefore, for a non-metallic element system that will effectively seal an annulus at high temperatures and withstand high pressure differentials without experiencing physical degradation. There is also a need for a downhole tool made substantially of a non-metallic material that is easier and faster to mill.
SUMMARY OF THE INVENTION
[0012] A non-metallic element system is provided which can effectively seal or pack-off an annulus under elevated temperatures. The element system can also resist high differential pressures as well as high and low pH environments without sacrificing performance or suffering mechanical degradation. Further, the non-metallic element system will drill up considerably faster than a conventional element system that contains metal.
[0013] The element system comprises a non-metallic, composite material that can withstand high temperatures and high pressure differentials. In one aspect, the composite material comprises an epoxy blend reinforced with glass fibers stacked layer upon layer at about 30 to about 70 degrees.
[0014] A downhole tool, such as a bridge plug, frac-plug, or packer, is also provided that comprises in substantial part a non-metallic, composite material which is easier and faster to mill than a conventional bridge plug containing metallic parts. In one aspect, the tool comprises one or more support rings having one or more wedges, one or more expansion rings and a sealing member disposed in a functional relationship with the one or more expansion rings This assemblage of components is referred to hereing as “an element system.”
[0015] In another aspect, a non-metallic mandrel for the downhole tool is formed of a polymeric composite material reinforced by fibers in layers angled at about 30 to about 70 degrees relative to an axis of the mandrel. Methods are provided for the manufacture and assembly of the tool and the mandrel, as well as for sealing an annulus in a wellbore using a downhole tool that includes a non-metallic mandrel and an element system.
BRIEF DESCRIPTION OF DRAWINGS
[0016] So that the manner in which the above recited features, advantages and objects of the present invention are attained and can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to the embodiments thereof which are illustrated in the appended drawings.
[0017] It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
[0018] FIG. 1 is a partial section view of a conventional bridge plug.
[0019] FIG. 2 is a partial section view of a non-metallic sealing system of the present invention.
[0020] FIG. 3 is an enlarged isometric view of a support ring of the non-metallic sealing system.
[0021] FIG. 4 is a cross sectional view along lines A-A of FIG. 2 .
[0022] FIG. 5 is partial section view of a frac-plug having a non-metallic sealing system of the present invention in a run-in position.
[0023] FIG. 6 is section view of a frac-plug having a non-metallic sealing system of the present invention in a set position within a wellbore.
[0024] FIG. 6A is an enlarged view of a non-metallic sealing system activated within a wellbore.
[0025] FIG. 7 is a cross sectional view along lines B-B of FIG. 6 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0026] A non-metallic element system that is capable of sealing an annulus in very high or low pH environments as well as at elevated temperatures and high pressure differentials is provided. The non-metallic element system is made of a fiber reinforced polymer composite that is compressible and expandable or otherwise malleable to create a permanent set position.
[0027] The composite material is constructed of a polymeric composite that is reinforced by a continuous fiber such as glass, carbon, or aramid, for example. The individual fibers are typically layered parallel to each other, and wound layer upon layer. However, each individual layer is wound at an angle of about 30 to about 70 degrees to provide additional strength and stiffness to the composite material in high temperature and pressure downhole conditions. The tool mandrel is preferably wound at an angle of 30 to 55 degrees, and the other tool components are preferably wound at angles between about 40 and about 70 degrees. The difference in the winding phase is dependent on the required strength and rigidity of the overall composite material.
[0028] The polymeric composite is preferably an epoxy blend. However, the polymeric composite may also consist of polyurethanes or phenolics, for example. In one aspect, the polymeric composite is a blend of two or more epoxy resins. Preferably, the composite is a blend of a first epoxy resin of bisphenol A and epichlorohydrin and a second cycoaliphatic epoxy resin. Preferably, the cycloaphatic epoxy resin is Araldite® liquid epoxy resin, commercially available from Ciga-Geigy Corporation of Brewster, N.Y. A 50:50 blend by weight of the two resins has been found to provide the required stability and strength for use in high temperature and pressure applications. The 50:50 epoxy blend also provides good resistance in both high and low pH environments.
[0029] The fiber is typically wet wound, however, a prepreg roving can also be used to form a matrix. A post cure process is preferable to achieve greater strength of the material. Typically, the post cure process is a two stage cure consisting of a gel period and a cross linking period using an anhydride hardener, as is commonly know in the art. Heat is added during the curing process to provide the appropriate reaction energy which drives the cross-linking of the matrix to completion. The composite may also be exposed to ultraviolet light or a high-intensity electron beam to provide the reaction energy to cure the composite material.
[0030] FIG. 2 is a partial cross section of a non-metallic element system 200 made of the composite, filament wound material described above. The element system 200 includes a sealing member 210 , a first and second cone 220 , 225 , a first and second expansion ring 230 , 235 , and a first and second support ring 240 , 245 disposed about a body 250 . The sealing member 210 is backed by the cones 220 , 225 . The expansion rings 230 , 235 are disposed about the body 250 between the cones 220 , 225 , and the support rings 240 , 245 , as shown in FIG. 2 .
[0031] FIG. 3 is an isometric view of the support ring 240 , 245 . As shown, the support ring 240 , 245 is an annular member having a first section 242 of a first diameter that steps up to a second section 244 of a second diameter. An interface or shoulder 246 is therefore formed between the two sections 242 , 244 . Equally spaced longitudinal cuts 247 are fabricated in the second section to create one or more fingers or wedges 248 there-between. The number of cuts 247 is determined by the size of the annulus to be sealed and the forces exerted on the support ring 240 , 245 .
[0032] Still referring to FIG. 3 , the wedges 248 are angled outwardly from a center line or axis of the support ring 240 , 245 at about 10 degrees to about 30 degrees. As will be explained below in more detail, the angled wedges 248 hinge radially outward as the support ring 240 , 245 moves axially across the outer surface of the expansion ring 230 , 235 . The wedges 248 then break or separate from the first section 242 , and are extended radially to contact an inner diameter of the surrounding tubular (not shown). This radial extension allows the entire outer surface area of the wedges 248 to contact the inner wall of the surrounding tubular. Therefore, a greater amount of frictional force is generated against the surrounding tubular. The extended wedges 248 thus generate a “brake” that prevents slippage of the element system 200 relative to the surrounding tubular.
[0033] Referring again to FIG. 2 , the expansion ring 230 , 235 may be manufactured from any flexible plastic, elastomeric, or resin material which flows at a predetermined temperature, such as Teflon® for example. The second section 244 of the support ring 240 , 245 is disposed about a first section of the expansion ring 230 , 235 . The first section of the expansion ring 230 , 235 is tapered corresponding to a complementary angle of the wedges 248 . A second section of the expansion ring 230 , 235 is also tapered to complement a sloped surface of the cone 220 , 225 . At high temperatures, the expansion ring 230 , 235 expands radially outward from the body 250 and flows across the outer surface of the body 250 . As will be explained below, the expansion ring 230 , 235 fills the voids created between the cuts 247 of the support ring 240 , 245 , thereby providing an effective seal.
[0034] The cone 220 , 225 is an annular member disposed about the body 250 adjacent each end of the sealing member 210 . The cone 220 , 225 has a tapered first section and a substantially flat second section. The second section of the cone 220 , 225 abuts the substantially flat end of the sealing member 210 . As will be explained in more detail below, the tapered first section urges the expansion ring 230 , 235 radially outward from the body 250 as the element system 200 is activated. As the expansion ring 230 , 235 progresses across the tapered first section and expands under high temperature and/or pressure conditions, the expansion ring 230 , 235 creates a collapse load on the cone 220 , 225 . This collapse load holds the cone 220 , 225 firmly against the body 250 and prevents axial slippage of the element system 200 components once the element system 200 has been activated in the wellbore. The collapse load also prevents the cones 220 , 225 and sealing member 210 from rotating during a subsequent mill up operation.
[0035] The sealing member 210 may have any number of configurations to effectively seal an annulus within the wellbore. For example, the sealing member 210 may include grooves, ridges, indentations, or protrusions designed to allow the sealing member 210 to conform to variations in the shape of the interior of a surrounding tubular (not shown). The sealing member 210 , however, should be capable of withstanding temperatures up to 450° F., and pressure differentials up to 15,000 psi.
[0036] In operation, opposing forces are exerted on the element system 200 which causes the malleable outer portions of the body 250 to compress and radially expand toward a surrounding tubular. A force in a first direction is exerted against a first surface of the support ring 240 . A force in a second direction is exerted against a first surface of the support ring 245 . The opposing forces cause the support rings 240 , 245 to move across the tapered first section of the expansion rings 230 , 235 . The first section of the support rings 240 , 245 expands radially from the mandrel 250 while the wedges 248 hinge radially toward the surrounding tubular. At a predetermined force, the wedges 248 will break away or separate from the first section 242 of the support rings 240 , 245 . The wedges 248 then extend radially outward to engage the surrounding tubular. The compressive force causes the expansion rings 230 , 235 to flow and expand as they are forced across the tapered section of the cones 220 , 225 . As the expansion rings 230 , 235 flow and expand, they fill the gaps or voids between the wedges 248 of the support rings 240 , 245 . The expansion of the expansion rings 230 , 235 also applies a collapse load through the cones 220 , 225 on the body 250 , which helps prevent slippage of the element system 200 once activated. The collapse load also prevents the cones 220 , 225 and sealing member 210 from rotating during the mill up operation which significantly reduces the required time to complete the mill up operation. The cones 220 , 225 then transfer the axial force to the sealing member 210 to compress and expand the sealing member 210 radially. The expanded sealing member 210 effectively seals or packs off an annulus formed between the body 250 and an inner diameter of a surrounding tubular.
[0037] The non-metallic element system 200 can be used on either a metal or more preferably, a non-metallic mandrel. The non-metallic element system 200 may also be used with a hollow or solid mandrel. For example, the non-metallic element system 200 can be used with a bridge plug or frac-plug to seal off a wellbore or the element system may be used with a packer to pack-off an annulus between two tubulars disposed in a wellbore. For simplicity and ease of description however, the non-metallic element system will now be described in reference to a frac-plug for sealing off a well bore.
[0038] FIG. 5 is a partial cross section of a frac-plug 300 having the non-metallic element system 200 described above. In addition to the non-metallic element system 200 , the frac-plug 300 includes a mandrel 301 , slips 310 , 315 , and cones 320 , 325 . The non-metallic element system 200 is disposed about the mandrel 301 between the cones 320 , 325 . The mandrel 301 is a tubular member having a ball 309 disposed therein to act as a check valve by allowing flow through the mandrel 301 in only a single axial direction.
[0039] The slips 310 , 315 are disposed about the mandrel 302 adjacent a first end of the cones 320 , 325 . Each slip 310 , 315 comprises a tapered inner surface conforming to the first end of the cone 320 , 325 . An outer surface of the slip 310 , 315 , preferably includes at least one outwardly extending serration or edged tooth, to engage an inner surface of a surrounding tubular (not shown) when the slip 310 , 315 is driven radially outward from the mandrel 301 due to the axial movement across the first end of the cones 320 , 325 thereunder.
[0040] The slip 310 , 315 is designed to fracture with radial stress. The slip 310 , 315 typically includes at least one recessed groove (not shown) milled therein to fracture under stress allowing the slip 310 , 315 to expand outwards to engage an inner surface of the surrounding tubular. For example, the slip 310 , 315 may include four sloped segments separated by equally spaced recessed grooves to contact the surrounding tubular, which become evenly distributed about the outer surface of the mandrel 301 .
[0041] The cone 320 , 325 is disposed about the mandrel 301 adjacent the non-metallic sealing system 200 and is secured to the mandrel 301 by a plurality of shearable members 330 such as screws or pins. The shearable members 330 may be fabricated from the same composite material as the non-metallic sealing system 200 , or the shearable members may be of a different kind of composite material or metal. The cone 320 , 325 has an undercut 322 machined in an inner surface thereof so that the cone 320 , 325 can be disposed about the first section 242 of the support ring 240 , 245 , and butt against the shoulder 246 of the support ring 240 , 245 .
[0042] As stated above, the cones 320 , 325 comprise a tapered first end which rests underneath the tapered inner surface of the slips 310 , 315 . The slips 310 , 315 travel about the tapered first end of the cones 320 , 325 , thereby expanding radially outward from the mandrel 301 to engage the inner surface of the surrounding tubular.
[0043] A setting ring 340 is disposed about the mandrel 301 adjacent a first end of the slip 310 . The setting ring 340 is an annular member having a first end that is a substantially flat surface. The first end serves as a shoulder which abuts a setting tool described below.
[0044] A support ring 350 is disposed about the mandrel 301 adjacent a first end of the setting ring 340 . A plurality of pins 345 secure the support ring 350 to the mandrel 301 . The support ring 350 is an annular member and has a smaller outer diameter than the setting ring 340 . The smaller outer diameter allows the support ring 350 to fit within the inner diameter of a setting tool so the setting tool can be mounted against the first end of the setting ring 340 .
[0045] The frac-plug 300 may be installed in a wellbore with some non-rigid system, such as electric wireline or coiled tubing. A setting tool, such as a Baker E-4 Wireline Setting Assembly commercially available from Baker Hughes, Inc., for example, connects to an upper portion of the mandrel 301 . Specifically, an outer movable portion of the setting tool is disposed about the outer diameter of the support ring 350 , abutting the first end of the setting ring 340 . An inner portion of the setting tool is fastened about the outer diameter of the support ring 350 . The setting tool and frac-plug 300 are then run into the well casing to the desired depth where the frac-plug 300 is to be installed.
[0046] To set or activate the frac-plug 300 , the mandrel 301 is held by the wireline, through the inner portion of the setting tool, as an axial force is applied through the outer movable portion of the setting tool to the setting ring 340 . The axial forces cause the outer portions of the frac-plug 300 to move axially relative to the mandrel 301 . FIGS. 6 and 6A show a section view of a frac-plug having a non-metallic sealing system of the present invention in a set position within a wellbore.
[0047] Referring to both FIGS. 6 and 6A , the force asserted against the setting ring 340 transmits force to the slips 310 , 315 and cones 320 , 325 . The slips 310 , 315 move up and across the tapered surface of the cones 320 , 325 and contact an inner surface of a surrounding tubular 700 . The axial and radial forces applied to slips 310 , 315 causes the recessed grooves to fracture into equal segments, permitting the serrations or teeth of the slips 310 , 315 to firmly engage the inner surface of the surrounding tubular.
[0048] Axial movement of the cones 320 , 325 transfers force to the support rings 240 , 245 . As explained above, the opposing forces cause the support rings 240 , 245 to move across the tapered first section of the expansion rings 230 , 235 . As the support rings 240 , 245 move axially, the first section of the support rings 240 , 245 expands radially from the mandrel 250 while the wedges 248 hinge radially toward the surrounding tubular. At a pre-determined force, the wedges 248 break away or separate from the first section 242 of the support rings 240 , 245 . The wedges 248 then extend radially outward to engage the surrounding tubular 700 . The compressive force causes the expansion rings 230 , 235 to flow and expand as they are forced across the tapered section of the cones 220 , 225 . As the expansion rings 230 , 235 flow and expand, the rings 230 , 235 fill the gaps or voids between the wedges 248 of the support rings 240 , 245 , as shown in FIG. 7 . FIG. 7 is a cross sectional view along lines B-B of FIG. 6 .
[0049] Referring again to FIGS. 6 and 6A , the growth of the expansion rings 230 , 235 applies a collapse load through the cones 220 , 225 on the mandrel 301 , which helps prevent slippage of the element system 200 once activated. The cones 220 , 225 then transfer the axial force to the sealing member 210 which is compressed and expanded radially to seal an annulus formed between the mandrel 301 and an inner diameter of the surrounding tubular 700 .
[0050] In addition to frac-plugs as described above, the non-metallic element system 200 described herein may also be used in conjunction with any other downhole tool used for sealing an annulus within a wellbore, such as bridge plugs or packers, for example. Moreover, while foregoing is directed to the preferred embodiment of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.
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A non-metallic element system is provided as part of a downhole tool that can effectively seal or pack-off an annulus under elevated temperatures. The element system can also resist high differential pressures without sacrificing performance or suffering mechanical degradation, and is considerably faster to drill-up than a conventional element system. In one aspect, the composite material comprises an epoxy blend reinforced with glass fibers stacked layer upon layer at about 30 to about 70 degrees. In another aspect, a mandrel is formed of a non-metallic polymeric composite material. A downhole tool, such as a bridge plug, frac-plug, or packer, is also provided. The tool comprises a support ring having one or more wedges, an expansion ring, and a sealing member positioned with the expansion ring.
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BACKGROUND OF THE INVENTION
Construction of detention structures has been subject of intensive research due to the need for large quantities of jail space. The requirements of resistance to penetration of the enclosure as well as its need to be fire resistant have generated pre-cast concrete systems as the primary alternative to the standard techniques of formed cast in place concrete, all steel construction or reinforced unit masonry. Reinforced unit masonry is the least resistant to penetration, is subject to joint damage by abrading and is a slow and labor intensive method. Cast in place reinforced concrete can be made acceptably resistant to penetration if heavily reinforced, but is slow due to forming, stripping and curing time requirements, and it is labor intensive, space consuming and very heavy. Pre-cast systems can be built with greater speed than the cast in place concrete but otherwise have the same type of deficiencies, plus they require many special connectors as well as heavy equipment for erection. All steel systems are the most resistant to penetration or damage but are not fire resistant enough for most multi-story structures and are very expensive. The system of this invention overcomes these difficulties by being highly resistant to penetration, lighter weight, fire resistant, easy and fast to erect and highly efficient in use of materials and labor. This invention also provides a joint free cell interior.
Recent tests run on the herein described cementiciously filled light gauge steel structure invention have shown it to be more resistant to penetration than reinforced concrete or reinforced unit masonry. The standard impact test simulates an average man swinging a sixteen pound sledge hammer at one point of the assembly. A six inch thick reinforced concrete wall was penetrated with 1300 blows and an eight inch reinforced unit masonry wall with 800 blows. The light gauge metal sheathed and cementiciously filled wall described in this invention withstood an average of 1982 blows with only minor and easily repairable damage.
Light gauge steel framing used in this invention has been produced by many manufacturers since the late 1940's and is used in both load bearing and non-load bearing construction. It is normally used with finishes on both sides and a hollow or insulated cavity. Diagonal tension strap bracing for horizontal loads is usually screwed or welded to rigid connection points. The straps often are loose or bent during installation and allow damaging movement to occur in the building frame during lateral loading. The bearing wall structures normally built do not provide for continuity of the concrete diaphragm topping unless it is poured separately at each floor level and cured before the next level is erected. When the steel frame is erected with the concrete topping placed after erection in the present art, the continuity of the topping is interrupted at each wall and no continuous diaphragm is possible.
Filled cavity use of light gauge steel framing has been limited to a few systems wherein metal lath is placed on an open truss steel stud frame and the cavity is filled with cement plaster in a multiple pass pneumatic placement operation. Although there is a small composite effect with these methods, the strength of the pneumatically placed cement plaster and metal lath and the composite action are insufficient to appreciably aid in penetration resistance or load capacity of the assembly. The method is very slow, it is not used for multiple story construction, does not adequately provide for lateral forces and is very labor intensive. Several such systems using pneumatic placement of cement have been unsuccessfully marketed for security construction.
A light gauge framing method with reinforced cement finishes was described in U.S. Pat. No. 4,472,919, which relates principally to a method of allowing independent movement of the steel frame and the reinforced cement finish. The method described is not appropriate for penetration resistance in security construction and does not envision any composite action.
Modular building techniques described in U.S. Pat. No. 3,751,864 claim a concrete column and beam type structure created with modular boxes with corrugated steel walls and floor used as permanent forms. This patent limits the modules to one story at a time with structural loads carried by conventionally reinforced columns and beams. Concrete is poured at each story and must cure before the next story of modules is placed. This creates many of the same problems associated with concrete construction in that the concrete placement is subject to weather considerations and all concrete must cure on each floor before the next floor modules can be set. There is no great increase in speed of construction over normal methods and the steel is not acting in a composite way.
A structure of modular units is also described in U.S. Pat. No. 3,678,638 that describes a column and beam structure of concrete formed by the module walls. The steel framing of the modules is not intended to carry any permanent loads and the structure must be erected one story at a time and requires many special parts. Due to the one floor at a time pouring and curing of concrete it will not improve construction speed.
SUMMARY OF THE INVENTION
This invention relates to a method of constructing lightweight non-combustible detention structures and multi-level structures of all types. It utilizes a light gauge steel structure that may have cementicious fill placed after enclosure of several levels of the building. Means are provided for safe, enclosed working areas and for the convenient placing of cementicious fill in each level from above or, through pressure pumping, from other points in the structure. During adverse weather conditions, construction may proceed without interruption due to pre-enclosure of working areas. This invention provides means of increasing resistance to penetration, forming of monolithically placed concrete with permanent structural parts, safely improving the speed of construction, tensioning bracing straps, facilitating continuous diaphragm slabs, supporting wall finishes at the wall base and fireproofing steel parts heretofore unknown in the art.
It is, therefore, one of the primary objects of this invention to provide an improved method of constructing monolithically poured reinforced concrete buildings utilizing permanent lightweight metal forming members that also serve as the building structure either independently or in combination with subsequently placed concrete.
Another object of the present invention is to maximize the properties of metal and cementicious materials in a structural arrangement for high resistance to penetration and impact damage for primary use in detention structures and to allow rapid enclosure of space while providing safe working surfaces composed of permanent parts of the structure and giving easy accessibility within a controlled environment for installation of piping, ducting and wiring concurrently, without interfering with each other or with other trades.
A further object of the present invention is to permit direct visual inspection of the concrete for the full height of the pour while it is being placed into permanent forms that are a part of the structural load resisting elements and to allow tensioning of lateral load resisting diagonal tension straps in a manner that simultaneously distributes some lateral loads into both understressed vertical load resisting members and moment resisting members.
A still further object is to allow placement of concrete floor topping after erection of a light gauge metal framed floor structure in a manner allowing a continuous diaphragm design and also providing backing at the base of wall finishes and to provide a lightweight wall bearing structure that distributes loads onto the foundations in a linear pattern, thereby allowing construction on low bearing capacity soils with simple slab type foundations.
Another object is to provide a light gauge, steel reinforced concrete structure that temporarily supports up to 6 levels of construction loads prior to the curing of the cementicious materials of the composite structure, the completed composite structure produced thereby providing greater load capacity and thus higher and more fire resistant structures than the light steel acting alone with surface finishes only and to provide a thermal storage mass on the conditioned air side of the enclosure to aid in the economical heating and cooling of the enclosed space.
An additional purpose is to provide a means of creating a sheathed cavity with materials that provide a stressed skin effect for the composite structure as well as a base for interior and exterior finishes and durable enclosure during construction, to provide a monolithic acoustic barrier from one side of the structural wall to the other side, and to permit cementicious fire proofing to be simultaneously placed with the wall or floor cavity cementicious fill.
A structure of light gauge metal beam or channel members is either stick built or panelized and erected upon a foundation. Sheathing material is applied to the exterior surfaces and roof framing and sub-flooring may be applied to the floor framing. Windows, doors, louvers, exterior insulations, etc., may then be installed along with a roof waterproofing, thereby providing an enclosed working environment. After erection of the first level steel structure, safe interior working areas with walking surfaces are created which allows convenient placement of wiring, piping and ducting installations within the wall and ceiling cavities. As each further level is erected, the enclosed areas formed create similar safe working areas for immediate installation of all other trade work such as wiring, piping, ducting and other work within the cavities of the walls and ceilings. Interior sheathing is applied and the wall cavity may be filled with cementicious material. Sub-flooring may be topped with cementicious material at any convenient time during the construction process after the wall cavity therebelow has been filled with cementicious materials and, where moisture sensitive finishes are used, waterproofing has been installed thereabove. The cementicious cavity fill material is placed from above at each level through special holes in the top and bottom tracks of the light gauge steel framing as each level is ready. The fill may be alternatively pumped into the wall and/or floor cavities at any convenient points using high pressure pumps. Insulation may be applied to the exterior surface of the sheathing either before panel erection or after panel erection at any convenient time, and exterior finish may then be applied over the insulation. In the construction of multi-level structures, the steel framing may be erected many levels above the previously filled and cured cementicious wall fill.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric sectional view showing the components of the cementiciously filled wall and floor for a detention structure;
FIG. 2 is an isometric view of a light metal framed, multi-level construction showing floor, wall and diagonal tension strap framing;
FIG. 3 is a cross-sectional detail showing the short beam tension strap connection through a floor system;
FIG. 4 is an isometric view of the diagonal strap tensioning beam connection;
FIG. 5 is an isometric view showing the continuous diaphragm slab at a panel wall;
FIG. 6 is a side elevational view, shown partially in cross-section through a light metal framed multi-story structure showing the simultaneous phases of construction;
FIG. 7 is an isometric view of Z shaped and C shaped edge and corner furring members, respectively showing one possible perforation pattern for the web portions thereof; and
FIG. 8 is a sectional view through the floor/wall connection where pre-cast concrete slabs are used for floor construction.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now more specifically to the drawings, and to FIG. 1 in particular, numeral 10 designates generally an isometric sectional drawing of an exterior wall panel 12 supporting and being supported upon a floor panel 14 in a typical configuration that may be used for a detention structure. Walls 12 are built of multiple, light gauge, metal stud members or channels 16 with a central web formed for retaining cementicious fill 18. The stud members are normally 12 to 20 gauge steel or other suitable material, as are the floor joists and floor/ceiling tracks which are described hereinbelow. The stud members or channels used for the outer wall construction and the interior wall construction are generally similar. While slight variations may be used, one of the objects of the present invention is to use basically interchangeable materials. Thus, the invention utilizes generally U-shaped channels, generally C-shaped channels, and a form of corrugated channel, shown in FIG. 1 as numeral 16, which provides a central web with an offset configuration to increase the surface area thereof.
The stud members are inserted into top and bottom U-shaped tracks 20, through apertures 22 formed therein. The stud members are secured therein by welding, self-tapping screw fasteners, or other conventional means, as are the hereinbelow described metal to metal contacts at wall, ceiling and floor intersections, except as specifically noted. Horizontal reinforcing rods 24, normally of steel, are inserted through holes made therefor in the studs 16 at spacings required for security penetration and structural strength such as six to eight inches on center. Vertical reinforcing rods 26 are attached to the horizontal rods as required for structural strength and penetration resistance with similar spacings. Z-shaped furring members 28 are attached to the exterior faces of studs 16 and expanded metal lath sheathing 30 is attached to the free end flange 40 of the Z-shaped furring member. Insulation foam 42 is applied over the sheathing 30 and an outer layer of expanded metal lath sheathing 44 is fastened through the foam into the end flange 40. The above described assembly may be pre-fabricated and placed upon a load bearing surface. A cement plaster or other finish 46 is applied over the sheathing 44 on the assembly prior to or after erection. Doors and windows (shown hereinafter) may be framed and installed prior to erection as needed.
Floor/ceiling 14 is built of light gauge metal joists 48 inserted into generally u-shaped tracks 50 and fastened thereto by welding or other suitable operation. Expanded metal lath sheathing 52 is attached to the bottom of the joists 48 except where the joist will be in contact with a wall-receiving track 20 after erection. Such sheathing 52 may also be secured to the top of the joists 48 where desired. Reinforcing rods 54, perpendicular to the joists 48 may be inserted through holes in the joists or over the top of the joists and additional reinforcing rods 56 are attached to the said inserted rods 54, running parallel to the joist, as required for penetration resistance and/or structural requirements, the spacing being as described hereinabove. The above described floor/ceiling assembly may be prefabricated and placed upon the wall panel 12 and fastened thereto as described, for example, by welding or other means. The floor/ceiling assembly thus provides an upper surface which serves as a floor or deck for one level of the present building invention and a lower surface that serves as a ceiling for the level therebelow. A roof panel with roofing attached as shown in FIG. 6 may be similarly pre-fabricated and erected upon the uppermost wall track.
The above described method of panelizing floors, walls and roof and placing them in sequence can continue until the entire building frame is erected. At that point, an enclosed enviroment has been provided that allows plumbers, electricians and other mechanical tradesmen to install piping, wiring and ductwork within the spaces between joists 48 and/or studs 16 or through holes cut through the webs or the outer flange portions thereof. Upon completion of work that is installed within the walls or floor structures, additional Z-shaped furring members 28 may be installed over studs 16 and a screed angle 58 installed over the furring members at the finished height of the cementicious floor fill 60. Metal lath sheathing 80 is then attached to the interior free end flange 82 of the Z-shaped furring members 28 and angle 58. Cementicious fill 60 is then pumped into the lowest floor or wall panel through holes in the tracks 20. Placement of said fill is observed through the metal lath sheathing 80 to assure solid filling of all spaces. Cementicious floor fill 60 is then placed between joists 48 and screeded off level against screed angle 58. The above sequence is continued upon initial set of the cementicious fill on each level until the entire building has been completed. After initial set of the cementicious fill on any level a cement plaster or other finish 84 is normally applied over the cementicious fill that has extruded out through the openings in the metal lath 80. The preferred cementicious fill mix is a low slump, portland cement, pea gravel concrete that can be pumped through a small diameter fill hose that is inserted through the holes 22 in tracks 20. With a low slump concrete mixture, this preferred fill extrudes through the lath 80 sufficiently to form a superior bonding surface for subsequently applied cement plaster 84. The preferred mix for the cement plaster contains acrylic and glass or polypropylene fibers to allow a 5000 psi compressive strength for resistance to damage. A similar mix is preferred for the ceiling plaster 86 which is installed over cementicious fill that has extruded slightly through metal lath sheathing 52 below the floor joists.
Interior metal lath sheathing 80 is usually a relatively rigid rib-type lath to allow it to retain the cementicious fill without bowing due to the fluid pressure exerted on the lath during placement of the fill material. The lath 80 is a very important element in detention structures because it allows visual inspection of the fill during placement. Gaps and voids in concrete fill placed between reinforced masonry block walls, where visual inspection is not possible, have allowed prisoners to escape by finding the hollow parts. The prisoner is able to break through the masonry quickly when the core fill is defective. This invention eliminates any voids or gaps in the concrete fill.
A hard surface finish 88 is optionally applied over the cement plaster interior 84 and/or exterior finish 46 and/or ceiling plaster 86 to prevent staining. A polyurethane enamel is suitable for this purpose on the interior and an acrylic is typically used for the exterior.
The wall panels 12 may be constructed without the Z-shaped members 28 if a fire rating of one hour is all that is required. In this instance, the bearing or non-bearing studs 16 would be fire protected by the thickness of the cement plaster 84 only. Where fire ratings of up to 4 hours are desired, the depth of the perforated Z-shaped members 28 is increased to allow cementicious fill 18 to encase the studs 16 with the required thickness of fireproofing. For example, a one inch plaster covering over the studs generally provides a one hour fire rating, one and one-half inches of plaster provides a two hour rating and a two inch covering provides a four hour rating. Thus, the inherent safety of the present structure, due to the materials used in construction, can easily be enhanced.
FIG. 2 is an isometric view of the light gauge framing members in a multiple story structure at an interior, horizontal, load-resisting bearing wall showing foundation and first floor wall framing, portions of two floor spans, part of the second floor wall framing and the unique, horizontal load-resisting diagonal tension strap system which is a characteristic of the present invention. A slab-type foundation 90 is formed and cured to receive bearing wall panels. Other types of conventional foundations, such as concrete block, may also be used. A light gauge metal wall panel 92 is constructed of multiple light gauge bearing studs, including C-shaped studs 94 and U-shaped studs 96. The studs are inserted into and fastened to top and bottom U-shaped tracks 98 by welding or other conventional fastening means. Horizontal bridging rods 100 are fastened to each stud, again, by welding or other suitable means.
As shown in FIGS. 2 and 4, the wall panel sections have diagonal tension straps 120 fastened generally between the upper and lower diagonally opposed corners thereof. As noted earlier, either the C-shaped, or corrugated studs or channels may be used as structural members. Thus, these wall panels are shown with C-shaped members running vertically. At the panel edges, however, the last two uprights on each side consist of a C-shaped stud and a U-shaped stud normally secured back-to-back at 122 with the U-shaped studs facing inwardly for accepting horizontal beam members 124 and 127, respectively, above and below the floor/ceiling frame panels, secured by welding as at 125. Floor framing panels of light gauge C-shaped joist members 126 are inserted into and fastened to U-shaped joist-receiving track members 128 at each end with appropriate bridging (not shown) between the joists, at intervals sufficient to prevent rotative movement. A space is left between the top and bottom short beams 124 and 127 and between the U-shaped joist tracks 128 over the bearing wall for receiving bolts 130. Additional wall panel and floor panel members or sections are similarly placed until the structure is to the desired height.
When the second level wall panel has been placed, the diagonal tension straps 120 on the first floor are tensioned by drawing up bolts 130 which are inserted between the horizontal beams 124 at the bottom of the second floor or upper level wall panel, through the lower and upper tracks 98, between the space left between the joist-receiving tracks 128, and then between the short beams 127 at the upper level of the first or lower level, depending on the level being erected. The bolts have washers 132 at the top and bottom ends thereof, and are secured with nuts 134. The first level diagonal wall panel straps 120 are permanently attached to U-shaped structural steel channel connector beams 136 which are secured through a U-shaped floor track 138 with bolts 140 into foundation 90.
As each additional wall panel is installed, the tension straps 120 are similarly tensioned in the panel below so that the structure is capable of resisting lateral loads as it is erected. Upon completion of the described structure, horizontal loads applied to any floor above the second causes a distribution of the horizontal load into each tension strap below, which is then transmitted into bending forces in the short horizontal beams 124 and 127. The resultant horizontal loads are thus distributed to many additional load resisting members, thereby reducing load concentrations encountered in the present art and allowing selection of lighter framing members while concomitantly reducing foundation costs. The bending moments induced into the said short beams 124 and 127 by the tension straps 120 helps to dissipate lateral load energy with reduced potential damage to the structure from seismic or wind forces.
FIG. 3 is a section through the short horizontal beams 124 and 127 at the top and bottom of a wall panel, respectively and the ends of two floor panels showing the through bolts 130 used to tension the diagonal tension strapping 120. Short beam members 124 and 127 are inserted between the end flanges 160 of the U-shaped wall vertical members 96 and fastened thereto at all interfaces with a space 162 left between the short beams 124 and 127 and the wall tracks 98. Bolts 130 are inserted between short beams 124 and 127 and floor joist-receiving tracks 128 and through tracks 98 near the ends of floor joist members 126, over which is shown a corrugated decking 164. Large washers 132 are placed between bolts 130 and nuts 134 and the upper or lower ends of the short beams 124 and 127 to distribute the loads.
This invention allows the diagonal tension straps 120 to be stressed sufficiently to allow them to immediately pick up any lateral loads applied to the building. In the present state of the art, diagonal tension straps cannot be tensioned and often are bent or bowed between framing points which causes a delayed response to lateral loads with attendant undesirable movement in the building frame. Sometimes the diagonal straps in the present art are so loose that shock loads can occur in the building frame when the straps become tensioned by lateral loading. These shock loads are very damaging to fasteners and can eventually cause major structural movement to occur. The invention described herein eliminates these problems.
FIG. 4 is an enlarged, partial isometric view of the diagonal strap/short beam connection at a typical floor construction. The short beams 124 and 127 span between two vertical, U-shaped framing members 96 and are fastened between flanges 160 at each end. The beam 127 at the upper end of the wall panel is temporarily attached as with bolts (not shown) through holes 166 in flanges 160, leaving a gap 162 between the beam and the wall track 98, thereby allowing the beam to bend. Diagonal tension straps 120 are temporarily fastened through holes 166 to the upper and lower short beams 124 and 127 with a through bolt (not shown) that allows the strap 120 to pivot as the beams 124 and 127 change position upon tightening of bolts 130.
In sequence, the U-shaped structural steel channels 136 are permanently fastened before the bolts 130 are tightened. The nuts 134 are then tightened on bolts 130 until the straps 120 are tight. The temporarily fastened short beams 127 (at the upper end of the wall panel) are then permanently attached to the receiving track 96 and the strap 120 is then permanently attached to beam 127. When tension from lateral loads occurs in strap 120 above the floor, beam 124 above the floor bends upwardly and in so doing, through bolts 130, induces bending in beam 127 below the floor. This induces tension in strap 120 below the floor which is attached to the channel 136 at the base or to another beam 124 therebelow which also bends and tensions the next level's strap 120. In this manner, the majority of the lateral load is dissipated in the bending of short beams 124 and 127 throughout the structure. The balance of the lateral load is converted to tension or compression loads in vertical members 94 and 96 and retainer flanges 160 at each end of each short beam.
