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BACKGROUND OF THE INVENTION
The present invention relates to a telescoping tower formed of a plurality of nesting sections, including an inner section, an outer section, and generally one or more intermediate sections, with the inner and intermediate sections being slidable relative to an adjacent exterior section between a nested or retracted position, a deployed or locked position, and a release position. The tower of the present invention is especially suitable for use as part of a transportable broadcast antenna. Of particular importance to the present invention is a latch or locking mechanism which allows the tower sections to be locked and unlocked by an operator from ground level.
Various telescoping towers have been described in the prior art. For example, U.S. Pat. No. 3,361,456 to Durand describes a telescoping tower, such as a crane tower, having a locking system in which support arms on an inner tower section extend outwardly to rest on beating surfaces on an adjacent tower section when the tower is extended, and are pivoted away from the bearing surfaces to allow the tower to be lowered. The arms initially extend downward. When the tower is deployed, the arms are moved above the bearing surfaces, and are pivoted outward by contact with pins. The inner tower is then lowered so that the arms rest on the surfaces to hold the inner section in the extended position. When the tower is to be lowered, the inner section is further extended to contact the arms with pins, pivoting the arms downward, and allowing the inner section to be lowered without the arms contacting the beating surfaces.
U.S. Pat. No. 1,899,742 to Bay describes a locking mechanism for an extension ladder having a triangular inner section which telescopes from a triangular outer section. The mechanism comprises pivotal hooks which are cammed away from the ladder rung on their upward movement, and then engage a rung when lowered. To release the latch, the inner ladder section is extended further upward, to close fingers over the hooks, preventing their engagement with a rung on the downward movement.
U.S. Pat. No. 4,254,423 to Reinhard describes a locking mechanism for an antenna mast. The antenna is formed of a plurality of nested, telescoping sections which are deployed by hydraulic or pneumatic means. In the fully extended position, spring loaded lever arms extend into recesses to hold the section is a upright position. To release the locking mechanism, the operator pulls on a rope to pivot the lever arms out of the recesses by forcing a camming surface against the arms.
U.S. Pat. No. 4,483,109 to MacDonald et al describes an emergency latching system for a telescoping boom comprised of a pivotal latch plate which engages a slot in an adjacent inner section of the boom if the telescoping chain breaks.
U.S. Pat. No. 5,228,251 to Frigon describes a telescoping mast which may be used to support an antenna. The nested sections of the mast may be locked in an extended position with tabs which are bent inwardly to engage the bottom of the adjacent inner section. To retract a mast section, the inner section is raised and the tab is bent outwardly to remove it from the path of the inner section.
U.S. Pat. No. 3,284,972 to Werner describes a telescoping antenna tower comprised of a plurality of nesting triangular sections. The Werner tower is assembled horizontally while on the ground and then raised into position. Sections are held in the extended position by locking pins.
U.S. Pat. No. 4,932,176 to Roberts et al describes a transportable, telescoping antenna carried on the back of a track. The antenna is pivoted from a horizontal position to a vertical position by hydraulic means. The antenna sections are extended by a cable extending around a series of pulleys, with the cable being pulled by a winch, and are held in the extended position by cable tension.
U.S. Pat. No. 5,101,215 to Creaser describes a telescoping tower comprised of a plurality of nesting triangular sections that are extended by retracting a single cable running from the top of each section to the bottom of the adjacent inner section, and then up to the top of that section.
U.S. Pat. No. 4,871,138 to Sauter describes a telescoping tower in which each inner section is locked in the extended position by a latching mechanism including a locking pin which is cammed into a slot in the adjacent outer section, and withdrawn when the tower is lowered.
U.S. Pat. No. 5,163,650 to Adams et al describes a latching mechanism involving the use of a rotatable disk which is rotated into locking position beneath a bar on the adjacent inner section to lock the sections in an extended position, and then rotated to unlock the sections.
While the above and other telescoping towers are described in the prior art, there is still a need for a tower comprised of telescoping sections which can be securely latched in the deployed position, and then released from ground level by the operator. A latching mechanism which will support high loads and levels of stress is also desired, as is a latching mechanism which will provide a greater contact area between tower sections, and thus improved conductivity, when the tower is used as a broadcast antenna.
SUMMARY OF THE INVENTION
These and other aspects are achieved by the present invention which relates to a telescoping tower which can be mounted on a wheeled carrier, and in particular to a telescoping tower including a latch to lock adjacent tower sections in a secure deployed position, that may be subsequently released, by the operator from ground level. The tower may be used as a broadcast antenna, as well as for other purposes.
The present tower is comprised of an outer tower section and an inner tower section. In most instances the tower will also include one or more intermediate tower sections between the outer and inner sections. The outer tower section has the largest cross-section, and the other sections have progressively smaller cross-sections, so that the sections can be nested. Preferably, the cross-section of the tower is triangular, although other cross-sections, e.g., rectangular, are contemplated by the present invention.
Each tower section has at least three outer surfaces and is preferably constructed of at least three parallel, spaced rods or robes, e.g., positioned at the comers of an equilateral triangle, with cross braces joining adjacent robes to form a rigid structure. The tubes and cross-braces are preferably formed of aluminum for weight considerations. The tubes, and thus the tower sections, may be of any length, although a length of from about 15 to about 20 feet is preferred to minimize the number of sections required to meet the desired tower height, while providing ease of transportation.
When transportation of the tower to different locations is desired, the tower sections are mounted on a wheeled carrier, e.g., a trailer, which includes a tower support bed to hold the tower in a horizontal position. The outer tower section is joined near its lower end to the trailer with a hinge, allowing the tower to be pivoted between a horizontal position for transportation, and a vertical position for deployment and use. An actuator, such as a hydraulic or pneumatic piston joins the trailer and the tower to move the tower between horizontal and vertical positions. The trailer may also include storage cabinets to store radials, antenna tunig equipment, a transmitter, and other components during transportation, a trailer hitch to join the trailer to a vehicle, and adjustable stabilizers to prevent the trailer from tipping when the tower is extended.
When the tower is deployed, the intermediate and inner tower sections will each be extended by sliding the section, along with any sections nested inside the section, upwardly from inside the adjacent exterior tower section to an extended or deployed position, where the section will be secured to the adjacent outer section by a latch to be described hereinafter. When the section is to be retracted, the section will be further extended beyond the deployed position to a release position, where the latch will be released and disabled. The section will then be lowered to its nested position.
Preferably, the tower sections are deployed, or retracted as the case may be, in a sequential fashion, with the outermost intermediate section being deployed first, followed sequentially by the next outermoste intermediate section, and finally the inner section, until all intermediate sections and the inner section are extended. During retraction the inner section is retracted first, followed by retraction of the intermediate sections, beginning first with the innermost intermediate section. It is within the scope of the invention, however, to simultaneously deploy or retract all, or a plurality, of the sections.
A powered or manually operated control means is provided to extend and retract the tower sections. Since it is contemplated that the present invention will be used under circumstances requiring rapid and manual deployment by a limited number of personnel, and under conditions where machinery requiting complex repair procedures is to be avoided, the control means is desirably as simple to operate and repair as possible.
Thus, the preferred control means is comprised of a set of ropes or cables extending from the lower end of the inner and each intermediate section, over the top of the adjacent exterior section, and then downward toward the bottom of the tower, where they can be reached by the operator. In order to reduce friction, the ropes may extend through pulleys attached to the tops of the outer and intermediate sections.
The operator pulls on each rope in sequence to raise the attached tower section, beginning with the outermost intermediate section and ending with the inner section. A winch or other means, preferably manually operated, may be used to assist in pulling or releasing the ropes. To lower a given section, the operator pulls on the rope attached to the section to raise the section above the latched position to the release position, and then feeds the rope out to lower the section to its retracted position.
The inner tower section and each intermediate tower section is secured to the adjacent tower section when in the extended position by a latch which can be released by the operator from the ground. This latch is comprised of a latch receiving member mounted at the top end of each intermediate or outer section, and a latching member mounted at the bottom end of the inner and each intermediate section. When a latch receiving member or latching member is described herein as being mounted "at" the top or bottom end of a tower section, as the case may be, it is meant that the member is positioned within about 3 feet or so of the top or bottom end of the section. Generally, the member should be positioned from about 1 foot to about 2 feet from the end of the section.
Each latch receiving member including an upper latch deflecting surface, a lower latch deflecting surface, and a latch receiver, e.g., a latch receiving slot between these surfaces. As used herein the term "slot" includes an opening through the receiving member as well as a recess into the member. Preferably, the latch receiving member includes a shoulder or latch plate supporting surface adjacent the interior of the slot along its lower edge to aid in guiding the plate and to act as a pivotal support for the latch plate when adjacent tower sections are latched together in the deployed position.
The latch receiving member may be formed of an upper plate that overlaps a lower plate which is attached along the upper portion of its outer face to the lower portion of the inner face of the upper plate. In this configuration, the upper plate will include a horizontal, upper latch deflecting surface and a slot or cut-out section. The lower plate will includes a horizontal, upper latch deflecting surface or shoulder extending rearwardly from the lower edge of the slot or notch. Lower plate will also include a horizontal latch deflecting surface along its lower edge.
The latching member includes a latch plate, a latch plate connector, a latch support to mount the latch plate and connector on the tower section, and a spring or other means to urge the latch plate in a normally horizontal, outwardly extending attitude. The latch plate is movable between a ready position, a latched position and a release position. The latch support may be in the form of a cylindrical, horizontal support robe or rod extending between corner robes of a tower section, and the connector may be a sleeve encircling the rod, and slidable around it. The latch plate preferably extends radially from the connector, with an inner end integral with the connector, e.g., welded thereto, and a free outer end positioned to engage the surfaces of the latch receiving member.
In order to prevent the intermediate and inner tower sections from moving inwardly past their nested positions, outwardly projecting restraining plates may be attached to the tops of the inner and intermediate sections, so that the plates contact the top edges of the adjacent exterior tower section. An antenna mast may be connected to the top of the inner section. Guy wire attachments, such as eyelets, may be attached to the tops of the tower sections so that upper ends of guy wires can be attached to the towers and extended to anchors or attachment points at ground level to secure the tower in an upright position.
During deployment or retraction of the sections, the outer surface of the tower section being moved will necessarily contact the inner surface of the adjacent exterior tower, resulting in wear and abrasion. Normally, this contact is between the upright tubes of the tower being moved and the cross braces of the adjacent tower section. To minimize the effect of this contact, it is desirable to position a contact means such as rollers or guide shoes at locations on the tower sections where this contact may occur.