FIG. 5 is a partial isometric view of a continuous floor topping slab 168 at a bearing wall and floor intersection in the middle portion of a wall panel. Light metal angles 170 are fastened to vertical structural members 96 at the finished elevation of floor topping 168. The cementicious slab or topping 168 is placed upon metal sheathing/decking 164 which is fastened to the light metal floor joists 126. The ends of the joists may be braced with bearing clips 172 or angles to carry loads from studs 96. The cementicious slab 168 is poured and screeded using angle 170 as a screed. The poured fill 168 is also placed between studs 96 over the top of the track 98 to the bottom of or higher than the bottom of angle 170. This allows the cementicious fill 168 to be continuous across the base of the wall and thus forms a continuous diaphragm slab that is poured after the light gauge framing construction is completed.
A distinct advantage of this invention is that the concrete fill can be placed in environmentally controlled conditions after the entire building frame is completed and all mechanical work is roughed in. The cementicious topping thus not only is a continuous diaphragm but also seals all piping and duct work that may project between floors. The topping also forms an excellent acoustic and fire stop within the wall cavity. There are no delays in construction while topping is curing because the next floor topping can be placed while the lower floors are still setting, due to the structural integrity of the metal framing. The time savings, cost savings and improvement in structural quality of the completed building are very important improvements over the prior art. Also, the screed angles 170 provide backing for wall finishes, such as gypsum or wall board to be applied later and, when concrete fill is placed higher than the floor surface of slab 168 between the angles 170, an excellent acoustic seal is provided at the base of the wall, as opposed to the high sound transmission between floors and opposed walls in conventional structures.
FIG. 6 is a side elevational and partial cross-sectional view of a light metal frame, multiple story structure showing the simultaneous phases of construction. Wall panels are erected upon foundation slab 90 and fastened thereto as shown in FIG. 2. Wall panels consist of studs 16, 94, or 96, diagonal straps 120, insulation 42 and finished exterior cement plaster 46 on metal lath 44. Floor panels 14 are installed and fastened on top of wall panels 12. Floor panels 14 consist of joist members 126 and decking 164. Second story wall panels 12 are then erected upon the first floor panel 14 and fastened thereto. The third story floor panel 14 then is placed upon second story wall panel 12 and fastened. The third story wall panel 12 next is fastened on top of the third story floor and the fourth story floor is fastened on top of the third story wall. The fourth story wall is then erected over the fourth story floor and a roof truss 174 is placed upon the uppermost wall. Roofing 176 is then installed after erection of truss 174 and an enclosed environment has been created in a very short time with insulated walls, walkable deck surfaces and waterproof roof.
Where the wall panels 12 are to be left hollow, as in a non-security structure, windows 178 and/or doors, (not shown) can be framed and installed prior to the wall panel erection. Where all wall and floor panels are to be filled with cementicious fill after erection, as in a detention structure, temporary closures may be provided over the window openings until the cementicious fill has been completed. After the metal frames of the first story floor, walls, and ceiling have been erected, electrical and plumbing conduits 180 may be installed while the upper levels are being erected. Upon completion of electical and similar work on each level, metal lath/sheathing 44 is attached and the wall cavities filled with cementicious fill 18 through a fill hose 182 inserted from above through holes 22 in the stud tracks. Upon initial set of fill 18, windows 178 are installed and interior finish 84 is placed.
After the interior finish is completed, base trims, window trims and finish electrical and mechanical work may be done. Using the simultaneous activities possible with this invention, a 4 level building as illustrated in FIG. 6 may be completed in 5 weeks or less after the foundation has cured and any number of levels are possible within similar short schedules. The safe, dry and convenient work areas, simple consistent materials, and short erection time allows construction of high quality, low cost buildings.
FIG. 7A shows an isometric view of a typical Z-shaped furring member 28 made of light gauge metal. This member is used to separate the metal lath or sheathing from the light gauge metal structural members so that cementicious wall or floor/ceiling fill can encase the said structural member during filling operations as previously described. An inside flange 184 is formed to receive fasteners that attach the sheathing to the vertical studs or horizontal floor joists in the wall or floor system. Flange 184 may be any convenient dimension required by the type of fasteners used. For screw type fasteners, flange 184 is usually 3/4" to 2" wide. The web 186 or central portion of the Z member is perforated, punched or formed with openings 188 and with a short section of non-perforated metal 190 at the web/flange transition. The perforations 188 may be any shape desired that allows the cementicious fill to penetrate the opening but not freely run through it and that keeps direct metal conduction paths from flange to flange as long as possible. The non-perforated web section 190 is usually 1/4" wide, but may be from 1/8" to 1/2" as required, to provide stiffness to the flanges. Outer flange 40 may be any convenient dimension required by the type of fasteners used to attach the metal lath thereto. For screw type fasteners, flange 40 is usually 3/4" to 2" wide. The entire Z-shaped member is formed from the lightest gauge metal, usually 20 to 30 gauge, that will support the liquid pressure (normally 200-300 pounds per square foot) of the cementicious fill and not deform during placement of lath/sheathing and the cementitious fill.
FIG. 7B shows an isometric view of a typical C-shaped furring member 192 made of light gauge metal. This member is used at the ends or corners of panels and functions the same as the Z-shaped member shown in FIG. 7A. Perforations 194 and solid sections 196 of the web 198 are as described for FIG. 7A. The outer flange 200 is formed shorter than the inner flange 202 to allow fasteners to be placed through flange 202 directly from the front. Flange 200 is usually from 1/2" to 11/2" wide and flange 202 from 1" to 2" wide although narrower or wider dimensions may be used for either. Other features are as described for the Z member in FIG. 7A.
FIG. 8 shows an alternate method of constructing the floor panel using a pre-cast, reinforced concrete slab 204, reinforced with rods 206, with holes 208 cast into it directly over the holes 22 in the wall tracks 20. In this embodiment, the wall panels are constructed as described at FIG. 1 with studs 16, tracks 20 and reinforcing 24 and 26, except that the screed angle may be eliminated where floor topping is not required. The cementicious wall fill 18 is placed thru the holes 208 in the slab and tracks 20 into the wall panel below and up to the top of the pre-cast slab floor 204. Dowel rods 210, normally of steel, are then inserted into the cementicious fill while it is in the plastic condition and allowed to project up to the next level wall panel. These dowel rods 210 are designed to hold the panels together as a monolitic structure. When the pre-cast floor slab alternative is used, a groove 212 is cast into the top and bottom of the slab within the area of contact of the cement plaster finish 46. The cement plaster 46 penetrates the grooves during placement and thus still provides the important feature of a jointless cell interior. Joints in normal pre-cast concrete construction allow prisoners a place to hide contraband and said joints are also subject to vandalism requiring frequent repair. With this embodiment, all joints in the cell interiors are eliminated.
This invention provides a more economical and quick way to build improved detention structures that have high resistance to escape penetration while maintaining the non-combustible ratings required for fire safety. This invention also provides a means of easily constructing all types of multi-level buildings with efficient multiple function use of materials. It allows simultaneous construction operations with safe construction occupancy of lower levels while structure erection is still underway above. For most wall bearing structures, this invention allows many levels of construction to be built much quicker at a cost savings of at least 25% over standard construction.
The above description shall not be construed as limiting the ways in which this invention may be practiced but shall be inclusive of many other variations that do not depart from the broad interest and intent of the invention.
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A method of constructing multiple story buildings and particularly detention structures as disclosed in which the framing members are lightweight steel channel members which are generally similar and in certain applications, interchangeable. The walls and floors of the building are framed with the channel members and lath sheathing is applied thereto for receiving cementitious fill therebetween. A unique diagonal tension strap system is used whereby diagonal straps are permanently attached at their lower end and tensioned at their upper end with adjustable fasteners before being permanently fastended at the upper end. The system provides for a more rapid and inexpensive construction schedule over conventional construction and affords high resistance to fire and to penetration of the filled walls.
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RELATED APPLICATIONS
[0001] The application claims priority to German Application No. 10 2006 023 447.2, which was filed on May 18, 2006.
BACKGROUND OF THE INVENTION
[0002] The present invention generally relates to an electromechanical clutch. More particularly, but not exclusively, the present invention relates to an electromechanical ball clutch for use in a power driven system such as a motorized tailgate or hatchback door for a vehicle, for example.
[0003] In power driven systems, there is a need to provide a manual back-up mode in case there is a battery failure, for example. Such a manual back-up mode should provide an effort similar to a standard manual system. It is necessary to disengage a drive unit during the manual back-up mode and also when a user wishes to operate the system manually. One way of allowing disengagement of the drive unit is to provide an electromagnetic clutch between mechanical elements, for example between a motor and a reduction unit that benefits from a lower torque provided by the electromagnetic clutch.
[0004] In existing systems, clutching is done by clamping two metal plates together with a magnetic force produced by an electromagnetic coil. The transmitted torque is dependent on a coil pull force and a clutch diameter; i.e., the larger the required torque, the bigger the electromagnetic clutch needs to be. Therefore, in order to have an electromagnetic clutch that transfers a large torque, packaging and weight of the electromagnetic clutch must be increased, which is inconvenient and costly. To reduce the power demand on the electromagnetic coil, a permanent magnet can be added in the electromagnetic clutch to work in conjunction with an electromagnet. The permanent magnetic field of this magnet will then create a permanent drag in the system. When this system is used in a tailgate, for example, this drag can be used to hold the tailgate in an intermediate position without having to keep the power on to power the electromagnetic coil. However, the drag caused by the permanent magnet is very uncomfortable for a user operating a tailgate manually in the event of a power failure because the presence of drag means that it is very difficult to open and close the tailgate.
[0005] The present invention has been devised with the foregoing in mind.
SUMMARY OF THE INVENTION
[0006] Thus, the present invention provides a clutch that includes an input pinion, and an output pinion associated with a rotatable locking member with a surface inclined with respect to an axis of rotation. The surface cooperates with an engagement member, and the rotatable locking member is movable between a first position and a second position. In the first position, the surface forms a recess to receive the engagement member. In the second position, the surface forms a projection to force the engagement member into abutment with the input pinion to establish a driveable connection between the input pinion and the output pinion. The surface amplifies a force that acts on the engagement member, which results in a higher torque that can be transmitted in a small clutch package.
[0007] As the rotatable locking member slides from the first position to the second position, the rotatable locking member provides a recess for the engagement member that evolves into a projection in a smooth movement. This can be achieved by having a locking member with a frustro-conical shape or a substantially conical shape with sides tapering inwards towards an end furthest away from the output pinion.
[0008] In one example, the input pinion comprises a notch to receive the engagement member so that, when the locking member moves into the second position and pushes the engagement member into engagement with the input pinion, the engagement member engages with the notch. The notches permit the clutch to transmit a higher torque in a much smaller package.
[0009] In one example, the locking member and engagement members are ferromagnetic. In this example, the locking member is actuated to move between the first position and the second position by varying a magnetic field. The magnetic field can be provided by an electromagnetic coil. The engagement member can be a ball or a roller.
[0010] In one configuration, the locking member is biased in the first position by a spring, which is compressed as the locking member moves from the first position to the second position.
[0011] In one example, the clutch further comprises a permanent magnet that assists in holding the locking member in the second position. In the second position, which is also referred to as a closed position, there is only a small air gap between the locking member and the permanent magnet so that the permanent magnet pulls or biases the locking member with a relatively high force into the second position. This allows transmission of a high torque. In the first position, which is also referred to as an open position, the permanent magnet does not have sufficient strength to provide a force that can pull the locking member against a spring force. This is due to a large air gap between the locking member and the permanent magnet. However, the permanent magnet does have sufficient strength to hold the engagement members in contact with the locking member and thereby away from the input pinion when the locking member is in the first position. Thus, the addition of a permanent magnet and a spring gives two stable positions to the clutch in the open and closed positions.
[0012] Furthermore, if output of the clutch is maneuvered to reverse the mechanism, a certain amount of torque will be resisted due to the permanent magnetic force and, by virtue of the locking member being connected to the output, the load exerted by both the engagement members to the locking member and a spring compression load will overcome the force of the permanent magnet, and the locking member will return to the open position. To close the clutch again, it is necessary to pass current through the electromagnetic coil in a direction that will generate a magnetic field which, when added to the magnetic field from the permanent magnet, creates a force sufficient to compress the spring such that the locking member moves to the second position and the engagement member is forced into abutment with the input pinion.
[0013] To open the clutch electrically, current is passed through the electromagnetic coil in the opposite direction. A repulsive force is then generated by the electromagnetic coil, which cancels or counteracts that of the permanent magnet, and the spring pushes the locking member back to the first position.
[0014] The clutch is advantageously used in a mechanism moving an aperture such as a tailgate, a trunk lid, a hatchback or a sliding door, for example. When the mechanism is in a normal automatic mode, the mechanism is driven by a motor, and motor torque is transmitted through the clutch. When the motor is stopped, for example in the event of a power failure or if the user wants the aperture to be held in an intermediate position, the electromagnetic coil can be deactivated. The permanent magnet will produce enough force in the clutch to hold the aperture in the position the aperture was in when the current was stopped. In this position, the aperture can be moved electrically or manually. If the aperture is moved manually, a sensor can be provided in the system, which informs a control system of a manual movement. As soon as the movement stops during a defined time, the control system can activate the electromagnetic coil again so that the locking member is returned to the second position and the clutch is closed. Therefore, in the case of battery failure, even in the middle of an automatic maneuver when the clutch is engaged, the manual maneuver will automatically declutch the system and permit a movement with no drag on the clutch.
[0015] Further advantages and characteristics of the invention ensue from the description below, and from the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 a ) is a left side view of a cross-section of a clutch in an open position according to the invention;
[0017] FIG. 1 b ) is a right side view of a cross-section of the clutch in a closed position according to the invention;
[0018] FIG. 2 a ) is a top left view of the clutch in the open position according to the invention; and
[0019] FIG. 2 b ) is a top right view of the clutch in the closed position according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0020] Referring now to FIGS. 1 a )- 1 b ) and 2 a )- 2 b ), a clutch 10 has an input pinion 11 connected to a drive mechanism (not shown), for example an electric motor, which causes the input pinion 11 to rotate. The clutch 10 also has an output pinion 12 that is connected to a moving mechanism (not shown) that moves a tailgate, for example. The output pinion 12 is rotatable about a central axis of rotation A and is arranged to be freely rotatable on a central shaft. The input pinion 11 is provided with notches 19 .
[0021] Associated with the output pinion 12 is a frustro-conical locking member 14 that has an inclined surface. The locking member 14 is also rotatable about the central axis of rotation A and is arranged rotatably on the central shaft to be capable of rotating synchronously with the output pinion 12 . The inclined surface of the locking member 14 tapers inwards towards the end of the locking member 14 furthest away from the output pinion 12 . A plurality of engagement members 13 is arranged between an inner surface of the input pinion 11 that has the notches 19 and a conical surface of the locking member 14 . In this example, the engagement members 13 are formed as balls. In order to accommodate the balls, the output pinion 12 has fork-like structures or holes so that the balls are entrained rotationally when the output pinion 12 is rotated.
[0022] The locking member 14 is displaceable on the central shaft in a direction that is axial with respect to the central axis of rotation A between a first position that is shown in FIG. 1 a ) and which is referred to as the open position, and a second position that is shown in FIG. 1 b ) and which is referred to as the closed position.
[0023] In the first position, the engagement members 13 are in contact with a portion of the inclined surface that has a small diameter. This portion acts like a recess that allows the engagement members 13 to occupy a position that is close to the central axis of rotation A and spaced from the inner surface of the input pinion 11 . In the second position, the engagement members 13 are in contact with a portion of the inclined surface that has a large diameter. This portion acts like a projection that urges the engagement members 13 radially outwards against the inner surface of the input pinion 11 .
[0024] A spring 16 is positioned underneath the locking member 14 to bias the locking member 14 into the first position. Further, an electromagnetic coil 15 is provided adjacent to the spring 16 , and a permanent magnet 17 is arranged underneath the spring 16 and the electromagnetic coil 15 . As the engagement members 13 and locking member 14 are made from a ferromagnetic material, the engagement members 13 are held spaced from the notches 19 of the output pinion 12 and in contact with the inclined surface when the locking member 14 is in the first position.
[0025] When the moving mechanism is idle, the clutch 10 is in the open position, as shown in FIGS. 1 a ) and 2 a ). The locking member 14 is biased by the spring 16 so that the locking member 14 is in a raised position. This causes the engagement members 13 abutting the locking member 14 to be in contact with a lower part of the locking member 14 towards an apex of the inclined surface. A magnetic loop passing through a housing, the engagement members 13 and the locking member 14 ensures that the engagement members 13 remain in contact with the lower part of the locking member 14 . It can be seen that a lower part of a surface of the locking member 14 provides a recess into which the engagement members 13 fit. Thus, when the locking member 14 is in the raised position, the engagement members 13 are held away from and out of contact with the input pinion 11 , and the input pinion 11 is free to rotate.
[0026] When it is required to operate the moving mechanism and close the clutch 10 , as shown in FIGS. 1 b ) and 2 b ), an electric current is applied to the electromagnetic coil 15 . The electromagnetic field produced by the electromagnetic coil 15 then acts on the locking member 14 , which slides downwards in a direction parallel to the central axis of rotation A of the clutch 10 , thereby compressing the spring 16 . As the locking member 14 moves downwards, the locking member 14 slides against the engagement members 13 , pushing them outwards. The locking member 14 thus forces the engagement members 13 towards the input pinion 11 , by virtue of the surface of the locking member 14 being inclined outwards towards a top of the locking member 14 so as to form a wedge. Thus, the surface of the locking member 14 changes from forming a recess to forming a projection. At a maximum compression of the spring 16 , the locking member 14 is at its lowest point with respect to the central axis of rotation A and maximum projection with respect to the engagement members 13 . At this point, the surface of the locking member 14 forces the engagement members 13 into contact with input pinion 11 and then into the notches 19 provided on a circumference of the input pinion 11 .
[0027] Thus, as the input pinion 11 rotates, the engagement members 13 are entrained into a rotational movement as they are engaged into the notches 19 . The rotation of the engagement members 13 is transmitted, as the engagement members 13 are accommodated in holes or fork-like configurations of the output pinion 12 , to the output pinion 12 as the locking member 14 prevents the engagement members 13 from escaping from the notches 19 of the input pinion 11 . Finally, the moving mechanism is driven.
[0028] The notches 19 provided in the input pinion 11 permit the clutch 10 to have a higher transmitting torque in a much smaller package. The torque transmitted from the input pinion 11 to the output pinion 12 is dependent on the magnetic field generated by the electromagnetic coil 15 ; i.e., the coil pull force, the angle of inclination of the surface of the locking member 14 and the diameter of the engagement members 13 .
[0029] The permanent magnet 17 is provided to reduce the required size of the electromagnetic coil 15 and to maintain the clutched position when power is off and forces applied to the clutch 10 are below a limit constituted by the torque plus the spring force tending to declutch. When the clutch 10 is closed, the force provided by the permanent magnet 17 pulls the locking member 14 with a force higher than the compression force of the spring 16 due to a small air gap 18 b (about 0.2 mm), which permits the magnetic field to pass through the locking member 14 . When the clutch 10 is open, the strength of the permanent magnet 17 is not sufficient to generate a force large enough to pull the locking member 14 downwards against the force of the spring 16 . However, the strength of the field from the permanent magnet 17 is sufficient to pass through the engagement members 13 to keep them away from the input pinion 11 .
[0030] If power to the electromagnetic coil 15 is cut, or if it is required to operate the moving mechanism manually, the moving mechanism connected to the output pinion 12 can be maneuvered manually. This places a certain torque on the output pinion 12 while the input pinion 11 is braked by motor and gear, for example. The tendency of the output pinion 12 to rotate biases the engagement members 13 out of the notches 19 , resulting in a force that acts on the inclined surface of the locking member 14 in a radial direction. As a result of the inclination of the inclined surface, the radially acting force provides an axial component, which can make the locking member 14 overcome the holding force of the permanent magnet 17 . This causes the locking member 14 to slide up to the raised position, the engagement members 13 to move away from the input pinion 11 , and the clutch 10 to open so that the moving mechanism is no longer connected to the drive mechanism. The clutch 10 can also be opened electrically by passing current through the electromagnetic coil 15 in the opposite direction that causes the clutch 10 to close. This cancels out, or counteracts, the force of the permanent magnet 17 , and the spring 16 can then push the locking member 14 to the raised position such that the engagement members 13 are brought out of contact with the input pinion 11 .
[0031] Although the present invention has been described hereinabove with reference to specific embodiments, it is not limited to these embodiments and no doubt alternatives will occur to the skilled person that lie within the scope of the invention as claimed.
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A clutch comprises an input pinion and an output pinion associated with a rotatable locking member that has a surface inclined with respect to an axis of rotation of the locking member. The surface cooperates with an engagement member, and the locking member is movable between a first position and a second position. In the first position, the surface forms a recess to receive the engagement member, and in the second position, the surface forms a projection to force the engagement member into abutment with the input pinion to establish a driveable connection between the input pinion and the output pinion.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
TECHNICAL FIELD OF THE INVENTION
The present invention relates to structural bearings. In particular, but not exclusively the invention relates to bridge bearings.
For convenience, the invention is hereinafter described with particular reference to bridge bearings but it is to be understood that the invention is applicable to other structural bearings.
BACKGROUND OF THE INVENTION
Structural bearings are intended to be interposed between a support and a member such as a slab or beam supported thereby. The structural bearing absorbs relative movement between the support and the beam or slab. Such movement may be caused by, for example, temperature changes, curing shrinkage of concrete, or settling of foundations. The movement may be horizontal displacement of the slab or beam and/or rotational movement of the slab or beam about a horizontal axis.
A first known type of bridge bearing is in the form of a monolithic block consisting of a stack of parallel metal plates, which in use of the bearing are horizontal, embedded in rubber. Layers of rubber separate each two adjacent plates and cover the top plate and the bottom plate. Also rubber completely covers the edges of the plates. Thus there are no exposed surface areas of the metal plates and the metal plates are protected against rusting or other corrosion. In use of the bearing the layers of rubber deform to absorb relative movement between the support and the beam or slab and the metal plates resist excessive laterally outwards or horizontal deformation of the rubber. The bearing is manufactured by making a stack of the metal plates and unvulcanized rubber sheets, the rubber sheets being disposed between each pair of adjacent metal plates and below the bottom plate and above the top plate. The stack of metal plates and rubber sheets is then subjected to pressure (applied to the top and bottom of the stack) and to heat to cause the rubber to vulcanize and to cause the rubber to form an integral body containing the metal sheets. Disadvantages of this vulcanization process are that the layers of rubber between the metal plates tend to be of variable uncontrolled thicknesses and it is difficult to ensure that the rubber at the interior of the bearing is satisfactorily vulcanized and the rubber adjacent the exterior of the bearing is not overvulcanized. A further disadvantage is that the vulcanization process has to be carried out slowly to control, as far as possible, the degree of vulcanization throughout the bearing. Consequently the rate of production of the bearing is slow and, in view of the capital cost of the necessary vulcanization equipment, costly. Another disadvantage is that the bridge bearing has to be made as a single unit of the desired size.
The aforementioned disadvantages are overcome or mitigated by a second type of bridge bearing, such as disclosed in British patent specification No. 1,192,744 (originally in the name of Silent Channel Products Limited). This bridge bearing comprises a stack of modular elements, namely an upper modular element, one or more intermediate modular elements and a lower modular element. The or each intermediate element has a layer of rubber adhered to and interposed between two metal plates. The upper element has a layer of rubber on top of and adhered to a metal plate and the lower element similarly has a layer of rubber below and adhered to a metal plate. The plates are provided with holes in which are located circular members such as rings or discs which key together the adjacent metal plates of adjacent elements, each circular member being located in corresponding holes in both of the plates. To prevent relative rotation of each two keyed together plates, it is necessary that at least two of the circular members are used to key together the plates. The layers of rubber overlap the metal plates and extend around and are adhered to the edges of the metal plates but the opposed faces of the metal plates of adjacent elements are free of rubber. Since the edges of the plates are covered by rubber, the metal plates are effectively encased by rubber and protected against corrosion. The elements after manufacture can be assembled into a bridge bearing of the desired height by using a selected number of intermediate elements. However, one disadvantage of the bearing is that moisture can penetrate between adjacent elements and cause corrosion of the metal plates at their surfaces not covered by rubber. Another disadvantage is that when the rubber has a tendency to break away from the edges of the plates when the bearing is under load and the rubber layers are being compressed and deformed laterally and outwardly. Yet another disadvantage is that the exposed metal surfaces of the elements tend to corrode on storage prior to assembly to form the bridge bearing.
The disadvantages referred to above are overcome or mitigated by a third type of bridge bearing disclosed in British patent specification No. 2,054,092A (Dixon International Limited). In this type of bridge bearing, both the upper and lower surfaces and the edge of each metal plate are covered by rubber.
It is normal with bridge bearings of the second and third types to adhere the assembled elements together prior to installation in a bridge structure. The purpose of this is to facilitate handling of the bearing and to prevent the bearing coming apart and the keying members, which are essential, being lost or not replaced in the bearing.
The intermediate elements of the second types of bridge bearing are manufactured by locating the lower metal plate of the element on the bottom mould plate of a press, placing a plurality of sheets of rubber on the lower metal plate, and locating the upper metal plate on the top mould plate of the press, the upper metal plate being held against the top mould plate by magnets. Both the lower and upper metal plates are accurately located by pins on the bottom and top mould plates, respectively mounted on the upper and lower platens of the press, the pins engaging in openings in the plate. The press is then operated to compress the sheets of rubber between the plates and to heat and vulcanize the rubber.
The intermediate element of the third type of bridge bearing is manufactured similarly to the intermediate element of the second type of bridge bearing but, in addition, sheets of rubber are placed between the bottom mould plate and the lower metal plate and between the upper metal plate and the top mould plate.
The upper and lower elements are also manufactured similarly in a press, but only one metal plate is used in each element.
Although in the manufacture of the intermediate elements of both the second and third types of bridge bearings the upper and lower plates can be accurately located, the locating of the upper plate tends to be time consuming. Moreover if the upper plate is curved or otherwise deformed from a planar state, as not infrequently happens, (due to e.g. metal surface treatments, such as shot-blasting, for the purpose of preparing the metal surface to achieve good mechanical bonding with the rubber) the plate cannot be held securely to the upper mould plate by the magnets and may become displaced from its desired position.
Moreover, with both the second and third types of bridge bearing it is necessary to manufacture the upper and lower elements (which may be identical) in addition to the intermediate elements.
DESCRIPTION OF THE INVENTION
This invention aims to overcome the aforementioned disadvantages.
In accordance with the first aspect of the present invention, there is provided a method of manufacturing a modular element for a bridge bearing or other structural bearing comprising: providing a press having relatively movable upper and lower members, the lower member having one or more upstanding posts or pins; positioning on the lower member, successively, one or more rubber sheets, a lower metal plate, one or more rubber sheets, an upper metal plate and one or more rubber sheets, the one or more posts or pins extending through holes in the metal plates and the rubber sheets and locating the metal plates to prevent lateral movement thereof; operating the press to move the upper and lower members together and to subject the rubber sheets to pressure and subjecting the rubber sheets to heat to effect vulcanization of the rubber and to bond the rubber to the metal plates whereby an intermediate layer of rubber is formed between the two plates and the upper and lower layers of rubber are formed respectively above and below the upper and lower plates, the rubber deforming around and bonding to the edges of the metal plates, whereby the plates become completely encased in rubber; removing the resulting modular element from the press; and inserting a vulcanised rubber plug into the or each of the holes left by the one or more posts or pins. Preferably the posts of the lower member of the press and the holes of the metal plates are so relatively dimensioned that a rubber flash is formed around the edges of the holes in the plates and connects the upper and lower layers of rubber with the intermediate layer of rubber between the plates.
Because all surfaces of the metal plates are covered by rubber, an individual modular element prepared by the method of the invention may be used as a bridge bearing. Normally however a plurality of such modular elements would be made into a stack, the adjacent metal plates of adjacent modular elements being keyed together by metal members inserted into the holes of the plates.
The rubber plugs are required in order to prevent stress on the rubber surrounding the holes in the intermediate layer of rubber, in use of the bridge bearing.
The rubber plugs need only be of a thickness equal to that of the intermediate layer of rubber. This leaves the opening in the metal plates free to receive the keying member or a dowel of structural part of a bridge with which the bearing engages. However, where one of the surfaces of the modular element is to engage a structural part of a bridge and be held in position by friction only, the plug preferably is flush with that surface of the modular element.
In a second aspect, the present invention provides a bridge or other building structure having a structural member and support therefor, between the structural member and the support there being interposed a single modular element manufactured by the method of the invention, the modular element being in contact with both the structural member and the support.
In a third aspect, the present invention provides a bridge bearing or other structural bearing comprising a stack of modular elements manufactured by the method of the invention, the modular elements being adhered together ready for installation in a bridge or other building structure, the upper and lower surfaces of the upper and lower modular elements respectively being exposed for contact with respectively a structural member and a support therefor of the structure.
It will be appreciated that modular elements produced by the method according to the invention can be stored indefinitely without corrosion of the metal plates and used singly as structural bearings or assembled when required into structural bearings comprising a desired number of the modular elements.
The invention is further described below by way of example with reference to the accompanying drawings, wherein:
FIG. 1 is a sectional view through a press for use in the process of the invention, and showing a modular element being manufactured;
FIG. 2 is a section view of a modular element according to the invention;
FIG. 3 is a plan view of a modular element according to the invention;
FIG. 4 is a sectional view through a bridge bearing according to the invention; and
FIG. 5 is a sectional view, partly exploded, of a further bridge bearing according to the invention.
Referring to the drawings, for manufacturing bridge bearings according to the invention a press (FIG. 1) is provided having a fixed platen 1 and a vertically movable platen 2. Mounted on the platen 1 are the bottom plate 20 of a mould and two upstanding locating posts or pins 3. Mounted on the platen 2 is the top plate 21 of the mould.
In use of the press to manufacture a modular element for a bridge bearing, successively one or more rubber sheets 4, a metal plate 5, a plurality of rubber sheets 6, a metal plate 7 and one or more rubber sheets 8 are placed on the platen 1. The rubber sheets and the plates each have two holes through which fit the posts 3.
The press is then closed, the top platen being brought down so that the top and bottom plates of the mould meet to apply pressure to the rubber sheets and the metal plates, and the platens being heated so that heat is applied to the rubber sheets and the metal plates in order to vulcanize the rubber and cause the rubber to adhere to the metal plates. The rubber sheets are vulcanized together to form a layer of rubber 9 (FIG. 2) below the metal plate 5, a layer of rubber 10 between the metal plates 5 and 7 and a layer of rubber 11 above the metal plate 7. The mould, when closed, defines a mould cavity larger in area than the metal plates 5 and 7 and thus the rubber forms a surround 12 integral with the rubber layers 9, 10 and 11 and covering the edges of the plates. The holes in the metal plates are slightly larger in diameter than the posts 3. Consequently the rubber penetrates into the holes in the plates and forms fillets or a flash (not shown in the drawings) interconnecting the rubber layers 9 and 10 and 11 and covering the edges of the metal plates 5 and 7.
The press is then opened and the element thereby formed is withdrawn. Vulcanized rubber plugs 13 are inserted into the holes in the layer 10. The plugs 13 are a push fit in the holes.
The rubber element thus formed may be used alone as a bridge or other structural bearing. The plugs 13 may be the same thickness as the intermediate rubber layer 12, so that recesses 15 are defined at the top and bottom of the bridge bearing to receive dowels or spigots embedded in the two structural members between which the bearing is located.
A bridge or other structural bearing may alternatively be formed by making a stack of two or more of the modular elements (FIG. 4) with the recess 15 of adjacent elements in register, the modular elements being keyed together by circular metal discs 16 located in the recesses 15, and in particular located in the holes in the metal plates 5 and 7, a single one of the discs being located in each two registering recesses 15. For convenience of transport and handling the modular elements are adhered together.
The bridge bearing is located between two structural members 101 and 102, such as a bridge support and a bridge beam and located by dowels 103 embedded in the structural members and engaged in the recesses 15 at the top and bottom of the bridge bearing.
In a modification of the bridge bearing of FIG. 2, the plugs 13 may be of increased thickness and extend to the top and/or bottom face of the bridge bearing. (However, the plugs must be at least coextensive in thickness with the intermediate layer 10 of the bearing). The bridge bearing is then held located, at the relevant face or faces, or the structural member solely by friction, no dowels being used.
FIG. 5 shows a modification of the bridge bearing of FIG. 4. Referring to FIG. 5, the plugs 13 of the top modular element are of increased thickness and extend to the top face of that element. The bearing is then held located at its top face, with respect to the structural member 102, solely by friction, no dowels being used. Also (although not as shown in FIG. 5) the plugs 13 of the bottom modular element may be of increased thickness and extend to the bottom face of that element. The bridge bearing is then held located on the structural element 101 solely by friction, no dowels being used. In both cases, of course, the plugs 13 must be coextensive in thickness with the intermediate layer 10 of the top and bottom modular elements.
In use of the bridge bearings described above, the plugs 13 are necessary to avoid internal stress around the holes left by the posts 3. Without the plugs 13, the rubber around the holes might split or crack and lose its adherence with the plates 5 and 7.
It will be appreciated that in the modular elements according to the invention described above, the entire surfaces of the netal plates are covered by rubber. Hence the modular elements can be stored indefinitely without corrosion of the metal plates before use as or in bridge bearings and without application of preservative which would need to be subsequently removed. Moreover an individual modular element can be used as a bridge bearing or a plurality of such elements can be assembled into a bridge bearing, the bridge bearing consisting solely of like (substantially identical) modular elements, apart possibly from plugs of increased thickness in the top and/or bottom elements. There is moreover no metal-to-metal contact in the bearings.
In addition, the bridge bearings according to the invention, whether consisting of only one modular element or of a plurality of modular elements comply with B.S.I. Technical Memorandum B 1/76, which requires all metal parts of bridge bearings to be completely encased in rubber.
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A modular element for a bridge or structural bearing having metal plates encased within layers of vulcanized rubber is formed in a press including a lower member with at least one post or pin extending upwardly through corresponding holes in the metal plates. A vulcanized rubber plug is inserted and retained in each hole in the modular element after it is removed from the press.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
This invention relates generally to toilets and more specifically to those toilets that can remove waste from the bowl using a reduced amount of water.
In gravity feed toilets, such as are used in most residential homes and many buildings, a storage tank is prefilled from the water supply to a predetermined level and is controlled by a float actuated valve. When the toilet is flushed, a flush valve in the tank opens, releasing water to the toilet bowl. A siphon connects the lowermost "sump" portion of the toilet bowl to a drain pipe allowing the flushing water and waste to exit the toilet bowl. See e.g. U.S. Pat. No. 4,232,410.
However, an effective flushing process requires much more than simply adding water to the toilet bowl. Without a forceful siphon action, added water simply dilutes the waste. Accordingly, an effective flushing process comprises a series of stages.
During the first "siphoning" stage, a water jet, often, at least in part, from a separate orifice in the bowl positioned near the sump, imparts its momentum to the standing water and waste in the sump. See e.g. U.S. Pat. No. 3,131,402. This causes a first slug of water and waste, sufficient in amount to block the backflow of air, to proceed into the upleg of the siphon and over its verge to establish siphon action. The downleg of the siphon, attached to the drain pipe, is designed to insure that the siphon action continues until the original standing water and waste are completely drained. Continued application of more water prevents backwash from the siphon into the bowl when the siphon is broken.
The second "cleaning" stage, sometimes overlapping with the siphoning stage, involves the scrubbing of the sides of the bowl, usually by a series of cleaning streams of water directed downward into the bowl from the bowl's rim. Both the water jet and the cleaning streams are typically supplied by the stored water in the tank.
A third "seal recovery" stage refills the bowl to establish a seal of water. This water is sometimes provided directly from the water supply, the water in the tank having been exhausted during the earlier stage(s), and comes from diverting a small percentage of the water used to refill the tank directly into the bowl. For this reason, the amount of water used during seal recovery stage can be dependent on the time the tank takes to refill, a time that is often longer than optimal.
Increased interest in water conservation has led to the development of water conserving toilets which use less water, during each flush, than standard toilets. A standard residential toilet may use three and one-half gallons per flush, compared to a water conserving toilet which may reduce this amount by about half.
The amount of water needed for the "cleaning" and "seal recovery" stages of the flushing process can to some extent be reduced by controlling the size of the tank and bowl. Reducing the amount of water used in the "siphoning" stage, however, is more difficult because a minimum amount of water is normally required to achieve sufficient momentum to ensure reliable and complete emptying of the waste and water from the bowl. Reducing the flow of water during the siphoning stage of the flushing process may cause incomplete flushing.
Some solutions have involved the use of complex and relatively expensive systems in the tank to pressurize the water. Other solutions have relied on reducing water usage by techniques that significantly reduce the cleaning capacity of the bowl. In practice, users will often flush such toilets twice to achieve the desired waste removal. Other solutions made the front of the bowl appear very shallow, which gave a user the feeling that splashing might occur. Thus, a need exists for an improved low cost water conservation toilet.
SUMMARY OF THE INVENTION
The present invention provides a water conserving toilet that generates a reliable siphon action.
Specifically, the toilet has a bowl with an upper lip and a lower wall having a sump at its base. The sump is connected through a bowl outlet to a siphon for the discharge of a cleaning liquid and waste. A hollow rim, receiving the cleaning liquid, has a first and second hole in its floor and is attached to the bowl so that the cleaning liquid may pass through the holes from the rim to the bowl. The second hole is in a plateau and opens into the rim at a higher level than the first hole.
It is thus one object of the invention to provide a toilet where ample water is provided to siphon initiating jet holes, without unduly interfering with the water flowing through the other holes during the "cleaning" and "seal recovery" stages. Another object is to use a plateau structure to achieve an effective, low cost water conserving toilet.
It is yet another object of the invention to maximize the effectiveness of the flushing water, in a toilet of the above kind. This is achieved by venting air trapped within the rim through a unique multi-plateau vent, and by a focusing channel in the bowl floor.
These and other objects and advantages of the invention will be apparent from the description that follows. In the description reference is made to the accompanying drawings which form a part hereof and in which there is shown by way of illustration a preferred embodiment of the invention. Such embodiment does not necessarily represent the full scope of the invention however and reference is made therefore to the claims herein for interpreting the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a preferred water conserving toilet of the present invention;
FIG. 2 is an elevational cross-section of the toilet of FIG. 1, taken along line 2--2 of FIG. 1, showing the toilet shortly after the start of the flushing process;
FIG. 3 is a top plan, cross-sectional view of the front of the rim of FIG. 2, taken along line 3--3 of FIG. 1, showing a vent hole and an enlarged set of four holes on a multi-plateau boss;
FIG. 4 is a vertical cross-section of the portion of the rim shown in FIG. 3, taken along curved line 4--4 of FIG. 3; and
FIG. 5 is a plan view of the rim and bowl of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, a toilet 10 that conserves cleaning liquid (normally water) has a tank 12 connected to a water supply (not shown) to store water 13 between the flushing cycles of the toilet 10. The filling of the tank 12 is by processes well known in the art (e.g. a float activated inlet valve). The tank 12 is positioned on a shelf 15 at the rear, and above, an upwardly facing bowl 16. As is well known, the tank could instead be integrally formed with the bowl. The bowl 16 is surrounded at its upper lip by a hollow rim 18.
A flush lever 14 on the tank 12 allows the toilet 10 to be flushed in the conventional manner. A skirt 20 generally supports the underside of the bowl 16 and hides a siphon trapway 22 at its rear. The siphon trapway 22 provides a passage from the bowl 16 to a vertical drain pipe (not shown) in the floor. If desired, the drain could also be formed towards a wall behind the toilet.
Referring to FIG. 2, the tank 12 has an opening 24 in its bottom wall matched to a similar opening 26 in the upper surface of the shelf 15 of the rim 18. A conventional flapper valve 28 blocks the passage formed by openings 24 and 26 in the usual manner, and is held in place over the opening 24 by the pressure of the water 13 within tank 12. As is well known, flapper valve 28 may be lifted by means of a chain (not shown) attached between the flapper valve 28 and the flush lever 14.
Beneath opening 26 in shelf 15 is a receiving chamber or entry passage 29. Water 13 passing from tank 12 through openings 24 and 26, and strikes floor 30 of the receiving chamber 29 which is sloped beneath the opening 26. This redirects the velocity of water towards the rim 18, minimizing the water's loss of momentum through turbulence (such as might be caused if floor 30 were all horizontal).
The receiving chamber 29 communicates at its front edge with the rim 18 so as to direct water along both sides of the bowl (in both a clockwise and counter-clockwise direction about the interior of rim 18) toward the front of the toilet 10.
The rim 18 has a generally rectangular cross section, on the sides of the bowl, and the lower side of the rim forms a floor 32. FIG. 5 shows that floor 32 is perforated by a plurality of holes 34, 36 and 38. The rim 18 is mounted so that the floor 32 projects inward over the bowl 16 to allow the water passing from inside the rim 18 through holes 34, 36 and 38 to flow down the inner surfaces of the bowl 16. Holes 34 produce cleaning streams 72, whereas holes 38 and 36 produce a siphon initiating jet 66 and shepherding streams 68.
Referring again to FIG. 2, the lowermost portion of bowl 16 forms a sump 40. The sump 40 is a steep depression in the inner surface of bowl 16 intended to concentrate solid waste within its volume. Sump 40 communicates with the siphon trapway 22 having a upleg 46 passing over trap verge 48 and connecting to a downleg 50 communicating with the floor drain 52. Prior to flushing the toilet 10, the sump 40 is filled with water to level 55 generally defined by the height of the trap 48. Additional water added to the bowl 16, that would raise the water level above level 55, passes over the trap verge 48 to the floor drain 52. The water in the sump 40 seals the siphon trapway 22 as is well known.
During the initial stage of the flush process, flapper valve 28 is raised by a chain attached to the flush lever 14 allowing water 13 from the tank 12 to pass down into the receiving chamber 29. The water passing through openings 24 and 26 initially strikes the sloped floor 30 of the receiving chamber 29 and is then propelled forcefully forward into the rim 18. Referring also to FIG. 5, the water from the receiving chamber 29 passes into the rim 18, as shown by arrows 54, to travel through the rim 18 in both a clockwise and counter-clockwise direction.
During this stage of the flush, the water passes with great speed to the front of the rim 18 with very little exiting through holes 34. A peak water level 56 may be identified based on the usual rest volume of the water in tank 12, the volume of the rim 18 and receiving chambers 29, and the dynamic properties of the water flowing out into the bowl 16 through the holes 34, 36 and 38.
Referring now to FIGS. 3 and 4, a multi-plateau boss 58 rises above the floor 32 of the rim 18. Two vent holes 60, cut through the boss 58, provide a passage from inside the rim 18, above the peak water level 56, to outside the rim 18 beneath the floor 32 to the bowl 16. These holes 60 allow the passage of air 61 from inside the rim 18 to outside of the rim 18, unobstructed by flowing water. In particular, during the initial rush of water from the receiving chamber 29, a high flow rate of water from the tank 12 through the receiving chamber 29 and into the rim 18 is critical to producing an initial surge of water that will quickly create the needed siphon initiating jet stream 66. However, air must exit the rim for this to occur. The exiting air can, if not properly vented, delay needed water from reaching the front exit hole.
Note that the boss 58 is positioned within the rim 18 opposite the receiving chamber 29 and approximating the point at which the bifurcated streams of water from the receiving chamber 29 meet after passing in counter-clockwise and clockwise direction through the rim 18.
The second plateau 62 on the boss rises from the floor 32 of the rim 18 and holds the set of holes 36 and 38 that are used to create the siphon initiating jet stream 66. The radii of holes 36 and 38 are substantially larger than the radius of holes 34.
The holes 36 and 38 are positioned on the plateau 62 so that they open within the rim 18 at a threshold height 63 above the floor 32, but lower than the peak water level 56. When water fills the rim 18 from the tank 12 during the flush, the water should exceed the height of the plateau 62 for the siphoning stage, allowing water to flow through holes 36 and 38. Later during the cleaning stage of the flushing process, when the siphon inducing jet stream 66 is not needed, the water level within the rim 18 will have dropped below the threshold height 63 and water will abruptly cease flowing through holes 36 and 38. This quick shut off optimizes water usage.
In this regard, the sides of the plateaus are substantially vertical. Thus, not only does the water flowing through holes 36 and 38 stop relatively abruptly at the end of the siphoning stage, but for the period of time during the cleaning and seal recovery stages, when the water is below the height 63, the holes 34, not on the boss, remain covered by an ample height of water. This insures substantially equal flow 72 among the holes 34 for a period of time.
Referring to FIGS. 2, 3 and 4, plateau 62 is centered along a longitudinal discharge axis 64. Preferably this is the same axis that the water from the bowl 16 follows into the upleg 46 of the siphon trapway 22. The vector 65 describes the vector of momentum which must be absorbed from the jet stream 66 by the water and waste in the sump 40, to best accelerate that water and waste in a sufficient slug up into the siphon 42. Accordingly, water flowing through holes within the boss 62, down the bowl 16, is positioned to provide the desired high momentum jet stream 66.
As mentioned, holes 38 are larger than holes 36. This insures that the jet streams 66 can promptly start the siphon action for the siphoning stage of the flush. Holes 38 are positioned closest to the discharge axis 64 and symmetrically on either side of the discharge axis 64 to best align the momentum of the jet stream 66 with the discharge axis 64. Flanking the holes 38, and are further removed from the discharge axis 64, are smaller diametered holes 36. Holes 36 create shepherding streams of water 68 which serve to contain the spread of the jet streams 66 and thus to focus the jet streams 66 into a single high momentum jet. It has been determined that the smaller radius of the holes 36, still larger than holes 34, provides a savings in water without substantially reducing the effectiveness of this shepherding.
Referring to FIG. 5, for ease of manufacturing, the holes 36 are cut straight through the lower plateau 63 and thus do not provide significant direction to the shepherding streams 68. Nevertheless, the shepherding streams 68 angle in towards the streams 66 and the discharge axis 64 to perform the shepherding function, both because of the retained momentum of the rushing of the water through the rim 18 and the increased component of inward curvature of the bowl 16 with the displacement of the shepherding streams 68 from the discharge axis 64.
The combined streams 66 and 68 are focused into an even more concentrated jet 73 by focusing groove 70. Preferably the groove is in converging form (e.g., a V-shape trough). The groove extends from a point just below the seal recovery water level 55 to the sump 40. The depression of the focusing groove 70 diverts the cleaning streams 72 from holes 34, concurrent with the jet and shepherding streams 66 and 68, to a direction more perpendicular to the discharge axis 64, thus serving to compress the flow of streams 66 and 68 at groove 70 into a compact, high momentum jet 73. This compact jet 73, impinging upon the water and waste collected in sump 40, insures that a substantial volume of water is accelerated up the upleg 46 of the siphon trapway 22 and down the downleg 50.
Once the siphoning stage of the flushing process is complete, water drains in cleaning streams 72 out of the rim 18, through holes 34 only. This is because the water level in the rim 18 will have dropped below the threshold height 63 of plateau 62. The prevention of additional flow of water out of holes 36 and 38 by plateau 62 ensures that a sufficient volume of water for the cleaning and seal recovery stages will be available through holes 34, without the use of additional water from the supply lines feeding the toilet 10, as is conventionally done in standard toilets.
The water used during the cleaning and seal recovery stages of the flushing process is controlled by adjusting the volume in the rim 18 between the floor 32 and the threshold height 63. In a standard toilet, in which water for the cleaning and seal recovery is obtained from the supply lines during the refilling of tank 12, this volume of water used during these stages is not well controlled, causing wasted water.
Likewise, the water used during the siphoning stage of the flushing process may be accurately determined by adjusting the distance between the peak water height 56 and the top of boss 62 so as to ensure that just enough water is present in rim 18 to provide adequate siphoning action.
While a preferred embodiment of the invention has been described, but it should be apparent to those skilled in the art that many variations can be made without departing from the spirit of the invention.
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A water conserving toilet having a set of holes around the rim to provide a washing of the bowl includes enlarged holes towards the front of the rim to create a focused jet of water used to initiate siphon action. The enlarged holes are positioned on an elevated multi-plateau boss within the rim. The boss extends beyond the highest normal level of water in the rim and has a vent to vent air from the rim. A sloped entry within the receiving chamber connects the tank of the toilet to the rim to further increase the momentum of this water. The jet from the enlarged front holes in the rim is further focused by a groove extending on the bowl's lower wall.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
[0001] This invention has to do with a measuring tool for use in the construction profession with particular applicability to finish carpentry, framing carpentry, wall layout, drywall installation, fitting countertops, piping layouts, floor and ceiling installations and cabinetry. It also has direct applications in the graphic arts field, the engineering and drafting fields and other manufacturing situations where angle measurements are performed. This invention has direct applications in virtually every situation requiring an angle measurement, and it has a multitude of professional and household applications, providing precise angle readings for any carpentry project and any other project that requires angle measurement, angle copying, angle transferring, and/or angle projection. Such projection of an angle may be accomplished with a laser, scope or other means of projecting or sighting to a distant point, line, plane or planes.
[0002] This invention is used in the fitting of trim and decorative pieces, or any material, to the surface of wall surfaces, or any surfaces, which meet at an angular junction. This angular junction is commonly referred to as a miter joint. A miter saw/miter box is used to cut the trim and decorative pieces, or any material, in a precise manner so that a clean and accurate miter joint is established.
[0003] The invention is also used for fitting single pieces of trim, or any material, into any angle that is encountered. A miter saw/miter box is used to cut the material in a precise manner so that a clean and accurate fit is established between the freshly cut piece and the work surface(s).
[0004] In addition to the above-mentioned functions, which are specific to the angle scale that is virtually universal to the miter saw/miter box, this invention also has scales for determining the actual angle, or any interpretation of the actual angle, throughout an entire revolution (zero degrees through 360 degrees).
[0005] This invention has additional scales for determining, transferring and laying out the angles for common roof pitches. In the preferred embodiment, these scales are laid out in the standard “inches of rise per lineal foot.” The indicated roof pitch is simultaneously converted to a protractor or miter saw/miter box setting.
[0006] This invention also has scales for determining, transferring and laying out gradients. In the preferred embodiment, the slopes (grades) are presented for reading in percentages wherein 0% slope is horizontal and 100% slope is a 45° angle with respect to horizontal.
[0007] While a miter saw/miter box is the preferred and generally most accurate way to achieve the angled cuts determined by the invention, other means such as a hand saw, hand-held circular saw, radial arm saw, table saw, jig saw and any other means for achieving the determined cuts are contemplated by the inventor.
[0008] This invention has a laser/scope accessory and provision is made for said laser/scope accessory to be attached to the invention. The union of this invention with the laser/scope accessory provides a means for projecting any angle setting from a chosen point of origin along the angle chosen and out to a distance limited only by the power of the laser/scope. Such a laser/scope projection is useful in the layout of walls and construction angles, regardless of what plane they are in. Such a laser/scope projection is also useful in the electrical, plumbing, drywall and landscaping fields, as well as any trade or endeavor that requires the accurate determination, and/or projection, of any angle. It should be understood that a laser/scope, or lasers/scopes, might also be incorporated in the body of the tool as a permanent fixture(s). All such alternative means for employing a laser(s), scope(s) or other means of projecting or sighting on the measuring tool are contemplated by the inventor.
BRIEF SUMMARY OF THE INVENTION
[0009] It is an object of this invention to provide an easy to use tool to transfer angle readings from a work place surface(s) to a miter saw/miter box, to any other cutting device, or directly to any work piece, in a one-step operation.
[0010] It is a further object of this invention to measure and/or project with a laser, scope or other means, an angle, its complementary angle, its supplementary angle, common roof pitch angles, gradients and/or any angle measurement to which the several scales might be adapted. In the preferred embodiment all of these angle measurements are measured and projected simultaneously.
[0011] In the preferred embodiment of the invention an angle measurement tool is provided that in its final form has two interacting legs and a plurality of interacting gears. The first of the two legs has a fixed gear assembly at the axis of the two interacting legs. The second leg has one or more gears which are driven by the aforementioned fixed gear assembly on the first leg. One or more of these gears serve as dials for the purpose of displaying and reading a variety of angle measurements. Both of the legs and those gears employed as dials have a plurality of scale measurements scribed upon them. The tool is so constructed that the movement of the two legs relative to each other will result in an angle being formed there between that will be measured by referring to a setting on the scales so provided for the gears and the legs.
[0012] The tool can be utilized to measure the miter joint angle, bevel and miter settings for compound angles, the actual angle made by the legs of the tool, the complementary angle of the actual angle, the supplementary angle of the actual angle, the common roof pitch angle, gradients, and/or any angle measurement to which the several scales might be adapted. In the preferred embodiment, all of these angle measurements are measured simultaneously. The tool can also be utilized with its laser/scope accessory (or integral laser[s] and/or scope[s]) to measure, layout and project wall angles, construction angles and any angle encountered or required. This improvement is accomplished by attaching the twin-beamed laser/scope to the invention and projecting/sighting a line along a chosen angle from a known point to any other point along the laser beam(s) or sighted line(s). Said point, or points, along the projected laser beam(s), or sighted line(s), must be located in order to achieve a proper rendition of the angle required, and the laser/scope accessory achieves that purpose in a one-step operation. It should be understood by those practiced in the art that many additional deployments of lasers or scopes might be employed for a variety of angle projections that are calculated by the measuring tool. The laser, or lasers, can be used to project planes as well as points along a line. These lasers can be deployed in many useful layouts that are directly related to any of the many angle functions to which the tool can be calibrated. It should be further understood that said laser(s), or scope(s), might also be integrated into the measuring tool, in addition to, or as an alternative to the laser (or scope) accessory.
[0013] A first alternate embodiment is presented in which both legs are provided with a fixed gear assembly at the axis of the two interacting legs. Both legs are similarly fit with one or more gears which are driven by the aforementioned fixed gear of the respective opposite leg. This improvement provides the ability to have additional indicia bearing gears and thus the ability to provide additional angle measurements.
[0014] In addition, a second alternate embodiment is presented which improves on the gear trains in both the preferred embodiment and the first alternate embodiment. As will be evident in the descriptions and drawings to follow, this second alternate embodiment employs compound gears on either or both legs of the tool to provide angle measurements to a still greater degree of precision as compared to those measurements provided by a non-compound gear train.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is a perspective view of all of the components of tool 10 as assembled with the legs forming an acute angle.
[0016] FIGS. 2A , 2 B, and 2 C are orthographic views of bottom leg 18 .
[0017] FIGS. 3A , 3 B, 3 C and 3 D are orthographic views of top leg 14 .
[0018] FIG. 4 is a section view of top leg 14 .
[0019] FIG. 5 is a section view of top leg 14 .
[0020] FIGS. 6A , 6 B and 6 C are orthographic views of gear cover 22 .
[0021] FIGS. 7A , 7 B, 7 C and 7 D are orthographic views of gears 26 , 30 , 34 , 38 and 42 .
[0022] FIGS. 8A , 8 B and 8 C are orthographic views of ‘O’ ring 46 .
[0023] FIGS. 9A , 9 B and 9 C are orthographic views of bolt 50 .
[0024] FIG. 10 is an exploded view of tool 10 .
[0025] FIG. 11 is a plan view of tool 10 as assembled in a closed position. Direction of movement is shown by arrows. Gear cover 22 is not shown.
[0026] FIG. 12 is a section view of tool 10 as assembled in a closed position.
[0027] FIGS. 13A , 13 B, 13 C and 13 D are orthographic views of the laser device 54 .
[0028] FIG. 14 is a perspective view of laser device 54 .
[0029] FIG. 15 is a perspective view of laser device 54 .
[0030] FIG. 16 is a perspective view of all of the components of tool 11 as assembled with the legs forming an acute angle.
[0031] FIGS. 17A , 17 B, 17 C and 17 D are orthographic views of bottom leg 19 .
[0032] FIG. 18 is a section view of bottom leg 19 .
[0033] FIG. 19 is a section view of bottom leg 19 .
[0034] FIGS. 20A , 20 B, 20 C and 20 D are orthographic views of top leg 15 .
[0035] FIG. 21 is a section view of top leg 15 .
[0036] FIG. 22 is a section view of top leg 15 .
[0037] FIGS. 23A , 23 B and 23 C are orthographic views of gear cover 22 of tool 11 .
[0038] FIGS. 24A , 24 B, 24 C and 24 D are orthographic views of fixed gear assembly 78 .
[0039] FIGS. 25A and 25B are, respectively, elevation and plan views of assembly washer 70 .
[0040] FIGS. 26A , 26 B, 26 C and 26 D are orthographic views of gears 86 , 90 , 94 , 98 and 102 .
[0041] FIGS. 27A , 27 B and 27 C are orthographic views of ‘O’ ring 47 .
[0042] FIGS. 28A , 28 B and 28 C are orthographic views of bolt 51 .
[0043] FIG. 29 is an exploded view of tool 11 .
[0044] FIG. 30 is a plan view of tool 11 as assembled in a closed position. Direction of movement is shown by arrows. Gear cover 22 is not shown.
[0045] FIG. 31 is a section view of tool 11 as assembled in a closed position.
[0046] FIG. 32 is a plan view of tool 10 as assembled in a closed position. Direction of movement is shown by arrows. Gear cover 22 is not shown.
[0047] FIG. 33 is an exploded view of the components shown in section view 34 . Gear cover 22 is not shown.
[0048] FIG. 34 is a section view which applies universally to leg 14 of tool 10 and to legs 15 and 19 of tool 11 .
DETAILED DESCRIPTION OF THE INVENTION
[0049] As can be seen in the FIGS. 1-12 the preferred embodiment of angle measurement tool 10 is constructed from several components including top leg 14 , bottom leg 18 , bolt 50 and a plurality of interacting gears. Legs 14 and 18 are the same width and both have a circular shaped end 20 . It should be understood that circular shaped end 20 of both leg 14 and leg 18 is a semicircle of a circle having a diameter equal to the width of leg 14 and leg 18 . It should be further understood that leg 14 and leg 18 might be wider or narrower than circular shaped end 20 where the legs extend beyond the circle described by circular shaped end 20 . It should also be understood that leg 14 and leg 18 might have non-parallel edges and tool 10 will still function as intended. Leg 14 is provided with projected axis spindle 12 at the center of the circle of which circular shaped end 20 is a part. Axis spindle socket 16 of bottom leg 18 is provided at the center of the fixed gear assembly 24 which is at the center of the circle of which circular shaped end 20 is a part. In the preferred embodiment, projected axis spindle 12 is circular in shape and has a diameter equal to or less than the diameter of axis spindle socket 16 , as shown in the figures. It should be understood that projected axis spindle 12 has a diameter equal to or less than the diameter of the axis spindle socket 16 as a function of the assembly of tool 10 and thus to facilitate precisely pivoting legs 14 and 18 secured by bolt 50 . It should be further understood that projected axis spindle 12 does not have to be in the shape of a circle in order for tool 10 to operate in the fashion described. Variable friction adjustment for the pivoting legs 14 and 18 is provided when ‘O’ ring 46 is compressed by projected axis spindle 12 into axis spindle socket 16 when bolt 50 is tightened through bolt hole 32 in leg 18 and into threaded bolt hole 36 in leg 14 , as shown in the figures. Bolt hole 32 and threaded bolt hole 36 are at the center of the circle of which circular shaped end 20 is a part. With legs 14 and 18 so engaged, fixed gear assembly 24 meshes with gear 26 in a secure and rotationally precise manner. Fixed gear assembly 24 of leg 18 is housed within fixed gear cavity 53 in leg 14 in the assembled tool 10 . When the legs 14 and 18 are pivoted around their common axis as defined by projected axis spindle 12 and axis spindle socket 16 , fixed gear assembly 24 meshes with and turns gear 26 , which in turn meshes with and turns gear 30 , which meshes with and turns gear 34 , which meshes with and turns gear 38 , which meshes with and turns gear 42 . Gears 26 , 30 , 34 , 38 and 42 are each precisely located for accurate meshing and rotation by axis pivots 40 located in close tolerance within gear center holes 44 as shown in the figures. Any or all of the gears may include dial indicia 43 for the purpose of measuring any angle reading throughout a full revolution of either leg 14 or leg 18 . As indicated in FIG. 11 , each of the gears 24 , 26 , 30 , 34 , 38 and 42 is supplied with dial indicia 43 which are comprised of straight lines radiating outward from the rotational center of these gears. The purpose of these several gears is to simultaneously provide a variety of useful angle measurements on scales specifically suited to the work at hand. For example, the indicia on fixed gear assembly 24 would be marked with a protractor scale, in a 0°-180°-0° format, providing the actual angle determined by the relative positions of leg 14 and leg 18 ; in turn, gear 26 would provide the protractor scale in a 180°-0°-180° format, gear 30 would provide a scale for the miter saw setting for miter joints, gear 34 would provide a scale for the miter saw setting for butt joints, gear 38 would provide a scale for the roof pitch reading in ‘inches of rise per lineal foot’, gear 42 would provide a scale for gradients expressed as a percentage. This example is one of many configurations possible, dependent only on the angle measurements chosen for the several gears and the relative positions of these several interchangeable gears, whose interchangeability is described below. In the preferred embodiment, fixed gear assembly 24 and gears 26 , 30 , 34 , 38 and 42 are the same diameter and have the same number of gear teeth, thus gears 26 , 30 , 34 , 38 and 42 are interchangeable to suit the user's preference. Gears 26 , 30 , 34 , 38 and 42 may also be reversible, thus providing their reverse side for additional angle measurements. Further, the interchangeable design of the gears provides the opportunity to substitute additional gears provided with specialized scales for use in any field of endeavor requiring precise measurement and layout of particular angles for particular purposes. The various gears would be so marked, or colored, as to provide immediate identification and differentiation of the various scales. It should be apparent to those practiced in the art that interchangeability and reversibility of the gears is not a necessary component of the invention and that the various gears need not be identical in shape, interchangeable or reversible for the invention to function as intended; all such non-interchangeable and non-reversible configurations are contemplated by the inventor. A means for accurately reading these several angle measurements is provided by indicator line 28 placed along the center of gear cover 22 as shown in the figures. It should be understood that many other locations for indicator line(s) 28 on gear cover 22 and/or leg 14 are possible and are contemplated by the inventor. In the preferred embodiment gear cover 22 is transparent and indicator line 28 is provided on the surface of gear cover 22 which is closest to gears 24 , 26 , 30 , 34 , 38 and 42 . In the preferred embodiment gear cover 22 is of a form that provides beveled edges 48 which securely mate with dovetail channel 52 providing a secure location for gear cover 22 . Gear cover 22 is retained by friction, ball catch, screw(s), latch(es), magnet(s) or any of the many suitable means that should be apparent to those skilled in the art. The inventor contemplates all such means of securing gear cover 22 in its assembled location within dovetail channel 52 . So located, gear cover 22 retains gears 26 , 30 , 34 , 38 and 42 securely in their proper working locations with their respective gear center holes 44 engaged with their respective axis pivots 40 . Areas of the surfaces of gear cover 22 which are not necessary areas for viewing angle readings determined by indicator line 28 may be masked so as to provide a well delineated reading environment for the several angle readings so provided. It should be understood by those practiced in the art that gear cover 22 may be opaque and readings can be accomplished through openings and/or lenses in its surface; further, it should be understood that many variations of gear retention and reading means for the various scales and indicia are possible and that all such alternatives are contemplated by the inventor. It should be understood that fixed gear assembly 24 may or may not be constructed in union with leg 18 , but in its final form tool 10 comprises a bottom leg 18 that is in fixed union with fixed gear assembly 24 , such that, in operation, leg 18 is a single piece rigidly attached to, or constructed with, fixed gear assembly 24 . In operation tool 10 simultaneously provides the miter joint angle measurement, the actual angle made by the legs 14 and 18 , the complementary angle measurement of the actual angle, the supplementary angle measurement of the actual angle, roof pitch angles, gradients and/or any angle measurement to which the several scales are adapted. It should be understood by those practiced in the art that any number and any size or variety of gears can be employed in infinite configurations and that all such alternate deployments of gears driven by fixed gear assembly 24 are contemplated by the inventor. It should be further understood by those practiced in the art that, as an alternative, supplement, or addition to the preferred embodiment in which the various gears mesh directly with one another, that a gear-toothed belt drive, friction belt drive, or similar means might be employed as an alternative, supplementary or additional means of rotating all, or some, of the various gears and/or dials and that the inventor contemplates all such variations. Further, the inventor wishes it to be understood that various other friction inducing means other than ‘O’ ring 46 should be apparent to those practiced in the art and that the inventor contemplates all such friction inducing means including the substitution of a suitable magnet for ‘O’ ring 46 and bolt 50 , said magnet located in the bottom of the axis spindle socket 16 and magnetically engaging a magnetized projected axis spindle 12 . Alternate embodiments are contemplated by the inventor in which a wide variety of angle readings may be accomplished on the top surfaces, bottom surfaces and edges of, either or both of legs 14 and 18 in which leg indicia 45 and certain scales are employed at various significant intersections of legs 14 and 18 as they bypass each other while being adjusted to the work surfaces which are being measured.
[0050] As can be seen in FIGS. 3A , 3 B, 3 C and 3 D, leg 14 is provided with three peg holes 58 , 59 and 60 . In the preferred embodiment peg holes 58 , 59 and 60 are flush and perpendicular with the top surface of leg 14 . Peg holes 58 , 59 and 60 are entirely contained between the bottom and top surfaces of leg 14 . Peg holes 58 , 59 and 60 may be similarly placed in leg 18 . Peg holes 58 , 59 and 60 may be of the same shape as each other or they may be unique shapes. FIGS. 13A , 13 B, 13 C, 13 D, 14 and 15 illustrate laser device 54 . Laser device 54 is intended for projecting diametrically opposed laser beams 64 and 65 in diametrically opposite directions from each other. Laser device 54 is fitted with three pegs 67 , 68 and 69 that precisely match the shape or shapes of peg holes 58 , 59 and 60 . Pegs 67 , 68 and 69 may be of the same shape as each other or they may be unique shapes. Pegs 67 , 68 and 69 are fit perpendicular to the bottom surface 62 of laser device 54 . Bottom surface 62 is in a single plane. Bottom surface 62 is parallel with laser beams 64 and 65 . The relative positions of pegs 67 , 68 and 69 are such that they fit respectively in peg holes 58 , 59 and 60 and in so doing they attach laser device 54 to leg 14 or leg 18 such that laser beams 64 and 65 are parallel to the angle chosen on leg 14 or leg 18 , according to the application chosen. In the preferred embodiment pegs 67 , 68 and 69 are circular and made of steel, either magnetized or not magnetized. It should be understood that other shapes and materials are contemplated for pegs 67 , 68 and 69 . It should also be understood that magnetic attachment is one of many means contemplated for attaching laser device 54 to leg 14 and/or leg 18 . Laser beams 64 and 65 are energized from a battery(ies) contained within laser device 54 . Laser beams 64 and 65 may be generated from a single source and redirected on diametrically opposite paths. Laser beams 64 and 65 may also be generated separately. Laser beams 64 and 65 may be generated not only as single lines, but might also be projected as planes or any number of planes. In operation laser device 54 is affixed to tool 10 by placing pegs 67 , 68 and 69 in peg holes 58 , 59 and 60 . It should be recognized by those practiced in the art that various other means of attaching laser device 54 to tool 10 are possible and those ways are contemplated by the inventor. Laser beams 64 and 65 are employed to project angles. In the preferred embodiment, the union of tool 10 and laser device 54 projects laser beams 64 and 65 along one side of the angle made by the legs 14 and 18 . The other side of the angle made by the legs 14 and 18 represents the base line from which the particular angle is being calculated and projected. Whichever of the legs 14 and 18 that does not have the laser device 54 mounted on it is the leg that is set parallel to the base line. Laser beams 64 and 65 are by design always parallel to one side of the angle being measured and projected. Laser beam 64 is aimed at the spring point of the angle that is to be projected. Laser beam 65 projects the chosen angle along and beyond the angle made by the legs 14 and 18 . It should be understood by those practiced in the art that there are alternate embodiments for a laser, or lasers, in which the laser function(s) are an integral part of tool 10 in addition to laser device 54 , or in place of laser device 54 . All such alternate embodiments are contemplated by the inventor. It should be understood that sighting scopes may be substituted for, or mounted in unison with, the laser beam in laser device 54 . Laser device 54 as herein described is also intended for use with tool 11 , described in the first alternate embodiment below. Additionally, laser device 54 is intended for all alternate embodiments described herein and those other embodiments contemplated by the inventor which should be apparent to those practiced in the art.
[0051] The following description of the first alternate embodiment of the invention utilizes the same reference numbers as those described in the preferred embodiment above in such cases where members are the same in both embodiments. New reference numerals have been assigned in cases where members are new or in some respects different when comparing the two embodiments. FIGS. 16-31 disclose the first alternate embodiment, tool 11 , in which leg 15 is provided with a projected axis spindle 13 at the center of the circle of which circular shaped end 20 is a part. The projected axis spindle 13 is provided with threaded bolt hole 37 at the center of the circle of which circular shaped end 20 is a part, as shown in the figures. Leg 19 is provided with axis spindle socket 84 at the center of the circle of which circular shaped end 20 is a part. Leg 19 securely houses assembly washer 70 which is so constructed as to provide a secure fit in recess 71 for rotatably engaging projected axis spindle 13 with bolt 51 as bolt 51 passes through bolt hole 33 which is provided in washer 70 at the center of the circle of which circular shaped end 20 is a part. A portion of projected axis spindle 13 is provided with projected axis spindle gear teeth 74 for reasons that will become apparent below. As shown in the figures, fixed gear assembly 25 is housed within fixed gear cavity 53 in order to drive the gear train of top leg 15 in the same fashion as fixed gear assembly 24 drives the gear train of top leg 14 of tool 10 in the preferred embodiment; the latter being illustrated in FIG. 11 . As tool 11 is assembled, bolt 51 passes through bolt hole 33 into threaded bolt hole 37 , so assembling leg 15 and leg 19 such that they rotate securely in relation to each other with an axis the center of which is located at the center of the circle of which circular shaped end 20 is a part. ‘O’ ring 47 is provided as a frictional interface between projected axis spindle 13 and washer 70 , with adjustable rotational friction for legs 15 and 19 provided as bolt 51 is tightened or loosened to the tool user's preference. In this first alternate embodiment ‘O’ ring 47 is located in ‘O’ ring channel 80 which is concentrically located on the end of projected axis spindle 13 which houses threaded bolt hole 37 at its center. Accurate rotation of legs 15 and 19 is ensured by the close-tolerance fit of projected axis spindle 13 as it revolves within axis spindle socket 84 . Projected axis spindle gear teeth 74 are fixedly engaged with fixed gear assembly 78 by meshing with the mating internal gear 82 contained at the center of fixed gear assembly 78 ; fixed gear assembly 78 then meshes with and turns gear 86 , which in turn meshes with and turns gear 90 , which meshes with and turns gear 94 , which meshes with and turns gear 98 , which meshes with and turns gear 102 . Gears 86 , 90 , 94 , 98 and 102 are each precisely located for accurate meshing and rotation by axis pivots 72 located in close tolerance within gear center holes 76 as shown in the figures. Any or all of the gears may be provided with dial indicia 43 for the purpose of determining any angle reading throughout a full revolution of either leg 15 or leg 19 . As indicated in FIG. 30 each of the gears 78 , 86 , 90 , 94 , 98 and 102 is provided with dial indicia 43 which are comprised of straight lines radiating outward from the rotational center of these gears. The purpose of these several gears is to simultaneously provide a variety of useful angle measurements on scales specifically suited to the work at hand. For example, the indicia on fixed gear assembly 78 would be marked with a protractor scale, in a 0°-180°-0° format, providing the actual angle determined by the relative positions of leg 15 and leg 19 ; in turn, gear 86 would provide the protractor scale in a 180°-0°-180° format, gear 90 would provide a scale for the explementary angle in a 0°-360° format, gear 94 would provide a scale for the explementary angle in a 360°-0° format, gear 98 would provide a scale for the miter saw settings for constructing equiangular polygons employing miter joints, gear 102 would provide a scale for the miter saw settings for constructing equiangular polygons employing butt joints. This example is one of many configurations possible, dependent only on the angle interpretations chosen for the several gears and the relative positions of these several interchangeable gears, whose interchangeability is described below. In the preferred embodiment, fixed gear assembly 78 and gears 86 , 90 , 94 , 98 and 102 are the same diameter and have the same number of gear teeth, thus gears 86 , 90 , 94 , 98 and 102 are interchangeable to suit the user's preference. Gears 86 , 90 , 94 , 98 and 102 may also be reversible, thus providing their reverse side for additional angle measurements. Further, the interchangeable design of the gears provides the opportunity to substitute additional gears provided with specialized scales for use in any field of endeavor requiring precise measurement and layout of particular angles for particular purposes. The various gears would be so marked, or colored, as to provide immediate identification and differentiation of the various scales. It should be apparent to those practiced in the art that interchangeability and reversibility of the gears is not a necessary component of the invention and that the various gears need not be identical in shape, interchangeable or reversible for the invention to function as intended; all such non-interchangeable and non-reversible configurations are contemplated by the inventor.