When the tower is to be used as an antenna, it is constructed of a metal, e.g., aluminum, or other conductive material. A connector is provided for attaching a cable from the transmitter. Copper ground radials may be attached to the tower and extend radially outward along the ground therefrom
During deployment, a nested tower section is extended upwardly. When the latching mechanism reaches the latch receiving member, the latch plate is pivoted downwardly due to contact with the member's lower surface. Upon further extension, the front edge of the latch plate rides along the inner face of the latch receiving member until passing the shoulder and engaging the slot. The operator lowers the tower section to seat the latch plate fully into the slot, and then releases the pull on the rope, whereby the weight of the tower section is supported on the latch plate, with both faces of the latch plate contacting the latch receiving member.
When the tower section is to be retracted, the operator pulls on the rope to further extend the tower section, withdrawing the latch plate from the slot. The front edge of the latch plate then slides upwardly along the inner face of the latch receiving member until reaching the member's upper surface where it is release from engagement with the latch receiving member. The latch plate is then urged to the horizontal position.
The operator then begins to lower the tower section. When the latching member reaches the latch receiving member, the latch plate contacts the member's upper surface and is pivoted upward, and in held in the upward position by the inner face of plate during further lowering, thereby preventing the plate from being inserted into the slot during retraction.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the broadcast antenna with the tower in a vertical, deployed state, and radials extended.
FIG. 2 is a perspective view of the tower in a vertical, deployed state on a wheeled trailer.
FIG. 3 is a perspective view of the tower in a retracted, horizontal, stowed state on a wheeled trailer.
FIG. 4 is a perspective view of the outer tower section with some cross-braces removed for clarity.
FIG. 5 is a perspective view of an intermediate tower section with some cross-braces removed for clarity.
FIG. 6 is a perspective view of the inner tower section with some cross-braces removed for clarity.
FIG. 7 is a perspective view of the latch receiving member.
FIG. 8 is a perspective view of the latching member.
FIGS. 9a-9f are diagrammatic side views showing the cooperation between a latch receiving member and a latching member at various stages of deployment, latching and retraction.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In the following description, terms such as horizontal, upright, vertical, above, below, beneath, and the like, are used solely for the purpose of clarity in illustrating the invention, and should not be taken as words of limitation. Similar reference characters are used to identify corresponding parts.
As best shown in FIG. 1, the antenna of the present invention is comprised of a multi-sectional, telescoping tower, generally 10, which is pivotally mounted on a wheeled trailer, generally 12, for transportation in a horizontal position, and deployment in a vertical position. Tower 10 is comprised of an outer or lower section 14, intermediate sections 16, and an inner or upper section 18. Radials 20 are attached to the lower end of tower 10 and extend radially therefrom. Guy wires 22 are provided to secure tower 10 in the vertical position.
FIG. 2, illustrates the tower on a trailer in the vertical, deployed position, with the tower attached to trailer bed 24 with hinge 26, and extended hydraulic pistons 28 have one end attached to bed 24 and the opposite end attached to the outer tower section 14. Trailer 12 also includes a hitch 30, retractable and adjustable stabilizers 32, and storage boxes 34. When tower 10 is stowed for transportation, as best shown in FIG. 3, intermediate sections 16 and inner section 18 are nested within outer section 14, and the sections are supported horizontally on bed 24.
Outer tower section 14, illustrated in FIG. 4, the cross-section of which is in the shape of an equilateral triangle, is comprised of three comer tubes 36, joined by cross-braces 38, partially removed for clarity. Latch receiving members, generally 40, are horizontally positioned near the top edge of section 14, with their ends attached to corner tubes 38. A rope 42 extends over a pulley 44 attached to the top of tower section 14. Rope 44 has an inner end extending down to the bottom of the intermediate tower section adjacent section 14, where it is attached. The opposite free end of rope 44 extends outside the tower and down to an operator at ground level. A manually powered winch 46 is mounted on the outside of tower section 14 near the bottom of the tower where it can be conveniently reached by the operator.
Intermediate tower section 16, shown in FIG. 5, also includes three corner tubes 36 and latch receiving member 40 adjacent its upper end extending between corner robes 36, which are of the same construction as the corresponding elements of section 14. The cross-section of section 16 is less than that of section 14, so that section 16 will nest within section 14. Section 16 also includes a pulley 48 attached to its upper end and a rope 50 extending from the lower end of the adjacent tower section inside section 16, which may be another intermediate section or the inner tower section, through the pulley and downwardly outside the tower to the operator.
Tower section 16 also has latching members 52 attached adjacent the bottom of the tower section beneath latch receiving members 40. Horizontal stops 54 extend outwardly from the upper edges of section 16 to engage the upper ends of the adjacent exterior section when section 16 is retracted, preventing section 16 from moving into the adjacent section beyond the nested position. Guy wire attachment means 56 are fitted at the upper corners of section 16 to facilitate attachment of guy wires 22.
Inner tower section 18, shown in FIG. 6, is also comprised of three parallel corner robes 36 and cross-braces 38. A pair of latching members 52 are horizontally positioned between corner tubes adjacent the lower end of tower section 18. An antenna mount 58 is attached to the top of section 16, to facilitate attachment of an antenna, not shown. Section 18, like section 16, has horizontal stops 54 at the top to limit the distance section 18 can be inserted within the adjacent exterior section.
All sections of the tower include guide shoes 60, at least on the cross-braces to reduce friction and wear resulting from contact of adjacent tower sections. Guide shoes 60 are preferably made of a low friction material, such as Teflon.
Each latch receiving member 40, shown in detail in FIG. 7, is comprised of an upper plate 62 and a lower plate 64, which overlap, with the lower, inner face of plate 62 being joined to the upper, outer face of plate 64. Upper plate 62 includes a horizontal, upper latch deflecting surface 66, and a horizontal lower edge 68, with a cut-out section or notch 70 therein which has a horizontal upper surface 72. Lower plate 64 includes a horizontal, upper latch deflecting surface or shoulder 74 extending rearwardly from the lower edge of notch 70. Notch 70 and shoulder 74 together form latch receiving slot 76. Lower plate 64 also includes a lower, horizontal latch deflecting surface 78, formed by the lower edge of plate 64. Surfaces 66, 72, 74 and 78 may be radiused, i.e., rounded, to facilitate latch deflection, insertion and removal.
Latching member 52, shown in detail in FIG. 8, comprises a cylindrical, horizontal support bar 80 extending between tubes 36, and a connector sleeve 82, slidable around bar 80. A rectangular latch plate 84 has its inner end joined to sleeve 82, and a radiused, free end or forward edge 86 extending away from sleeve 82. Springs 88 and 90 join sleeve 82 to bar 80 to urge latch plate 84 to a normally horizontal attitude. Other means may be used to urge plate 84 to the normal horizontal attitude. For example, FIG. 6 illustrates the use of springs 92 extending from the rear of the sleeve member to a central point connected to an opposed tower cross brace.
FIGS. 9a-9f diagrammatically illustrate the different relationships of latching member 52 and latch receiving member 40 during deployment, release and retraction of adjacent tower sections, in which latching member 52 is supported on an interior tower section and latch receiving member 40 is supported on an adjacent, exterior tower section in a position to be engaged by latch plate 84.
Specifically, FIG. 9a shows initial contact of latch plate 84 with plate 64 pivoting plate 84 downwardly. FIG. 9b shows plate 84 immediately after passing shoulder 74 in front of slot 76. FIG. 9c shows latch plate 84 engaged in slot 76 with the upper face of plate 84 engaging surface 72 and the lower face of plate 84 engaging shoulder 74. FIG. 9d shows latch plate 84 against the inner face of plate 62 as the inside tower is moved to the release position. FIG. 9e shows latch plate 84 at the release position, where plate 84 is released from contact with latch receiving member 40 and again moves to the horizontal position. FIG. 9f shows the relationship of plate 84 and latch receiving plate 62 at the initiation of retraction of the inside tower, immediately after latch plate 84 engages surface 66, which pivots plate 84 upwardly to prevent insertion of plate 84 into slot 76 during retraction.
In operation, trailer 12 with tower 10 supported thereon in a horizontal position is pulled to the desired destination. Stabilizers 32 are set in place, and hydraulic jacks 28 are extended, e.g., by a hydraulic pump, not shown, to pivot tower 10 about hinge 26, moving tower 10 to a vertical attitude. The outer end of rope 42 is then attached to winch 46, which is turned by the operator to raise the outermost intermediate tower section and all of the sections within it from inside outer tower section 14. When latching member 52 reaches the level of latch receiving member 40, latch plate 84 contacts lower surface 78, causing plate 84 to pivot downwardly. The front edge 86 of latch plate 84 then rides along the inner face of plate 64 until reaching shoulder 74.
Plate 84 is then released from contact with plate 64 and moves under the influence of springs 92 into engagement with plate 62 with front edge of latch plate 84 being adjacent slot 76. The operator then lowers section 18 slightly to seat latch plate 84 fully into slot 76, with the upper face of plate 84 contacting surface 72 and the lower face of plate 84 contacting shoulder 74, thus providing a large contact area between the sections. The operator then unwinds, or releases, rope 42 from winch 46, whereby the weight of tower section 16 and the interior tower sections supported on latch plate 84.
The next intermediate tower section 16 and the remaining interior sections are then raised in a similar manner by pulling on the rope attached to the bottom of the section, extending over pulley 46. Latching member 52 and latch receiving member 40 cooperate as described above. This procedure is repeated for all intermediate sections, progressing from the exterior of the tower to the interior. Finally, interior section 18 is raised in a similar manner by pulling on rope 50.
When the tower is to be retracted, beginning with inner section 18, the operator connects rope 50 to winch 46 and further extends inner tower section 18 to withdraw latch plate 84 from slot 76. Front edge 86 of plate 84 moves from slot 76 and rides upwardly along the inner face of plate 62 until reaching upper surface 66. After passing surface 66, latch plate 84 is urged to the horizontal position by springs 88 and 90. The operator then begins to release rope 50, lowering section 18. Latch plate 84 is pivoted upward by contact with upper surface 66, and in held in the upward position by the inner face of plate 62, thereby preventing plate 84 from engaging slot 76 during retraction. This procedure is repeated for all intermediate sections sequentially from the interior to the exterior of the tower until all sections have been retracted.
In the preferred embodiment illustrated in the drawings, two latches are used to connect adjacent tower sections, providing additional contact surface, and an extra degree of safety. The above description applies to the operation of all latches, with all latches joining a given pair of tower sections operations simultaneously. The present invention is applicable to towers having one latch per section pair, as well as to towers having more than two latches per section pair.
Also, the above description is for a tower comprising an inner section, an outer section, and one intermediate section. It is within the scope of the invention to provide towers formed of only an inner section and an outer section, as well as towers with an inner section, an outer section and more than one intermediate section. In the case of towers with more than one intermediate section, the same steps will be followed during the deployment and retraction of each intermediate tower section.
In order to ensure stability of the tower, guy wires 22 are preferably attached at the tops of each section to wire attachments 56, before deployment of the section, and are extended to ground anchors away from the tower. When the tower is to be used as a broadcast antenna, the outer tower section will also include means to attach a transmitter cable, and radials will be connected to the tower and extended radially along the ground away from the tower.