[0052] A means for accurately reading these several angle measurements is provided by indicator line 28 which is placed along the center of gear cover 22 as shown in the figures. It should be understood that many other locations for indicator line(s) 28 on gear cover 22 and/or legs 15 and 19 are possible and are contemplated by the inventor. In this first alternate embodiment gear cover 22 is transparent and indicator line 28 is provided on the surface of gear cover 22 which is closest to gears 78 , 86 , 90 , 94 , 98 and 102 . In this first alternate embodiment gear cover 22 is of a form that provides beveled edges 48 which securely mate with dovetail channel 52 providing a secure location for gear cover 22 . Gear cover 22 is retained by friction, ball catch, screw(s), latch(es), magnet(s) or any of the many suitable means that should be apparent to those skilled in the art. The inventor contemplates all such means of securing gear cover 22 in its assembled location within dovetail channel 52 . So located, gear cover 22 retains gears 86 , 90 , 94 , 98 and 102 securely in their proper working locations with their respective gear center holes 76 engaged with their respective axis pivots 72 . Areas of the surfaces of gear cover 22 which are not necessary areas for viewing angle readings determined by indicator line 28 may be masked so as to provide a well delineated reading environment for the several angle readings so provided. It should be understood by those practiced in the art that gear cover 22 may be opaque and readings can be accomplished through openings and/or lenses in its surface; further, it should be understood that many variations of gear retention and reading means for the various scales and indicia are possible and that all such alternatives are contemplated by the inventor. It should be understood that fixed gear assembly 25 may or may not be constructed in union with leg 19 , but in its final form tool 11 comprises a bottom leg 19 that is in fixed union with fixed gear assembly 25 . In operation tool 11 simultaneously provides the miter joint angle measurement, the actual angle made by the legs 15 and 19 , the complementary angle measurement of the actual angle, the supplementary angle measurement of the actual angle, the explementary angle measurement of the actual angle, roof pitch angles, gradients, miter saw settings for constructing equiangular polygons employing miter joints, miter saw settings for constructing equiangular polygons employing butt joints and/or any angle measurement to which the several scales are adapted. It should be understood by those practiced in the art that any number and any size or variety of gears can be employed in infinite configurations and that all such alternative deployments of gears driven by fixed gear assembly 25 and projected axis spindle gear teeth 74 are contemplated by the inventor. It should be further understood by those practiced in the art that, as an alternative, supplement, or addition to the preferred embodiment in which the various gears mesh directly with one another, that a gear-toothed belt drive, friction belt drive, or similar means might be employed as an alternative, supplementary or additional means of rotating all, or some, of the various gears and/or dials and that the inventor contemplates all such variations. Further, the inventor wishes it to be understood that various other friction inducing means other than ‘O’ ring 47 should be apparent to those practiced in the art and that the inventor contemplates all such friction inducing means including the substitution of a suitable magnet for ‘O’ ring 47 and bolt 51 , said magnet located in the bottom of the projected axis spindle 13 and magnetically engaging a magnetized assembly washer 70 . In this alternate embodiment there would be no bolt 51 and assembly washer 70 would have no bolt hole 33 and thus assembly washer 70 would be secured to leg 19 with screws at a point or points located around the outer edge of assembly washer 70 or by any of several other means which should be apparent to those practiced in the art. Alternate embodiments are contemplated by the inventor in which a wide variety of angle readings may be accomplished on the top surfaces, bottom surfaces and edges of either or both of legs 15 and 19 in which leg indicia 45 are employed at various significant intersections of legs 15 and 19 as they bypass each other while being adjusted to the work surfaces which are being measured. Tool 11 , so constructed in this first alternate embodiment, provides a gear train on both legs 15 and 19 for the purpose of displaying dial indicia 43 for any and all angle measurements that might be provided by the precisely pivoting legs which pivot around the center of the circle of which circular shaped end 20 is a part. It should also be understood by those practiced in the art that the first alternate embodiment here described may be so employed so as to deploy a gear train on leg 19 alone, or leg 15 alone, as might be desired for a given assembly of the inventions here described.
[0053] It should be understood by those practiced in the art that there are a number of arrangements of interlocking “pins”, “springs”, “cams”, “clips”, “catches”, “levers”, “latches”, “screws”, “projections”, “magnetism”, “holes”, “grooves” and “openings” that will secure projected axis spindle 12 / 13 of leg 14 / 15 in rotational union with axis spindle socket 16 / 84 of leg 18 / 19 together such that they provide tool 10 / 11 with a leg 18 / 19 that revolves securely and accurately around projected axis spindle 12 / 13 of leg 14 / 15 . The inventor contemplates all of these embodiments, including ‘snap-together’ designs and designs employing spring loaded ball catches (with or without an ‘easy release’ button) in addition to those represented in the figures.
[0054] The following description of the second alternate embodiment of the invention utilizes the same reference numbers as those described in the preferred embodiment and first alternate embodiment above in such cases where members are the same as those used in either or both of those embodiments as well as in this second alternate embodiment. New reference numerals have been assigned in cases where members are new or in some respects different as utilized in the second alternate embodiment. The second alternate embodiment is applicable to any of the gear trains illustrated in the preferred embodiment and first alternate embodiment described above, as detailed below. FIGS. 32-34 disclose the second alternate embodiment which employs compound gears, the purpose of which are to employ compound gearing to rotate certain gears at a compounded rate as compared to fixed gear assembly 24 of leg 18 of the preferred embodiment, as well as fixed gear assembly 25 of leg 19 and fixed gear assembly 78 of leg 15 of the first alternate embodiment. The compounded rate of rotation of one gear relative to another provides the ability to have certain gears with accurate fractional readings of those results provided by any of the gears described in the preferred embodiment and first alternate embodiment above. It should be understood that the number of gear teeth shown on particular gears in the Figures are not necessarily indicative of the actual number of gear teeth; the depictions of the gear teeth in the Figures are in some instances abbreviated or drawn out of scale for the purpose of clear illustration. For example, FIG. 32 is a plan view of the second alternate embodiment's compound gear train illustrating a gear assembly 110 which revolves at the same, directly proportional, rate as either of the fixed gear assemblies 24 , 25 or 78 , just as each of the gears in the depicted embodiments of tool 10 and tool 11 revolve at the same, directly proportional, rate as fixed gear assemblies 24 , 25 or 78 ; in every case gear assembly 110 is either directly engaged with either of the fixed gear assemblies 24 , 25 or 78 , or is engaged by idler gears such that gear assembly 110 rotates at the same, directly proportional, rate as the fixed gear assemblies 24 , 25 or 78 . In the second alternate embodiment, gear 114 revolves at a rate 180 times greater than that of gear assembly 110 . A full revolution of gear 114 thus provides its full dial face for depiction of fractional readings of any single whole degree increment portrayed on gear assembly 110 , in doing so a more precise reading of a specific angle is accomplished. More specifically, in this example gear assembly 110 is providing the readings for miter cuts on a miter saw, for which the entire 360° dial must be divided into 180 equally spaced dial indicia 43 . Gear 114 thus turns one full revolution for each 1/180 th revolution of gear assembly 110 . The result is a gear 114 which displays fractional readings in tenths, hundredths, or whichever fractional reading is desired. For the purpose of this example, gear 116 is marked as a 180°-0°-180° protractor and revolves at the same rate as gear assembly 110 . The increased number of rotations for gear 114 in comparison to gear assembly 110 and gear 116 is accomplished with compound gears as described below and illustrated in the figures. FIG. 33 is an exploded view of the second alternate embodiment's compound gear train illustrating the components shown in section view 34 and depicted in FIG. 34 . For the purpose of this description leg 14 is the leg upon which the second alternate embodiment's compound gear train is depicted. It should be understood that the second alternate embodiment's compound gear train is suitable for any and all of the legs 14 , 15 , and 19 and that the inventor contemplates all such embodiments. FIG. 34 is a section view of the second alternate embodiment depicted in plan in FIG. 32 . As assembled, gear assembly 110 is located on axis pivot 122 ; idler gear 118 is located on axis pivot 124 ; compound gear 112 is located on top of idler gear 118 on axis pivot 124 ; idler gear 120 is located on axis pivot 126 ; gear 114 is located on top of idler gear 120 on axis pivot 126 ; and gear 116 is located on axis pivot 128 . Gear assembly 110 , while manufactured or assembled as a single piece, comprises two gears, the lower of those two gears, lower gear 106 is closest to leg 14 and engages idler gear 118 , while the upper gear, upper gear 108 , engages the upper gear 113 of compound gear 112 . Compound gear 112 is manufactured or assembled as a single piece and comprises two gears, the lower of those two gears, lower gear 111 is closest to gear 118 and engages gear 114 , while the upper gear, upper gear 113 , engages gear 108 . Idler gear 118 , being thus engaged with lower gear 106 , in turn engages idler gear 120 , which in turn engages gear 116 . This train of gears 106 , 118 , 120 and 116 is driven by a fixed gear assembly, either 24 or 25 or 78 , directly or through idler gear(s), the result being gears 106 and 116 which revolve at the same, directly proportional, rate as the fixed gear assemblies 24 or 25 or 78 . Upper gear 108 of gear assembly 110 contains 120 teeth around its circumference and is engaged with the 6 toothed upper gear 113 of compound gear 112 . The lower gear 111 of compound gear 112 has 45 teeth around its circumference and is engaged with 5 toothed gear 114 . In this second alternate embodiment, compound action of the upper level gears causes the compounded increase in the number of revolutions of gear 114 , providing the fractional readings desired by providing a gear 114 which turns 180 full revolutions for each single revolution of gear assembly 110 . It should be understood by those practiced in the art that infinite deployments of gear ratios may be employed in such a compound gear train and the inventor contemplates them all. It should be further understood that the second alternate embodiment's compound gear train may comprise as few or as many compound gears as desired, in any number of layers and ratios, and that the inventor contemplates all such combinations of gears. Further, it should be understood that the second alternate embodiment's compound gear train herein described is driven by either fixed gear assembly 24 or fixed gear assembly 25 or fixed gear assembly 78 , just as the fixed gear assemblies 24 and 25 and 78 drive the gear trains previously described and depicted in the preferred embodiment and first alternate embodiment denoted respectively as tool 10 and tool 11 above and in the figures. It should be further understood by those practiced in the art that, as an alternative, supplement, or addition to the second alternate embodiment in which the various gears mesh directly with one another, that gear-toothed belt drives, friction belt drives, or similar means might be employed as an alternative, supplementary or additional means of rotating all, or some, of the various gears and/or dials and that the inventor contemplates all such variations. It should be further understood that the compounding of the gear action might be accomplished with epicyclic or planetary gearing or by other gearing means and the inventor contemplates all such variations.
[0055] It should be further understood that any number of different scales and indicia can be deployed on any of the gears, leg surfaces or leg edges of the invention, throughout an infinite number of conceivable angle layouts. The inventor contemplates all such variations of the layout of the scales and indicia.
[0056] It should be understood by those practiced in the art that all of the above described gears, and those parts in contact or close proximity with those gears, as assembled, may include any of a number of common friction reduction means such as, but not limited to, low-friction materials employed in the construction of the several legs, gears, and gear covers; low-friction washers, bushings, lubricants, or bearings at points of contact between a gear face and another gear face or a gear face and either of the legs 14 , 15 and 19 and/or gear cover 22 . Such a friction reduction means might be a separate part or might be molded, or affixed, directly onto the gear or the contact area of legs 14 , 15 , and 19 and/or gear cover 22 . Similarly placed ball-bearings, roller bearings or other means might be used to reduce friction and might be a part of, or intermediary for, any of the gears, axis pivots, legs, or gear covers. The inventor contemplates all such friction reduction means.
[0057] Although specific embodiments of the invention have been described it should be recognized that additional modification and other alternate embodiments may be apparent to those skilled in the art.
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An angle measurement tool having two legs joined together about a common axis so that one of the legs rotates with respect to the other to form a desired angle the value of which is read utilizing gears that are housed in said legs in combination with indicia means indicating the degree of rotation of the gears.
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BACKGROUND OF THE INVENTION
The invention relates to a plant or production facility for the mechanized fabrication of masonry, having a turnover device which receives a plurality of building stones that are intended for a building-stone course, and while taking into account mutual distances apart, secures them in place, pivots them together about a horizontal axis running at a distance parallel to the wall to be produced and transposes them with the top side down.
German Patent 3,520,788 discloses a turnover device of this type. This single device is essentially loaded manually. By means of a special lifting tackle, the worker picks up the building stones individually from the delivered pallet and joins the building-stone row together on the turnover table serving as a turnover device. If openings in the masonry are to be provided, the distances between the stones are measured. Other stones, in each case following the laying plan, are shortened by means of a stone-cutting saw. A disadvantage here is that the turnover table must be stopped during the time required for joining the building-stone course together; the time required for transposing a building-stone row is composed of the joining time plus the turnover and displacing time.
Furthermore, for the purpose of partial automation, it is known from the abovementioned patent specification to join the building-stone course together on the turnover table itself by means of a roller conveyor conveying in the longitudinal direction. Although this may shorten the joining time, nothing changes the fact that the times for the movement of the turnover table have to be added thereto in order to obtain the total time for transposing a building-stone course.
SUMMARY OF THE INVENTION
The object of the invention is to speed up the production of masonry panels with such a device and in addition to provide a plant for the efficient further processing of the finished masonry panels.
Starting from a production facility of the type designated at the beginning, this object. is achieved according to the invention in that a stationary device for joining together the building-stone course and a transfer device for transposing the prepared building-stone course in one piece to the turnover device are provided. Consequently, the joining and transposing are non-interactive with regard to timing, i.e. the corresponding devices can work at least partly simultaneously, which increases their utilization factor and increases the output of the plant.
It is proposed that the transfer device be integrated into the turnover device by the latter being designed as a clamping frame which comes down from above around the prepared building-stone course. In this case, the frame takes the place of the turnover table on which the building stones have to be laid. In contrast, the frame can receive the building stones at its underside and deliver them at its topside, which lies at the bottom in the turned-over state. In this arrangement, it may be necessary to mount the clamping frame in a displaceable and driveable manner inside the supporting construction which connects it to the turnover shaft.
Another preferred embodiment of the transfer device consists in this transfer device being a vertically displaceable turnover table which is equipped with clamping devices and which receives the prepared building-stone course, pivots it and pivots it back after the correct height is set, and deposits it on a second turnover table which in turn constructs the wall. Here, the device for joining together the building-stone course is preferably arranged in such a way that it is located beneath the second turnover table located in the loading position. The axis of the first turnover table extends and moves in a plane parallel to the wall to be produced, which, however, is further away from this wall than the axis of the second turnover table. The turnover tables are controlled in such a way that the first turnover table receiving the building-stone course is first of all pivoted out of the area of movement of the second turnover table. The first turnover table then travels up or the second turnover table travels down so far that the transfer of the building-stone course can take place.
The device for joining together the building-stone course preferably comprises a conveyor belt program-controlled in steps and a program-controlled stone depositing means which picks up the building stones one after the other from a supply and deposits them in the same position always at the same location on the conveyor belt. The conveyor belt in each case then travels one stone length or one additional length further if an opening in the masonry is to be formed.
To avoid manual work in connection with the sawing of building stones, it is furthermore proposed that a stone-cutting saw displaceable in the length of the building stone in a program-controlled manner be provided in order to shorten if necessary a building stone deposited on the conveyor belt. In particular, the building stone to be shortened is conveyed by means of a turnover device from the conveyor belt to the stone-cutting saw and back again, the sawn-off and unwanted part of the building stone being ejected laterally. All these operations can be controlled by means of drive devices known per se according to an individual program which is drawn up with reference to the building plan in the course of job planning.
A progressive and decisive efficiency measure in this prefabricated-unit method of construction, which can be planned individually, consists in the wall panels being erected on transport cars which can be conveyed in a circular course through a plurality of finishing stations. It is advantageous if the transport cars can be turned carousel-like through 180° so that two parallel walls can be erected thereon by means of a stationary wall machine. In a first finishing station the walls should be provided with the requisite transport scaffolds or suspension reinforcement. At further finishing stations the individual constructional features are to be considered, for example the insertion of windows, the fitting of parts of the electrical and water installation, the rendering of the wall surfaces, the fitting of shutters and the like. Substantial savings in working time are thereby made, since the fitters do not have to travel to varying places of work. The transport of material is dispensed with, since the material stores are provided along the circular course of the transport cars. The working conditions are substantially better, since heavy manual work is dispensed with, the risk of accident is reduced and the environmental conditions (heated hall) can be better. Nonetheless, the previous individual building system, i.e. the individual planning and the use of various wall thicknesses and building stones can be retained by the proposed plant.
BRIEF DESCRIPTION OF THE DRAWINGS
An exemplary embodiment of the invention is explained below with reference to schematic drawings, in which, specifically:
FIG. 1 shows the view of a production facility for producing masonry in a narrow sense, having one device each for joining together, transferring and transposing the building stones, viewed in the axial direction or the longitudinal direction of the wall,
FIG. 2 shows, on a smaller scale, a side view of the device for joining together the building stones according to FIG. 1 including a feed device and a stone-cutting saw, without the turnover tables,
FIG. 3 shows a plan view of the arrangement according to FIG. 2, and
FIG. 4 shows, on a smaller scale, a ground plan of an entire plant, extended by the finishing stations, for producing masonry.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows, in end elevation, on the left a wall panel 1 which has been started and to the right of it two double pillars 2 and 3 which are part of two portal structures in which the horizontal shafts 4 and 5 of two turnover tables 6 and 7 are accommodated in a vertically adjustable and rotatable manner. The individual travelling and pivot drives of the turnover tables are not shown. A horizontal conveyor belt 9 which, like the shafts 4 and 5, extends parallel to the wall panel 1, is located between the double pillars 2 and 3 and vertically below the wall bearing surface 8, which according to FIG. 4 can be designed as a transport car. The turnover tables 6 and 7 have schematically indicated clamping devices, each consisting of a stop strip 10 fastened to the turnover table and radially movable clamping strips 11 which secure a number of building stones 12 in a reclining or suspended position on the relevant turnover table, which building stones 12 are laid one behind the other and form a building-stone course to be transposed in one piece. Finally, FIG. 1 also shows a mortar dispenser 13 travelling back and forth at a desired height above the crest of the wall.
FIGS. 2 and 3 show in particular the joining device for the building-stone course. Its base is formed by the conveyor belt 9, which is recognizably longer than the turnover tables and wall panel to be produced. Next to the conveyor belt at the front end of the wall panel 1 is the place for putting a pallet 14, from which the delivered building stones are removed by means of a gripper 15 and are laid individually at the front on the conveyor belt 9. The gripper works likes a robot with fully automatic, electronic control, which is possible in so far as each pallet nonetheless contains the same number of building stones in the same arrangement. The building stones are preferably tall perforated bricks which have at least one larger opening 16 in the extruding direction, into which opening 16 the gripper pushes and opens out. The building stone is then turned through 90° by the gripper and placed with the opening 16 at the top onto the conveyor belt 9.
In order to minimize the displacements of the gripper 15, provision is made for the pallet to lie on a lifting table 16a which, after clearing one building-stone course in each case, travels up by the height of one building stone. The full pallets are conveyed forward on one side and the empty pallets are removed at right angles thereto.
Located to the left in extension of the conveyor belt 9 is a smaller turnover device having a turnover table 17 and a horizontal shaft 18 running transversely to the conveyor belt 9. This turnover device, if provided for in the building plan, serves to remove a building stone from the place where it is laid at the start of the conveyor belt and, after turning over through 180°, to move it into the area of a stone-cutting saw 19, whose saw blade is designated by 20. The feed direction of the stone-cutting saw during sawing runs transversely to the conveyor belt. On the other hand, the entire saw can be displaced in the direction of the conveyor belt by precisely determinable lengths in a program-controlled manner on an appropriate slide. The clamping devices (not shown) on the turnover table 17 move transversely to the conveyor belt, that is, in the direction of the turnover shaft 18. In this way, after the sawing operation, the shortened stone remaining can be reliably held in place irrespective of its length and put back onto the conveyor belt 9 again. During the sawing, however, the building stone must additionally be held in place on the turnover table 17 in such a way that the saw blade is not impaired. In addition, the abovementioned clamping device must dip down out of the way. A further device (not shown) pushes the cut-off and unwanted part of the building stone from the turnover table 17 and conveys it away.
After a complete or sawn-off building stone has been finally laid on the conveyor belt 9, the latter each time moves gradually so far to the right that the planned building-stone course forms, with or without a gap for the intended wall opening. Once the building-stone course is complete, the conveyor belt travels a slight distance further and brings it into the gripping area of the turnover table 7.
In summary, the following working sequence is obtained the first building-stone course joined together on the conveyor belt 9 is received by the turnover table 7 by the latter pivoting to the left and coming down on the building-stone course, whereupon its clamping device 10, 11 closes. The turnover table 7 then in any case pivots so far to the right and travels up so far that the turnover table 6 can pivot into its right hand position in which its receiving surface is turned over to the top, and can if need be travel down a slight distance. The conveyor belt 9 is meanwhile reloaded immediately after reaching its unloading position. When the turnover table 6 has reached the position reproduced in solid lines and the turnover table 7 is next to it in a position which is higher by the height of one building stone, the transfer can take place. For this purpose, the turnover table 7 pivots to the left and deposits the building-stone course on the turnover table 6. The clamping device of the turnover table 6 closes and that of the turnover table 7 opens. As soon as the turnover table 7 has pivoted back again to the right, the turnover table 6 pivots through 180° to the left and travels down so far that the suspended building-stone course is deposited on the bearing surface 8. If need be, a mortar bed has been prepared on this bearing surface beforehand by means of the mortar dispenser 13. The turnover table 6 then pivots back again through 180° and travels up so far that the turnover table 7, which has in the meantime travelled down, can fetch the next building-stone course, in the meantime joined together, without hinderance. Thus the building stones are transposed course by course until the wall panel 1 is finished and can be transported away. Accurate program control of the individual sequences of movement ensures their timed coordination and guarantees working of all components free of interruption, which ultimately leads to an exceptionally high production rate.
The program also determines the height at which the transfer of the building-block course from the turnover table 7 to the turnover table 6 is to take place. This can be an unchanged position at an average height as indicated in FIG. 1. But the transfer can also take place at a different height in each case, so that, after the transfer, the turnover table 6 does not have to cover a larger travelling distance in the vertical direction in order to transpose the building-stone row to the wall.
The expanded production plant according to FIG. 4 has a rectangular track layout 21 which individual transport cars 22 travel on preferably so as to circulate in the direction of the arrow. The wheels of the transport cars can be pivoted about vertical axes and are pivoted through 90° during the transfer from the narrow sides of the rectangle to the longitudinal sides or vice versa. In addition, the supporting tables of the transport cars 22 can be pivoted carousel-like on the base frames between two opposite positions. In this way, it is possible to erect two wall panels on on one transport car 22 by means of the wall-production facility designated overall in this figure by 23. Since this plant is stationary, the transport car 22 is moved away a slight distance after completion of the first wall panel and moved up to the plant again after rotation of the table through 180°. The adjoining track section having a large gauge serves as storage space for a plurality of transport cars having finished wall panels.
A plurality of stations now follow along the further circular course, in which stations the wall panels attain higher prefabrication stages. In a first station 24, vertical reinforcing bars are put in and cast in concrete, which reinforcing bars ensure the transportability of the wall panel and, for example, present fastening points for the crane hooks. Here, as at the further stations, stationary work scaffolds 25 can be provided in order to facilitate the work. In the next station 26, the concrete chords required in some wall panels are applied. The store for the formwork required for this is adjacent station 26. In the third station, windows are inserted and, as far as necessary, electrical and sanitary installations are fitted. A window store is designated by 28. In the fourth station 29, the wall surfaces are rendered, in particular plastered, for which purpose the wall panel is advantageously put into a horizontal position. The receiving and pivoting tables required for this can be provided in this station. A plaster store is designated by 30. Finally, in this example, the shutters are fitted in a fifth station 31.
The transport cars 22 are then either brought out of the circular course to a finished store or are emptied in an unloading station (not shown) and prepared for receiving further wall panels. These empty cars are then fed again to the wall-producing plant 23.
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A production facility for the mechanized fabrication of masonry includes a turnover table (6) which receives a plurality of building stones (12) intended for a building-stone course of a wall that is to be produced. The turnover table (6) secures the building stones (12) in place, pivots them together about a horizontal axis (4) running at a distance parallel to the wall (1) to be produced, and transposes them with the top side down. The turnover table (6) can be loaded quickly by a belt (9) and another turnover table (7) for transposing the building-stone course in one piece from the conveyor belt (9) to the other turnover table (6). As a result of the increased output thus effected, the production facility can be integrated into a factory having a plurality of finishing stations for further production stages.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
CROSS-REFERENCE TO RELATED APPLICATION
[0001] Not Applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable.
TECHNICAL FIELD
[0003] The invention relates to precast concrete products and more particularly to a precast concrete paver block.
BACKGROUND OF THE INVENTION
[0004] Precast concrete paver blocks are used for many applications, such as patios, driveways, sidewalks and courtyards. In the past, concrete paver blocks have generally been relative small, frequently from about the size of a brick up to about 2 feet square (about 61 cm square). In some applications, thin, decorative pavers are used as overlays on concrete foundations. Large pavers have not been available. One problem with larger paver blocks is to maintain a flat surface where the blocks abut. It is difficult to provide a flat foundation for the blocks and to prevent shifting of the blocks with ground movement, for example, due to frost or heavy rainfall.
BRIEF SUMMARY OF THE INVENTION
[0005] The invention is directed to large precast concrete paver blocks of a type suitable for constructing driveways, sidewalks, patios, courtyards, boat ramps, and the like. Optionally, the exposed surfaces of the blocks are textured and, optionally, colored, to simulate natural stone. The paver blocks are provided with interlocking edge joints so that abutting edges of adjacent paver blocks align when the blocks are installed and are maintained in alignment. At each edge joint, each block includes a tapered projection and a recess. When edges of two blocks are moved to abut each other, each tapered projection on each block enters a recess on the other block. The taper on the projections move the blocks into alignment. Preferably, there are at least two edge joints on each block edge which will abut another block edge. The edges of the blocks are angled or relieved below the joints to ensure a tight fit at the top of the paver blocks.
[0006] Accordingly, it is an object of the invention to provide cast concrete paver blocks with edges which interlock for initially aligning and for maintaining alignment of abutting block edges.
[0007] Other objects and advantages of the invention will become apparent from the following detailed description of the invention and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] [0008]FIG. 1 is a fragmentary perspective view showing an exemplary layout for a driveway, a sidewalk, steps and a patio constructed with cast concrete paver blocks according to the invention;
[0009] [0009]FIG. 2 is a top plan view of a rectangular paver block according to the invention;
[0010] [0010]FIG. 3 is a top plan view of a corner paver block according to the invention;
[0011] [0011]FIG. 4 is a top plan view of a square paver block according to the invention;
[0012] [0012]FIG. 5 is a top plan view of a triangular paver block according to the invention;
[0013] [0013]FIG. 6 is an enlarged fragmentary cross sectional view showing details of the connection between abutting edges of two paver blocks according to the invention;
[0014] [0014]FIG. 7 is a fragmentary side view of abutting edges of two paver blocks which have a slight angle between the blocks; and
[0015] [0015]FIG. 8 is a fragmentary cross sectional view showing details of one joint on one of the paver blocks.
DETAILED DESCRIPTION OF THE INVENTION
[0016] Referring to FIG. 1, an exemplary layout 10 is shown for a residential application including a driveway 11 , a sidewalk 12 , steps 13 and a patio 14 made from different types of cast paver blocks. The illustrated layout 10 is formed from four different shaped blocks, consisting of rectangular paver blocks 15 , corner paver blocks 16 , square paver blocks 17 and triangular paver blocks 18 . Although the four illustrated block shapes will work for most applications, it will be appreciated that other block shapes also may be made to meet specific application requirements.
[0017] The blocks 15 - 18 are cast from concrete and, preferably, are reinforced with steel mesh or with rebar rods to provide the strength required for the application. For example, greater reinforcement will be needed for paver blocks used in a driveway 11 which must support the weight of heavy vehicles, than for paver blocks used in a patio 14 or in portions of a sidewalk 12 which do not cross a driveway. The blocks 15 - 18 are cast to a desired thickness, such as 4 inches (10.2 cm). In order to provide a pleasing appearance, the exposed top surfaces and any exposed edges of the blocks 15 - 18 may be textured, for example, to simulate natural stone. The block surfaces also may be stained or otherwise colored to more closely simulate stone using techniques which are well known in the art or to provide a desired appearance.
[0018] According to the invention, the sides of the blocks which abut the sides of other blocks are provided with one or more joints 19 which engage complimentary joints on the other blocks. The joints 19 are spaced on each block side for engaging the complimentary joint 19 on an abutting block side. FIG. 2 shows the rectangular block 15 as having two short sides 20 and 21 , each having two joints 19 , and as having two long sides 22 and 23 , each having three joints 19 . The rectangular block 15 may have, for example, a width of 4 feet (122 cm) and a length of 6 feet (183 cm).
[0019] [0019]FIG. 3 shows details of the corner block 16 . The block 16 is substantially trapezoidal in shape having a side 24 which is either 4 feet (122 cm) or 6 feet (183 cm) long, two angled sides 25 and 26 which are 4 feet (122 cm) long and, for example, form an angle of 30° to each other, and a side 27 which is shorter than the side 24 . In order to keep the width of the block at 4 feet or the width of the rectangular blocks 15 , ends 28 of the side 24 are slightly angled. By arranging the sides 25 and 26 at an angle of 30°, three corner blocks 16 can be used to form a 90° bend. If the sides 25 and 26 were angled at 45°, two blocks 16 would be used to form a 90° bend. The block 16 is intended to have the sides 25 and 26 abut sides of other blocks 15 - 18 . Thus, the sides 25 and 26 are each provided with two joints 19 . The center portion of the side 24 (without the ends 28 ) may be of the same length as the side 27 , for example, either 4 feet (122 cm) or 6 feet (183 cm). This will allow abutting a block to the center portion of the side 24 .
[0020] [0020]FIG. 4 shows the square block 17 , which has four sides 29 - 32 , each of which is 4 feet (122 cm) long. Each side 29 - 32 has two joints 19 .
[0021] [0021]FIG. 5 shows the triangular block 18 , which has two adjacent 4 feet (122 cm) long sides 33 and 34 which form a 90° angle and a long side 35 . Each of the sides 33 and 34 has two joints 19 for engaging joints on the other blocks.
[0022] [0022]FIGS. 6-8 show details of a construction for the joints 19 . Each joint 19 extends along an edge 38 of the block parallel to a top surface 39 of the block. Each joint 19 consists of a projecting rib 40 and of a groove 41 sized and shaped to receive a projecting rib 40 from a joint 19 on an abutting block. Preferably, the rib 40 is triangular or wedge shaped in cross section with sides 42 and ends 43 which taper to an apex 44 . Thus, the sides 42 are trapezoidal shaped and the ends 43 are triangular shaped. The groove 41 has complementary tapered sides and ends which are sized to receive the rib 40 . Consequently, when two joints 19 are moved into position where the adjacent sides 38 abut, as shown in FIG. 6, the top surfaces 39 of the adjacent blocks are moved into alignment when the rib 40 is moved into the groove 41 . Tapering the ribs 40 in two directions facilitates alignment of the blocks when they are positioned to form a desired layout. In the drawings, the rib 40 and the groove 41 for each joint 19 are shown as being aligned and adjacent each other. It will be appreciated that the rig 40 and the groove 41 may be spaced from each other, so long as they have the same spacing from the top surface 39 .
[0023] A lower portion 45 of the edge 38 on each block may be angled slightly inwardly from the joint 19 to a bottom 46 of the block to form an angle between the lower portion 45 and the bottom 46 greater than 90°. Optionally, a chamfer may be provided between the lower portion 45 and the bottom 46 to eliminate sharp edges which may be subject to impact damage when installing the paver block. The angled lower portion 45 serves two functions. First, it allows a relief area for any dirt or other foundation material which may be trapped between the abutting edges. Second, it allows two adjacent blocks to be slightly angled relative to each other when the ground on which the blocks are placed is not level, while maintaining a tighter fit at the top of the paver block.
[0024] The joints 19 are formed to have the same configuration on each side of the block which will abut a side of another block. Thus, when looking at an elevational view of any block side having a joint 19 , the rib 40 will be on the left side of the joint 19 and the recess 41 will be to the right of the rib 40 . As a consequence, when any two sides are moved into an abutting arrangement, the two joints are complementary and each rib 40 will align with a recess 41 . Alternately, all of the joints 19 can be made with the ribs 40 on the right and the recesses 41 on the left.
[0025] The joints 19 may be omitted from edges of the cast paver blocks which will not abut an adjacent paver block, especially any of these sides which may be visible after the blocks are installed. These edges may be textured with a pattern and colored similar to the exposed top surface of the block.
[0026] It will be appreciated that various modifications and changes may be made to the above described preferred embodiment of a cast concrete paver block without departing from the scope of the following claims. Although a preferred construction for the joints 19 has been described, it will be appreciated that other configurations also may be used to achieve the same results. For example, the ribs 40 can be replaced with round or oval knobs and the recesses 41 can be configured to receive the knobs. Also, the number of joints 19 on each side of the paver blocks may be changed to meet the needs for any particular application.
[0027] The block dimensions provided herein are intended to be exemplary. It will be appreciated that the block dimensions can be modified to meet local building codes and conventional sized in the community in which the blocks are used. However, the invention is particularly useful for paver blocks having a minimum dimension of at least 3 feet (91 cm) for providing larger hard surfaces.
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Precast concrete paver blocks are provided with interlocking edge joints so that abutting edges of adjacent paver blocks align when the blocks are installed and are maintained in alignment. At each joint, each block includes a tapered projection and a recess. When edges of two blocks are moved to abut each other, the tapered joint projection on each block enters the joint recess on the other block. The taper on the projections move the blocks to align the block surfaces. The edges of the blocks are angled or relieved below the joints to ensure a tight fit at the top of the paver blocks.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
This invention relates to a wicket dam lifting assembly and in particular, the invention relates to a removable hydraulic lifting module for a wicket dam which is removably mounted as a unit from the wet cylinder chamber in the sill.
This invention relates to a wicket dam assembly, and, in particular, to an apparatus for aligning the lifting cylinder and the wicket.
This invention relates to a wicket dam assembly, and, in particular to a prop for supporting the wicket having a weak link for facilitating a controlled failure under excessive loads.
Wicket dams are employed to establish and maintain the height of navigable waterways. Such dams operate by moving wickets or gates to an elevated position, the upper end of which establishes the minimum height of the waterway. Vessels are moved around the dam by means of a system of locks. When the water level is high as in times of Spring runoff and heavy rain, the level of the waterway is sometimes raised to the level of the upper edge of the wicket. Under such circumstances, the wicket gate is retracted and traffic bypasses the locks.
A gate is a hinged structure which is pivoted between retracted and elevated positions at the upper end of the dam spillway or sill. In its retracted position, the wicket lies generally horizontally along the river bottom or sill. In its elevated position, the wicket is disposed near the vertical at an angle of about 65° to 70°.
A lifting mechanism in the form of a hydraulic lifting cylinder engages a bearing on the back side of the gate to lift it into position. Known lifting mechanisms for relatively small wicket dams employ a hydraulic cylinder which is pivotable about an axis parallel to the spillway and the pivot axis of the gate. The method for raising such a wicket uses a lifting cylinder oriented at an angle so that the bearing or lifting point is always in line with the piston rod once the wicket is set in its raised position. However, in large constructions, such known arrangements do not provide sufficient maneuverability for the hydraulic lift cylinder Thus, the size of the wicket which can be lifted is limited. In addition, the known design has a problem, such that, if the wicket should for some reason lower prematurely, the piston rod would not be in alignment and the wicket could not be easily raised Under such circumstances, an auxiliary lifting means, such as a lifting barge upstream of the dam, is required to reposition the wicket.
It is inevitable that repair and maintenance of the lifting cylinder is required on a periodic basis. Thus, if repairs cannot be effected quickly at the site, removal of the equipment is necessary. In known arrangements, the cylinder must be partially or fully disassembled if it is to be removed from the site. Such disassembly often requires opening of hydraulic lines in the wet cylinder chamber below the dam sill which is difficult. The known arrangements are therefore difficult to maintain and repair. Further, because the environment presents a danger to repair crews working on the sill, it is desirable to remove the equipment for repair or maintenance at a site remote from the dam. Presently, there is no means available to quickly remove and replace the hydraulic lifting system from the sill.
The lifting cylinder is in a harsh environment subject to damage from falling debris and silt carried by the waterway. Accordingly, protection for the lifting cylinder mechanism is desirable.
Wickets are held aloft by a device known as a prop. The prop is typically hinged to the back side of the wicket and the prop rotates about an axis parallel to the gate axis. The free end of the prop rides along a track guide known as a hurter on the sill floor. When the gate is lifted from the retracted, horizontal position, the prop slides along the hurter until it engages a check point or bearing against which it rests. The wicket may be lowered by lifting it to raise the wicket further and thereby release the prop in a known manner.
The prop structure is susceptible to damage when overloaded. If a large vessel, such as a loose barge, moves against the wicket, the prop will break away. Under such circumstances, damage to the wicket and the prop can be considerable. Realizing that the prop may be overloaded, it is desirable to provide a weak point in the prop which will fail in a controlled manner and which is more easily repaired.