Certain modifications and improvements will occur to those skilled in the art upon a reading of the foregoing description. By way of example, the latch described herein can be used to lock sections of towers other than broadcast antennas. The tower can also be transported on other vehicles, or even mounted at a stationary location. Also, the latching member can be positioned on an exterior tower section, and the latch receiving member on an adjacent interior tower section. It should be understood that all such modifications and improvements have been deleted herein for the sake of conciseness and readability but are properly within the scope of the follow claims.
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A transportable broadcast antenna supported on a moveable carriage comprising a telescoping tower having plurality of nesting sections, including an outer section, and intermediate and inner sections, each section slidable relative to the adjacent exterior tower section between retracted, deployed and release positions, and latches to hold the section in the deployed position. The latches disengage when the section is further extended to the release position, and is prevented from locking when the tower is retracted. Radials join the tower and extending outwardly therefrom.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Patent Application No. 60/596,936 filed on Oct. 31, 2006 which is incorporated herein by reference.
TECHNICAL FIELD
[0002] The present invention relates generally to an apparatus for supporting a toilet, and more particularly to a support for a wall mounted toilet.
BACKGROUND
[0003] Wall mounted toilets provide the advantage of improved cleaning ability, since the floor underneath can be accessed with a mop. Wall mounted toilets have a limitation in that they are typically capable of supporting between 300 to 350 pounds, which is somewhat less than a typical floor mounted toilet. The wall mounted toilet is usually supported by a carrier installed inside the wall to which the toilet is attached. Often, the carriers installed inside the wall are only rated to 300 pounds. That is, the toilets secured to the carriers are engineered to hold a person weighting no more than 300 pounds.
[0004] There are a number of people that weigh over 300 and many over 400 pounds. If such a person uses a typical wall mounted toilet, they exceed the weight limit of the wall mounted toilet. Since wall mounted toilets are common in hospitals, hotels, airports, and various other locations, there is a likelihood that a person of a weight that exceeds the weight limit of a wall mounted toilet, may use a wall mounted toilet, causing it to break off from its supporting carrier. Injury, discomfort, and embarrassment may result when this happens. Therefore, what is needed is an effective means for supporting a wall mounted toilet, to prevent these situations, thereby reducing injury, as well as legal liability for the owners of facilities with wall mounted toilets.
SUMMARY OF INVENTION
[0005] The present invention provides a support for a wall mounted toilet. An adjustable leg is attached to a bumper. The bumper supports the bowl, and the leg rests on the floor, providing additional vertical support. The present invention increases the weight limit of a wall mounted toilet to approximately 1,000 pounds, thereby safely accommodating obese people.
[0006] It is an object of the present invention to provide a toilet support that is compatible with a variety of toilets from various manufacturers.
[0007] It is another object of the present invention to provide a toilet support that is quick and easy to install.
[0008] It is yet another object of the present invention to provide an aesthetically pleasing toilet support, suitable for use in places such as hotels and restaurants.
[0009] It is still another object of the present invention to provide an aesthetically pleasing toilet support that is retractable and allows for full cleaning access to the floor.
[0010] According to the present invention, there is disclosed an apparatus for supporting a wall mounted toilet, comprising a toilet bumper in contact with the underside of the wall mounted toilet; an adjustable support leg having an upper end mounted to the toilet bumper; and a support foot mounted a lower end of the adjustable support leg and being adapted to rest against a floor.
[0011] Further according to the present invention, the toilet bumper has a three sided curved shape in plane view with a rear wall between two outside corners of the bumper and two side walls between the two outside corners and a front corner. Also the upper surface of the toilet bumper has a concave shape and the toilet bumper includes a sidewall which extends about the three sided curved shape in a perpendicular direction to a bottom surface of the toilet bumper.
[0012] Still further according to the present invention, the upper surface of the toilet bumper has a three sided cavity formed therein and extending from the rear wall and inward of the two side walls and towards the front corner. Also the three sided cavity has a bottom surface at a depth extending partially towards a lower surface of the toilet bumper.
[0013] Yet further according to the present invention, the toilet bumper has an insert disposed within the three sided cavity. The insert is a four sided insert and has an upper surface with a concave shape that matches the concave shape of upper surface of the toilet bumper and the insert has a lower surface that has a shape that matches the shape of bottom surface of cavity so that the insert can be inserted within cavity so that the toilet bumper is used as a unified structure.
[0014] Still further according to the present invention, the distance from where the upper surface of the toilet bumper intersects the rear wall of the toilet bumper is less than the distance from where the upper surface intersects the two side walls at the front corner of the toilet bumper.
[0015] Also according to the present invention, the bottom surface of the toilet bumper has a cylindrical bore extending towards the upper surface of the toilet bumper and the cylindrical bore has an outer bottom surface and an inner bottom surface wherein the outer bottom surface extends closer to the upper surface of the toilet bumper than the inner bottom surface. The cylindrical bore further includes a central bore projecting from the inner bottom surface towards the upper surface of the toilet bumper, the central bore having an insert with a threaded bore.
[0016] Yet further according to the present invention, the adjustable support leg includes a primary thin walled cylindrical shaped leg section open at opposite ends and having a threaded rod projecting through the primary cylindrical shaped leg section and wherein the threaded rod is mounted to an interior wall of the primary cylindrical shaped leg section. Also the adjustable support leg includes a secondary thin walled cylindrical shaped leg section, wherein the secondary thin walled cylindrical shaped leg section is open at one end and has a base portion closing the opposite end, and wherein the base portion has a threaded bore adapted to threadedly receive the threaded rod projecting through the primary cylindrical shaped leg section so that the secondary thin walled cylindrical shaped leg section is telescopedly receive within the secondary thin walled cylindrical shaped leg section.
[0017] Further according to the present invention, the support foot is a circular plate having a cylindrical thin walled connector secured thereto and adapted to be received within the open end of the secondary thin walled cylindrical shaped leg section.
[0018] Also according to the present invention, the toilet bumper is constructed of a silicon material.
[0019] According to the present invention, there is disclosed a method of supporting a wall mounted toilet, comprising the steps of: providing an apparatus for supporting a wall mounted toilet including a toilet bumper adapted to contact with the underside of the wall mounted toilet, an adjustable support leg having an upper end mounted to the toilet bumper and a support foot mounted a lower end of the adjustable support leg and being adapted to rest against a floor; placing the apparatus under the wall mounted toilet so that the toilet bumper is in contact with the underside of the wall mounted toilet; and adjusting the support leg so that the support foot is resting against a floor.
[0020] Still further according to the present invention, the method includes the steps of providing the toilet bumper with an upper surface with a concave shape; and disposing the upper surface with a concave shape against the bottom surface of the wall mounted toilet.
[0021] Further according to the present invention, the method includes the steps of providing the toilet bumper with an upper surface having a three sided cavity formed therein and an insert disposed within the three sided cavity wherein the upper surface of the insert has a concave shape that matches the concave shape of upper surface of the toilet bumper and the toilet bumper is used as a unified structure; and placing the apparatus under the wall mounted toilet so that the upper surface of the toilet bumper and the upper surface of the insert are in contact with the underside of the wall mounted toilet.
[0022] Yet further according to the present invention, the method includes the steps of providing the toilet bumper with a concave shaped upper surface having a three sided cavity having a bottom surface formed therein; and placing the apparatus under the wall mounted toilet so that the concave upper surface of the toilet bumper and the bottom surface of the insert are in contact with the underside of the wall mounted toilet.
[0023] Still further according to the present invention, the method includes the steps of retracting the support leg so that the support foot is not resting against the floor.
[0024] Further according to the present invention, the method includes the step of applying a bead of adhesive, such as silicone, between the toilet bumper and the bottom of the toilet bowl.
[0025] These and other advantages will be apparent from the following detailed description of preferred embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] The structure, operation, and advantages of the present invention will become further apparent upon consideration of the following description taken in conjunction with the accompanying figures (Figs.). The figures are intended to be illustrative, not limiting.
[0027] Certain elements in some of the figures may be omitted, or illustrated not-to-scale, for illustrative clarity. The cross-sectional views may be in the form of “slices”, or “near-sighted” cross-sectional views, omitting certain background lines which would otherwise be visible in a “true” cross-sectional view, for illustrative clarity.
[0028] In the drawings accompanying the description that follows, often both reference numerals and legends (labels, text descriptions) may be used to identify elements. If legends are provided, they are intended merely as an aid to the reader, and should not in any way be interpreted as limiting.
[0029] FIG. 1 shows a three dimensional view of the present invention being used with a wall mounted toilet.
[0030] FIG. 2A shows a close-up three dimensional view of the toilet bumper and telescoping leg according to the present invention present invention.
[0031] FIG. 2B shows a close-up three dimensional view of the toilet bumper with the insert removed according to the present invention present invention.
[0032] FIG. 3 shows a three dimensional bottom view of the toilet bumper according to the present invention.
[0033] FIG. 4 shows a cross-sectional view through line 4 - 4 of FIG. 3 .
[0034] FIG. 5 shows an isometric view of the telescope leg of the present invention.
[0035] FIG. 6 shows a cross-sectional view through line 6 - 6 of FIG. 5 .
[0036] FIG. 7 shows a cross-sectional view of the foot of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0037] FIG. 1 shows the use of the toilet support 100 of the present invention in use with a typical wall mounted toilet 102 . The mounted toilet 102 is secured to a carrier installed inside the wall (not shown) to which the toilet is attached with a plurality of bolts. The toilet support 100 includes a toilet bumper 104 , a support leg 106 and a support foot 108 . Toilet bumper 104 is shown in contact with the underside of the wall mounted toilet 102 . The toilet bumper 104 is mounted towards the front end of wall mounted toilet 102 so that the bumper can support the toilet in the event that a heavy person is sitting on the toilet. The adjustable support leg 106 is arranged so that an upper end portion 106 a is mounted to the toilet bumper 104 and a lower end portion 106 b is on the floor. Note that a support foot 108 is provided at the lower end 106 b of the adjustable support leg 106 and is adapted to rest against a floor.
[0038] FIG. 2A shows a detailed three dimensional view of the toilet support 100 of the present invention. As mentioned before, toilet support 100 is comprised of three main components, a toilet bumper 104 , a support leg 106 and a support foot 108 . With regard to the toilet bumper 104 , it has a three sided curved shape in plane view with a sidewall 118 including a rear wall 120 between two outside corners 122 , 124 of the bumper and two side walls 126 , 128 between the two outside corners and a front corner 130 . The sidewall 118 extends generally in a perpendicular direction (as shown in FIGS. 3 and 4 ) to a bottom surface 140 of the toilet bumper 104 .