SUMMARY OF THE INVENTION
The invention is designed to overcome and obviate the various shortcomings and limitations of the described prior arrangements. In one embodiment of the invention, a dam wicket is secured in an elevated position by means of a prop pivotably mounted to the backside of the wicket. A free end of the prop has a fork and a prop bearing secured therein which engages a hurter bearing in the sill of the dam. The prop bearing comprises a break-away block pivotally secured in the fork. Forces exerted on the prop, in excess of a selected limit, cause shear pins in the fork to fail whereby the pivot block moves out of engagement with the hurter bearing to release the prop without further damage. A slidable pivot secures the block to the fork end of the prop, allowing the block to rotate upon failure of the shear pins.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic side sectional view of a wicket dam employing an alignable hydraulic lifting cylinder module in accordance with the present invention with the wicket retracted;
FIG. 2 is similar to FIG. 1 but with the wicket shown in the elevated position in solid lines and with the wicket shown raised further to the release position in phantom view;
FIG. 3 is a side sectional view showing details of the lifting cylinder module shown in FIGS. 1 and 2;
FIG. 4 is a side view similar to FIG. 1 with the wicket and prop raised to a vertical position and showing a work boat removing the lifting cylinder module;
FIG. 5A-5D are fragmentary side views of a prop having a pivotable breakaway bearing in accordance with the present invention;
FIG. 6 is a sectional view taken along line 6--6 of FIG. 5A;
FIG. 7 is a sectional view taken along line 7--7 of FIG. 5A;
FIG. 8 is a partial sectional view taken along line 8--8 of FIG. 5A; and
FIG. 9 is an end view in partial section taken along line 9--9 of FIG. 5A.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1 and 2 generally illustrate an arrangement employing an apparatus in accordance with various aspects of the present invention. In FIGS. 1 and 2, a wicket dam 10 is generally illustrated. The dam 10 includes an upstream sill 12 on the high water or upstream side 14 of the sill. A wicket gate 16 is pivotably mounted to the sill by means of a gate hinge 18. The gate hinge 18 lies on an axis 19 parallel with the dam 10.
The dam 10 includes a downstream sill portion 20 located on the downstream side 22. The downstream sill 20 is stepped and is lower than the upstream sill 12.
The gate 16 is operative between a lower retracted position (FIG. 1) and an upper or raised position (FIG. 2 solid lines). The gate 16 is raised or lowered by means of a hydraulic lift cylinder 30 (FIG. 3) which is secured in a frame 32 supported in an open upper end 34 of a hydraulic cylinder chamber 36. The cylinder 30 is pivotably supported in the frame 32 by means of a trunion bearing 38 which allows the cylinder 30 to rotate about trunion axis 39 which is parallel to the axis 19 of the hinge 18.
The cylinder 30 has an extendable piston rod 41 and an upper free end 42 of which carries a separable cup bearing 44. The gate 16 carries a spherical wicket bearing 46 which is mounted to a rear side 48 of the wicket 16. In the position shown in FIG. 1, when the rod 41 is retracted and the wicket 16 is down, as shown, the cup bearing 44 is spaced from but aligned with the spherical bearing 46. As the rod 41 is extended, as shown in FIG. 2, cup bearing 44 engages the spherical bearing 46 and the cylinder 30 rotates about axis 39 of the trunion bearing 38 as the gate 16 is lifted. It should be understood that the weight of the gate 16 is sufficient to cause the cup bearing 44 and the spherical bearing 46 to engage with sufficient force so that the cylinder 30 follows the gate 16 as illustrated.
A prop 60 is hinged at one end 62 to the rear side 48 of the gate 16 by means of a pin or clevis bearing 64. The prop 60 has a free end 66 which carries a slotted bearing 68. The slotted bearing 68 rides in a hurter 70 which is supported on the downstream sill 20, as illustrated.
The hurter 70 has a downstream end 72 wherein the prop 60 rests when the gate 16 is down, as illustrated in FIG. 1. The hurter 70 also has a prop bearing 74 located at an upstream end 76. The hurter 70 has a cam surface 77 downstream of the hurter bearing 74. The hurter 70 also has a hurter switch 79 upstream of the hurter bearing 74. When the gate 16 is lifted to the upright position, as illustrated in FIG. 2, the slotted bearing 68 rides along the hurter 70 and over the cam surface 74, whereupon the prop bearing 68 engages the hurter bearing 74. In the embodiment shown, the prop bearing 68 drops into a locking position to thereby support the gate 16 against its own weight and the force of any water on the upstream side 12 of the dam 10.
As shown in FIG. 2, when it is desired to lower the gate 16, the cylinder 30 is rotated by cylinder 90. Then rod 41 is extended and the cylinder 30 is caused, as hereinafter described, to align the cup bearing 44 with the spherical bearing 46. The rod 41 is further extended to thereby move the gate 16 to a release position (shown in phantom lines in FIG. 2), slightly above the raised position (shown in solid line in FIG. 2). In the release position, the prop bearing 68 moves further upstream and engages the hurter switch 79. As the rod 41 is retracted, the prop bearing 68 is caused by the switch 79 to ride around the hurter bearing 74 towards the downstream position 72 of the hurter 70 whereby the gate 16 is lowered as shown in FIG. 1.
In accordance with one aspect of the invention shown in FIG. 3, an alignment cylinder 90 is secured in the frame 32. The alignment cylinder 90 has a piston rod 92 which has a movable end 94 pivotably attached to the cylinder 30. In the arrangement illustrated, the moveable end 94 of the piston rod 92 is secured to the outside wall of the cylinder 30 by a clevis 96, as illustrated.
In accordance with the invention, after the gate 16 is raised to the elevated position (FIG. 2), the piston rod 41 is retracted and the cylinder 30 is positioned, generally by gravity to a vertical rest position (FIG. 1). When it is desired to release the gate 16, the rod 41 is raised and at the same time, the alignment cylinder piston rod 92 is extended causing the lifting cylinder 30 to rotate in the trunion bearing 38 counterclockwise so that the cup bearing 44 engages the spherical bearing 46. When so engaged, the piston rod 41 is further extended to cause release of the prop 60 as described above.
In accordance with another aspect of the invention, the lifting cylinder 30 is preferably formed as a modular, easily removable unit. Referring to FIG. 3, the frame 32, which supports the lifting cylinder 30, comprises a pair of spaced apart I beams 100 which rest on recessed ledges 102 in the upper end 34 of the cylinder chamber 36. The trunion bearings 38 rest, one each, on the upper surface 104 of the I beams 102. Shaft stubs 106 extend diametrically from the upper end 108 of the cylinder 30 and are secured in the circular openings of the trunion bearings 38.
The frame 34 further includes upstanding side wall portions 120 which form an open box-like structure 122. The I beams 100 are welded or secured to respective front and rear side walls 120F and 120R as illustrated. Lateral side walls 120L are secured to the front and rear side walls 120 F and 120R to form the box-like structure. C channel stiffeners 124 are secured between the I beams 100 and to the front and rear walls 120F and 120R of the frame 10 to form a rigid structure.
Upper margins 126 of the side walls 120 have flange portions 128 which rest in recesses 130 formed in the downstream sill 20. The recess 130 may be lined with a metal liner 132, as shown. Lower margins 133 of the side walls 120 engage the stepped portion 137 of the chamber opening 34. The frame 10 has an open bottom portion 138 which allows the cylinder 30 to swing between extreme positions.
A pair of cross members 140 are secured between the I beams 100 and carry the alignment cylinder 90 as illustrated. Flexible hydraulic lines 142 are coupled between the lifting cylinder and rigid hydraulic supply lines 144. The flexible lines 142 are coupled to the rigid lines 144 by quick disconnect couplers 146. Likewise, the alignment cylinder 90 has flexible hydraulic lines 148 coupled to rigid supply lines 150 by means of quick disconnect couplers 152.
The frame 10 has a sealed cover portion 160 which is secured to the flange portion 128 by suitable fasteners. The cover 160 has a watertight hatch 162 secured in an aperture 164. The hatch 162 is above the quick disconnects 146 and 152 and allows manual access thereto by maintenance personnel.
The cover 160 also has a domed portion 168 formed with a lateral slot 170 which is generally perpendicular to the gate axis 19. The upper end 108 of the lift cylinder 30 and the rod 41 extends through the slot 170 which is sufficiently elongated so that the cylinder may move between the extreme positions. A domed cover plate 172 is secured to an extension 109 of the upper end 108 of the cylinder 30 and matingly engages the domed portion 168 of the cover 160. The domed cover plate 172 covers the slot 170 as it slidably engages the domed portion 168 thereby shielding interior portions of the frame 32 from debris which may accumulate in and around the area of the downstream sill 20.
A flexible boot 174 is coupled between a lower side surface 176 of the domed portion 168 below the slot 172 and an upper wall portion 180 of the upper end 108 of cylinder 30. The boot 174 is secured by means of apertured rings 182 and a series of bolts 184. In accordance with this aspect of the invention, the cover plate 172 protects the interior of the module 10 from large debris and other objects. The plate 172, however, does not provide a watertight seal. Accordingly, the boot 174 prevents waterborne contamination including silt from entering the module.
Lifting bolts 190 with eyelet portions 191 are secured to the frame 32 through apertures 192 in the cover 160 and the upper side 104 of the I beams 100 as illustrated. As shown in FIG. 4, the eyelet portions 191 of the lifting bolts threaded with a cable 193 for engagement by the hook 194 of a crane 196 to lift the entire frame 32 including cylinder 30 out of the cylinder chamber 36. In the illustration, work boat 200 carries the crane 196 which reaches over the upstream side 12 of the dam 10. In the arrangement illustrated, the gate 16 is retracted to a full upright or vertical position by means of a wench 204. Also, the prop 60 is rotated out of the way and held in the vertical position.
In accordance with the invention, the entire frame 32 and lifting cylinder 30 are removable from the cylinder chamber 36 as a unit. It should be understood that prior to removal of the lifting module, the hatch 162 is opened and the quick disconnect couplers 146 and 152 are separated from the corresponding rigid lines 144 and 150.
As illustrated in FIG. 4, a spare module 32' may be installed in the chamber 34 and the gate 16 may be put back into service. A distinct advantage of the arrangement of the present invention is that repair work may be completed at another location remote from the site which is less hazardous to the work crews. Further, the work may be completed with less time pressure so that the quality of the repair and maintenance is thereby enhanced.
In accordance with another aspect of the invention illustrated in FIGS. 5A-5D and 6-9, a weak link 210 for the prop 60 is provided. As illustrated, the free end 66 of the prop 60 carries the slotted bearing 68. The weak link 210 comprises a forked casting or fork 212 having parallel wall portions 213 (FIG. 6) which is located at the butt or free end 66 of the prop 60. The weak link 210 also includes a block casting 214 which is bolted to the fork 212 between the wall portions 213 As further shown in FIG. 6, the block 214 has a slot 216 which rides in the hurter 70. The block 214 may be a single casting or it may be formed of laminated plates.
The fork 212 has a slot 218 formed between opposing interior faces 220 of walls 213. The block 214 is secured in the slot 218 by at least one and preferably a plurality of shear bolts 222 which are located in corresponding aligned bolt holes 224F and 224B in the fork 212 and block 214. The bolt holes 224F and 224B are aligned with the force F exerted along the prop 60. As illustrated in FIGS. 2 and 5A, when the prop 60 is located against prop bearing 74, the gate 16 is secured in the upright position.
The block 214, secured in the slot 216 has a terminal end 226 which is separated by space 230 from a corresponding terminal end 228 of the fork 212. The space 230 allows the block 214 to move with respect to the fork 212 when an axial force F is exerted on the prop 60 which exceeds the shear strength of the bolts 222. In other words, if the force F exerted against the gate 16 exceeds the strength of the weak link 210, the shear bolts 222 fail and the block 214 is forced along the slot 218 in the fork 212.
The fork 212 has elongated slots 234 formed in the side wall portions 213. The slots 234 are not aligned with the force F exerted along the prop 60 but forward and upward. The block 214 has a pivot pin 232 which extends into and is slidable in the elongated slots 234. Thus, when the force F on the prop 60 exceeds the shear strength of the bolts 222, the bolts 222 fail and prop 60 with block 212 moves forward towards the terminal end 226 of the block 214. The pivot pin 232, however, moves in the slot 230 and is not sheared. Instead, as the prop 60 moves toward block 214 in the direction of the force F along the axis of the prop 60, the slot 230 accommodates slidable motion pivot pin 232 and allows the block 214 to both slide askew of the prop 60 and rotate clockwise as the prop 60 rides past the hurter bearing 74.
An important feature of the invention is that the connection between the block 214 and the fork 212 requires the space 230 which thereby allows the thrust of the force F to drive the fork 212 for relative movement with respect to the block 214 to thereby allow the shear bolts 222 to fail. In accordance with another embodiment of the invention, a single shear bolt may be used, however, two or more are preferred for the loads on this application. In addition, other devices such as pins or dogs may be used to secure the block for relative motion with respect to the fork.
In accordance with the invention, if the prop 60 fails, it fails at a repairable weak link 210. The repair may be made by replacing the destroyed shear pins 222 at the site. The gate 16 may be then lifted and secured in the elevated position with the prop 60 relocated in the hurter 70.
While there have been described what at present are considered to be the preferred embodiments of the present invention, it will be readily apparent to those skilled in the art that various changes may be made therein without departing from the invention and it is intended in the claims to cover such changes and modifications as fall within the true spirit and scope of the invention.
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The invention is directed to a breakaway prop for a wicket employing a slble and rotatable prop bearing which is secured to the prop by shear pins. Upon application of sufficient force, the shear pins release the prop bearing and allow the wicket to drop without damaging the prop.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
FIELD OF THE INVENTION
[0001] This invention relates in general to wellhead assemblies and in particular to an energizing ring nose profile that allows increased compression of a seal before a U-seal is locked down.
BACKGROUND OF THE INVENTION
[0002] Seals are used between inner and outer wellhead tubular members to contain internal well pressure. The inner wellhead member may be a casing hanger located in a wellhead housing and that supports a string of casing extending into the well. A seal or packoff seals between the casing hanger and the wellhead housing. Alternatively, the inner wellhead member could be a tubing hanger that supports a string of tubing extending into the well for the flow of production fluid. The tubing hanger lands in an outer wellhead member, which may be a wellhead housing, a Christmas tree, or a tubing head. A packoff or seal seals between the tubing hanger and the outer wellhead member. In addition to the seal between the inner and outer wellhead members, another annular seal, or emergency seal, may be located below this seal.
[0003] A variety of seals located between the inner and outer wellhead members have been employed in the prior art. FIG. 1 shows a portion of a seal assembly in the prior art within a wellhead housing 10 . Housing 10 is typically located at an upper end of a well and serves as an outer wellhead member. An energizing ring 2 is typically forced downward by a running tool or the weight of a string to force it into a slot 3 defined by a U-type metal seal ring 4 . This deforms inner and outer walls of the seal ring 4 apart into respective sealing engagement with inner and outer wellhead members 15 , 10 . The energizing ring is typically a solid wedge-shaped member. The deformation of the inner and outer walls exceeds the yield strength of the material of the seal ring 4 , making the deformation permanent. Prior art seals may also include elastomeric and partially metal and elastomeric rings. Prior art seal rings made entirely of metal for forming metal-to-metal seals are also employed.
[0004] The seals may be set by a running tool, or they may be set in response to the weight of the string of casing or tubing. Located below the seal ring 4 is an emergency seal 5 , in case seal ring 4 fails, that rests on a shoulder 6 formed on an inner wellhead member, such as a hanger 15 . The emergency seal 5 may be fabricated from metallic, non-metallic, or elastomeric materials, or a combination thereof. The emergency seal 5 may be compressed when downward force from the string is applied to the energizing ring 2 to thereby cause emergency seal 5 to bulge outwards to contact the inner and outer wellhead members 15 , 10 at a point below the seal ring 4 above. However, the energizing ring 2 also deforms the metal seal ring 4 against the outer wellhead member 10 and the inner wellhead member 15 . If the metal seal ring 4 is deformed against the inner and outer wellhead members 15 and 10 before the emergency seal 5 is compressed sufficiently to bulge outwards against the outer wellhead member 10 , then the emergency seal 5 may not be able to perform its function as an emergency seal and pressure integrity may diminish.
[0005] A need exists for a technique that addresses the seal leakage problems described above. In particular a need exists for a technique to compress an emergency seal a desired amount prior to deformation of the walls of the metal-to-metal seal. The following technique may solve these problems.
SUMMARY OF THE INVENTION
[0006] In an embodiment of the present technique, a seal assembly is provided that forms a metal-to-metal seal and has features that enhance sealability in the seal assembly. The seal assembly also includes features that enhance emergency or backup sealing capabilities. The seal ring has inner and outer walls separated by a slot and an elastomeric seal is located below the seal ring and has a bottom portion that contacts an upward facing shoulder of a hanger. A metal energizing ring has a tapered nose that may be pushed into the slot during installation to deform the inner and outer walls into sealing engagement with inner and outer wellhead members having wickers formed thereon. A radial gap exists between the outer wall of the seal and the inner wall of the mating housing. Such gap is required for installation in the field and is sufficiently large to require plastic deformation of the seal body, but not the energizer ring.
[0007] In an illustrated embodiment, the nose of the energizing ring has a compound angle configuration that can be tuned to allow a predetermined amount of force to be transmitted to the emergency seal below the seal ring. The compound angle also determines how much the nose travels into the slot when a force is applied to the energizing ring. This force and the accompanying reaction force from the shoulder of the hanger compresses the elastomeric seal to cause it to bulge outwards. The outward bulging of the elastomeric seal creates a seal between the inner surfaces of the inner and outer wellhead members. Once the elastomeric seal is compressed to a desired level, the load on the energizing ring has increased to the point that the tapered nose of the energizing ring will further enter the slot and force the outer and inner walls of the metal seal into sealing engagement with the inner and outer wellhead members. At this point, no additional compression of the elastomeric seal is possible.
[0008] In an example embodiment, the seal assembly also comprises the energizing ring that engages the slot. The retainer ring rests in a machined pocket on the outer surface of the energizing ring. The outer leg of the seal ring is machined with a taper that engages a taper formed on the retainer ring. The engagement ensures that the seal assembly remains intact as one solid structure during landing, setting, and retrieval operations. The retainer ring can alternatively rest in a machined pocket on the inner surface of the energizing ring to lock the seal onto the hanger.
[0009] The combination of stored energy provided for by the energizing ring, the compound angle configuration of the energizing ring nose, and the compressible elastomeric seal below the seal ring, advantageously provide enhanced emergency sealing if the metal-to-metal seal fails.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a sectional view of a seal assembly of the prior art with an energizing ring locked to the seal, but unset, and with an emergency seal decompressed;
[0011] FIG. 2 is a sectional view of a seal assembly being lowered between outer and inner wellhead members, in accordance with an embodiment of the invention;
[0012] FIG. 3 is a sectional view of the seal assembly of FIG. 2 landed between outer and inner wellhead members in an unset position and with compression of an emergency seal, in accordance with an embodiment of the invention;
[0013] FIG. 4 is a sectional view of the seal assembly of FIG. 2 landed between outer and inner wellhead members in a set position, in accordance with an embodiment of the invention;
[0014] FIG. 5 is a sectional view of the nose of an energizing ring before entering the slot of a seal ring, in accordance with an embodiment of the invention;
[0015] FIG. 6 is a sectional view of the nose of an energizing ring after entering a slot of a seal ring and deforming walls of the seal ring, in accordance with an embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0016] Referring to FIG. 2 , an embodiment of the invention shows a portion of a wellhead assembly that includes a high pressure wellhead housing 10 . In this example, the housing 10 is located at an upper end of a well and serves as an outer wellhead member of the wellhead assembly. Housing 10 has a bore 11 located therein. In this example, an inner wellhead member is a casing hanger 15 , which is shown partially in FIG. 2 within bore 11 . Alternately, wellhead housing 10 could be a tubing spool or a Christmas tree, and casing hanger 15 could instead be a tubing hanger, plug, safety valve, or other device. Casing hanger 15 has an exterior annular recess radially spaced inward from bore 11 to define a seal pocket 17 . Wickers 12 are located on a portion of the wellhead bore 11 and wickers 18 are located on a portion of the cylindrical wall of seal pocket 17 . In this example, the profiles of each set of wickers 12 , 18 are shown as continuous profiles on the bore 11 and seal pocket 17 . However, the wickers 12 , 18 may be configured in other arrangements.
[0017] Continuing to refer to FIG. 2 , a metal-to-metal seal assembly 21 is lowered between the housing 10 and casing hanger 15 and located in seal pocket 17 . Seal assembly 21 includes a seal ring 23 formed of a metal such as steel. Seal ring 23 has an inner wall 25 that is an inner seal leg 27 for sealing against the cylindrical wall of casing hanger 15 . Seal ring 23 has an outer wall surface 29 comprised of outer seal leg 31 that seals against wellhead housing bore 11 . Each wall surface 25 , 29 is cylindrical and smooth and engages the wickers 12 , 18 when deformed against the bore 11 of the housing 10 and seal pocket 17 of the casing hanger 15 . The wickers 12 , 18 enhance the grip to aid in the prevention of axial movement of the seal assembly once set.
[0018] In the example FIG. 2 , seal ring 23 is uni-directional, having an upper section only; however, a seal ring that is bi-directional may optimally be used. The upper section has a slot 35 . The inner and outer surfaces forming slot 35 comprise generally cylindrical surfaces, that when viewed in an axial cross-section are generally parallel and each follow a straight line.
[0019] An annular energizing ring 41 engages slot 35 on the upper side. As shown, the energizing ring 41 has an axis A R that is substantially parallel with an axis (not shown) of the wellhead assembly. Energizing ring 41 is forced downward into slot 35 by a running tool (not shown) connected to grooves 43 on the inner diameter of upper energizing ring 41 during setting. Alternatively, seal assembly 21 and energizing ring 41 may be part of a string that is lowered into bore 11 , the weight of which forces energizing ring 41 into slot 35 . If retrieval is required, the grooves 43 can be engaged by a retrieving tool (not shown) to pull energizing ring 41 from set position. Energizing ring 41 can be formed of metal, such as steel. The mating surfaces of energizing ring 41 and outer seal leg 31 may be formed at a locking taper.
[0020] In an embodiment of the invention, an outwardly biased retainer ring 44 is carried in a pocket 45 on the outer surface of upper energizing ring 41 . Ring 44 has grooves 47 on its outer surface and an edge that forms an upward facing shoulder 49 . On the upper end of the outer seal leg 31 and on its inner surface, is a downward facing shoulder 51 that abuts against shoulder 49 of retainer ring 44 , preventing energizing ring 41 from pulling out of seal ring 23 once the two are engaged.
[0021] As shown in FIGS. 2 , 3 , and 4 , a recess 53 is formed below shoulder 51 on the inner surface of outer seal leg 31 . Grooves 55 are formed on the inner surface of outer seal leg 31 just below recess 53 . Referring now to FIG. 4 , the energizing ring 41 is put in a set position by downwardly ratcheting the ring 41 to align grooves 47 with grooves 55 . When energizing ring 41 is set, as in FIG. 4 , retainer ring 44 will move radially from pocket 45 , and grooves 47 on the outer surface of retainer ring 44 will engage and ratchet by grooves 55 on the inner surface of outer seal leg 31 , locking energizing ring 41 to seal ring 23 . Retainer ring 44 can move downward relative to grooves 55 , but not upward.
[0022] Energizing ring 41 has a nose 61 or engaging portion that engages slot 35 . Energizing ring 41 has an inner surface 63 and an outer surface 65 for engaging the opposite inner sidewalls of slot 35 in seal ring 23 . Inner and outer surfaces 63 , 65 may be straight surfaces as shown, or optimally curved surfaces. Key features of the nose 61 of the energizing ring 41 are discussed in more detail in the description of FIGS. 5 and 6 .
[0023] In the example embodiment of FIG. 2 , a lower extension 100 secures by threads to the lower portion of seal ring 23 . The lower extension 100 extends down and connects to an upper metal ring 102 . The upper metal ring 102 may be bonded, soldered, welded, or fastened to the lower extension 100 . In this example, the upper metal ring 102 together with a lower metal ring 104 , hold an emergency or backup seal 106 in between. The emergency seal 106 may be bonded to both metal rings 102 , 104 and may be fabricated from elastomeric, metallic, or non-metallic materials, or a combination thereof. In this example, a landing nose 108 is connected to the a back end of the lower metal ring 104 to facilitate landing on an upward facing shoulder 110 formed on the interior of the casing hanger 15 . The shoulder 110 provides a reaction point during setting operations.
[0024] Referring to FIGS. 5 and 6 , an enlarged sectional view of the nose 61 of the energizing ring 63 is shown in the unset and set positions, respectively. The nose 61 may have a vent 70 to prevent hydraulic locking and may have a first tapered surface or portion 72 that tapers downwards at an angle 74 and have a second tapered surface or portion 80 . The inner and outer legs 27 , 31 of the seal ring 23 have tapered, upward facing shoulders 76 , 82 at their upper ends and proximate the opening of the slot 35 . The shoulders 76 , 82 form a corresponding surface on which the second tapered surface 80 of the nose 61 rests when in the unset position. The taper of the first and second tapered surfaces 72 , 80 form a compound angle that may be varied to achieve a delay in the entry of the energizing ring 63 into the slot 35 of the seal ring 23 . For example, if less taper is provided to the second tapered surface 80 such that it is flatter, more force will be required to be applied to the energizing ring 41 ( FIG. 2 ) to force the nose 61 into the slot 35 and consequently the emergency seal 106 will be compressed more than if a lesser force were applied. The second tapered surface 80 may vary in taper from 0 degrees (flat), which provides the most resistance, up to 90 degrees. The first tapered surface 72 may have a taper angle 74 that varies between 0 and 30 degrees. Various combinations of angles for both tapered surfaces 72 , 80 may be used depending on the applications and may be affected by the material and construction of the emergency seal 106 .
[0025] By delaying the entry of the energizing ring nose 61 into the slot 35 as force is applied to the energizing ring 41 ( FIG. 2 ), setting of the legs 27 , 31 of the seal ring 23 is delayed and the force is thereby transmitted to the shoulder 110 ( FIG. 3 ) on the hanger 15 , which acts as a reaction point. The force on the energizing ring 41 and the reacting force from the shoulder 110 ( FIG. 3 ) thereby compress the emergency seal 106 ( FIGS. 2-4 ) to cause it to bulge outwards until it forms a seal against the bore 11 of the housing 10 ( FIG. 3 ). Once the emergency seal 106 is compressed sufficiently to bulge outwards against the outer wellhead member 10 , the surface force between the second tapered surface 80 of the nose 61 and the upward facing shoulder 76 may be overcome by the force applied to the energizing ring 41 ( FIG. 4 ) to thereby initiate the entry of the nose 61 into the slot 35 . In an example embodiment, the first tapered surface 72 of the nose 61 is significantly more tapered than that of the second tapered surface 80 to facilitate entry of the nose 61 into the slot 35 and thereby deform the legs 27 , 31 of the seal ring 23 against the wickers 12 , 18 of the housing 10 and hanger 15 . Once the legs 27 , 31 are set, generally the elastomeric seal 106 ( FIG. 4 ) cannot be compressed further. Control of the amount of compression in the elastomeric seal 106 ( FIG. 4 ) can also be tuned by varying the surface area between the contacting surface of the second tapered surface 80 and the upward facing shoulder 76 . A larger surface area at this contact surface may aid the delay of entry of the nose 61 into the slot 35 .
[0026] In an example of operation of the embodiment shown in FIGS. 2-6 , a running tool or string (not shown) is attached to seal assembly 21 ( FIG. 1 ) and lowered into the seal pocket 17 Seal assembly 21 may be pre-assembled with energizing ring 41 , retainer ring 44 , seal ring 23 , extension 100 , and emergency seal 106 , all connected as shown in FIG. 2 . The running tool or string (not shown) can be attached to grooves 43 on energizing ring 41 . The outer wall 29 of outer seal leg 31 will be closely spaced to wickers 12 on the wellhead bore 11 . The inner wall 25 of inner seal leg 27 will be closely spaced to the wickers 18 on the cylindrical wall of seal pocket 17 . By pushing the energizing ring 41 downward (such as by the running tool) with sufficient force such that the second tapered surface 80 at the nose 61 of the energizing ring 41 transmit force via the upward facing tapered shoulders 76 , down through the seal ring 23 to the emergency seal 106 , to thereby compress the seal 106 as shown in FIG. 3 . Compression of the emergency seal 106 causes it to bulge radially outwards and sealingly engage the bore 11 of the housing 10 . After the seal 106 is compressed sufficiently to cause it to bulge outwards against the outer wellhead member 10 , continued force is applied to the energizing ring 41 to overcome the surface forces between the second tapered surfaces 80 of the nose 61 and the tapered shoulders 76 of the seal ring 23 , to insert the nose 61 in the slot 35 . Urging the nose 61 into the slot 35 is facilitated by the first tapered surfaces 72 of the nose 61 because they have significantly more taper and thus less resistance than the second tapered surfaces 80 . Further, engagement of nose 61 with the slot 35 causes the inner and outer seal legs 27 , 29 to move radially apart from each other as shown in FIGS. 4 and 6 . The inner wall 25 of inner seal leg 27 will embed into wickers 18 in sealing engagement while the outer wall 29 of outer seal leg 31 will embed into wickers 12 in sealing engagement. Once the inner and outer seal legs 27 , 31 seal against the wickers 12 , 18 of the wellhead members 10 , 15 , the emergency seal 106 can no longer be compressed.
[0027] During the downward movement of the energizing ring 41 relative to the seal assembly 21 , the outwardly biased retainer ring 44 rides against recess 53 . As shown in FIG. 4 , as the wedge member 61 of the energizing ring 41 advances into slot 35 , the retainer ring 44 and grooves 55 engage and ratchet by grooves 55 on the inner surface of seal leg 31 . As a result, retainer ring 44 locks energizing ring 41 to seal ring 23 as shown in FIG. 4 , preventing retainer ring 44 from working its way out of the seal ring 23 . Vent passages or penetration holes 70 ( FIG. 5 ) may be incorporated across wedge member 61 and through upper energizing ring 41 so that a hydraulic lock condition does not prevent axial make-up of the energizer and seal system.
[0028] Subsequently, during production, hot well fluids may cause the casing to grow axially due to thermal growth. If so, the casing hanger 15 may move upward relative to the wellhead housing 10 . The inner seal leg 27 will move upward with the casing hanger 15 and relative to the outer seal leg 31 . The retainer ring 44 will grip the grooves 55 to resist any upward movement of energizing ring 41 relative to outer seal leg 31 . The wickers 12 , 18 will maintain sealing engagement with the inner wall 25 of inner seal leg 27 and the outer wall 29 of outer seal leg 31 .
[0029] If the seal formed by the wickers 12 , 18 and the inner and outer seal legs 27 , 31 is compromised due to excessive thermal growth cycles or higher operating pressures, then the emergency seal 106 can maintain seal integrity between the outer and inner wellhead members 10 , 15 .
[0030] In the event that seal assembly 21 is to be removed from bore 11 , a running tool is connected to threads 43 on upper energizing ring 41 . An upward axial force is applied to upper energizing ring 41 , causing it to withdraw from slot 35 and retainer ring 44 to disengage grooves 55 on seal leg 31 . However, due to retaining shoulders 49 , 51 , energizing ring 41 will remain engaged with seal ring 23 , preventing the two from fully separating ( FIG. 2 ).
[0031] In an additional embodiment (not shown), the wellhead housing 10 could be a tubing spool or a Christmas tree. Furthermore, the casing hanger 15 could instead be a lockdown hanger, tubing hanger, plug, safety valve or other device.
[0032] While the invention has been shown in only one of its forms, it should be apparent to those skilled in the art that it is not so limited but is susceptible to various changes without departing from the scope of the invention. For example, the seal could be configured for withstanding pressure in two directions, if desired, having two energizing rings. In addition, each energizing ring could be flexible, rather than solid.
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A wellhead seal assembly that forms a metal-to-metal seal between inner and outer wellhead members. A metal seal ring has inner and outer walls separated by a slot. An elastomeric seal is located below the seal ring and has a bottom portion that contacts an upward facing shoulder of a hanger. An energizing ring with a tapered nose is moved into the slot. The tapered nose has a compound angle that determines how much the nose travels into the slot when a force is applied to the energizing ring. Once the elastomeric seal is compressed to a desired level, the load on the energizing ring has increased to the point that the tapered nose of the energizing ring will further enters the slot and force the outer and inner walls of the metal seal into sealing engagement with the inner and outer wellhead members.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
CROSS-REFERENCE TO RELATED APPLICATION
This application claims the benefit of U.S. Provisional Application No. 60/301,809 filed Jul. 2, 2001, incorporated by reference herein.
FIELD OF THE INVENTION
The present invention relates to tools used to remotely manipulate vehicle, enclosure or building access where there is a potentially dangerous or hazardous situation.
BACKGROUND OF THE INVENTION
When trying to open doors, cabinets, drawers or other panels in a potentially dangerous or hazardous environment, there is a requirement to quickly and remotely manipulate these items to safely pull them open from a safe distance. The same requirement arises when attempting to clear and declare safe a potentially booby-trapped vehicle or when removing a suspect package from an office or vehicle via length of rope.
Presently, a bomb technician, or other law enforcement officer, must improvise some device for this purpose. The devices are commonly improvised using already existing and readily available items such as vice-grips, rope, duct tape and hooks, which need to be configured and adapted according to each unique situation.
Many times these panels are also latched in some manner, requiring that the latch be manually released prior to opening the panel.
SUMMARY OF THE INVENTION
Disclosed is a remotely operable latched panel opening mechanism designed to both release a latch on a panel and open the panel after the latch has been released.
According to one aspect, the remotely operable latched panel opening mechanism for potentially booby-trapped latch panels comprises a clamp member for clampable engagement with a structure on said panel, and a displaceable actuator mounted on said clamp member. The displaceable actuator has a protruding element engageable with a latch on said latched panel and a coupling element for connection to a line to permit remote activation of said actuator to release said latch and thereby permit said latched panel to be opened by remotely pulling on said clamp member. The panel may be a door, a drawer, a car hood or any other such barrier means. The line may be a rope, cable chain or the likes, serving as a pulling means.
These clamps mainly consist of two arms, each having a jaw end and a handle end. The two members are pivotably joined by means to maintain the clamp in the closed position when released. Further, one of the members of these clamps has a passage for an adjustable blocking element, which abuts on the other member. The jaw ends of the clamp can have different teeth configurations to allow clamping engagement with the structure to be remotely manipulated.
The displaceable actuator allows a latch to be remotely released in a separate action from using the clamp to open the panel. The displaceable actuator includes pivoting and sliding adjusting mechanisms for adaptation to particular situations.
In another embodiment, there is provided a method of opening potentially booby-trapped latched panels using a remotely operable opening mechanism comprising a clamp member and a displaceable actuator mounted on said clamp member, said displaceable actuator having a protruding element and a coupling element, the method comprising the steps of clamping the clamp member with a structure on the panel, engaging the protruding element with a latch on the panel, and connecting the coupling element to a line to permit remote activation of said actuator to release said latch and thereby permit said latched panel to be opened by remotely pulling on said clamp member.
In another embodiment, there is provided a kit of remotely opening latched panels, comprising a clamp member for clampable engagement with a structure on said panel, and a displaceable actuator mounted on said clamp member, said displaceable actuator having a protruding element engageable with a latch on said latched panel and a coupling element for connection to a line to permit remote activation of said actuator to release said latch and thereby permit said latched panel to be opened by remotely pulling on said clamp member.
The mechanism allows law enforcement officers to release and open potentially booby-trapped panels.
Other aspects and advantages of embodiments of the invention will be readily apparent to those ordinarily skilled in the art upon a review of the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the invention will now be described in conjunction with the accompanying drawings, wherein:
FIG. 1 is a perspective view of one embodiment of a clamp in accordance with the present invention;
FIG. 2 illustrates a bolt that may be used as a blocking means to adjust the gap between the teeth of a clamp;
FIG. 3 illustrates a perspective view of a finger latch attachment;
FIG. 4 illustrates a top view of the finger latch attachment of FIG. 3;
FIG. 5 illustrates a side view of the finger latch attachment of FIG. 3;
FIG. 6 illustrates a perspective view of the finger latch attachment of FIG. 3 mounted on the clamp of FIG. 1;
FIG. 7 illustrates a perspective view of a thumb latch attachment;
FIG. 8 illustrates a top view of the thumb latch attachment of FIG. 7;
FIG. 9 illustrates a side view of the thumb latch attachment of FIG. 7;
FIG. 10 illustrates a perspective view of the thumb latch attachment of FIG. 7 fastened to the clamp of FIG. 1;
FIG. 11 is a perspective view of an example of a clamp of larger dimension;
FIG. 12 is a perspective view illustrating the teeth shape of a basic small nose clamp;
FIG. 13 is a side view of a small long nose clamp;
FIG. 14 is a side view of a small short nose clamp;
FIG. 15 is a perspective view illustrating the teeth shape of a small needle nose clamp;
FIG. 16 is a side view of a small needle nose clamp;
FIG. 17 is a perspective view illustrating the teeth shape of a inner locking clamp;
FIG. 18 is a side view of a small inner locking clamp;
FIG. 19 is a top view of a large inner locking clamp;
FIG. 20 is a side view of the large inner locking clamp of FIG. 19;
FIG. 21 is a top view of a large double inner locking clamp;
FIG. 22 is a side view of the large double inner locking clamp of FIG. 21;
FIG. 23 is a perspective view illustrating the teeth shape of a small flat clamp;
FIG. 24 is a side view of a small flat clamp;
FIG. 25 is a perspective view illustrating the teeth shape of a basic small clamp for use with vehicle door handles;
FIG. 26 is a side view of a small round clamp;
FIG. 27 is a side view of a small v-nose clamp;
FIG. 28 is a top view of a hood latch;
FIG. 29 is a side view of the hood latch of FIG. 28;
FIG. 30 is a top view of a spring loaded car door pull;
FIG. 31 is a side view of spring loaded car door pull of FIG. 30;
FIG. 32 is a top view of a locking car door pull; and
FIG. 33 is a side view of the locking car door pull of FIG. 32 .
This invention will now be described in detail with respect to certain specific representative embodiments thereof, the materials, apparatus and process steps being understood as examples that are intended to be illustrative only. In particular, the invention is not intended to be limited to the methods, materials, conditions, process parameters, apparatus and the like specifically recited herein.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A basic clamp member is shown in FIG. 1 . This comprises two clamp arms 1 , 2 , each having a jaw end 3 and a handle end 4 . The jaw end 3 can embrace different teeth configurations as described below. The jaw end 3 is used for clamping engagement with a structure on a panel, such as a door knob or handle. In an exemplary embodiment shown in FIG. 1, there are two teeth 10 , which are curved and sharpened so that the clamp member can be placed over and behind the structure to be pulled via pulling means, such as a cable or a rope (not shown). The members are pivotably joined together by means 5 (typically a spring) to maintain the clamp in clamping engagement with the structure to be pulled when released.
Since these clamps are sometimes pulled with excess force, blocking means (illustrated in FIG. 2) can be used to avoid opening of the clamp when pulled. As an example, the blocking means is shown in FIG. 2 to be a screw 55 . The blocking means cooperates with a passage 9 in one arm of the clamp to abut on the opposite interior side of the other arm of the clamp. This blocking means is adjustable to variable depth depending on the desired gap between the jaw teeth 10 .
Preferably, the clamp has a hole 8 in the handle end 4 of at least one arm to allow attachment of a pulling means (not shown), preferably a rope or a cable. Alternatively, the pulling means may attach at two holes 8 in each handle end. There is provision of a second passage 7 to fasten accessories or tools with the blocking means to be used in cooperation with the clamps
As mentioned above, quite often the panel to be opened has a latch which must first be released. In this case, the clamp is used with a displaceable actuator designed to release a latch on a panel to be opened. A first such tool is shown in FIGS. 3, 4 and 5 . This finger latch mechanism 50 is used when a latch, usually designed to be pulled by a finger, has to be retracted prior to opening a panel, such as a door. This finger latch 50 comprises a latch operation end 20 having a boss 21 shaped to protrude behind the latch to pull on it. A pulling end 26 has a hole 27 used to attach pulling means (not shown), preferably a rope or a cable or any type of line to permit remote activation of actuation to release the latch. The latch operation end 20 and the pulling end 26 are joined together by two bars 24 , 25 . A sliding element 23 movably retains the bars 24 , 25 over the clamp with a second blocking means 22 .
This mechanism is preferably bolted to the clamp via hole 7 after the clamp has been positioned on the structure to be pulled. FIG. 6 shows the finger latch 50 mounted on clamp 40 . The entire mechanism can be mounted upside down if needed, in particular when the finger latch is hinged horizontally along the length of a door handle. The rope is attached to the mechanism such that the attachment slides along the length of the clamp when the rope is pulled.
In operation, the clamp is installed over a structure to be pulled, such as a handle, adjacent to the latch The finger latch attachment 50 is installed such that the boss 21 is behind the latch to be pulled. A line serving 27 a as pulling means is attached to the hole 27 in the pulling end 26 of the mechanism. The latch is then retracted by operating the latch attachment 50 by remotely pulling the line 27 a from a safe distance, and the door can then be opened by continuing to pull on the line.
A second such displaceable actuator 60 is shown in FIGS. 7, 8 and 9 . This thumb latch mechanism is used when a latch, usually designed to be pushed by a thumb, has to be pressed prior to opening a door. This thumb latch 60 comprises a latch operation end 57 , a pivoting portion 55 and a pulling end 59 . The pivoting portion 55 and the pulling end 59 form an arcuate elongated member. The latch operation end 57 is at the opposite end of the pulling end 59 and is substantially perpendicular to the pivoting portion 55 . The pivoting portion comprises a series of holes 54 spaced to adapt to a wide variety of thumb latch spacing dimensions. The pulling end 59 has a hole 56 used to attach pulling means (not shown). The distance between the selected hole 54 according to the situation and the pulling end hole 56 provides the necessary lever action to push on the latch. FIGS. 8 and 9 illustrate the bolt 65 threaded in a selected hole. The latch operation end 57 has an adjustably mounted plunger 51 to press on the latch. An elongated hole 58 provides a first axis adjustment of a plunging means 51 . The adjustments on the plungers on the plunger 51 help to accurately position the plunger 51 for maximum force. A threaded element joining the plunger 51 to a knob 53 , in cooperation with a bolt 52 , provides a second axis adjustment perpendicular to the first axis adjustment. When the plunger 51 is axially aligned with the center of the latch, the operator can block the plunger 51 in position by turning the knob 53 . The latch can now be pressed by pulling line attached to the pulling end hole 56 , and the door can be opened by pulling on the clamp.
This mechanism is preferably bolted to the clamp via hole 7 after the clamp has been positioned on the structure to be pulled. FIG. 10 shows the thumb latch 60 mounted on the clamp member 40 . The whole mechanism can be oriented to accommodate various situations, as with the finger latch mechanism.
With the use of the pulling means operating the clamp member and the displaceable actuator, a latch is released in an independent action from the pulling action of the clamp to open the panel. In an alternate embodiment, another pulling means is attached to the hole 8 of one handle end 4 of the clamp, such that one pulling means operates displaceable actuator and another pulling means operates the clamp.
Various configurations of clamp teeth may be used on the jaw ends 3 of the clamp to be adapted to all kinds of structures, including hinges, knobs or handles. As will be obvious to one skilled in the art, the clamps can be also of various dimensions, adapted to the ease of installation. For most clamp dimensions, the external shape of the clamps are similar, but when the clamp become larger, the external shape changes, in order to obtain a larger gap 63 between the teeth, as seen in FIG. 11 .
The foregoing is by way of example only and is not intended to be limiting in any way. FIGS. 12 to 27 illustrate possible shapes of clamp teeth that may be used.
FIG. 12 illustrates the basic shape of a small nose clamp. The clamp teeth size may vary. FIG. 13 illustrates a small long nose clamp, and FIG. 14 illustrates a small short nose clamp. The clamp of FIG. 14 is a shorter version of the clamp illustrated in FIG. 13, to allow it to fit in places where the longer clamp of FIG. 13 will not fit. Both these clamps are spring loaded clamps with a split in the opening end to enable the clamp to be fastened around hood latches that have a pull handle mechanism. The ends are curved and sharpened so that the clamp can be placed over and behind the structure to be operated via a rope, and the pull direction of the pulling means is along the length of the clamp.
FIGS. 15 and 16 illustrate a small needle nose clamp which is a spring loaded clamp with a narrow end to enable the clamp to be inserted and fastened around narrow items such as head rest supports, wires or other items where there is insufficient room for a larger clamp. The ends are curved and sharpened so that the clamp can be placed over and around the structure to be operated via a rope and the pull direction of the pulling means is along the length of the clamp.
FIG. 17 illustrates the basic shape of an inner locking clamp. The clamp teeth size may vary. FIG. 18 illustrates a small inner locking clamp, which is a spring loaded clamp with a full width end to enable the clamp to be inserted and fastened around a variety of objects. It is a general purpose clamp that can be used to attach to vehicle door handles, vehicle rain gutters and numerous other surfaces and protrusions. The ends are curved and sharpened so that the clamp can be placed over and around the structure to be operated via a rope and the pull direction of the pulling means is along the length of the clamp.
FIGS. 19 and 20 illustrate a large inner locking clamp, which is a larger version of the clamp of FIG. 18 with a full width jaw to enable the clamp to be inserted and fastened around a variety of objects. It is designed to attach to large railings, water pipes, road signs, wheel covers, car frames, commercial business door handles and may even be attached to 2″ pipe bombs. The ends are curved and sharpened so that the clamp can be placed over and around the structure to be operated via a rope and the pull direction of the pulling means is along the length of the clamp. This clamp is most often used with pulleys for change of direction during hook and line procedures.
FIGS. 21 and 22 illustrate a large double inner locking clamp, which is a wider version of the clamp of FIGS. 19 and 20 with a triple width jaw to enable the clamp to be inserted and fastened around a variety of objects. It is designed to attach to large railings, water pipes, road signs, wheel covers, car frames, commercial business door handles and may even be attached to 2″ pipe bombs. With the increased width, the clamp will stay exactly where it is placed on a pipe and will not slide or twist when attached. The ends are curved and sharpened so that the clamp can be placed over and around the structure to be operated via a rope. This clamp is most often used with pulleys for change of direction during hook and line procedures.
FIGS. 23 and 24 illustrate a small flat clamp, which is a spring loaded clamp with one side sharpened and curved and the other side flat. It is designed to attach to vehicle hood releases which are hinged on one side. The flat side is placed behind the hood release and the clamp is pushed all the way across the release until the curved end is completely around the hinge, and the pull direction of the pulling means is at 90 degrees to the length of the clamp. The ends are curved and sharpened so that the clamp can be placed over and around the item to be pulled via a rope.
The clamp of FIG. 25 illustrates the basic shape of another small clamp. FIG. 26 illustrates a small round clamp of this type which is a spring loaded clamp with a sharpened and split end. While this clamp can be used for many other applications, it was specifically designed to hold the latch attachments in place on vehicle door handles. The clamp is attached to the vehicle door handle at right angles to the handle. The handle is placed in the first opening of the clamp since the clamp must be held firmly in position on the handle. The appropriate latch attachment either the thumb latch or finger latch mechanism is then bolted to the clamp via the threaded insert and a rope is attached to the latch attachment rather than to the clamp. As the rope is pulled in the appropriate manner, the attachment either depresses the thumb latch or pulls the finger latch behind the handle.
The clamp of FIG. 27 is a small v-nose clamp which has a similar use to the clamp of FIG. 26 . While this clamp can be used for many other applications, it was specifically designed to hold the latch attachments in place on vehicle door handles. The handle is placed in the first opening of the clamp since the clamp must be held firmly in position on the handle. The first opening in the clamp is smaller than that of FIG. 26 . The clamp is used with the thumb latch attachment on narrower vehicle door handles, where the clamp of FIG. 26 is too large.
Preferably, the thumb latch attachment is used in conjunction with the clamps of FIGS. 26 and 27 when manipulating the car door handle, since the series of mounting holes accommodate the wide range of thumb latch spacing dimensions possible for vehicle door handles. This will permit the plunger 51 to be centered over the thumb latch so that when the rope is pulled, the plunger 51 will pivot on the appropriate mounting hole and depress the thumb latch mechanism. The choice of either the clamp of FIG. 26 or 27 is determined by the thickness of the vehicle door handle. The whole mechanism can be mounted upside down depending on whether the thumb latch is on the right or left side of the handle.
The clamp of FIG. 27 is the primary clamp for use on finger latches, since the smaller opening prevents the clamp jaws from protruding too far behind the door handle, thus preventing the finger latch from retracting sufficiently enough to open the door. The clamp of FIG. 27 prevents the finger latch mechanism from retracting all the way on narrower door handles because the jaws almost meet when attached to the door handle at right angles. The clamp of FIG. 27 is also a spring loaded clamp with a sharpened and split end.
In operation, the appropriate latch attachment is bolted to the clamp with teeth of FIG. 27 via the threaded insert, and a rope is attached to the latch attachment rather than the clamp. As the rope is pulled, the appropriate attachment either depresses the thumb latch or pulls the finger latch behind the handle. Once the latch is fully depressed, continued pull on the rope will cause the door to swing open. The first opening on this clamp is small so that the jaws do not protrude too far behind the handle and block the retraction of the finger latch, therefore, there is a limited portion of the clamp jaws attached to the door handle.
The clamping member may also be a specialized clamp member designed for specific situations. FIGS. 28 and 29 illustrate a hood release 70 which is designed to attach to structures which are hinged, flat or have a lip where only one side of the clamp can be inserted. It can also be attached to engine compartment hood release mechanisms, as well as to the hood itself, to pull the hood open after the locking mechanism has been manipulated. The clamp member comprises a body 71 having a split jaw 72 defining two teeth 73 and a split 74 . The slide spring 75 is retracted to open the jaw 72 so that the end can be fitted behind the structure to be pulled. When attached, it will hold itself in place via the spring 75 . The jaws are split so that the clamp can be attached around protruding portions to whatever it is attached.
FIGS. 30 and 31 illustrate a spring loaded car door pull, which is designed as a universal, hinged car door handle attachment which when attached to the door handle is held in place by the spring tension. The clamp has been designed to take advantage of the raised lip on the rear edge of all door handles of this type. This raised portion of the handle helps keep the fingers from sliding off the handle during opening. It also acts as a drip lip and runs the entire length of the handle on the reverse side. The narrow portion of the clamp is placed behind the handle and over top of the raised portion on the rear edge of the handle. There is sufficient tension on the clamp to keep the clamp attached to the handle during the pull. The spring tension is sufficient in almost all cases to prevent the clamp from sliding over the raised edge of the handle and disengaging. The larger rounded portion of the clamp provides a larger surface friction on the front of the handle surface and helps keep the clamp from sliding or twisting during normal pulls. The pull is kept substantially perpendicular to the door handle, since it is only the substantial spring tension which holds the clamp in place.
FIGS. 32 and 33 illustrate a locking car door pull, which is designed as a universal, hinged car door handle attachment which can be manually locked on the handle by turning the threaded eye bolt on the end. There are instances where there is a misalignment of the car door on its frame which makes it difficult to open the door by pulling even after the door mechanism has functioned correctly. This misalignment can cause the clamp of FIGS. 30 and 31 to break away from the door handle when the pull is particularly difficult, since it is only held in place by the spring tension. In these situations the clamp of FIGS. 32 and 33 can be forcefully attached so that it will not slide off during the pull. The flat portion of the clamp is placed behind the door handle taking advantage of the raised portion of the handle. This raised edge is present on the reverse side edge of all door handles of this type. It prevents the fingers from slipping off the handle when pulling it open. The wide round portion of the opposite side of the clamp provides a wider surface area on the front of the handle to increase the holding ability and prevent the clamp from twisting during the pull. The direction of pull is not as critical when this clamp is forcefully attached.
To be ready for any situation, all the parts are part of a kit, which can include a set of clamps of different shapes, dimensions and jaw teeth, along with the finger latch and thumb latch mechanisms and their accessories. The kit is brought to the site by the intervention team, so that they can select the proper clamp(s)/accessory(ries) in view of the situation.
Numerous modifications may be made without departing from the spirit and scope of the invention as defined in the appended claims.
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A remotely operable opening mechanism for potentially booby-trapped latched panels has a clamp member for clampable engagement with a fixed structure on the panel. A displaceable actuator is mounted on the clamp member. The displaceable actuator has a protruding element engageable with a latch on the latched panel and a coupling element for connection to a line to permit remote activation of the actuator to release the latch member and thereby permit the latched panel to be opened from a safe distance.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
FIELD OF THE INVENTION
The present invention relates to door sweeps and door thresholds. More specifically, the invention relates to a magnetic door sweep and a magnetic threshold whose magnets have specifically arranged polarities to create a controlled magnetic seal between the door sweep and the threshold.
BACKGROUND OF THE INVENTION
The major parts of a door sealing system consist of a door sweep, which is located at the bottom of most entry doors to assist in sealing the bottom of the door, and a threshold cap, which makes contact with the door sweep to seal and help prevent water, air and pests from passing beyond the threshold. While current door sealing systems have generally proven to be satisfactory for their applications, each is associated with its share of limitations.
One major limitation of many current door sealing systems relates to their inability to consistently form a consistent seal due to variation between the door and the threshold throughout the life of the door seal. Due to current designs, door sweeps become deformed, lose their shape and ultimately leave gaps in the seal thus compromising the integrity of the entire seal. This permits water, air and pests to pass beyond the threshold.
Another limitation of many known door sweeps is the harsh noise created by the door sweep and threshold when the doors are opened or closed. The noise is caused by the door sweep being dragged across the threshold. Additionally, this noise may be made worse by thresholds that have a grooved surface. However, door sweeps that contact thresholds upon opening have traditionally been necessary to create and maintain a seal between the door and its corresponding threshold.
Another limitation of current door sweeps and their associated thresholds is their propensity to wear through due to constant scuffing of the door sweep on the threshold. This creates a need for maintenance and as the door sweep wears, its sealing effectiveness generally diminishes.
What is needed then is a device that does not suffer from the above limitations. This in turn, will provide a device that repeatedly creates a proper seal between the door sweep and its associated threshold every time the door is opened and closed, regardless of which direction the door is opened or closed. Furthermore, a door sweep device will be provided that does not lose its shape after repeated door openings and closings. Additionally, a door sweep and its associated threshold is needed that does not make harsh noises upon every opening and closing of an associated door. Finally, a door sweep is needed that does not wear out or at least is capable of experiencing a longer life than current door sweeps. It is, therefore, an object of the present invention to provide a door sweep and threshold that achieves the above-identified advantages.
SUMMARY OF THE INVENTION
In accordance with the teachings of the present invention, a magnetic door sweep and magnetic threshold are provided that reliably align and seal to prevent water, air and pests from crossing the threshold of a door. Additionally, the magnetic door sweep and magnetic threshold will prevent shape loss of the door sweep. The magnetic door seal includes with a primary seal and a door seal magnetic element having a first set of poles located on the bottom edge of a door. A magnetic threshold includes a threshold cap and a threshold magnetic element having a second set of poles. The door seal is positionable relative to the threshold as the door is closed such that the first set of pole are attracted to the second set of poles when said door seal is positioned proximate to the threshold allowing the primary seal to extend between the door and the threshold.
Continuing with advantages, the magnetic door sweep and magnetic threshold will prevent dragging of the door sweep across the threshold which will, in turn, prevent undesirable noise from emanating from the door sweep area and prevent abrasive wearing of the sweep jacket, which will prolong the life of the sweep jacket.
Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:
FIG. 1 is a cross-sectional view of a door sweep and threshold showing the polar arrangements of a door sweep magnet and a door threshold magnet according to teachings of the present invention;
FIG. 2 is a cross-sectional view of a door sweep and threshold in a situation in which the door sweep is approaching the threshold according to teachings of the present invention;
FIG. 3 is a cross-sectional view of a door sweep and threshold in which the door sweep is at its maximum height over the threshold according to teachings of the present invention;
FIG. 4 is a cross-sectional view of a door sweep and threshold in which the door sweep is nearly in its final position over the threshold before sealing according to teachings of the present invention; and
FIG. 5 is a cross-sectional view of a door sweep and threshold in which the door sweep is in its sealed position over the threshold according to teachings of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The following description of the preferred embodiment is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses. FIG. 1 depicts a cross-sectional view of a magnetic door sweep and a magnetic threshold 10 according to teachings of the present invention. The magnetic door sweep and magnetic threshold 10 has a magnetic door sweep 20 and a magnetic threshold 50 . Turning to the magnetic door sweep 20 , a door 22 has a door sweep base plate 28 attached along a bottom edge thereof. The door 22 has an inside surface 24 and an outside surface 26 , which respectively represent the inside of a building and an outside of a building. Attached to the door sweep base plate 28 is a door seal 30 , which has a flexible bellows 32 attached to a magnet 34 . As presently preferred, magnet 34 is a bar magnet having a north pole “N” along one longitudinal edge and a south pole “S” along opposite longitudinal edge. The magnet 34 may be covered with a jacket 36 that is made of a material that is suitable for sealing such as rubber or plastic.
In addition to the door seal 30 , the magnetic door sweep 20 has an inside sweep seal 38 and an outside sweep seal 40 . These seals 38 , 40 provide aesthetic appeal since they shield the door seal 30 from the view of door users and they act as an additional level of sealing from wind, water, pests, etc. Since the inside sweep seal 38 and the outside sweep seal 40 may minimally touch the threshold cap 52 , or reach to just above the threshold cap 52 , they are effective in their purpose of sealing and providing aesthetic value to the magnetic door sweep and magnetic threshold 10 . Attached to the outside portion of the door sweep base plate 28 is a base plate shield 42 , which is provided for aesthetic qualities as it blocks the view of the door seal 30 .
With continued reference to FIG. 1 , the magnetic threshold 50 will be explained. The magnetic threshold 50 has a threshold cap 52 and a magnet 54 that is attached within the interior volume 56 of threshold cap 52 by an adhesive or mechanical fastener such as a screw. Alternately, the threshold cap 52 may have an interior support formed within the interior volume thereof to support the magnet 54 . As presently preferred, magnet 54 is a bar magnet having a north pole “N” and a south pole “S” which are positioned in an opposite orientation relative to the poles of magnet 34 . The width between the poles of magnet 54 is greater than the width between the poles of magnet 34 . In this way, magnet 34 and the door seal 30 is generally centered over the magnet 54 in the threshold 50 . Thus, a positive seal between the door 22 and the threshold 52 can be assured. The threshold cap 52 is supported by a door plate 58 and a door sill 60 . The door plate 58 is located on the outside of a building and is typically aluminum but can be made of a ferrous metal, wood or other material capable of withstanding the repeated weight of door users. The door sill 60 is typically wood, but can be made of plastic or other material capable of withstanding the repeated weight of door users. The door sill 60 provides added support to the door plate 58 and threshold cap 52 .
With continued reference to FIG. 1 , the sealing of the magnetic door sweep and magnetic threshold 10 , when the door 22 is in its closed and sealed position, will be explained. In this closed position, a magnetic seal is created because of the opposed positioning of the polarities of the magnets 34 , 54 when the door is in its closed position. As can be seen in FIG. 1 , the north pole “N” of the top magnet 34 is proximate to and attracted to the south pole “S” of the bottom magnet 54 . Additionally, the south pole “S” of the top magnet 34 is attracted to the north pole “N” of the bottom magnet 54 . Between the north pole “N” and the south pole “S” of the top magnet, exists a transitional range of polarity strength from the north pole to the south pole. That is, as the distance from the north pole to the south pole increases, the strength of the north pole decreases and the strength of the south pole increases.
With respect to the top magnet 34 , the maximum strength of the north pole “N” is at the inside edge of the top magnet 34 , that is, at the outside side of the bellows 32 , while the maximum strength of the south pole “S” is at the outside edge of the top magnet 34 , that is, at the inside side of the bellows 32 . The inside side and outside side of the bellows 32 is equivalent to the inside surface 24 of the door 22 and the outside surface 26 of the door 22 . The same relationship is true of the bottom magnet 54 , although the maximum strength of the south pole “S” is at the outside edge of the bottom magnet 54 and the maximum strength of the north pole “N” is at the inside edge of the bottom magnet 54 . The inside seal 38 and the outside seal 40 generally do not move during the opening and closing of the door 22 . The seals 38 , 40 provide an extra level of protection at the bottom of the door 22 against airflow. They also provide aesthetic aspect to the magnetic door sweep and magnetic threshold 10 by shielding the magnetic door sweep and magnetic threshold 10 from the view of door users.
With reference to FIGS. 2 through 5 , the process of sealing when the door moves from an open position to its closed and sealed position, will be explained. FIG. 2 is a cross-sectional view of a magnetic door sweep 20 and a magnetic threshold 50 in a situation in which the door 22 is closing and the door seal 30 is approaching the magnetic threshold 50 according to teachings of the present invention. With reference to FIG. 2 , the magnetic door sweep 20 moves in the direction of arrow 62 toward its closed position. The closed position of the door 22 and its associated door seal 30 occurs when the magnetic door sweep 20 is directly above the magnetic threshold 50 , as seen in FIG. 1 . Continuing with reference to FIG. 2 , as the magnetic door sweep threshold 20 moves, the door seal 30 with its top magnet 34 is still in a retracted position due to the memory of the bellows 32 . That is, the top magnet is unaffected by the magnetic force of the bottom magnet 54 of the magnetic threshold 50 . The retracted position of the door sweep 30 , and more specifically, the flexible bellows 32 and top magnet 34 , is in its natural suspension position when it is unaffected by any magnetic forces. FIG. 2 shows such a position.
FIG. 3 is a cross-sectional view of a magnetic door sweep 20 and a magnetic threshold 50 in which the door seal 30 is at its maximum height over the magnetic threshold 50 according to teachings of the present invention. As the magnetic door sweep 20 approaches the magnetic threshold 50 according to the direction of motion noted by arrow 62 , the door seal 30 is pushed upwardly from the repelling force of the north pole “N” of the top magnet 34 when located directly over or proximate to the north pole “N” of the bottom magnet 54 . This repelling force causes the flexible bellows 32 of the door seal 30 to contract in the direction noted by arrow 64 . When the door seal 30 contracts, the jacket 36 surrounding the top magnet 34 does not contact the threshold cap 52 , which provides several advantages. The advantages of the jacket 36 not contacting the threshold cap 52 is that there is no noise generated, which normally occurs when a door sweep contacts or is dragged across a threshold, and there is no wearing of the jacket 36 , which normally occurs when the jacket 36 would otherwise contact the threshold cap 52 . The contraction of the bellows 32 and lifting of the door seal 30 above the threshold cap 52 continues as the magnetic door seal 30 moves over the magnetic threshold 50 .
FIG. 4 is a cross-sectional view of a magnetic door seal 30 and a magnetic threshold 50 in which the door seal 30 is approaching its sealing position over the threshold cap 52 and bottom magnet 54 according to teachings of the present invention. FIG. 4 depicts a situation in which the magnetic door seal 30 continues moving in the direction of arrow 60 . As the magnetic door seal 30 continues to move, the position of the top magnet 34 is different than it was in FIG. 3 , with respect to the bottom magnet 54 . In FIG. 4 , the top magnet 34 is closer to its sealing position. This means that the door seal 30 has begun its decent toward the threshold cap 52 . This is caused by the changing attraction between the top and bottom magnets 34 , 54 .
In FIG. 4 , the north pole “N” of the top magnet 34 is approaching or proximate to the south pole “S” of the bottom magnet 54 , and the south pole “S”of the top magnet 34 is approaching or proximate to the north pole “N” of the bottom magnet 54 . The locations of the magnets 34 , 54 in FIG. 4 create a magnetic attraction force between the magnets 34 , 54 . Therefore, the door seal 30 begins moving in the direction of arrow 66 causing the bellows 32 to begin to open, expand or reach toward the threshold cap 52 . At the same time, the magnetic door seal 30 continues to move in the direction of arrow 62 , which causes an increase in the attraction forces due to continued alignment and positioning of the magnetic polarities.
FIG. 5 is a cross-sectional view of a magnetic door seal 30 and a magnetic threshold 50 in which the door seal 30 is in its sealed position on the threshold cap 52 according to teachings of the present invention. At the position shown when the door seal 30 is on the threshold cap 52 , the jacket 36 on the top magnet 34 contacts the threshold cap 52 . In this position, the bellows 32 is fully extended in the direction noted by arrow 66 . Additionally, the distance between the corner north pole “N” of top magnet 34 and the corner south pole “S” of the bottom magnet 54 is equal to or nearly equal to the distance between the corner south pole “S” of the top magnet 34 and the corner north pole “N” of the bottom magnet 54 . Thus, the magnet 34 and hence the door seal 30 is generally centered over the magnet 54 and threshold cap 52 .
The magnetic attraction created by the specific positioning of the polarities of the magnets 34 , 54 creates a magnetic attraction between the top magnet 34 and bottom magnet 54 that seals the jacket 36 of the door seal 30 to the top surface of the threshold cap 52 . Since the contact seal of the jacket 36 and the top surface of the threshold cap 52 does not occur until the above-explained positioning of magnetic polarities occurs, there is no other contact between any of the parts. Because of this, there is no noise associated with the door seal 30 and threshold cap 52 upon closing the door. Additionally, because there is no dragging contact before the jacket 36 seals with the threshold cap 52 , there is no associated wearing of the parts. The door seal 30 essentially reaches out to the threshold cap 52 when the desired magnetic polarity alignment has occurred, and causes a head-on magnetic contact between the top magnet 34 , which is surrounded by the jacket 36 , and the bottom magnet 54 , which is covered by the threshold cap 52 .
Upon opening of the door, the magnetic door sweep 20 works in a generally reverse order to that described above. The magnet force holding the door seal 30 against the threshold cap 52 is overcome by the opening force of the door 22 . As the magnet 34 moves relative to the magnet 54 , the polarity of the magnets 34 , 54 causes the seal to be urged away from the threshold 50 , thereby unsealing the door 22 from the threshold 50 .
The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. For example, the preferred embodiment is described as having a set of bar magnets. However, one skilled in the art will recognize that other magnetic elements may be employed in the present invention. In this regard, discrete magnet elements could be incorporated into the threshold cap in place of the singular bar magnet. Such variations are not to be regarded as a departure from the spirit and scope of the invention.
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A magnetic door sweep and magnetic threshold is disclosed which reliably aligns and seals to prevent water, air and pests from crossing the threshold of a door. Additionally, the magnetic door sweep and magnetic threshold will prevent shape loss of the door sweep. The magnetic door seal includes a primary seal and a door seal magnetic element having a first set of poles located on the bottom edge of a door. A magnetic threshold includes a threshold cap and a threshold magnetic element having a second set of poles. The door seal is positionable relative to the threshold as the door is closed such that the first set of poles is attracted to the second set of poles when said door seal is positioned proximate to the threshold allowing the primary seal to extend between the door and the threshold.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of application Ser. No. 07/605,731 filed Oct. 30, 1990, entitled CASING SLIPS AND SEAL MEMBER, now abandoned, inventors Charles D. Bridges and Henry Lang.
BACKGROUND OF THE INVENTION
1. Field of the invention
This invention relates in general to wellhead assemblies, and in particular to an apparatus for supporting and sealing casing in a wellhead.
2. Description of the Prior Art
There are many types of wellhead assemblies. When drilling a well, surface casing will be set to a selected depth below the surface. Often, a starter head will be attached to this surface casing. The starter head is typically attached by welding, threading, or hydraulic crimping. Welding is time consuming and may leak if not done properly. The hydraulic crimping operations require expensive equipment.
Slips are used in the prior art to support pipe within a housing for many purposes. Generally, slips will be segments having a wedge-shaped cross-section with teeth on the interior to qrip the pipe. Seals of various types are employed above the slips
SUMMARY OF THE INVENTION
A method and apparatus is employed with this invention for attaching a wellhead housing to surface casing. A lower wellhead housing is placed over the surface casing. The lower wellhead housing has an upward facing conical section. An annular slip member is placed in the conical section of the lower wellhead housing. The slip member has a lower conical section that lands on the conical section of the lower wellhead housing. The slip member has an upper exterior conical section, and an annular exterior seal. The interior of the slip member is cylindrical and contains a set of circumferential teeth. A seal is also located in the interior of the slip member.
The upper wellhead housing has a bore with a conical section that matches the conical section of the slip member. The upper member is placed over the slip member, then clamped to the lower wellhead housing. While clamping, the upper wellhead housing and lower wellhead housing will move toward each other. The slip member cannot move once it is in tight contact with the lower wellhead housing. This creates a wedging action which deflects the slip member inward. The teeth will embed into the casing. The exterior seal on the slip conical section will seal in the bore of the upper wellhead housing.
In a second embodiment, a retaining ring locates in an annular recess on the exterior of the slip member between the upper and lower conical sections. The ring protrudes radially outward from the recess. The upper housing has a downward facing shoulder that engages the ring to push the slip member downward when the upper housing is clamped to the lower housing. The lower housing has an upward facing shoulder that is contacted by the ring, stopping downward travel of the slip member when fully set.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a wellhead apparatus constructed in accordance with this invention.
FIG. 2 is a perspective view of the slip and seal member utilized with the wellhead apparatus of FIG. 1.
FIG. 3 is a sectional view of the slip and seal member of FIG. 2.
FIG. 4 is a sectional view of a second embodiment of a wellhead apparatus constructed in accordance with this invention.
DETAILED DESCRIPTION OF THE INVENTION
The well may have large diameter conductor pipe 11 extending into the well a short distance. The conductor pipe 11 is cylindrical. A string of surface casing 13 will extend into the well a greater depth. Casing 13 is also cylindrical. The upper end of casing 13 will be cut a short distance above the upper end of the conductor pipe 11.
A lower wellhead housing 15 may be secured to the conductor pipe 11, such as by welding. The lower wellhead housing 15, is a flange member. It has a flat upper end 17. A bore 19 extends axially through the lower wellhead housing 15, concentric with the axis of the conductor pipe 11. Bore 19 surrounds the casing 13, but does not touch it. A conical section 21 extends from the upper end 17 downward a selected distance. The conical section 21 tapers downward, having a larger diameter at its upper end than at its lower extent.
An upper wellhead housing 23 will connect to the lower wellhead housing 15. Upper wellhead housing 23 has a flat lower end 25 that abuts the upper end 17 of the lower wellhead housing 15. Threaded rods 27 extend through holes in the upper wellhead housing 23. Nuts 29 serve as means along with rods 27 for clamping the upper wellhead housing 23 to the lower wellhead housing 15. An upper tubular member 31 of conventional nature may be mounted to the upper wellhead housing 23 for supporting a smaller diameter string of casing (not shown).
Upper wellhead housing 23 has a bore 33 extending axially through it. A conical section 35 extends upward from the lower end 25. Conical section 35 tapers upward, having a larger diameter lower end than its upper extent. In the embodiment shown, the degree of taper of the bore conical sections 21 and 35 is the same.
A slip member 37 locates between the upper wellhead housing 23 and lower wellhead housing 15. Slip member 37 provides a seal in the annular space between the upper wellhead housing 23 and the casing 13. Slip member 37 also grips the casing 13 to prevent axial movement between the casing 13 and the upper and lower wellhead housings 23, 15.
As shown in FIGS. 2 and 3, slip member 37 has an exterior upper conical section 39. The upper conical section 39 tapers upward, having a larger outer diameter on its lower end than on its upper end. The upper conical section 39 has the same degree of taper as the upper wellhead housing conical section 35. The upper conical section 39 is a smooth conical surface for contact with the upper wellhead housing conical section 35.
In the embodiment shown, slip member 37 also has a lower conical section 41 on its exterior. Lower conical section 41 tapers downward, having a larger outer diameter at its upper extent than at its lower extent. Lower conical section 41 has the same degree of taper as the lower wellhead housing conical section 21. Lower conical section 41 is a smooth conical surface for contact with the lower wellhead housing conical section 21.
A midsection comprising an exterior recess 43 and an interior recess 45 locates between the upper and lower conical sections 39, 41. The recesses 43, 45 are annular. The radial wall thickness of the midsection at the recesses 43, 45 is less than the wall thickness of the upper conical section 35 at its lower end, and less than the lower conical section 41 at its upper end.
The interior of slip member 37 is cylindrical. Two sets of teeth 47, 49 are formed in the interior. The upper teeth 47 and the lower teeth 49 both comprise circumferential grooves, each groove located in a plane perpendicular to the axis of the slip member 37. In the preferred embodiment, each tooth of the sets of teeth 47, 49 is triangular in shape, having 45 degree upper and lower flanks. The root between the flank of one of the teeth 47, 49 and an adjacent one is curved The inner recess 45 separates the upper teeth 47 from the lower teeth 49.
The slip member 37 is a solid continuous annular member. There are no vertical splits in slip member 37. Slip member 37 is of a steel material, preferably having a yield strength of about 60,000 pounds per square inch. In the embodiment shown, outer and inner elastomeric seals 51, 53 (FIG. 1) are employed. Outer elastomeric seals 51 locate on the exterior of slip member 37. One of the outer elastomeric seals 51 is located near the upper end of the upper conical section 39, while the other elastomeric seal 51 is located near the lower end of the lower conical section 41. Similarly, one of the inner elastomeric seals 53 is located near the upper end of the upper teeth 47. The other inner elastomeric seal 53 is located near the lower end of the lower teeth 49. The outer seals 51 seal against the conical sections 21, 35, while the inner seals 53 seal against the casing 13.
In operation, the conductor pipe 11 may be installed in the well. The lower wellhead housing 15 will be welded to the conductor pipe 11. The casing 13 will be lowered into the well and cemented in place once the well has been drilled to the desired surface casing depth.
The casing 13 will be cut off to a desired height. The slip member 37 will be placed around the casing 13 and in the lower wellhead housing conical section 21. The upper wellhead housing 23 will be placed over the casing 13, slip member 37 and lower wellhead housing 15. The upper wellhead housing conical section 35 will contact the slip member upper conical section 39.