[0039] As shown in FIGS. 2 and 3 , an upper surface 132 of toilet bumper 104 has a concave shape which is adapted to the shape of the bottom of a conventional wall mounted toilet. The bumper 104 is shaped so that when the bumper is mounted to the bottom of a toilet, the front corner 130 is higher than the rear further away than the outside corners 122 , 124 . This can be seen by referring to FIG. 4 , where the distance x from where the upper surface 132 intersects the rear wall 120 of the toilet bumper 104 to the bottom surface 140 is less than the distance y from where the upper surface intersects the two side walls 126 , 128 at the front corner 130 of the toilet bumper to the bottom surface 140 .
[0040] Sometimes, the underside of a toilet is shaped so that the concave shape of the upper surface 132 of bumper 104 does not sufficiently engage the underside of the toilet. To accommodate different shaped toilet bottoms, the toilet bumper 104 , as shown in FIGS. 2A and 2B , has a removable insert 150 which fits within a three sided cavity 152 formed in the toilet bumper. As shown in FIG. 213 , the cavity 152 has two side walls 152 a , 152 b , a forward wall 152 c and a bottom surface 152 d . The cavity 152 is formed so that a portion of rear wall 120 of toilet bumper 104 which is between the side walls 152 a and 152 b is narrower than the remainder of rear wall 120 .
[0041] The four sided insert 150 , as shown in FIGS. 2A and 2B , has two side walls 150 a and 150 b , a front wall 150 c and a rear wall 150 d . The upper surface 150 e of insert 150 has a concave shape that matches the concave shape of upper surface 132 of toilet bumper 104 . The lower surface 150 f of insert 150 has a shape that matches the shape of bottom surface 152 d of cavity 152 . The insert 150 can be inserted within cavity 152 as shown in FIG. 2A so that the toilet bumper 104 is used as a unified structure to support wall hanging toilet 102 . Alternatively, insert 150 can be remove from cavity 152 as shown in FIG. 2B . It is also within the terms of the present invention to remove only a portion of insert 150 so that the bumper 104 can accommodate a particular shape of a wall hanging toilet.
[0042] Both the toilet bumper 104 and the insert 150 are preferably constructed of a chemical and stain resistant non-porous rubber material such as silicon which can absorb shock created by a heavy individual sitting on toilet 102 and loading the toilet support 100 .
[0043] Referring to FIGS. 3 and 4 , there is shown the bottom of toilet bumper 104 . There is shown a bottom surface 140 that would be substantially parallel to a floor on which the toilet support 100 is used. A cylindrical bore 160 extends from bottom surface 140 towards the upper surface 132 of the toilet bumper 104 . There is an outer bottom surface 162 of cylindrical bore 160 and an inner bottom surface 154 . The outer bottom surface 162 extends closer to the upper surface 132 of the toilet bumper 104 than the inner bottom surface 164 . Also, a central bore 166 projects inward from the inner bottom surface 164 towards the upper surface 132 of the toilet bumper 104 . The central bore 166 opens to an insert 168 with a threaded bore 170 .
[0044] Referring to FIGS. 5 and 6 , there is shown the adjustable support leg 106 . Support leg 106 includes a primary thin walled cylindrical shaped leg section 172 open at opposite ends 174 and 176 . A threaded rod 178 projects through the primary cylindrical shaped leg section 172 and is mounted to an interior wall 180 of the primary cylindrical shaped leg section by any means, such as an integral cylindrical sleeve 182 . One end of rod 178 projects from end 174 and the other end of rod 178 projects from end 176 primary thin walled cylindrical shaped leg section 172 .
[0045] The adjustable support leg 106 includes a secondary thin walled cylindrical shaped leg section 184 . The secondary thin walled cylindrical shaped leg section 184 is open at one end 186 and has a base portion 188 closing the opposite end 190 . The base portion 188 has a threaded bore 192 extending there through and adapted to threadedly receive the threaded rod 178 projecting through the primary cylindrical shaped leg section 172 so that the secondary thin walled cylindrical shaped leg section 184 is telescopedly receive within the primary thin walled cylindrical shaped leg section. By rotating either the primary leg section 170 or the secondary leg section 184 , the height (length) of support leg 106 is adjusted.
[0046] The end of threaded rod 178 that projects from end 174 of the primary cylindrical shaped leg section 172 is received within the threaded bore 170 of insert 168 . As the primary leg section 170 is rotated, the threaded rod 178 moves through threaded insert 168 , thereby securing the leg 106 to the toilet bumper 104 . Preferably, the primary leg section 170 is rotated until the end cylindrical wall 174 is received in the outer bottom surface 162 of cylindrical bore 160 and the inner bottom surface 164 can be against the integral cylindrical sleeve 182 so that the leg 106 is securely attached to the toilet bumper 104 .
[0047] In operation, the toilet support 100 may be affixed to toilet 102 by applying adhesive, silicone adhesive or caulking to bumper 104 (note that the bumper can be formed of a silicon material.) Leg 106 is affixed to bumper 104 by the threaded screw 178 engaging screw insert 168 as described herein before. The lower leg member 106 a is then rotated until foot 110 makes contact with the floor surface. The lower leg 106 a can be rotated in an opposite direction to raise it when cleaning the floor. This provides the cleaning advantages of a wall mounted toilet, with the weight capacity properties of a floor mounted toilet.
[0048] It should be noted that no bolts or fittings need to be adjusted on the wall mounted toilet 102 when installing toilet support 100 . The bumper 104 can be molded in a color to match the toilet 102 , providing a discrete toilet support that blends in with the toilet itself.
[0049] Although the invention has been shown and described with respect to a certain preferred embodiment or embodiments, certain equivalent alterations and modifications will occur to others skilled in the art upon the reading and understanding of this specification and the annexed drawings. In particular regard to the various functions performed by the above described components (assemblies, devices, etc.) the terms (including a reference to a “means”) used to describe such components are intended to correspond, unless otherwise indicated, to any component which performs the specified function of the described component (i.e., that is functionally equivalent), even though not structurally equivalent to the disclosed structure which performs the function in the herein illustrated exemplary embodiments of the invention. In addition, while a particular feature of the invention may have been disclosed with respect to only one of several embodiments, such feature may be combined with one or more features of the other embodiments as may be desired and advantageous for any given or particular application.
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The present invention relates to an apparatus and method for supporting a wall mounted toilet with a toilet bumper in contact with the underside of the wall mounted toilet; an adjustable support leg having an upper end mounted to the toilet bumper; and a support foot mounted a lower end of the adjustable support leg and being adapted to rest against a floor.
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RELATED APPLICATION
This is a continuation-in-part of Applicant's application Ser. No. 07/990,046 filed Dec. 14, 1992 now U.S. Pat. No. 5,375,891, issued Dec. 27, 1994, for which all right under 35 U.S.C. 120 is claimed.
INTRODUCTION AND DESCRIPTION OF THE PRIOR ART
The invention disclosed in U.S. Ser. No. 07/990,046 provided a universal hinged connector to connect dissimilarly cross sectioned downspouts and extensions, while still permitting the elevation of the downspout for lawn mowing or whatever purpose required. The connection is achieved by having a tube of approximately circular cross section, or more properly a square cross section with very pronounced rounded corners on the square, hinged with a second tube of approximately square cross section; more properly a square cross section with slightly rounded corners on the square. These are approximations of common forms for both downspouts and drainage extensions; and moreover, the hinged connector in that invention is provided with simple screws with instructions to apply them in appropriate configurations, so that either tube can be connected either on the exterior surface of a downspout or the interior of a drainage extension as required.
This invention is directed towards improvements in the shape of the hinged connector portions; which improvements allow more types of common residential downspouts and extensions to be accommodated by the connector. These improvements take three distinct forms:
1. The two main segments that are joined to form the connector are now each fashioned in differently-sized steps, so that multiple types of tubes will fit within the downspout portion and outside the extension portion, respectively. This will be made more clear with reference to the diagrams herein.
2. In the case of the downspout-fitting segment, the cross sections of the stepped portions are varied to conform to specific industry-standard tubing so that this tubing will be held securely.
3. Again in the case of the downspout-fitting segment, a removable face is fashioned so that one specific size of common tubing, being 21/2"×21/2" square vinyl, can be accommodated by removal of the face.
With these improvements each end of the hinged connector fits at least six different shapes of industry standard pipe dimensions which are:
3" round metal pipe;
25/8"×25/8" square metal pipe;
21/2"×21/2" square vinyl pipe;
21/4"×3" rectangular vinyl pipe; and
23/4" round vinyl pipe.
The present improved connector is able to accommodate an unusually small downspout or unusually large extension simply by reversal of the connector, or by friction fitting the connector inside the downspout or outside the extension; or both. Further sizes may be accommodated by a small amount of bending of the downspouts, extensions, or connector.
Details of attachment of the connector to the downspout and extension are identical to those disclosed in U.S. Ser. No. 07/990,046 and are not illustrated or repeated herein. Reference to the aforementioned application and incorporation of its disclosure herein is made as if the aforementioned application is a part hereof.
DETAILED DESCRIPTION OF THE INVENTION
For this description, refer to the following diagrams, wherein like numerals refer to like parts;
FIG. 1, the improved hinged connector, perspective view;
FIG. 2, outflow tube segment of the improved hinged connector with ghosted drainage extensions, side elevation view;
FIG. 3A, input tube of the invented hinged connector including removable face exploded, cross section along plane 3A of FIG. 1;
FIG. 3B, input tube of the invented hinged connector, cross section along plane 3B from FIG. 1;
FIG. 3C, input tube of the invented hinged connector, with downspout pipe outlines; end view;
FIG. 3D, input tube of the invented hinged connector with removable panel removed to accommodate alternative downspout; end view;
FIG. 3E, input tube of the invented hinged connector with alternative downspout outline; cross section along plane 3B from FIG. 1;
FIG. 4A, improved hinged connector in usage position during water flow; partial cross section, side elevation; and
FIG. 4B, improved hinged connector in usage position during water flow, with alternative downspout and extension; partial cross section, side elevation.
DESCRIPTION OF THE INVENTION
The preferred embodiment of the improved hinged connector is generally indicated as 10 in FIG. 1. Hinged connector 10 consists of two main sections attached by hinge pins 12; these sections are outflow tube generally indicated at 14 and input tube generally indicated at 18.
Outflow tube 14 has an integral projecting U-flange portion 15 which fits alongside and outside U-flange 19 of downspout tube 18. Note that outflow tube 14 steps down in size, as is obvious in FIG. 2, showing a small drainpipe extension 30 (ghosted) snugly fit over a smaller step 14', and a larger drainpipe extension 32 (also ghosted) snugly fit over the larger step 14".
Input tube 18, to refer again to FIG. 1, can be seen to have similarly larger step 18" and smaller step 18'. In addition, input tube 18 has removable side panel 28, which snaps on or off from larger step 18". The shape of input tube 18 may be more readily appreciated with reference to FIG. 3A, which is a cross section of larger step 18" along the lines 3A from FIG. 1. Similarly, the cross section of small step 18' is shown in FIG. 3B. These shapes will now be explained in conjunction with the use of the improved connector 10.
In FIG. 3C, industry standard 21/4"×31/4" "rectangular" metal pipe external surface 40 (which actually is made with slightly rounded corners 40') fits snugly into corresponding rounded channels 100 in input tube 18. 21/4"×3" rectangular vinyl pipe, owing to its thicker wall, will also fit sufficiently snugly in these same channels 100, and so ghosted pipe 40 can be taken to represent the external surface of this size of vinyl pipe also. Also shown on FIG. 3C is 25/8"×25/8" (approximately square) metal pipe external surface 42, shown ghosted, which fits into lower corners 101 of input tube 18 and underneath removable panel 28. In FIG. 3D, nominal 21/2"×21/2" square vinyl pipe external surface 43 is accommodated by removal of the panel 28. FIG. 3E, a cross section along 3B from FIG. 1 of smaller step 18' shows 3" round metal pipe external surface 44, ghosted, inserted snugly along channel 104 of input tube 18, 23/4" round vinyl pipe external surface would fit in the same path as this metal pipe external surface 44. Support projections 46 held keep surface 44 firmly in place.
Two of the thirty-six possible combinations are shown schematically in FIGS. 4A and 4B (this thirty-six is calculated by each of the six types being accommodated on both the input tube 18 and the outflow tube 14; the other thirty-four combinations are not shown).
In the example of FIG. 4A, during water flow, connector 10 operates as follows: water flows along path of arrow F from 3" round metal downspout 44, over input U-flange 19, onto output U-flange 15, through outflow larger step 14", through outflow smaller step 14', and into extension 50, which may, for example, be 21/2"×21/2" square vinyl pipe.
A second illustrated example of the multiple combinations possible is shown in FIG. 4B, where instead the downspout is 21/4"×3" rectangular vinyl pipe 47 and the extension is 23/4" round vinyl pipe 51. Water flows again along path indicated as arrow F.
As described in detail in the corresponding U.S. Ser. No. 07/990,046 which, as mentioned previously, disclosed a connector without the improvements described herein, storage of extending portion of the system described herein (such as extension 51 and attached outflow tube 14, in FIG. 4A) involves merely pivoting the connector 10 at hinge pins 12. (Such pivoting is not illustrated herein.)
Securement of connector 10 in the pivoted position, as well as secure attachment of the downspout and extensions to the connector 10, are identical to that disclosed in the corresponding U.S. Pat. No. 5,375,891 and are not itemized herein.
Finally, it should be noted that whereas a particular hinged connector 10, such as that shown in FIGS. 1 through 5, is designed to accommodate particular common cross sections of pipe, such a hinged connector 10 will also be fittable by other close sizes and shapes of downspout and drainage extension pipe, with small amounts of adaptation, since such pipe commonly is made of thin metal or plastic that can be easily bent or formed at such a join. Thus virtually all known, and probably many heretofore unknown, residential downspouts and extensions can be fitted to this universal hinged connector.
The foregoing is by example only and the scope of the invention should be limited only by the appended claims.
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An adaptor for eavestrough downspouts has two portions of different cross sections. The first section fits outside the downspout and the other fits inside the drainage extensions. The two portions are hinged together. The adaptor is formed with step-down sized cross sections and a removable panel to allow more sizes of downspouts and extensions to be connected.
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CROSS-REFERENCE TO RELATED APPLICATIONS
The present application claims priority from Australian Provisional Patent Application No 2006902915 filed on 31 May 2006, the contents of which is incorporated herein by reference.
FIELD OF THE INVENTION
This invention relates to a compacting wheel apparatus of the type fitted to earthmoving machinery for compacting soil, particularly in trenches.
BACKGROUND
It is a requirement in cable- and pipe laying, and civil engineering in general, to compact soil in a trench, or other confined space, to return the soil to its original grade. For reasons of cost, safety and consistency of results, it is normal to fit a rotatable wheel or drum to a suitable earthmoving machine, the wheel or drum being rolled back and forth over the soil area to be compacted until a suitable level of compaction is obtained.
FIG. 1 shows one such arrangement. A wheel-type compacting device 1 is mounted to a backhoe excavator 2 in place of the usual bucket. The device 1 is able to rotate freely about an axis 3 that is parallel to the axes 4 and 5 about which the backhoe's dipper (sometimes alternatively called stick) 6 and boom 7 rotate. The backhoe operator positions excavator 2 so that axes 4 and 5 are perpendicular to the length of a trench 8 . The operator can then readily position the device 1 at the base of the trench, and by operation of boom 7 and stick 6 , roll the device backwards and forwards along the trench to compact the soil therein. The device 1 is typically provided with radially projecting feet 9 to enhance the compaction effect but may also take the form of a plain-surfaced wheel or drum.
In some circumstances vibration devices may be employed with the device 1 for better compaction, and sometimes no vibration capability is provided, reliance being placed simply on repetitive pressing downward of the soil surface by the feet of the wheel.
Other types of machines may be used for mounting the compacting devices such as device 1 . For example, device 1 may be mounted to other types of excavators, such as telescopic-boom excavators (sold by Gradall Inc., USA), and to the boom-and-stick backhoe arrangements that are often fitted to the rear of wheeled loaders. With suitable adaptors, front-end loaders of the articulated or skid steer type may also be fitted with compacting devices.
Compacting devices that comprise a single drum with feet projecting therefrom and which is supported for rotation between fork arms can lead to difficulties in compacting soil adjacent the walls of a trench. This may be due to the fact that the fork arms are of a size that can prevent the drum accessing the soil at the perimeter of the trench, adjacent the longitudinal walls of the trench. It is therefore known to provide compacting devices, such as device 1 , that employ several individual wheel disks 10 on a common shaft, with supporting members 11 arranged therebetween. In the arrangement as shown in FIG. 1 , supporting members 11 are secured to a structure 12 releasably attached to the stick 6 and provide support for an axle (not shown) on which are mounted the wheel disks 10 .
However, devices of this type, have their own problems. Gaps are needed between some wheel disks 10 to provide clearance for the support members 11 and the ground below such gaps receives no significant compaction. Therefore, to provide adequate and even compaction over the whole width of a trench floor, it may be necessary to shift the device 1 laterally one or more times to ensure that all the soil within the trench is compacted. This can be a time consuming process that requires significant operator skill in manoeuvring the machine.
Therefore, there is a need to provide a compacting device that provides improved soil compaction in a relatively simple manner.
Any discussion of documents, acts, materials, devices, articles or the like which has been included in the present specification is solely for the purpose of providing a context for the present invention. It is not to be taken as an admission that any or all of these matters form part of the prior art base or were common general knowledge in the field relevant to the present invention as it existed before the priority date of each claim of this application.
SUMMARY OF THE INVENTION
In a first aspect, the invention provides a compacting device for attachment to an earthmoving machine to compact a substrate, including:
a plurality of wheel assemblies mounted for rotation together in bearings; and
a support having a base adapted to be mounted to the earthmoving machine and one or more bearing support members that extend from the base and between the wheel assemblies to support the bearings;
wherein each wheel assembly includes a set of ground-contacting feet secured to and peripherally spaced apart around a rim portion of the wheel assembly such when the device is rolled over the substrate a first foot of the set of ground engaging feet contacts the substrate between axial width limits that differ from axial width limits of a second foot of the set of ground engaging feet.
In one embodiment, the axial width limits of the first foot partially overlap the axial width limits of the second foot. The first and second feet may be peripherally adjacent members of said set of feet.
The first and second feet may be comprised in a multi-foot pad secured to the wheel assembly. The multi-foot pad may comprise two feet only of the set of ground engaging feet. Conveniently, the first and second feet may be integrally formed in said multi-foot pad.
The multi-foot pad may be secured to the wheel assembly by at least one of welding, bolting, riveting, and pinning by means of at least one pin. In another form, the multi-foot pad may be formed integrally with the wheel assembly by casting or the like.
In another embodiment, for ease of fitting, the multi-foot pad has locating surfaces that, when the multi-foot pad is placed on the wheel assembly for securing thereto, bear against the wheel assembly so as to correctly position the feet radially and/or axially on the rim portion of the wheel assembly. This arrangement may be particularly convenient when the multi-foot pad is to be secured by welding.
The multi-foot pad may have a groove within which the rim portion of the wheel assembly is received so as to locate the multi-foot pad on the wheel assembly axially and radially.
In another embodiment, when the multi-foot pad is secured to the rim portion of the wheel assembly, the axially leftmost width limit of the first foot is on an opposite side of the rim portion of the wheel assembly from the axially rightmost width limit of the second foot.
The first and second feet of the multi-foot pad may have approximately the same shape as each other, save for being oppositely handed in an axial direction, and wherein when the multi-foot pad is secured to the wheel assembly the first and second feet may be approximately equally displaced in opposite axial directions from the rim portion of the wheel assembly.
At least one of the wheel assemblies may include an endmost wheel assembly that may be secured to an outermost wheel assembly of the device to increase its working width.
In another embodiment, the compaction device or the machine to which it is mounted may be provided with means for vibrating the wheel assemblies to enhance the compaction effect where required.
In a further aspect, the invention provides a multi-foot ground engaging pad for a compacting device of the type having a wheel assembly comprising one or more wheels adapted to be rolled over a substrate to be compacted, the pad including a plurality of ground engaging feet integrally formed on a base that is securable to a rim portion of the one or more wheels whereupon said feet are spaced peripherally on said wheel.
In an embodiment of this aspect, during rolling of the wheel assembly on the substrate, a first ground engaging foot on the pad contacts the substrate between axial width limits that differ from axial width limits of a second ground engaging foot on the pad.
In one form, the axial width limits of the first ground engaging foot may partially overlap the axial width limits of the second ground engaging foot.
In one embodiment, the multi-foot pad may comprise two ground engaging feet only. The multi-foot pad may be securable to the wheel by at least one of welding, bolting, riveting, and pinning by means of at least one pin.
The multi-foot ground engaging pad may have locating surfaces that, when the pad is placed on the wheel for securing thereto, bear against the wheel so as to correctly position the ground engaging feet radially and/or axially on the wheel. A groove may be provided within which an outer rim of the wheel may be received so as to locate the pad on the wheel axially and radially.
The multi-foot pad may be so proportioned that when the pad is secured to the wheel the axially leftmost width limit of the first foot is on an opposite side of a rim portion of the wheel from the axially rightmost width limit of the second foot. The first and second ground engaging feet of the pad may have approximately the same shape as each other save for being oppositely handed in an axial direction. In this regard, when the pad is secured to said wheel the first and second feet may be approximately equally displaced in opposite axial directions from the rim portion of the wheel.
In a still further aspect, the invention provides a method for compacting soil including the steps of:
securing a compacting device as disclosed herein to an earthmoving machine; and
using the machine to roll the device back and forth on a surface of the soil.