Nuts 29 will be tightened. This draws the upper wellhead housing 23 downward toward the lower wellhead housing 15, without rotation There will be some initial sliding engagement of the lower conical section 41 with the lower wellhead housing conical section 21 as the upper wellhead housing 23 pushes downward on the slip member 37. Once the slip member 37 wedges against the lower wellhead housing 15, the upper wellhead housing 23 will move downward relative to the slip member 37.
The downward movement of the upper wellhead housing 23 causes sliding engagement of the upper wellhead housing conical section 35 against the slip member upper conical section 39. The wedging action will cause radial deflection of the slip member 37. The upper conical section 39 will move radially inward, causing the upper teeth 47 to embed into the casing 13. The lower conical section 41 will also move radially inward, causing the teeth 49 to embed in the casing 13. The midsection recesses 43, 45 facilitate in this radial inward deflection. The deflection is not enough to permanently deform the slip member 37, rather the deflection is within the elastic limits of the material of the slip member 37. The amount of deflection will typically be about a 0.060 inch decrease in diameter from the initial position to the set position for 20 inch diameter casing 13.
Once the nuts 27 have been fully tightened, elastomeric sealing engagement will occur between the upper outer seal 51 and the upper wellhead housing conical section 35. Additionally, the upper inner elastomeric seal 53 will seal against the casing 13. Although not necessary, similar sealing will occur with the lower outer seal 51 against the lower wellhead housing conical section 21. Similar sealing will occur with the lower inner seal 53 against the casing 13. Additionally, the teeth 47, 49 will grip the casing 13 to prevent any axial movement of casing 13 relative to the upper and lower wellhead housings 23, 15
In the alternate embodiment of FIG. 4, a means is provided to prevent the application of too much radial force as the slip member 137 is set. Excessive radial force might cause the casing 113 to collapse. A stop is provided which will limit the downward travel of slip member 137 during setting. The stop includes an upward facing shoulder 55 located in bore 119 of lower wellhead 115. Upward facing shoulder 55 is perpendicular to the axis of bore 119. Upward facing shoulder 55 is located at the upper end of lower wellhead 115. Upward facing shoulder 55 is formed by machining a counterbore in the bore 119 at the termination of bore 119.
A similar downward facing shoulder 57 is formed in bore 133 of upper wellhead 123. Downward facing shoulder 57 is located at the lower end of upper housing 123. The shoulders 55, 57 define an annular cavity when the upper wellhead 123 is clamped to the lower wellhead 115.
A mating recess 59 is formed on the exterior of slip member 137. Recess 59 is rectangular in vertical cross section. The recess 159 has a lesser radial dimension than the shoulders 55, 57. Recess 59 is located in the vertical midsection of slip member 137, between the upper conical section 139 and lower conical section 141. When slip member 137 is in the set position, as shown in FIG. 4, recess 59 will align with shoulders 55, 57 to define an annular cavity that is generally rectangular in cross section
A retaining ring 61 is installed in recess 59 prior to installing slip member 137 in the wellheads 115, 123. Retaining ring 61 is a metal ring that is split so as to allow its installation. Once installed, it will fit closely within the recess 59. Retaining ring 61 has a radial width that is substantially the same as the radial dimension from recess 59 to the outer edges of shoulders 55, 57. As a result, retaining ring 61 will protrude radially outward past the exterior of slip member 137. Retaining ring 61 will substantially fill the cavity defined by the shoulders 55, 57 and the recess 59.
In the operation of the second embodiment, retaining ring 61 will be installed in recess 59 of slip member 137. Slip member 137 will be placed in the lower wellhead 115. The retaining ring 61 will be initially spaced above the upward facing shoulder 55. The upper wellhead 123 will be placed over the slip member 137. Initially, the downward facing shoulder 57 will be spaced above the retaining ring 61.
The operator will begin to clamp the upper wellhead 123 to the lower wellhead 115 by rotating the nuts 129. The upper wellhead 123 will slide downward on the upper conical section 139. Similarly, the slip member 137 will slide downward in the lower wellhead 115. Eventually the downward facing shoulder 57 will contact the retaining ring 61 and exert a downward force. Then, when at the fully set position, the retaining ring 61 will contact the upward facing shoulder 55. This contact will stop further downward travel of the slip member 137. The upper wellhead 123 will be tightened to lower wellhead 115 at that point, with the upper and lower ends of the wellheads 115, 123 abutting each other.
The invention has significant advantages. The slip assembly both grips pipe and provides a seal. The wellhead housing attaches to the casing without the need for welding or hydraulic crimping. The retaining ring avoids collapsing the casing due to too high of a radial force during setting of the slip assembly.
While the invention has been shown in only one of its forms, it should be apparent to those skilled in the art that it is not so limited, but is susceptible to various changes without departing from the scope of the invention.
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A method and an apparatus for attaching an upper wellhead housing to casing employs a combination slip and seal assembly. An annular metal slip member is supported by a lower wellhead housing. The slip member has a conical section with an annular external seal. The interior of the slip member contains circumferential teeth. When the upper wellhead housing is placed over the slip member and clamped to the lower wellhead housing, it wedges the slip member radially inward. The internal teeth will embed against the casing to grip the casing. The external seal seals against the upper wellhead housing bore conical surface. A retaining ring engages the slip member and locates between mating shoulders of the upper and lower housings to limit downward travel of the slip member.
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BACKGROUND OF THE INVENTION
[0001] All-terrain vehicles or ATV's are versatile all-season three or four-wheeled motorized vehicles designed for off-road use, including pedestrian and bicycle pathways. Typically ATV's are straddle-type vehicles, where the operator straddles the seat similar to a motorcycle or bicycle. They are generally designed to carry one or two passengers. Although primarily a recreational vehicle, more recently ATV's have been used as utility vehicles. To that end, various utilitarian accessories or implements, such as snow plow blades, can be attached to the ATV. Although the relatively light weight of the ATV allows for the use of small engines, the small engines limit the power capabilities; ATV's generally have a battery and battery recharging system having low amperage storage and low amperage recharging capability relative to a typically automobile. The term “all terrain vehicle” or “ATV” as used herein includes within its scope so-called utility task vehicles or “UTV's”, such as the Kawasaki MULE, the John Deere GATOR, the Polaris RANGER and PROFESSIONAL SERIES, the EZ-GO WORKHORSE, the Club Car CARRYALL and PIONEER and the Toro WORKMAN.
[0002] Conventional snow blade mounts for four wheel drive vehicles such as pick-up trucks can weigh hundreds pounds (e.g., 750 pounds), and generally include a chassis frame that can be permanently fixed to the vehicle chassis, usually behind the vehicle front bumper. A lift frame is then removably coupled to the chassis frame, and the snow blade is then coupled to the front end of the assembly via an A-frame and trip frame assembly. The A-frame with the snow blade attached is typically removable from the vehicle. Such assemblies, however, are too large and too heavy for practical use with the relatively small ATV.
[0003] One drawback of conventional snow blade mounts is the difficulty in readily removing the assemblies from the vehicle chassis, especially in view of their weight. The presence of an implement or accessory on an ATV can render the ATV useless as a recreational all-terrain vehicle. Accordingly, it is highly desirable that the blade be removed after use. However, since the mounting and dismounting operation can be cumbersome and time-consuming, the assemblies are often left on the ATV for the entire winter season.
[0004] It is therefore an object of the present invention to provide a utilitarian accessory mounting assembly for an ATV that is conveniently and easily attachable and removable from the vehicle.
[0005] It is a further object of the present invention to provide a snow blade assembly for an ATV that is mounted and dismounted from the vehicle using a self-aligning hitch mount devoid of mounting pins.
[0006] It is a still further object of the present invention to pivot the utilitarian accessory remotely.
SUMMARY OF THE INVENTION
[0007] The problems of the prior art have been overcome by the present invention, which provides a hitch mount assembly for snow blades or other accessories or implements for off-road vehicles such as all-terrain vehicles. The present invention includes an implement assembly readily removably coupled to the vehicle, such as in conjunction with a receiver that is mounted to the vehicle chassis or frame or is integrated therewith. The configuration of the receiver and implement assembly allows for self-alignment during the mounting operation. A switching mechanism and actuator also can be used to pivot the working implement remotely.
[0008] In one embodiment, a power winch is used to mount the assembly to the ATV. The winch is also used to vertically raise and lower the working implement relative to the ground. In another embodiment, the relatively light-weight of the assembly allows the assembly to be mounted to the ATV manually, without the use of a winch or other power-operated tool, simply by pushing the assembly towards the ATV or by driving the ATV towards the assembly.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] [0009]FIG. 1 is a perspective exploded view of a snow blade mounting assembly in accordance with the present invention;
[0010] [0010]FIG. 2 is a perspective view of a receiver in accordance with the present invention;
[0011] [0011]FIG. 2A is a perspective view of a receiver in accordance with another embodiment of the present invention;
[0012] [0012]FIG. 3 is a front view of the receiver of FIG. 2 shown mounted to the chassis of an ATV;
[0013] [0013]FIG. 4 is a perspective view of a snow blade mounting assembly shown partially mounted to an ATV in accordance with the present invention;
[0014] [0014]FIG. 5 is a perspective view of the blade pivoting mechanism in accordance with the present invention;
[0015] [0015]FIG. 6 is a perspective view of a portion of the mounting assembly in accordance with the present invention;
[0016] [0016]FIG. 6A is a view of a lift handle for manual actuation of a blade;
[0017] [0017]FIG. 7 is a perspective view of a portion of the mounting assembly in accordance with the present invention;
[0018] [0018]FIG. 8 is a perspective bottom view of the blade shown attached to the A-frame in accordance with the present invention;
[0019] [0019]FIG. 9 is a perspective view of the accessory actuator in accordance with the present invention;
[0020] [0020]FIG. 10 is a perspective view of the motor for pivoting the accessory in accordance with the present invention;
[0021] [0021]FIG. 11 is a partial perspective view of the spool and cable assembly in accordance with the present invention;
[0022] [0022]FIG. 12 is a schematic diagram of the switching system in accordance with the present invention; and
[0023] [0023]FIG. 13 is a perspective view of a portion of the mounting assembly in accordance with another embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0024] Turning first to FIG. 1, there is shown generally at 10 the blade and hitch assembly in accordance with a preferred embodiment of the present invention. The assembly 10 is relatively lightweight, preferably weighing between about 50 and about 300 pounds, and is most preferably sufficiently light to enable a single individual to slidingly push the assembly into mounting engagement with the receiver on the vehicle. Thus, its various components can be constructed of metal, steel, stainless steel, plastics or composites, for example, depending upon the relative strength required of each component. Vehicle mounted receiver 11 attaches to the vehicle chassis or frame, or is integrated therewith. Any suitable means can be used to secure the receiver 11 to the vehicle, such as bolting or manufacturing integration (e.g., as a stamped component of the vehicle chassis or frame) For example, as shown in FIG. 2, the receiver 11 can include a pair of U-shaped flanges 8 with holes for coupling the receiver to the vehicle chassis. The design of the receiver 11 interface for attachment to the chassis will depend upon the identity (and thus design) of the particular chassis, and is well within the skill in the art. Because in the embodiment shown the receiver 11 is situated under the chassis and is not obtrusive, it optionally can be permanently affixed to the chassis, regardless of whether the snow plow blade or other accessories or working implements are attached or in use. Alternatively, the receiver can be located on the vehicle frame where it does not extend below the frame so as to provide adequate ground clearance. It is fixed and preferably has no moving parts; its main purpose being to provide a means of attachment of the follow-on components. It also can absorb and transfer any shock loads imposed on the snow blade (or other accessory) into the vehicle. It can be made of any rigid material suitable for the job, such as steel, metal, stainless steel, plastic or composites, for example.
[0025] As best seen in FIGS. 2 and 3, the receiver 11 is preferably trapezoidal in shape, uniformly tapering inwardly from its open front end towards the rear. It has an optional top plate 6 , with opposite vertically depending side guides 7 a and 7 b as shown. Alternatively, the sides 7 a and 7 b could be independently attached directly to the chassis, directly to the frame, or integrated therewith, preferably defining between them a trapezoidal wedge. A front upwardly angled lip 9 is optionally provided at the receiver entry to assist in guiding the implement to be mounted into the receiver 11 , in the direction of the arrows shown in FIGS. 2 and 3. The sides 7 a , 7 b are in a tapered profile such that the distance between them decreases in the direction towards the vehicle rear when mounted thereto.
[0026] Turning back to FIG. 1, the blade and hitch assembly 10 is adapted to be releasably coupled to or engaged by the receiver 11 . In the embodiment shown, a blade 15 is illustrated as the utilitarian accessory or working implement, although those skilled in the art will appreciate that the present invention is not limited to mounting and dismounting of a blade. The blade 15 can be conventional in design. The preferred blade is made of sheet metal, or is a sheet of steel bumped or rolled to a semi-round shape. The blade 15 also can be in the form of an adjustable V-shaped blade. The blade is braced on the backside with a plurality of mounts 4 providing a means of attachment (such as via springs 3 ) to the support frame 20 .
[0027] As best seen in FIGS. 7 and 8, support frame 20 includes opposite side members 21 a , 21 b that preferably are bent along their lengths to define an A-frame portion 22 . The A-frame portion tapers towards an apex that can be pivotably coupled directly to the blade 15 , or is attached to the blade 15 through a trip flame assembly as discussed in greater detail below. Those skilled in the art will appreciate that although the term “A-frame” is used herein, the frame need not be in the shape of an “A”. Male hitch member 25 is coupled to a pivotable cross bar 26 (such as by welding to ears 97 ) that is pivotably supported between opposite sides 21 a , 21 b . At least a portion of the hitch member 25 corresponds in shape to receiver 11 , so that that portion of the hitch member 25 can be slidingly engaged by receiver 11 during the mounting operation. Thus, in the preferred embodiment, hitch member 25 has a trapezoidal portion, which tapers outwardly from the free end 25 a in the direction towards the implement 15 . In the embodiment shown, the taper extends to a maximum and then tapers inwardly to the opposite end of the member 25 . Those skilled in the art will appreciate that the free end of the hitch member 25 can be formed as two or more extensions rather than a single continuous end as shown. The hitch member 25 and cross bar 26 pivot about a horizontal axis, preferably about 200 from horizontal in each direction.
[0028] Turning now to FIG. 4, an optional trip frame assembly is shown that includes half-ring or A-frame retainer 36 supported on the top surface of the A-frame 22 . Those skilled in the art will appreciate that the half-ring 36 can be designed having shapes other than that shown. The trip frame assembly is connected to the blade 15 via springs 3 (two shown). The trip frame assembly allows the blade 15 to pivot forward, which allows it to trip over obstacles and absorb shock that would otherwise be transferred into the plow frame assembly and vehicle, which in extreme cases would cause substantial damage. If the trip frame assembly is eliminated, the blade can have a conventional trip edge as known in the art.
[0029] Extending from the half-ring or retainer 36 is a notched plate 37 , also supported on the A-frame 22 top surface, to set the blade angle. The plate 37 has a plurality of spaced notches 38 extending around the annular edge of the plate 37 as shown. As the blade 15 pivots, the notched plate 37 also pivots, and can be locked in place with locking mechanism 40 that, when properly aligned with a notch 38 , inserts into that notch 38 to prevent movement of the plate (and thus the blade 15 ) until it is retracted from the notch.
[0030] One suitable mechanism for actuating the locking mechanism uses cable 41 extending from the locking mechanism 40 to a location where it is readily accessible by the driver of the ATV. By tensioning the cable 41 by drawing it towards the vehicle rear, such as with remote control actuator 71 (FIG. 9), the locking mechanism is disengaged from the notch 38 , allowing the blade to pivot. More specifically, actuator 71 is slidably mounted in cable bracket 72 as is conventional in the art. By pulling actuator towards the vehicle rear, in the direction of arrow 73 , the cable 41 is tensioned and the locking mechanism is unlocked, allowing the blade 15 to freely pivot. Once the blade 15 is positioned as desired, the tension on the cable 41 is released by releasing the actuator 71 , allowing the locking mechanism to again latch into a notch 38 and lock the blade in place. Those skilled in the art will appreciate that the locking mechanism can be operated manually.
[0031] Proper angling of the blade 15 , when the blade is in a freely pivotable position, was conventionally accomplished manually, requiring the operator to leave the vehicle and physically pivot the blade. Alternatively, the operator would drive the blade into a stationary object, such as a tree, to pivot the blade. Either method was tedious and inconvenient. In accordance with one embodiment of the present invention, the blade angle preferably is controlled remotely, such as by the driver of the ATV when seated on the ATV in the driving position. Thus, the remote actuator 71 can be used not only to unlock the blade 15 as discussed above, but also to remotely pivot the blade. To that end, remote actuator 71 is modified with slotted member 77 that receives switch 76 in slot 78 . Switch 76 , such as rocker or toggle switch, is in electrical communication with a bi-directional motor 80 (FIGS. 4 and 10). It is preferably a double pole, double throw three-position switch, the center being the off position and the other two positions being momentary (FIG. 12 shows a suitable schematic of the switch). The motor 80 is preferably powered by the vehicle battery 90 and reversibly drives drum or spool 81 (FIG. 11) wrapped with two separate cables; one threaded through pulley 82 a and secured at or near an end of the blade 15 , and the other threaded through pulley 82 b and secured at or near the other end of blade 15 . The attachment of each cable to the blade 15 can be a direct attachment, or a spring 84 (FIG. 8) can be positioned between the blade and the cable for added play.
[0032] To pivot the blade 15 , the operator draws actuator 71 in the direction of arrow 73 to unlock the blade. The actuator is then rotated to the left or to the right, depending upon the desired angle of the blade, thereby actuating switch 76 which engages the motor 80 , driving spool 81 . When driven in one direction, the spool 81 deploys one cable and reels in the other, and when driven in the other direction, the opposite cables are deployed from and reeled onto the spool, respectively. The deploying or reeling in of cable pivots the blade accordingly. Once the blade is in the desired position, the actuator is rotated back to the normal position, which corresponds to the center position of the switch 78 , and is then released to lock the blade in place. Those skilled in the art will appreciate that the actuator for power angling of the blade need not be the same actuator used to unlock the blade from its fixed position; separate actuators can be used to accomplish these operations.
[0033] Further details will now be provided regarding the hitch mount of the present invention. As discussed above, receiver 11 , preferably made of ⅜″ mild steel, is attached to the vehicle by suitable means or is integrated therewith such as during manufacturing of the vehicle. Conveniently, some conventional ATV's come equipped with a round bar or rod 200 , solid or tubular, and generally about ⅜ to ½″ in diameter, secured to the vehicle front (FIG. 1). In the embodiment shown in FIGS. 4 and 7, the bar 200 extends horizontally a distance sufficient to be engaged at or near its opposite ends by one or more latch hooks 220 discussed in detail below. Those skilled in the art will appreciate that the bar 200 could be vertical or angled, and need not be continuous; two or more separate bars could be used such as at each end of the receiver 11 (FIG. 2A), as long as they are appropriately positioned for engagement by one or more latch hooks 220 . In addition, the bar need not be round; other shapes corresponding to the receiving shape of the latch hook could be used. Preferably the bar or bars are located above the plane of the receiver 11 . The receiver 11 need not be positioned directly under the bar or bars; the bar or bars could be positioned radially outwardly of the receiver 11 such as shown in FIG. 2A.
[0034] In ATV's where the rod 200 is not original equipment, it can be added. For example, as shown in FIG. 2A, the bar 200 can be part of the receiver 11 , as one continuous bar or as two or more separate bars. Again, the bar(s) could be vertical or angled with respect to horizontal, and need not be positioned directly over the receiver 11 . Where two or more separate bars are used, they are preferably positioned in the same plane. In the embodiment of FIG. 2A, there are two bars that each terminate in opposite free ends.
[0035] Receiver 11 includes generally longitudinally extending (in the direction from the vehicle front to the vehicle rear) side guide members 7 a , 7 b as discussed above, which help ensure proper alignment of the hitch assembly. The spacing or volume or distance between these guide members is configured to accommodate the male hitch 25 pivotably coupled to the frame 20 . Thus, in the embodiment shown, the hitch member 25 is tapered such that the length of its free engaging end 25 a is relatively short, and expands in the direction towards the implement 15 . Similarly, sides 7 a , 7 b are configured and placed such that the receiver volume is tapered, with its end farthest from the vehicle front being shorter than the end closest to the vehicle front. The sides 7 a , 7 b thus act as a track for receiving and aligning hitch member 25 . Free end 25 a of hitch member 25 can be formed with a notch 15 a (FIG. 1) to ensure that the hitch member 25 clears the nut and bolt that attaches the receiver 11 to the vehicle chassis. Those skilled in the art will appreciate that two or more receivers 11 can be used, in which case two or more hitch members would be used.
[0036] Pivotally coupled to spaced side brackets 54 , 55 via a pivot shaft is a latch 220 , which in the embodiment shown, is centrally located on cross bar 23 (FIG. 6). The side brackets 54 , 55 are spaced a sufficient distance to accommodate the latch 220 and allow for its movement. Although only one latch 220 is necessary, multiple latches could be used and are within the scope of the present invention. One such embodiment is illustrated in FIG. 13, where two opposite and aligned latches 220 A, 220 B are shown. Where multiple latches are used, the latches 220 can share a common pivot shaft, the pivot shaft extending from one latch to the other so that movement of the latches is coordinated; actuation of one latch results in a corresponding movement of the other latches. Alternatively, the multiple latches can be actuated separately.
[0037] Each latch 220 preferably has a hook shape including an arcuate recess 225 corresponding in angle to the circumference of the bar 200 . The latch is thereby adapted to receive bar 200 . Preferably the recess is shaped as a concentric cam, so that upon contact with the bar 200 , the latch 220 can automatically pivot to a closed position, locking onto the bar 200 . This design facilitates the grasping and interlocking of bar 200 as well as the dismounting operation. The latch 220 can include a handle 221 for manual actuation for use such as in the event the latch does not properly lock onto the bar 200 . A latch locking assembly 230 (FIG. 1) optionally can be used to lock the latch in place. One suitable locking assembly includes a spring loaded pin assembly, with spring biasing against a pin 241 . In the locked position, the spring forces pin 241 through an appropriately dimensioned aperture in the latch, thereby fixing the latch 220 in place. Lever 243 , shown in FIG. 4 in the locked (orthagonal) position, prevents pin 241 from retracting out of the aperture. In the unlocked position, the pin is retracted from the aperture, allowing movement of the latch for engagement or disengagement of the hitch.
[0038] The preferred method for attaching the hitch mounting assembly to the ATV will now be described with particular reference to FIG. 4. The vehicle 100 is positioned close to the hitch mounting assembly, and one end of a tether 70 , such as a rope, chain, cable, wire, links, etc., is attached to the vehicle 100 preferably at a location higher (to later facilitate lifting of the blade) than the mounting assembly. Most ATV's come equipped with a utility hook or clamp 71 coupled to a rope permanently attached at or near the top of the ATV body. This or any other convenient location typically at or near the front of the ATV can be used as the point of attachment of one end of the tether 70 . In ATV's where the clamp 71 is not original equipment, it can be added or another point of attachment can be used. The tether 70 is also attached to an actuator 75 such as a winch mounted on the mounting assembly, such as on the A-frame or on the working implement itself. In the embodiment shown, the winch 75 is electrically driven by the motor of the ATV, although it is within the scope of the present invention for the which to be powered separately. Actuation of the winch causes the tether to be reeled onto the spool of the winch, in turn causing the mounting assembly to be pulled towards the vehicle 100 . The free end of the hitch member 25 is thus pulled towards receiver 11 in the direction of arrow 90 . In view of the corresponding shapes of the receiver 11 and hitch member 25 , the mounting assembly properly aligns with the vehicle 100 as the hitch member 25 is engaged by the receiver 11 . As the tether continues to wrap around winch 75 and pull the mounting assembly towards the vehicle, the hitch member 25 continues to progress into receiver 11 , until latch 220 engages bar 200 . The engagement of the latch with the bar causes the latch to pivot into a closed position about the bar. The locking assembly is then actuated (either automatically, or manually via lever 243 ) to secure the latch in place. Continued actuation of the winch raises the blade, and thus the winch can be used during operation of the vehicle to raise and lower the blade. Alternatively, the blade can be raised and lowered in a conventional manner, such as manually with a lift handle 210 (FIG. 6A) positioned rearwardly of the blade, the lift handle 210 being pivotally mounted on a bracket 212 and connected to a bell crank to vertically lift or lower the blade. Such manual actuation of the blade is disclosed in U.S. Pat. No. 5,615,745, the disclosure of which is hereby incorporated by reference. In the embodiment shown, in the latched position the recess of the latch 220 faces downwardly towards the ground, although the latch 220 can be designed so that the recess faces upwardly.
[0039] Alternatively, the assembly can be mounted to the vehicle manually. In view of the design of the hitch member 25 and corresponding receiver 11 and the relatively light weight of the hitch assembly, the assembly can be simply “pushed” into mounting relationship by one or more individuals without the use of the winch. For example, an individual can stand in front of the working implement, place his hands on the implement, and slide the assembly 10 towards the receiver 11 , allowing the hitch member to enter the receiver 11 and progress towards the rear thereof until the latch or latches engages bar or bars 200 .
[0040] To remove the hitch mounting assembly from the vehicle chassis, the locking pin is released, and the lever 221 optionally is placed in the down position. Upon separating the vehicle from the assembly (such as by driving the vehicle away from the assembly or by manually pulling the assembly away from the vehicle), the latch moves away from the bar 200 , disengaging the same and actually pushing the receiver 11 away from the assembly. The electrical and mechanical connections are then disconnected to complete the dismount.
[0041] Alternatively still, the assembly can be mounted to the vehicle by driving the vehicle towards the assembly, and in particular, towards the free end of the hitch member 25 so that it can be received by the receiver 11 . As the mounting progresses, the latch or latches engage the bar 200 and are locked in place. To facilitate the mounting and minimize or prevent the assembly from moving away from the vehicle as it is engaged by the receiver, the assembly can be temporarily fixed in place, such as by positioning it in front of an obstruction.
[0042] Those skilled in the art will appreciate that although the foregoing illustrates a front-mounted assembly, mounting the same to the rear of the vehicle is within the scope of the present invention.
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Hitch mount assembly for snow blades or other accessories or implements for off-road vehicles such as all-terrain vehicles. The assembly includes a receiver for mounting to the vehicle chassis and an implement assembly readily removably coupled to the receiver. The configuration of the receiver and implement assembly allows for self-alignment during the mounting operation. A switching mechanism and actuator also can be used to pivot the working implement remotely. The mount assembly can be attached to the vehicle with a powered winch or manually.
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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 pertains to supporting devices such as those used to support roadway signs and barriers to advise nearby motorists and bystanders of construction sites and other hazards. The present invention also pertains to quick release mechanisms for deploying the supporting device.
2. Description of the Related Art
There has been increasing demand for warning and advisory information concerning worksite activities. For example, organizations charged with safety concerns have come to increasingly appreciate the effectiveness of lightweight temporary sign stands to warn oncoming motorists of nearby work activities. Typically such lightweight sign stands are made to be collapsible for compact storage. In order to complement the sign stand, the sign panels are made of lightweight foldable material. Such completed sign stand assemblies may be conveniently stored in work vehicles, available for ready deployment, thereby bypassing the need to withdraw the sign stand assemblies at a remote location and to schedule their delivery to the worksite. Such sign stand assemblies have offered a great advantage for work operations which last only a day, or part of a day. Work situations of this type present unique demands not associated with long term projects, since motorists will not encounter the worksite on a repeated basis and thus will not have the benefit of past experience as a forewarning. It is important that the sign stand assemblies offer reliable advisory and instructional assistance, particularly for motorists traveling at highway speeds. Sign stand assembles located adjacent a highway must withstand wind gusts generated by moving vehicles as well as wind gusts occurring at outdoor locations, which are usually unabated, especially for multiple lane highway constructions.
Substantial advances have been made in the art of lightweight collapsible sign stand assemblies. For example, commonly assigned U.S. Pat. No. 4,954,008 has been met with ready commercial acceptance and has been recognized not only for its provision of a strong reliable sign stand support, but has also been found to offer substantial labor savings when the sign stand is deployed, and again when the sign stand is collapsed for storage, after use. U.S. Pat. No. 4,954,008 provides a quick release mechanism located at the point where support legs are pivotally secured to a base for supporting the sign mast. The quick release mechanism is operated by depressing a lever arm in order to allow free rotating of the support leg with respect to the remainder of the sign stand assembly.
Frequently, sign stand assemblies must be erected or taken down in inclement weather. At times, the combination of wind gusts occurring during inclement weather and a sudden pressure burst from nearby traffic can substantially complicate a worker's task.
SUMMARY OF THE INVENTION
In researching ways in which sign stand assemblies can be improved, it has been discovered that different workers find manipulation of one type of quick release mechanism to be easier in a particular situation than other types of quick release mechanisms.
Improvements in sign stand assemblies are continually being sought. It is an object of the present invention to provide quick release mechanisms having different types of actuating motions associated with the deployment or storage of support legs pivotally mounted to a support base.
Another object of the present intention is to provide sign stand assemblies having improved stronger joinder of support legs to a support base.
A further object of the present invention is to provide support bases and quick release mechanisms therefor constructed from a minimum number of inexpensive components.
These and other objects of the present invention are provided in a foldable supporting device comprising:
a base member including a plurality of support flanges having respective outer peripheries;
a plurality of legs pivotally mounted to respective support flanges for pivotal movement between operational and storage positions;
said legs defining a slot for receiving portions of a respective support flange outer periphery as the leg is pivoted between unfolded and folded positions;
the outer peripheries of the support flanges defining at least one locking recess;
a plurality of locking pins extending through respective legs, the locking pins having an elongated double-ended body with an enlarged head at one end lying outside the leg and an exposed portion at the other end extending beyond the leg;
the locking pins carried by the legs so as to be positioned adjacent.the support flange outer periphery and so as to be movable between a locked position received in the locking recess and an unlocked position outside of the locking recess;
a plurality of spring bias means carried on respective legs so as to urge the locking pin body into the recess to lock the leg against pivoting about the support flange; and
the locking pin movable out of the recess when the exposed portion is deflected so as to oppose the force of the spring bias means.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a spring bias member according to the principles of the present intention;
FIG. 2 is a fragmentary perspective view of a sign stand support base;
FIG. 3 is a side elevational view thereof;
FIG. 4 top plan view thereof;
FIG. 5 is a side elevational view of the spring bias member;
FIG. 6 shows a portion of FIG. 4 on an enlarged scale;
FIG. 7 is a view similar to that of FIG. 6 showing actuation of the locking pin thereof;
FIG. 8 is a fragmentary view showing a self centering locking pin arrangement;
FIG. 9 is a view similar to that of FIG. 8 but showing a different s centering arrangement for the locking pin;
FIG. 10 is a perspective view of a sign stand according to the pent invention;
FIG. 11 is a fragmentary perspective view of an alternative spring bias arrangement.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, and initially to FIGS. 1-4, a foldable supporting device is generally indicated at 10 . The foldable supporting device includes a support base 12 and a plurality of support legs 14 . In the preferred embodiment, four support legs are employed, as shown in FIG. 4 . Two of these support legs have been omitted from FIG. 2 for clarity of illustration.
In the preferred embodiment, support base 12 is provided as a weldment including side plates 14 and a floor member 16 . Side plates 14 are preferably formed as a monolithic stamping of sheet metal material. Side plates 14 are stamped to form a pair of support flanges 20 extending from an intermediate upright wall 22 . The upright wall 22 is joined to floor 16 by a metallurgical joinder 24 by welding, brazing or the like conventional joining technique. In the preferred embodiment shown in FIG. 10, the support base 12 is covered by a hood member so as to enclose one or more springs for biasing an upright sign mast extending above the support base. Another example of the hood and sign mast arrangement is shown in commonly assigned U.S. Pat. No. 4,954,008, the disclosure of which is hereby incorporated by reference as if fully set forth herein.
As will be seen, for example in FIG. 2, legs 14 are of preferably rectangular, most preferably square tubing which are bifurcated or split at one end by an elongated notch 28 . If desired, legs of cylindrical or other shape can be used. The notch 28 is dimensioned to receive the support flanges 20 of support base 12 . Preferably, the support flanges 20 are of generally planar configuration, although other configurations may be employed for the support flanges 20 . As can be seen in the right hand portion of FIG. 2, the support flanges 20 are provided with an aperture 30 and recesses 32 , 34 spaced about an outer periphery 46 of the support flange. Pivot shafts in the form of bolt fasteners 40 pass through apertures 30 as well as complementary apertures formed in the legs 14 , so as to pivotally join the legs to corresponding support flanges 20 . The notches 28 are dimensioned so as to clear the outer periphery of the support flange allowing the legs to swing between opened and storage positions illustrated in solid lines and phantom lines, respectively, in the left hand portion of FIG. 3 . The leg 14 shown in the foreground portion of FIG. 2 is fixed in the open or deployed position extending at a relatively small acute angle to a support surface. The leg 14 shown in the background portion of FIG. 2 is locked in a closed or storage position, generally upright, at a normal angle to a support surface.
In the preferred embodiment, the peripheral portion 35 of flange 20 is made part circular and the notch 28 formed in leg 14 for receiving the flange is closely spaced with respect to the support flange outer periphery, as indicated in the background portion of FIG. 2 . The notch 28 in the foreground portion of FIG. 2 is shown exaggerated in length for illustration purposes. With a close sliding fit of the flange 20 within leg 14 , the leg receives continuous wobble-free support from the flange at all points of its operation between open and closed positions. If desired, the notch 28 can be made considerably larger than that needed to receive flange 20 and an optional sleeve or insert can be fitted within notch 28 , although this has not been found necessary in the preferred embodiment, as illustrated.
Referring to FIG. 4, a portion of a sign panel 46 supported by mechanism 10 is shown in phantom. The areas designated by the numeral 50 , herein the “inside portions” between sign legs 14 is located facing the planar faces of sign panel 46 . Spring strips 52 , one for each leg 14 , are located in these inside areas. The “outside portions” between support legs 14 are designated by the reference numeral 54 and generally are located facing an edge of sign panel 46 .
As shown in FIGS. 2 and 3, for example, the legs 14 are movable between an open or unfolded position shown at the bottom of FIG. 2 and a folded or storage position shown in the upper corner of FIG. 2 . FIG. 3 shows, in its right hand portion, a leg 14 intermediate the deployed and storage positions which correspond to notches 32 , 34 , respectively. Turning now to FIGS. 1 and 5 - 7 , a locking or detent mechanism for releasably securing the legs in either of the storage or deployment positions will now be described. As shown, a locking pin 60 is provided for each leg. As can best be seen in FIGS. 5-7, the locking pin 60 has a generally cylindrical body 62 and an enlarged head 64 .
With reference to FIG. 2, it can be seen that legs 14 are of generally hollow tubular construction with opposed side walls 14 a facing the “interior” of the support device and 14 b facing outside of the support device so as to be visible when standing to one side of the support device, in the manner depicted in FIGS. 3 and 10. With reference to FIGS. 6 and 7, a hole 70 is formed in sidewall 14 a of leg 14 and is closely dimensioned with respect to the cross-section of the body 62 of pin 60 . As can be seen in FIG. 6, the pin body 62 extends through a slot 72 formed in leg sidewall 14 b. Preferably, pin body 62 is dimensioned so as to extend a substantial amount beyond leg wall 14 b with an exposed free end suitable for grasping to operate the locking arrangement of the support device.
As can be seen in FIG. 2, for example, locking pin 60 extends through a slot 72 formed in the outboard wall 14 b of leg 14 . As can be seen for example in FIG. 7, while the end of locking pin 60 adjacent head 64 is free only to pivot or rock, the free end 62 of locking pin 60 is free to swing an arc, being limited by the dimension of slot 72 . As illustrated in FIG. 7, free end 62 of locking pin 60 is swung to its furthest, unlocked position. With additional reference to FIG. 2, the legs 14 are freed to pivot about their respective support flanges 20 with the support flanges passing through slot 28 formed in the legs 14 . As previously mentioned, recesses or detents 332 , 34 are formed in each support flange 20 . FIG. 6 shown locking pin 60 engaged in a lower recess 32 of support flange 20 , thus preventing rotation of the leg about threaded fastener 40 . The location of hole 70 and the lengthwise dimension of slot 72 are chosen such that, with locking pin 60 swung to its furthest unlocked position shown in FIG. 7, interior portions of the locking pin body clear the support flange thereby allowing leg 14 to pivot about threaded fastener 40 .
With reference to FIG. 7, unlocking of pin 60 from support flange 20 allows leg 14 to be swung in an upward direction. If desired, the locking pin can be released by the operator once the leg is unlocked, thereby allowing the locking pin to travel across the outer surface 36 of the support flange as the leg is swung to its upright storage position. On attaining the desired upright position, locking pin 60 falls into the recess 34 under bias force of spring 52 , thereby securely locking the leg in a storage position. In the storage position (as shown in the upper left hand portion of FIG. 2 and in phantom in the left hand portion of FIG. 3 ), an upward deflection of the free end 62 of locking pin 60 will release the leg to fall toward its open position under the force of gravity. With sufficient travel of leg 14 , the locking pin 60 carried with the leg will be urged into the lower recess 32 under force of spring strip 52 .