In one embodiment of this aspect of the invention, the earthmoving machine may include a backhoe mechanism having a boom and a dipper and the device may be secured to a free end of the dipper.
According to yet another aspect, the present invention provides a compacting device for attachment to an earthmoving machine to compact a substrate, the compacting device including:
a base adapted to be mounted to said earthmoving machine;
one or more support members extending from the base;
one or more bearings, the or each bearing being mounted to an end of the one or more support members;
a shaft rotatably supported within the one or more bearings; and
a plurality of wheel assemblies mountable to said shaft such that said one or more support members extend between said wheel assemblies;
wherein each wheel assembly includes a plurality of ground-contacting feet spaced apart around the periphery of the wheel assembly, said feet being alternately displaced laterally towards opposing sides of the wheel assembly such that when said wheel assemblies are rolled over a substrate surface said feet contact said substrate surface and compact said substrate.
In an embodiment of this aspect of the invention, the wheel assemblies are mountable to the shaft such that the ground contacting feet of adjacent wheel assemblies are circumferentially staggered.
In one form, at least two of the wheel assemblies may be directly mounted to the shaft. At least one wheel assembly may be mounted to one of the wheel assemblies directly mounted to the shaft.
Each ground contacting foot may be formed integral with at least one adjacent ground contacting foot to form a multi-foot pad attached to a rim portion of each wheel assembly. The multi-foot pad may have two ground contacting feet only. The multi-foot pad may be secured to the rim portion of the wheel assembly by at least one of welding, bolting, riveting, and pinning by means of at least one pin.
In one form, the multi-foot pad may have locating surfaces that, when the multi-foot pad is placed on the rim portion of the wheel assembly for securing thereto, bear against he rim portion of the wheel assembly so as to correctly position the ground contacting feet radially and/or axially on the rim portion of the wheel assembly. In another form, the multi-foot pad may have a groove within which the rim portion of the wheel assembly may be received so as to locate the multi-foot pad on the rim portion of the wheel assembly axially and radially.
In another embodiment of this aspect of the invention, the first and second feet of the multi-foot pad may have substantially the same shape. In this regard, when the multi-foot pad is secured to the rim portion of the wheel assembly the first and second feet may be approximately equally displaced in opposite lateral directions from the rim portion of the wheel assembly.
According to yet another aspect, the present invention provides a compacting device for attachment to an earthmoving machine to compact a substrate, the compacting device including:
a base adapted to be mounted to said earthmoving machine;
one or more support members extending from the base;
one or more bearings, the or each bearing being mounted to an end of the one or more support members;
a shaft rotatably supported within the one or more bearings; and
a plurality of wheel assemblies mounted on said shaft such that said one or more support members extend between said wheel assemblies, each wheel assembly having a plurality of ground-contacting feet spaced apart around the periphery of the wheel assembly such that when said wheel assemblies are rolled over the substrate surface said feet contact said substrate surface and compact said substrate,
wherein, one or more additional wheel assemblies are removably mounted to one or more of the plurality of wheel assemblies mounted on the shaft.
In an embodiment of this aspect of the invention, the one or more additional wheel assemblies are removably mounted to an end wheel assembly mounted on the shaft. The one or more additional wheel assemblies may be removably mounted to a hub that is removably mounted to an end wheel assembly mounted on the shaft.
The hub may comprise a first mounting disc for mounting said hub to a wheel disc of an end wheel assembly mounted on the shaft and a second mounting disc to which said additional wheel assembly is mounted. The first and second mounting discs may have a plurality of holes formed therethrough to receive one or more fasteners for facilitating mounting of the hub to the end wheel assembly and mounting of the additional wheel assembly to the hub. The plurality of holes may be formed around the periphery of the first and second mounting discs. Corresponding holes formed around the periphery of the first and second mounting discs may be offset such that the plurality of ground-contacting feet spaced apart around the periphery of the additional wheel assembly are circumferentially staggered with respect to the plurality of ground-contacting feet spaced apart around the periphery of the end wheel assembly when the additional wheel assembly is mounted to the end wheel assembly.
Other aspects and features will become apparent from the following detailed description.
Throughout this specification the word “comprise”, or variations such as “comprises” or “comprising”, will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps.
BRIEF DESCRIPTION OF THE DRAWINGS
By way of example only, the invention is now described with reference to the accompanying drawings:
FIG. 1 is a perspective view of a backhoe excavator fitted with a compacting wheel of known type;
FIG. 2 is a schematic diagram showing (upper part) a rear view of a compacting wheel and (lower part) a plan view of areas of a surface compacted by passage of the compacting wheel when rolling over a substrate;
FIG. 3 is a schematic diagram showing (upper part) a rear view of a further compacting wheel and (lower part) a plan view of areas of a surface compacted by passage of the compacting wheel when rolling over a substrate;
FIG. 4 is an elevation of three-wheel embodiment of the invention;
FIG. 5 is an elevation of a two-wheel embodiment of the invention;
FIG. 6 is a view from below of the embodiment shown in FIG. 5 ;
FIG. 7 is a perspective view of the embodiment shown in FIG. 5 ;
FIG. 8 is a side view of the embodiment shown in FIG. 5 ;
FIG. 9 is an elevation of a five-wheel embodiment of the invention;
FIG. 10 is a cross-sectional view of the embodiment shown in FIG. 9 , the section being taken at the centre of a shaft mounting wheels of the device;
FIG. 11 is a perspective view of the embodiment shown in FIG. 9 , partially cut away;
FIG. 12 is a perspective view of a foot assembly of a compacting device according to the invention;
FIG. 13 is a view of the foot assembly shown in FIG. 12 , looking in the direction of arrow “A”;
FIG. 14 is a view of the foot assembly shown in FIG. 12 looking in the direction of arrow “B”;
FIG. 15 is a cross-sectional view of an alternative embodiment of a five-wheel compacting device according to the present invention;
FIG. 16 is an isolated perspective view of a mounting hub mounted to a wheel in accordance with the embodiment of the device shown in FIG. 15 ;
FIG. 17 is perspective view of the mounting hub of FIG. 16 ;
FIG. 18 is a plan view of the mounting hub of FIG. 17 ;
FIG. 19 is a plan view of the mounting hub of FIGS. 16 and 17 connecting adjacent wheels of a compacting device of the present invention;
FIG. 20 is a perspective view of a wheel of a compacting device in accordance with one embodiment of the present invention;
FIG. 21 is a perspective view of the wheel of FIG. 20 mounted to a shaft of a compacting device by way of a locating block in accordance with an embodiment of the present invention; and
FIGS. 22A-22C show perspective, plan and cross-sectional views of an embodiment of the locating block of FIG. 21 .
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 shows a wheel-type compacting device 1 mounted on a backhoe excavator 2 and has been discussed above. The present invention provides an improved compacting device usable in the same way as compacting device 1 .
FIG. 2 shows a compacting device 20 such as that shown in the prior art device of FIG. 1 . In the upper part of FIG. 2 , a rear elevation of a compacting device 20 is shown, rolling on a substrate 21 . Device 20 comprises three wheels 22 , 23 and 24 , that are mounted on a single shaft (not shown) so as to rotate together rather than independently. The shaft is in turn supported for rotation in bearing assemblies 39 mounted to a pair of support members 38 located between wheels 22 and 23 , and 23 and 24 respectively. Wheel assemblies 22 , 23 and 24 each have compacting feet 29 whose outer surfaces 30 (all shown shaded) contact substrate 21 as the device 20 is rolled over the substrate 21 . No other constructional details of wheel assemblies 22 , 23 and 24 are shown. The lower part of FIG. 2 shows, in plan view, a portion of substrate 21 after the device 20 has been rolled over the substrate in a single rolling pass, with the areas 31 that are contacted by surfaces 30 indicated by shading.
It is apparent from FIG. 2 that a rolling pass of device 20 over substrate 21 provides compaction in three strips 32 , 33 and 34 , but does not directly compact substrate 21 in the two intervening strips 35 and 36 . These strips are not directly compacted by the device due to the support members 38 (similar to members 11 in FIG. 1 ) being provided between adjacent pairs of wheel assemblies 22 , 23 and 24 to support bearing assemblies 39 .
In practice, to compact the whole area of substrate 21 (which could be the floor of a trench) adequately and evenly, device 20 would need to be moved axially (i.e. in the direction of rotation axis 37 of device 20 ) from time to time and multiple rolling passes would need to be made at each axial position. This process also allows compaction to be carried out at the edges of a trench, despite the fact that the device 20 would in general be narrower than the trench width. As will be appreciated, in order to achieve effective soil compaction using such a process, significant operator skill and time is required.
According to the present invention, it has been found that, in at least some ground conditions, the performance of a device, such as device 20 , can be enhanced by making the individual feet on each wheel assembly narrower (in the axial direction) while maintaining the width of the strip contacted by each wheel assembly by offsetting some feet axially from others. One embodiment of such an arrangement is shown in FIG. 3 . In order to facilitate direct comparison of the device of the present invention as shown in FIG. 3 , and that of the prior art, as shown in FIG. 2 , the same item numbers with the suffix ‘a’ have been used for equivalent items. The effectiveness of the device 20 a , as shown in FIG. 3 , is thought to arise because the total area of the device 20 a in contact with the substrate 21 a is decreased, so leading to a higher level of compaction for a given downward force on the device 20 a . In successive passes of the device 20 a over the substrate 21 a , particularly if the device 20 a is lifted clear of the substrate 21 a at the end of each pass, the feet 29 a will not in general touch the substrate at identical positions as in previous passes, so that strips 32 a , 33 a and 34 a of the same width as strips 32 , 33 and 34 can be compacted, thereby providing improved compaction of the soil in these regions.
FIG. 4 shows a compacting device 40 in accordance with an embodiment of the present invention. The device 40 is shown as having three individual wheels 41 , 42 and 43 , each with feet 44 that are staggered in essentially the same way as the feet 29 a of the embodiment as shown in FIG. 3 . Wheels 41 - 43 are mounted to a single shaft (not shown) so as to rotate together as a unit, about a transverse axis 45 . Bearing assemblies 46 support the shaft and are themselves held by support members 47 . Support members 47 extend from a base 48 that is able to be secured (for example via a quick-hitch arrangement of known type, not shown) to an excavator stick in a similar manner to that shown for device 1 in FIG. 1 .
It will be appreciated that compacting devices according to the present invention may employ any number of individual wheels, and are not limited to having three wheels. Different numbers of individual wheels may be used to suit different work conditions, different trench widths and different supporting machinery. FIGS. 5 to 8 show a compacting device 50 having two wheels 51 and 52 and only one supporting member 53 positioned therebetween. Device 50 is otherwise similar to device 40 , especially in relation to the arrangement of the feet 54 provided on wheels 51 and 52 , and in this embodiment the wheels 51 and 52 also rotate together.
FIGS. 9 , 10 and 11 show another embodiment of a compacting device 60 according to the present invention. Device 60 has a total of five wheels, 61 , 62 , 63 , 64 and 65 , similar in their arrangement of feet 66 to wheels 41 - 43 of device 40 . Device 60 has only two support members 66 and 67 , having bearing assemblies 68 and 69 mounted respectively thereto. Support members 66 , 67 and bearing assemblies 68 , 69 are located between, firstly, wheels 62 and 63 , and, secondly, 63 and 64 . As can be seen in the sectional views of FIGS. 10 and 11 , wheels 62 , 63 and 64 are mounted to a single shaft 70 to rotate together. The outer wheels 61 and 65 are not mounted directly to shaft 70 but to hubs 71 and 72 , that are in turn bolted to wheel discs 73 and 74 respectively of wheels 62 and 64 . With this arrangement, outer wheels 61 and 65 are readily detachable so that device 60 is convertible to the narrower three-wheel device 40 , as required. This feature allows a narrow trench to be accommodated, or higher compaction with a given supporting machine weight, using three wheels 62 - 64 only when required or, alternatively, a wider trench can be accommodated using all five wheels 61 - 65 .
FIG. 15 shows an alternative embodiment of a compacting device 100 according to the present invention. As described the embodiment shown in FIGS. 9-11 , device 100 has a total of five wheels 101 - 105 . End wheels 101 and 105 are removable to enable the device 100 to be readily converted between a wide five-wheeled device and a narrow three-wheeled device, according to the requirements of the job to be performed. In this regard, device 100 also has two support members 106 , 107 having bearing assemblies 108 , 109 respectively mounted to an end thereof. A shaft 110 extends through the bearing assemblies 108 , 109 , and wheels 102 , 103 and 104 are mounted to the shaft 110 to rotate about the axis of the shaft 110 .
The end wheels 101 and 105 are respectively mounted to the shaft mounted wheels 102 and 104 by way of mounting hubs 115 . The mounting hubs 115 are mounted to the wheel discs of the wheels by appropriate bolts which allow ready attachment/detachment of the end wheels 101 and 105 , when required. This is shown in FIG. 16 wherein mounting hub 115 is mounted to the wheel disc 104 a of wheel 104 , in readiness to receive wheel 105 .
Mounting hub 115 is shown in more detail in FIGS. 17 and 18 and comprises a pair of mounting cups/discs 116 , 118 separated by a central core 117 . Each mounting cup/disc 116 , 118 is mounted to a wheel disc of the corresponding wheel pairs 104 / 105 and 101 / 102 such that rotation of the shaft mounted wheel 102 , 104 is transferred to the corresponding end wheel 101 , 105 . To facilitate mounting of the cups/discs 116 , 118 to the wheel discs, a plurality of holes 119 are formed around the periphery of each cup/disc to receive a fastener such as a bolt or the like. Holes 119 align with holes formed in the wheel discs of the wheels such that the fastener can pass through the wheel discs and cups 116 , 118 .
As shown more clearly in FIG. 18 , the holes 119 provided around the periphery of the cup/disc 116 are offset with respect to corresponding holes 119 provided around the periphery of cup/disc 118 . In the embodiment as shown the corresponding holes 119 are offset an angle θ with respect to the central axis of the mounting hub 118 . This offset angle θ is preferably between around 10° and 20°, more preferably 15°.
Such an offset angle between corresponding holes 119 formed in the periphery of the cups/discs 116 , 118 , ensures that when wheels 101 / 102 and wheels 104 / 105 are mounted together by way of the mounting hub 115 , the contacting feet of adjacent wheels are arranged in a circumferentially staggered manner. As discussed above, such a circumferentially staggered arrangement of contacting feet between adjacent wheels aids in facilitating improved soil compaction as the device 100 is rolled over the soil surface in multiple passes.
This circumferential staggered arrangement of the contacting feet of adjacent wheels can be seen more clearly in the isolated view of FIG. 19 . As shown, end wheel 105 is mounted to wheel 104 by way of mounting hub 115 in the manner as discussed above. When mounted in this manner, the contacting feet 120 a of end wheel 105 are circumferentially offset with respect to the contacting feet 120 b of wheel 104 . In this regard, when the device 100 is rolled over the soil to be compacted such that the adjacent wheels rotate together, the corresponding feet 120 a and 120 b on adjacent wheels do not contact and pass over the soil at the same time. This avoids the formation of a common path or plane of soil compaction extending orthogonal to the direction in which the device travels, which can cause corrugation in the compacted soil and inconsistent compaction.
One embodiment of the construction of the wheels of the compacting devices according to the present invention will now be described. This construction can be best seen in the sectioned views of FIGS. 10 and 11 that show wheels 61 - 65 . However, it is to be understood that essentially the same construction can be used in the wheels 41 - 43 of device 40 , wheels 51 , 52 of device 50 , and wheels 101 - 105 of device 100 .
Wheel 64 will be described by way of illustration. Wheel 64 has a hub 80 that is secured (by any suitable means known in the art such as a key or pin, not shown) to shaft 70 . A wheel disc 74 is then secured to hub 80 . This could be achieved by welding or bolting the wheel disc 74 to the hub 80 or by any other suitable manner known in the art. Alternatively, hub 80 and wheel disc 74 could be integrally formed, for example by casting. Secured to the outer edge of wheel disc 74 are foot assemblies 82 , each of which includes two feet 66 . The feet 66 of each foot assembly 82 are offset from each other in an axial direction (i.e. a direction parallel to shaft 70 in device 60 ). FIGS. 12 , 13 and 14 show one embodiment of the foot assembly 82 .
Foot assembly 82 is advantageously a single casting and has a base 83 that connects feet 66 and has an arc that which generally conforms to the arc of the circumference of the wheel disc 74 . Formed within base 83 is a groove 84 that is shaped and sized to snugly receive an outer peripheral part of wheel disc 74 . Foot assembly 82 can be secured to wheel disc 74 by positioning it on disc 74 so that the disc 74 is received in groove 84 with the outer circumferential edge of disc 74 abutting surface 85 of groove 84 , and then welding assembly 82 to disc 74 . This process is repeated for each of the assemblies 82 required to be secured around the periphery of wheel disc 74 . Assembly 82 is shown in use in devices 40 , 50 and 60 .
It will be apparent to persons skilled in the art that, as an alternative, an assembly similar to assembly 82 , namely having two offset feet 66 , could be made that would be able to be secured to wheel disc 74 by bolting therethrough or by pinning, rather than welding. The assemblies 82 may also be formed integral with the wheel disc 74 , by casting or other such methods. It will also be apparent that different numbers of feet than the two feet 66 could be incorporated in an alternative design of foot assembly (not shown) if required.
It will also be apparent that if the depth of groove 84 is suitably chosen, a foot assembly such as assembly 82 could be mounted to a range of diameters of wheel disc 74 .
An alternative wheel construction is shown in FIG. 20 as wheel 120 . Wheel 120 is cast as a single unit and includes an integral hub 122 that is adapted to be secured to a shaft of the device in a manner discussed below. A wheel disc 125 is formed about the hub 122 and has a plurality of holes 126 formed therethrough for mounting a mounting hub 115 in the manner as described above. A plurality of radial spoke elements 127 extend from the wheel disc 125 and hub 122 and terminate in an external rim 128 . A plurality of contacting feet 129 extend from the outer surface of the rim 28 , and each of the feet 129 are offset from each other in an axial direction (i.e. in a direction parallel to a shaft extending through the hub 122 ). The feet 129 function in the same manner as the feet 66 discussed above and have the same general shape characteristics.
The hub 122 has a pair of opposing recess portions 124 formed therein to facilitate mounting of the wheel 120 to a shaft 123 . As shown in FIG. 21 , each recess portion 124 is shaped to receive a locating block 130 . The locating block 130 is shown in more detail in FIGS. 22A-22C and is generally in the form of a wedge or insert having a head portion 132 and a body portion 134 . The body portion 134 is shaped to fit into the recess portion 124 such that the distal end of the body portion 134 abuts the shaft 123 , as shown in FIG. 21 . The head portion 122 is shaped to abut the surface of the hub 122 and has a pair of V-shaped wings 131 which are snugly received in a pair of V-shaped grooves formed in the surface of the hub 122 . Such an arrangement provides a snug fit between the locating block 130 and the hub 122 , such that the locating block 130 is able to be simply aligned into the recess portion 124 .
In order to secure the wheels 120 to the shaft 123 , holes 123 a are provided through the shaft 123 , as shown in FIG. 21 . The holes 123 a are provided at desired positions along the length of the shaft 123 and orientated in the same manner, for ease of construction. As shown in FIG. 22C , each locating block 130 has a hole 135 formed therethrough.
To assemble the device, the wheels 120 are positioned on the shaft 123 and the locating blocks are inserted into the recess portions 122 such that the hole 135 formed in the locating blocks aligns with the hole 123 a formed in the shaft 123 . A suitable pin or key may then be inserted through the aligned holes 135 and 123 a to secure the wheel 120 in position on the shaft 123 .
Such an arrangement overcomes the need to drill precise holes through the hub 122 , which can be difficult due to the orientation and size of the hub 122 and the tolerances required. Further, in order to orientate adjacent wheels 120 of the device such that the feet 129 of adjacent wheels 120 are arranged in a circumferentially staggered manner, it would be necessary to drill holes through the hub at different positions for each wheel 120 , such that when the wheels are secured to the shaft 123 they are correctly orientated with respect to neighbouring wheels.
By employing the locating blocks 130 of the present invention adjacent wheels can be relatively easily positioned and secured in place such that the contacting feet 29 of adjacent wheels are circumferentially staggered, in the manner as shown in FIG. 19 . This is achieved through forming the holes 135 in the locating block 130 at an angle β to the vertical axis, as shown in FIG. 22C . Such an orientation of the holes 135 provides a relatively simple way in which to control the orientation of adjacent wheels 120 when secured to the shaft 123 . The angle β can vary to provide a variety of circumferentially staggered arrangements. In a preferred form, in order to ensure that there is a constant 150 stagger between wheels, the angle β may be 7.5°. Therefore by inserting the locating blocks 130 within the recess portion 124 of the hubs 122 of adjacent wheels in opposite orientations, adjacent wheels 120 will have their contacting feet 129 circumferentially staggered by 15°. Such an arrangement enables a single type of wheel 120 and locating block 130 to be supplied for assembling the compacting devices to a variety of needs.
Plain bearings may be used to mount devices such as 40 , 50 , 60 , 100 , and 120 to their support members 47 , 53 , 66 , 67 , 106 , and 107 . These may use suitable plastics bushes. Alternatively, rolling element bearings may be used.
Although for each of the devices 40 , 50 , 60 , 100 and 120 the wheels 41 - 42 , 51 - 53 , 61 - 65 , and 101 - 105 have been described as rotating together, it is possible as an alternative to arrange for some or all of the wheels to be allowed to rotate separately.