With reference to FIGS. 5-7, it will be observed that spring 52 operates only on the enlarged head 64 of the locking pin. This arrangement provides substantial manufacturing advantages since springs internal to hollow legs 14 can be eliminated. Some operators of support devices prefer to visually observe operation of spring bias members and an advantage is obtained with the present invention, in the regard, as can be seen by comparing the position of spring 52 in FIGS. 6 and 7.
A further important advantage is obtained with the present invention in that the enlarged head 64 of the locking pin is substantially enclosed by the flat, smooth faced outer surfaces of spring strip 52 . As can be seen for example in FIG. 2, the spring strips 52 are located in the “inside” surfaces of the legs 14 , areas which are typically maintained clear of unwanted obstructions which may interfere with operation of the spring strips.
If further “shielding” of enlarged head 64 is desired, the arrangement shown in FIG. 11 can be employed where sidewalls 98 are added to spring strip 52 . As will be appreciated, the bias means shown in FIG. 11 can be readily formed using conventional metal stamping techniques. The sidewalls 98 are received in slots 102 formed in leg wall 14 a. If desired, the slots 102 , 92 can be merged to form a single continuous U-shaped slot and sidewalls 98 can extend to stop limit 82 . In general, this extra degree of shielding has been found unnecessary.
With reference to FIG. 1, additional protection for the spring strip 52 can be provided with an optional hook or L-shaped stop limit 82 , preferably formed as part of the stamping of bias member 52 . A first part 84 of stop limit 82 travels within a slot 92 formed in leg wall 14 a. The slot guides the position of leg 84 as spring strip 52 is expanded.
A second part 86 of stop limit 82 , in extreme excursions of the locking pin will contact the leg wall 14 a in the manner indicated in FIG. 7, thus effectively preventing disengagement of the free end of spring strip 52 from leg 14 .
The optional stop limit 82 of spring strip 52 also operates to prevent unwanted rotation of the spring strip and thereby further ensures that the enlarged head 64 of the lock pin will remain covered. If desired, other anti-rotation arrangements can be provided. For example, with reference to FIG. 5, an optional hole 94 can be formed in leg 14 to receive a projection (not shown) extending from the secured or closed end of the spring strip. For example, a finger-like portion (not shown) can extend from spring strip 52 adjacent threaded fastener 40 , with the free end of the finger being inserted in hole 94 .
As a further alternative, the round hole 94 shown in FIG. 1 can be replaced with a hole having an elongated, square or other non-round edge. For example, a pair of opposed elongated slots can extend outwardly from round hole 94 to receive a pair of complementary-shaped locking ears extending from the enlarged head of threaded fastener 40 .
As an optional provision, enlarged head 64 of locking pin 60 can be provided with a pair of anti-rotation ears 112 received in slots 114 formed in sidewall 14 a of arm 14 . As shown in FIGS. 8 and 9, ears 112 are arranged in diametrically opposed positions and are configured to promote rocking or pivoting of the locking pin, with the exposed portion of the locking pin constrained to travel within a plane. The anti-rotation ears may operate alone to limit travel of the free end of the locking pin within a plane, or they may cooperate with elongated slots 72 in this regard.
Referring now to FIG. 10, a sign assembly 200 includes a flexible sign panel 202 mounted on an upright support 24 which spans the upper and lower corners of the sign panel. The remaining horizontal corners of the sign panel are supported by a cross member (not visible) attached to upright 204 . Upright 204 is releasably joined to a base fitting 206 which includes a hood 208 partially enclosing a coil spring 210 . The spring 210 and hood 208 are mounted between upright walls 22 of foldable supporting device 10 . In FIG. 10, the operator 220 is located on the “outside” portions of legs 14 with the operator's foot 222 located immediately adjacent the protruding portions 62 of locking pin 60 . Thus, it is possible for the operator to engage exposed portion 62 with a shoe tip.
An advantage is offered by the present invention in restricting travel of the locking pin to a single direction. With reference to FIG. 6, it will be observed that locking pin 60 is, in its locked position, biased against one end 72 a of slot 72 . Thus, an operator who is not intimately familiar with the supporting device can safely nudge the exposed portion of the locking pin to determine the direction of travel permitted to it. If, with reference to FIG. 6, the operator should attempt to move the exposed portion 62 of the locking pin to the right, the locking pin will be supported by end 72 a of slot 72 which will prevent unintended damage. The operator will then be prompted to move the locking pin in the opposite direction, as shown in FIG. 7, which, with sufficient travel of the locking pin free end, will free the leg for travel to the folded position. If desired, the length of slot 72 can be chosen such that, with reference to FIG. 7, the locking pin will be constrained from slot 72 from over travel, and this alone may be sufficient to prevent over-bending of flat spring 52 . As mentioned, the flat spring can also be provided with the hook-shaped stop limit, described above.
The drawings and the foregoing descriptions are not intended to represent the only forms of the invention in regard to the details of its construction and manner of operation. Changes in form and in the proportion of parts, as well as the substitution of equivalents, are contemplated as circumstances may suggest or render expedient; and although specific terms have been employed, they are intended in a generic and descriptive sense only and not for the purposes of limitation, the scope of the invention being delineated by the following claims.
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A quick release mechanism for a sign stand base having support legs pivotally joined to a support flange. The support legs are notched to receive the support flange. A locking pin extends through the support leg and is positioned so s to selectively interfere with an outer periphery of the support flange. The locking pin is mounted for rocking or swiveling motion within the support leg and can be moved out of contact with the support flange, thereby allowing the support leg to pivot with respect to the support flange. A flat spring strip secured to an outer surface of the support leg biases the locking pin to a position engaging the support flange.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
This is a divisional application under 37 CFR 1.60 entitled “Pipe Pick-Up and Laydown Apparatus and Method”. The pending prior application is Ser. No. 11/089,706 filed on Mar. 24, 2005 by applicant for “Pipe Pick-Up and Laydown Apparatus”, the entire contents of which are hereby incorporated by reference. This application claims priority to prior application Ser. No. 11/089,706, which claims priority to U.S. Provisional Application Ser. No. 60/602,970 filed Aug. 18, 2004 by Applicant.
FIELD OF INVENTION
The present invention relates to a method and apparatus for manipulating a joint of pipe using a modular, self-contained, freestanding, portable pipe joint manipulating apparatus.
BACKGROUND OF INVENTION
Oil and gas drilling and production operations often require the use of long strings of pipe. Such pipe strings are typically comprised of individual segments or lengths of pipe called a pipe joint that are secured together. During such operations, individual pipe joints may be added or removed from a pipe string. These individual pipe joints are typically at least thirty feet in length and are extremely heavy. Consequently, some sort of pipe lifting apparatus is typically required as an aid for lifting, stacking or otherwise manipulating these pipe joints.
The present invention provides a method for manipulating a length of drill pipe or pipe joint using applicant's pipe pick-up and laydown apparatus. The proposed method provides for the use of a lifting apparatus in a self-contained, freestanding modular unit that is fully portable and easily operated. The method and apparatus of the present invention eliminates the complicated boom and cable systems as well as the cumbersome scissor jack lifting systems that have been typically employed in such lifting devices. The controls for Applicant's lifting device may be positioned at a point remote from the lift in order to place the device operator in a more secure environment.
SUMMARY OF INVENTION
The invention provides a longitudinally extending base frame assembly having a system of base rails or tracks, a movable carriage having a carriage frame and roller assembly for supporting the movable carriage on the frame base rails, and a pipe lifting structure that is mounted to this movable carriage. The carriage, and consequently the pipe lifting structure, is configured so that it may be moved as desired along the length of the base frame by means of the carriage rollers and base rail system to facilitate a desired lifting sequence.
The pipe lifting structure is further provided with a semicircular pipe support trough that is supported by first and second longitudinally spaced apart hydraulically driven telescopically extendable lifting arm assembles. The base end of each telescopically extendable lifting arm assembly is pivotally mounted to the carriage. The trough end of each lifting arm assembly is pivotally mounted to a lifting structure stabilizer frame that extends longitudinally between each lifting arm assembly.
Semicircular cradles or trough saddles are provided and positioned along the lifting structure stabilizer frame for supporting the pipe support trough. The pipe lifting trough is pivotally mounted at a point along its longitudinally axis to the ram of a trough lifting jack mounted to the lifting structure frame. The pipe support trough is further secured at its edges at the semicircular ends of each of the trough saddles of the lifting structure stabilizer frame by means of trough hinge assemblies having removable hinge pins. Selective removal and/or placement of the hinge pins of the trough hinge assemblies will allow the pipe support trough to be tilted to either side of the pipe lifting structure as may be desired by extension of the ram of the provided trough lifting jack.
An extendable and retractable ram mechanism is positioned between the first and second lifting arm assemblies and pivotally mounted to the carriage and to the first lifting arm assembly. In this manner an extension and retraction of the ram will raise, and lower as desired, the first lifting arm assembly, and the connected pipe trough, as it pivots at its carriage mounting end.
Because the second lifting arm assembly is connected to the first lifting arm by means of the pivotally connected lifting structure stabilizer frame, the second lifting arm assembly will also pivot at the carriage, follow the movements of the first lifting arm assembly and rise and fall as it supports the connected trough assembly. The pipe trough is tilted and lifted up in a swinging motion as the lifting arms are raised and lowed by extension and retraction of the carriage and lifting arm hydraulic ram assembly. The pipe trough may be further lifted, tilted or leveled by independent extension or retraction of the telescopically extendable first and second lifting arm assemblies.
It is thought that hydraulic cylinder means will be provided to extend the lifting arm and ram assemblies described herein though other means such a mechanically or electrically driven screw or ratchet mechanism may be utilized. It is also thought that an operator located at a centralized control point would control these mechanisms. Such a centralized control point would keep the operator away from the lifting areas and thus reduce the risk of injury to the operator. Electrical, hydraulic, pneumatic, or mechanical control systems, or combinations of these systems, may be employed to operate the lifting arm and ram assemblies.
Applicant's invention provides a pipe loading mechanism used to move pipe from a pipe rack to the pipe trough that employs hydraulically actuated lifting jack arms and a reversible pipe guide. The pipe guides may be reversed to change direction of the guide surface bumper so that pipe joints may be guided onto and then off of the pipe trough with the aid of the jack arms. The jack arms may be adjusted to different positions on the base rail to facilitate such lifts.
Applicant's invention provides a mechanism employed to roll the pipe joints out of the pipe trough. The mechanism employs the use of the aforementioned pipe trough/pipe saddle hinge and removable hinge pin mechanism. Selected removal and placement of the saddle and pipe trough hinge pins in association with the centrally positioned trough lifting jack described above will allow the pipe support trough to be tilted to either side of the pipe lifting structure as may be desired.
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. 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.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of the Applicant's claimed invention with the lifting trough in a lowered position.
FIG. 2 is a side view of the Applicant's claimed invention with the lifting trough in an elevated position at the first stages of a lift.
FIG. 3 is a side view of the Applicant's invention with the first and second lifting arm assemblies in a fully lifted position.
FIG. 4 is a side view of Applicant's claimed invention with the first lifting arm assembly in a lifted and extended position.
FIG. 5 is a side view of Applicant's claimed invention with the first and second lifting arm assemblies lifted and extended.
FIG. 6 is an end view of Applicant's claimed invention, showing the pivoting trough, pipe guide and pipe lifting jack.
FIG. 7 is a partial side view of Applicant's claimed invention showing the pivoting trough and pipe lifting jack.
FIG. 8 is an end view of Applicant's claimed invention with the pipe guide in place and with pipe jack on the frame in a lowered position.
FIG. 9 is an end view of Applicant's claimed invention with the pipe guide in place and with pipe jack on the frame in a lifted position.
FIG. 10 is an end view of the first lifting arm assembly.
FIG. 11 is a top view of a Trough Hinge Assembly.
FIG. 12 is a cross sectional view of the pipe lifting jack along sectional line 12 - 12 of FIG. 9 .
FIG. 13 is an exploded side view of the pipe lifting jack.
DRAWINGS
Reference Numerals
10 Apparatus
12 Base Frame
14 Base Support Rails
14 A Rail Stops
15 Pipe Joint
16 Carriage
18 Support Roller Assembly
20 Pipe Lifting Structure
21 Lower Lifting Arm Columns
22 Pipe Support Trough
22 A Trough Lift Bearing
23 Upper Lifting Arm columns
24 Telescoping Lifting Arm Assembly
25 Lifting Arm Extension Assembly
25 A Lifting Arm Extension Jack
26 Telescoping Lifting Arm Assembly
28 Lifting Arm Base Bearing
30 Stabilizer Frame
32 Stabilizer Frame Bearing
34 Trough Saddles
36 Trough Lift
36 A Trough Lift Ram
38 Trough Hinge Assembly
38 A Saddle Hinge Links
38 B Trough Hinge Links
38 C Removable Trough Hinge Pins
40 Lifting Arm Lift Assembly
40 A Lifting Arm Lift Ram
42 Lifting Arm Lift Ram Bearing
44 Pipe Loading Mechanism
46 Pipe Lifting Jack
48 Reversible Pipe Guide
52 Lifting Jack Strut
54 Bearings
56 Extendable Jack
58 Extendable Jack Ram
60 Pipe Lift
62 Upper Pipe Lift Support Bracket
63 Male Support Strut
64 Pipe Lift Lower Leg
65 Support Strut Socket
66 Bracket Bearing
68 Bracket Bearing
70 Lower Pipe Guide Frame
72 Pipe Guide Socket Column
74 Upper Pipe Guide Frame
76 Upper Pipe Guide Frame Legs
78 Pipe Guide Bar
80 Centralized Control Mechanism
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings and more particularly to FIG. 1 , there is shown a side view of the pipe pick-up and laydown apparatus ( 10 ) of Applicant's invention. The apparatus ( 10 ) is comprised of a base frame ( 12 ) that supports a system of support rails ( 14 ). A movable carriage ( 16 ) is positioned on the support rails ( 14 ) by means of carriage support roller assemblies ( 18 ).
The carriage ( 16 ) may be moved along the system of support rails ( 14 ) by means of the roller assemblies ( 18 ) and a carriage propulsion mechanism (not shown) to place the carriage ( 16 ) in a desired position along the base frame ( 12 ) to facilitate a desired lifting position or sequence. Rail stops ( 14 A) maintain the carriage ( 16 ) on the rail system ( 14 ).
It is thought that the carriage propulsion mechanism will employ the use of extendable and retractable hydraulic rams as the means to move the carriage ( 16 ) along the support rails ( 14 ). However, the carriage propulsion mechanism could also employ electrical, hydraulic, pneumatic or mechanical means, such as a motor driven pulley and cable system or a motor driven system of threaded rods and gears.
As can be seen in FIGS. 2-5 , a pipe lifting structure assembly ( 20 ) is shown mounted to the movable carriage ( 16 ). The pipe lifting structure assembly ( 20 ) is comprised of a semicircular pipe support trough ( 22 ) for holding a length of pipe or pipe joint ( 15 ). The pipe support trough ( 22 ) is pivotally supported on a first telescopically extendable lifting arm assembly ( 24 ) and a second telescopically extendable lifting arm assembly ( 26 ) spaced apart from each other along the longitudinal axis of the carriage ( 16 ). Each telescopically extendable lifting arm assembly ( 24 , 26 ) is pivotally mounted at its base to the carriage ( 16 ) by means of a lifting arm base hinged bearing ( 28 ).
As shown in FIGS. 6 and 7 , a lifting structure stabilizer frame ( 30 ) is pivotally attached to each telescopically extendable lifting arm assembly ( 24 , 26 ) at the ends distal from the carriage ( 16 ) by means of stabilizer frame bearings ( 32 ). The lifting structure stabilizer frame ( 30 ) extends longitudinally along the trough ( 22 ). The lifting structure stabilizer frame ( 30 ) is provided with semicircular cradles or trough saddles ( 34 ) to support the trough ( 22 ) on the lifting structure stabilizer frame ( 30 ). A trough lift ( 36 ) is mounted to the lifting structure stabilizer frame ( 30 ). The trough lift ( 36 ) has an extendable ram ( 36 A) pivotally attached to a trough lift bearing ( 22 A) located below the trough ( 22 ) at a point on its longitudinal centerline axis.
Trough hinge assemblies ( 38 ) further secure the trough ( 22 ) to the stabilizer frame ( 30 ). These trough hinge assemblies ( 38 ) are comprised of saddle links ( 38 A) mounted at the semicircular ends of each of the trough saddles ( 34 ), trough links ( 38 B) mounted on the perimeter of the trough ( 22 ) and removable trough hinge pins ( 38 C). Selective removal and/or placement of the hinge pins ( 38 C), will allow the pipe support trough ( 22 ) to be tilted on the trough bearing assemblies, as it pivots on trough lift bearing ( 22 A), to either side of the pipe lifting structure ( 20 ) as may be desired by the extension of the ram ( 36 A) of the trough lift ( 36 ). In this manner pipe lifted in the trough ( 22 ) can be rolled from the trough ( 22 ) to either side of the lifting assembly ( 20 ) as may be required by a user.
As shown in the Figures, lifting arm lift assemblies ( 40 ) having an extendable and retractable rams ( 40 A) are pivotally mounted to the carriage ( 16 ) positioned between the first ( 24 ) and second ( 26 ) lifting arm assemblies. The rams ( 40 A) of each ram assembly are pivotally mounted to a bearing ( 42 ) on the first lifting arm assembly ( 24 ) in a manner such that when the rams ( 40 A) are extended and retraced, the lifting arm assembly ( 24 ) will pivot on its lifting arm base hinged bearing ( 28 ). In this manner, extension and retraction of the rams ( 40 A) will raise, and lower as desired, the first lifting arm assembly ( 24 ), and the connected pipe trough ( 22 ) will be lifted, as the lifting arm assembly pivots at the carriage ( 16 ) on the lifting arm base bearing ( 28 ).
Because the second lifting arm assembly ( 26 ) is connected to the first lifting arm assembly ( 24 ) by means of the pivotally connected lifting structure stabilizer frame ( 30 ), the second lifting arm assembly ( 26 ) will also pivot at the carriage ( 16 ) on its lifting arm bearing ( 28 ). Thus, the second lifting arm assembly ( 26 ) will follow the movements of the first lifting arm assembly ( 24 ) as imparted by the lift assemblies ( 40 ) and rise and fall as it supports the connected trough assembly ( 22 ). The pipe trough ( 22 ) will move in a swinging motion as the lifting arm assembly ( 26 ) is raised and lowed by extension and retraction of the ram ( 40 A) of the ram assembly ( 40 ). The pipe trough ( 22 ) may be further lifted, tilted or leveled by independent extension or retraction of the telescopically extendable first and second lifting arm assemblies ( 24 , 26 ).
FIG. 10 shows an end view of the configuration of the telescoping lifting assembly ( 24 ). The assembly ( 24 ) is comprised of lower tubular columns ( 21 ) mounted to the lifting arm base hinge bearings ( 28 ). Corresponding retractable upper tubular columns ( 23 ) are inserted into the lower columns ( 21 ). The distal ends of the upper tubular columns ( 23 ) are mounted to the semicircular pipe support trough ( 22 ) by means of the lifting structure stabilizer bearings ( 32 ).
A central extendable lifting arm extension assembly ( 25 ) having an extendable jack ( 25 A) is mounted to the hinge bearing ( 28 ) between the columns ( 21 ). The jack ( 25 A) is also mounted to the lifting structure bearing ( 32 ). Extension or retraction of the jack ( 25 A) will serve to extend the columns ( 23 ), which serve as a guide and support for the extension assembly ( 25 ). Retraction and extension of the jack ( 25 A) will raise and lower the pipe support trough ( 22 ).
Lifting arm assembly ( 26 ) is similar to lifting arm assembly ( 24 ) and has a similar arrangement of columns ( 21 ) and ( 23 ) and bearings ( 28 ) and ( 32 ), along with a lifting arm extension assembly ( 25 ), to allow the attached pipe support trough ( 22 ) to be raised and lowered in the manner as described above. It is thought that hydraulic cylinder means will be utilized in the lift assembly ( 40 ) and in the extension assembly ( 25 ) to extend and retract the telescoping lifting arm described herein though other means such a mechanically or electrically driven screw or ratchet mechanism may be utilized.
FIGS. 8 and 9 show the pipe loading mechanism ( 44 ). This mechanism employs a pipe lifting jack ( 46 ) and a reversible pipe guide ( 48 ). The pipe lifting jack ( 46 ) has an L-shaped strut ( 52 ) to which is pivotally mounted by means of bearings ( 54 ) an extendable jack ( 56 ) having a ram ( 58 ). An L-shaped pipe lift ( 60 ), having an upper support bracket ( 62 ) and an opposing lower leg ( 64 ), is pivotally mounted at the support bracket ( 62 ) of the L-shaped lift ( 60 ) on the strut ( 52 ) by bearing means ( 66 ). The ram ( 58 ) of the jack ( 56 ) is pivotally mounted by bearing means ( 68 ) to the support bracket ( 62 ) of the L-shaped pipe lift ( 60 ).
Extension and retraction of the ram ( 58 ) will raise the lower leg ( 64 ) of the pipe lift ( 60 ) as the leg pivots on the bracket bearings ( 66 ) and ( 68 ). Continued extension of the ram ( 58 ) will tilt the L-shaped pipe lift ( 60 ) into the guide plane of the pipe guide bar ( 78 ) of the pipe guide ( 48 ). In this manner, a pipe joint ( 15 ) may be lifted by the lower leg ( 64 ) of the pipe lift ( 60 ) and retained on the leg ( 64 ) as the pipe lift ( 60 ) is moved through its pivoting arc. Further extension of the ram ( 58 ) will allow a retained pipe to roll of the pipe lift ( 60 ) and onto the pipe guide bar ( 78 ) of the pipe guide ( 48 ) and then guided into the pipe trough ( 22 ).
As shown in FIGS. 12 and 13 . The pipe lifting jack ( 46 ) has a male support strut ( 63 ) adapted to fit into a female support strut socket ( 65 ) positioned on the base frame ( 12 ) of pick up and laydown apparatus ( 10 ). A number of support sockets ( 65 ) may be placed on the frame ( 12 ) in desired locations to allow the pipe lifting jack ( 46 ) to be positioned on the frame ( 12 ) as desired or to accommodate the use of multiple pipe lifting jacks ( 46 ).
The pipe guide ( 48 ) is comprised of a lower frame ( 70 ) having socket columns ( 72 ) mounted on the carriage ( 16 ). A corresponding removable upper frame ( 74 ) having legs ( 76 ) fits into the corresponding socket columns ( 72 ). The upper frame ( 74 ) is configured to support a diagonally orientated guide bar ( 78 ) on its legs ( 76 ). Reversing the orientation of the upper frame ( 74 ) and reinserting it into the socket columns ( 72 ) will change the orientation of the guide bar ( 78 ). This changes the direction of the guide bar ( 78 ) to slope to or from the pipe trough ( 22 ) so that a pipe joint ( 15 ) may be guided onto and then off of the pipe trough with the aid of the pipe lift ( 60 ).
The trough hinge assemblies ( 38 ) are employed to roll a pipe joint ( 15 ) out of the pipe trough as shown in FIGS. 6 and 7 . The trough hinge assemblies ( 38 ) secure the trough saddles ( 34 ) to the trough ( 22 ) by means of a removable trough pin ( 38 C) inserted through the saddle links ( 38 A) mounted to the edges of the trough saddles ( 34 ) and the corresponding trough links ( 38 B) mounted at the edge of trough ( 22 ) as shown in FIG. 11 . The hinge assemblies ( 38 ) are utilized on both ends of the trough saddles ( 34 ) at the sides of the trough ( 22 ).
Selective removal and/or placement of the hinge pins ( 38 C) from the end of a trough saddle ( 34 ), at a desired side of the trough ( 22 ), will allow the pipe support trough ( 22 ) to pivot to the opposite side of the trough ( 22 ) by the extension of the ram ( 36 A) of the trough lift ( 36 ) as it pivots on the trough bearing ( 22 A). Continued extension of the ram ( 36 A) will tilt the trough ( 22 ) over on the desired side of the pipe lifting structure ( 20 ). In this manner pipe lifted in the trough ( 22 ) can be rolled from the trough ( 22 ) to a floor surface or on to the pipe guide ( 50 ) as may be required by a user.
The lifting operation of the apparatus ( 10 ) is shown in FIGS. 1 through 5 . It is contemplated that the entire apparatus ( 10 ) be operated by a system of hydraulic cylinders and rams and that these cylinders and rams will be remotely controlled from a control system positioned at a point away from the unit.
In FIG. 1 , the apparatus ( 10 ) is positioned in a nested position with the lifting structure assembly ( 20 ) in its lowest position on the movable carriage ( 16 ). As shown in FIGS. 2 and 3 , the extension of the rams ( 40 A) will tilt up and lift the first telescoping lifting arm assembly ( 24 ) as it pivots on its bearing ( 28 ) and as a result the movable trough ( 22 ) will be lifted. Simultaneously, the second lifting arm assembly ( 26 ) will be pulled upward by the connected lifting structure stabilizer frame ( 30 ) causing the other end of the trough ( 22 ) to elevate. The lifting structure stabilizer frame ( 30 ) supports and stabilizes the movable trough ( 22 ) during operation.
As shown in FIGS. 4 and 5 , further elevation of the trough ( 22 ) may be made by extension of the first lifting arm assembly ( 24 ) as described above. Extension of the second lifting arm assembly ( 26 ) will result in lifting the trough ( 22 ) to a level position as shown in FIG. 5 . In this manner the lift is accomplished to the full extension of the lifting arm assemblies ( 24 , 26 ). Lifts to intermediate positions are accomplished by tilting the lifting arm assemblies ( 24 , 26 ) to a desired level by means of the rams ( 40 A), and then extending or retracting the lifting arms ( 24 , 26 ) as desired by means of lifting arm extension assembly ( 25 ).
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.
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A method for lifting, stacking or otherwise manipulating a length of pipe is provided which includes the steps of providing a longitudinally orientated base frame; providing a movable carriage supported on the base frame, and providing a pipe lifting structure mounted to the carriage for independently supporting a length of pipe in a longitudinal position with respect to the base frame. The pipe lifting structure has first and second telescopically extendable lifting arm assemblies that are pivotally mounted to a longitudinally orientated pipe trough for supporting a length of pipe in the pipe trough. A means for pivotally raising and lowering the lifting arm assemblies and thereby said pipe trough and support length of pipe is provided. The method includes providing means for pivotally raising and lowering the lifting arm assemblies remotely located from the pipe lifting structure. Hydraulic cylinders and rams are provided to move the lifting structure.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
TECHNICAL FIELD
This invention relates to a technique for accomplishing a cable boring operation substantially parallel to an existing underground utility conveyance.
BACKGROUND ART
Utilities, such as those providing electric, gas, water and telephone service, often bury their conveyances (i.e., pipes and/or cables) underground for reasons of safety and aesthetics. Usually, the environment and terrain dictate the type of method employed for burying such conveyances. In rural areas, utilities prefer direct burial which they accomplish by plowing or trenching the earth. In urban environments, and when crossing waterways, boring is preferred. To complete such a boring operation, the utility, or a contractor under its employ, first excavates a pit at each of the opposite ends of the intended route for the conveyance. From the one pit, a boring machine (auger) forces a boring head horizontally through the earth into the other pit to create a tunnel through which a utility conveyance can pass.
Underground utility conveyance burial by boring does create a certain risk. An operator must carefully control the path of the boring head to avoid contact with one or more existing underground utility conveyances buried in proximity to the path created by the boring head. For this reason, many utilities, such as AT&T, have regulations governing the minimum allowable distance permitted between the boring head and an existing underground utility conveyance. To facilitate control of the boring head, most boring head manufacturers provide a transmitter (hereinafter referred to as a "sonde") in the boring head for transmitting a signal in the range of 33 Hz. to 9 kHz. The signal transmitted by the sonde radiates through the ground for detection by one or more receivers located above ground. By monitoring the signal radiated by the sonde in the boring head, the operator of the boring machine determines the relative position of the boring head as it bores a path through the earth to avoid contact with an existing underground utility conveyance.
Unfortunately, the signal radiated by the sonde head tends to induce electromagnetic signals in other facilities, such as other underground utility conveyances, causing one or more of them to radiate signals in the vicinity of the conveyance of interest. The receiver(s) tuned to receive the signal radiated by the sonde also receive the signals induced in, and radiated by, such other facilities, causing confusion regarding the actual position of the boring head. Since many boring operations occur in close proximity to existing underground utility conveyances, an error in determining the relative position of the boring head can prove disastrous. Indeed, boring operations have damaged existing underground conveyances, leading to service outages and lost revenues, not to mention the cost associated with repairs.
Thus, a need exists for providing an alert when a boring head lies within the minimum allowable distance from an existing underground utility conveyance, thereby avoiding damage to the conveyance
BRIEF SUMMARY OF THE INVENTION
Briefly, the present invention provides a technique for generating an alert during a boring operation when the boring head is within a minimum allowable distance from an existing underground utility conveyance. The method takes advantage of the fact that a typical existing underground utility conveyance radiates a locating signal that is unique to the service provider maintaining the conveyance. In accordance with the invention, the strength of the locating signal is monitored at the existing conveyance of interest, typically by means of an inductive clamp or the like for releasable attachment to the conveyance. The strength of the locating signal radiated by the existing conveyance of interest is also monitored at the boring head, typically by way of a second inductive clamp. The signal detected at the existing utility conveyance serves as a reference value with regard to the strength of the signal detected at the boring head. If the signal detected at the boring head exceeds a prescribed fraction of the strength of the signal detected at the existing conveyance, then the boring head is too close (i.e., within the minimum allowable distance from the existing conveyance) and an alert is generated.
In accordance with another aspect of the invention, the operation of the boring head may advantageously be controlled, in accordance with the strength of the locating signal, as detected at the boring head, in comparison to the strength of the locating signal detected at the conveyance. By controlling the boring head during boring such that the strength of the locating signal detected at the boring head is maintained at a relatively constant level relative to the signal detected at the conveyance, the boring head will bore substantially parallel to the conveyance. In this way, no damage occurs to the conveyance.
BRIEF SUMMARY OF THE DRAWING
FIG. 1 shows an apparatus in accordance with the invention for both monitoring and controlling a boring head; and
DETAILED DESCRIPTION
FIG. 1 depicts a boring operation conducted with the aid of a boring machine 10 known in the art. To complete a boring operation, a utility, such as AT&T, or its contractor, excavates first and second bore pits 12 and 14 at opposite ends of an intended path for a utility conveyance (not shown). Thereafter, the utility or contractor places the boring machine 10, in the first pit 12. An operator (not shown) operates the machine 10 to force a boring head 16 horizontally through that portion of the ground 18 between the boring pits 12 and 14. As boring machine 10 forces the boring head through the earth 18 from the first pit 12 into the second pit 14, the boring head creates a horizontal channel 20 for carrying a utility conveyance.
Often, a boring operation of the type described occurs in the vicinity of an existing conveyance 22, such as a fiber-optic cable. Since the boring operation occurs "blind," that is, without the ability to visually monitor the path of the boring head 16, the boring head may accidentally contact the fiber-optic cable 22, potentially damaging it. Presently, monitoring of the path of the boring head 16 is accomplished with the aid of a sonde 23 within the boring head for radiating a signal in the range of 33 Hz. to 9 kHz. One or more cable alert detectors 26 (see FIG. 1) are placed above the earth 18 and monitor the signal radiated by sonde 23, thereby providing an indication of the relative position of the boring head 16.
In practice, the signal radiated by the sonde 23 induces a like signal in other facilities, such as a metal sheath (not shown) surrounding the fiber-optic cable 22. In turn, the metal sheath of the fiber-optic cable 22 radiates the induced signal to other facilities. As a result, the receiver(s) 26 receive the signal radiated by such other facilities along with the signal radiated by the sonde 23. Hence, the receiver(s) 26 may not accurately determine the relative position of the boring head 16. Not knowing the relative position of the boring head 16 can prove disastrous, especially when the boring operation occurs in close proximity to existing utility conveyances, such as the fiber-optic cable 22.
To avoid the foregoing disadvantage, the present invention provides a technique for generating an alert when the boring 16 becomes too close to (i.e., within a minimum allowable distance from) the existing fiber-optic cable 22. The technique of the invention takes advantage of a locating signal that is radiated by the metal sheath of the fiber-optic cable 22. In practice, the sheath of the fiber-optic cable 22 carries at least one locating signal for the purpose of locating the cable in the manner taught by U.S. Pat. No. 5,644,237, issued Jul. 1, 1997, in the name of AT&T (herein incorporated by reference.) As will be discussed in greater detail below, the cable locating signal, and more particularly, its strength, serves as a point of reference for determining the relative position of the boring head 16 from the fiber-optic cable 22.
To ascertain the location of the boring head 16 relative to the fiber-optic cable 22, a differential signal monitor 28 receives on a first channel the signal radiated by the cable 22. In practice, the signal monitor 28 receives the signal through an inductive clamp 30 adapted for releasable engagement about the cable. Such inductive clamps are well known, and are exemplified by the type associated with current measurement devices. A second inductive clamp 32, of a construction similar to the clamp 30, couples the locating signal induced in the boring head 16 from the fiber-optic cable 22 to the signal monitor 28.
The signal monitor 28 compares the strength of the signal induced in the boring head 16, as detected via the clamp 32, relative to the strength of the locating signal at the fiber-optic cable 22, as detected via the clamp 30. The signal monitor utilizes the strength of the locating signal at the fiber-optic cable 22 as a reference value against which the strength of the signal received at the boring head 16 is compared. The strength of the locating signal induced in the boring head 16 generally varies inversely with the distance of the boring head from the fiber-optic cable 22. Thus, the closer the boring head 16 is to the fiber-optic cable 22, the greater the strength of the locating signal induced in the boring head. Conversely, the farther the boring head 16 is from the fiber-optic cable 22, weaker the signal induced in the boring head. However, strength of the locating signal on the fiber-optic cable 22 itself influences the strength of the signal induced in the boring head 16. Hence, it is necessary to take account of the strength of the locating signal when examining the strength of the locating signal induced in the boring head 16.
The signal monitor stores a reference value representing the ratio of the strength of the signal induced in the boring 16 to the strength of the locating signal at the fiber-optic cable 22 obtained when the boring head 16 is no closer to the fiber-optic cable 22 than the minimum allowable distance. Should the ratio of the strength of the locating signal detected at the boring head 16 to the strength of the locating signal at the fiber-optic cable 22 exceed the reference value, then the signal monitor 28 knows that the boring head is too close to the cable. Under such conditions, the signal monitor 28 actuates an alarm 30 that generates an alert, either in the form of a visual and/or audible warning, to apprise the operator of the boring machine 10 of the close proximity of the boring head 16 to the fiber-optic cable 22. Upon generation of the warning by the alarm 30, the operator of the boring machine 10 presumably takes appropriate action to avoid damaging the fiber-optic cable 22.
In addition to generating the warning signal 30 to the alarm 30, the signal monitor may also generate a control signal (represented by the dashed line in FIG. 1) to control the boring machine 10. The signal monitor 28 generates the control signal in accordance with the ratio of the strength of the locating signal detected at boring head 16 to the strength of the locating signal detected at the fiber-optic cable 22. In a feedback loop fashion, the boring machine 10 controls the operation of the boring head 16 to maintain the boring head 16 substantially parallel to the fiber-optic cable 22 at a prescribed separation distance therefrom in accordance with the control signal. If the control signal increases beyond a quiescent level that corresponds to the prescribed separation distance of the boring head 16 from the fiber-optic cable 22, the boring machine 10 displaces the boring head away from the cable. As a consequence, the signal monitor 28 reduces the strength of the control signal, causing the boring machine 10 to displace the boring head closer to the fiber-optic cable 22. As the boring head 16 moves closer to the fiber-optic cable 22, the control signal magnitude increases, causing the boring machine to displace the boring head away from the cable. By this process, the boring machine 10 controls the displacement of the boring head 16 so that the boring head bores substantially parallel to the fiber-optic cable 22.
The foregoing describes a technique for providing an alert when the boring head is within a minimum allowable distance from an existing underground utility conveyance, as well as for controlling the operation of the boring head to bore substantially parallel to the existing conveyance.
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The position of a boring head (16) during boring operation in the vicinity of an existing utility conveyance (22) that radiates a locating signal can be determined by establishing the ratio of the strength of the locating signal of the cable induced in the boring head to the strength of the locating signal on the conveyance. Should the ratio exceed a prescribed value, indicating that the boring head is too close to the existing conveyance, then an alert is generated. Advantageously, the position of the boring head during a boring operation may be controlled in feed-back loop fashion in accordance with the ratio to maintain the boring head substantially parallel to the existing conveyance.
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