The present invention provides various embodiments of a soil compacting device that can be readily attachable to a variety of machines to achieve improved soil compaction through greater distribution of soil compacting forces to the soil being compacted. The devices are constructed in a manner that enables the compacting wheels to be relatively easily attached/detached from the device. This facilitates conversion of the device between a narrow device suitable for compacting narrow soil regions, and a wider device suitable for compacting larger surface areas, depending on the type and nature of the task to be performed.
It will be appreciated by persons skilled in the art that numerous variations and/or modifications may be made to the invention as shown in the specific embodiments without departing from the spirit or scope of the invention as broadly described. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive.
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A compacting device ( 40 ) for attachment to an earthmoving machine ( 2 ) to compact a substrate is described. The compacting device ( 40 ) includes a plurality of wheel assemblies ( 41, 42, 43 ) mounted for rotation in bearings ( 46 ). A support is also provided, having a base part ( 48 ) that is adapted to be mounted to the earthmoving machine ( 2 ). One or more bearing support members ( 47 ) extend from the base part ( 48 ) and between the wheel assemblies ( 41, 42, 43 ) to support the bearings ( 46 ). Each wheel assembly ( 41, 42, 43 ) includes a set of ground-contacting feet ( 44 ) secured to and peripherally spaced apart around a rim portion of the wheel assembly ( 41, 42, 43 ). In this arrangement, when the device ( 40 ) is rolled over the substrate a first foot of said set of ground engaging feet ( 44 ) contacts the substrate between axial width limits that differ from axial width limits of a second foot of said set of ground engaging feet ( 44 ).
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You are an expert at summarizing long articles. Proceed to summarize the following text:
FIELD
The present invention relates to devices for securing doors. More particularly, the present invention relates to a door safety device which is suitable for securing a sliding glass door in a closed position.
BACKGROUND
Sliding glass doors are often installed in homes to separate a patio or balcony, for example, from the interior of the home. A conventional sliding glass door has a fixed window pane and a sliding glass door which is slidably mounted in a track. The sliding glass door can be selectively closed by sliding the door to a position adjacent to the fixed window pane and opened by sliding the door to a position in front of the fixed window pane. When in the closed position, the door may be locked using a conventional locking mechanism and additionally secured by inserting a shortened broom stick, for example, between the edge of the door and the facing in which the fixed window pane is mounted. Persons must typically bend over to insert the stick in place in order to secure the door in a closed position or remove the stick in order to facilitate opening of the door. This may be difficult for persons who suffer from back problems or for the elderly, for example.
SUMMARY
The present invention is generally directed to a door safety device. In an illustrative embodiment, the door safety device includes a lock member, an attachment member carried by the lock member and an attachment device carried by the attachment member.
The present invention is further directed to a method of securing a sliding door in a closed position in a sliding door assembly. In an illustrative embodiment, the method includes providing a door safety device comprising a lock member, an attachment member carried by the lock member and an attachment device carried by the attachment member; and inserting the door safety device between the sliding door and the door facing in the sliding door assembly.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described, by way of example, with reference to the accompanying drawings, in which:
FIG. 1 is a front view of an illustrative embodiment of a door safety device according to the present invention;
FIG. 2 is a left side view of an illustrative embodiment of a door safety device according to the present invention;
FIG. 2A is a sectional view illustrating an alternative technique for adjustably mounting a lock member on an attachment member element of an illustrative embodiment of a door safety device according to the present invention;
FIG. 3 is a front view of an illustrative sliding glass door assembly, illustrating an illustrative embodiment of a door safety device according to the present invention inserted in a door-securing position in the sliding glass door assembly to secure a sliding glass door in a closed position;
FIG. 4 is a cross-sectional view, taken along section lines 4 - 4 in FIG. 3 , of an illustrative sliding glass door assembly, with a door safety device inserted in a door-securing position in the sliding glass door assembly;
FIG. 5 is a front view of a sliding glass door assembly, with a door safety device according to the present invention inserted in a door-securing position in the sliding glass door assembly, more particularly illustrating a lock member element of the door safety device positioned in an upper position on an attachment member element of the door safety device;
FIG. 6 is a front view of a sliding glass door assembly, with an illustrative embodiment of a door safety device removed from the door-securing position in the sliding glass door assembly to facilitate opening of the sliding glass door;
FIG. 7 is a front view of an alternative illustrative embodiment of a door safety device according to the present invention;
FIG. 8 is a front view of an alternative illustrative embodiment of a door safety device according to the present invention, with a lock member element detached from a clamp element of the door safety device;
FIG. 9 is a left side view of a clamp element of an illustrative embodiment of a door safety device according to the present invention, with the clamp element slidably and adjustably mounted in a clamp slot provided in the attachment member element of the door safety device; and
FIG. 9A is a front view of a clamp element of an illustrative embodiment of a door safety device according to the present invention.
DETAILED DESCRIPTION
Referring initially to FIGS. 1-6 of the drawings, an illustrative embodiment of a door safety device according to the present invention is generally indicated by reference numeral 1 . As shown in FIG. 3 and will be hereinafter described, the door safety device 1 is suitable for securing a sliding glass door 13 in a closed position in a sliding glass door assembly 10 . The sliding glass door assembly 10 may be conventional and may include, for example, an opening 17 which is provided in a wall 11 of a home or business, for example. A window pane 12 is typically mounted in one half of the opening 17 , and a track 11 a is provided in the bottom of the opening 17 . A sliding glass door 13 includes a door frame 14 which is mounted in the track 11 a , a door handle 15 which is provided in or on the door frame 14 and a door pane 16 which is provided in the door frame 14 . The sliding glass door 13 is capable of being selectively positioned in a closed position, in which the sliding glass door 13 is adjacent to the window pane 12 , as shown in FIG. 3 , and an open position, in which the sliding glass door 13 is in front of the window pane 12 to permit ingress and egress through the open half 10 a ( FIG. 6 ) of the sliding glass door assembly 10 adjacent to the window pane 12 .
The door safety device 1 includes a lock member 2 which may have a generally elongated configuration and may be metal, wood or durable plastic, for example. A cap 3 , which may be rubber or plastic, for example, may be provided on a distal end 2 a of the lock member 2 . The door safety device 1 further includes an attachment member 6 which extends from the lock member 2 . The attachment member 6 may have a generally elongated configuration and may be metal, wood or durable plastic, for example. The attachment member 6 may be disposed at a generally perpendicular or 90-degree angle with respect to the lock member 2 . A proximal end 2 b of the lock member 2 may be fixedly or adjustably associated with the attachment member 6 . For example, in one embodiment shown in FIGS. 1 and 2 , a mount sleeve 4 is provided on the attachment member 6 and the lock member 2 extends from the mount sleeve 4 . The mount sleeve 4 slidably engages the attachment member 6 through a friction-fit or other mechanism in such a manner that the mount sleeve 4 can be adjusted to a selected position along the attachment member 6 , as indicated by the phantom lines in FIG. 1 . In an alternative embodiment, shown in FIG. 2A , a flange 2 c extends from the proximal end 2 b of the lock member 2 . A slot 6 a is provided in the attachment member 6 . The flange 2 c is slidably mounted in the slot 6 a through a friction-fit or other mechanism in such a manner that the lock member 2 can be adjusted to a selected position along the attachment member 6 as the flange 2 c slides in the slot 6 a.
An attachment device 7 may be provided on the attachment member 6 of the door safety device 1 to facilitate detachably securing the attachment member 6 to the window pane 12 or other element of the sliding glass door 10 in typical use of the door safety device 1 , as shown in FIG. 3 and as will be hereinafter described. The attachment device 7 may be, for example, at least one suction cup. However, it is to be understood that the attachment device 7 may be any suitable alternative device, such as hook-and-loop fasteners, for example, which is capable of detachably securing the attachment member 6 to the window pane 12 or other element of the sliding glass door 10 . Furthermore, the attachment device 7 may be any combination of devices which are capable of securing the attachment member 6 .
In typical use, the door safety device 1 secures the sliding glass door 13 in the closed position in the sliding glass door assembly 10 . Accordingly, the sliding glass door 13 is initially positioned in the closed position in the sliding glass door assembly 10 shown in FIG. 3 . The sliding glass door 13 may be locked in the closed position using a conventional locking mechanism (not shown). The door safety device 1 is then inserted between the door frame 14 of the sliding glass door 13 and the door facing inside the opening 17 in which the window pane 12 is mounted, as further shown in FIG. 3 . Prior to insertion of the safety device 1 , the lock member 2 may be adjusted to a selected position along the attachment member 6 , as shown in FIG. 5 . Alternatively, the lock member 2 may remain positioned at the lower end of the attachment member 6 , as shown in FIG. 3 . The cap 3 on the lock member 2 typically engages the door frame 14 of the sliding glass door 13 , and the attachment member 6 engages the door facing inside the opening 17 . The attachment device 7 is attached to the window pane 12 of the sliding glass door assembly 10 , as illustrated in FIG. 4 , to secure the door safety device 1 in an upright position. Accordingly, the lock member 2 with the attachment member 6 of the door safety device 1 span the gap between the door frame 14 and the door facing inside the opening 17 to prevent sliding of the sliding glass door 13 to the open position in the track 11 a . When it is desired to slide the sliding glass door 13 to the open position, the attachment device 7 is detached from the window pane 12 to facilitate subsequent removal of the door safety device 1 from the sliding glass door assembly 10 , as shown in FIG. 6 . It will be appreciated by those skilled in the art that a user (not shown) may insert the door safety device 1 in the sliding glass door assembly 10 and remove the door safety device 1 from the sliding glass door assembly 10 by manually grasping the attachment member 6 , thereby eliminating the need for the user to bend over during the insertion and removal steps.
Referring next to FIGS. 7-9 of the drawings, an alternative illustrative embodiment of a door safety device according to the present invention is generally indicated by reference numeral 20 . The door safety device 20 includes an attachment member 21 which may have a generally elongated configuration and may be metal, wood or plastic, for example. An attachment device 30 , which may be a suction cup or hook-and-loop fasteners, for example, or any combination of attachment devices, may be provided on the attachment member 20 . A clamp 24 is provided on the attachment member 21 and, as shown in FIG. 9 , includes a clamp interior 24 a which is adapted to receive a lock member 32 . The lock member 32 may be a shortened broom stick or the like, for example.
The clamp 24 may be adjustably mounted on the attachment member 21 , as shown in phantom in FIG. 7 . For example, a clamp slot 22 may be provided in the attachment member 21 . As shown in FIG. 9A , a clamp flange 25 extends from the clamp 24 and is inserted in the clamp slot 22 . The clamp flange 25 may be fitted in the clamp slot 22 through a friction fit or other technique. A clamp tab 26 may be provided on the clamp 24 to facilitate finger adjustment of the clamp 24 along the attachment member 21 . As shown in FIG. 9 , finger ridges 27 may be provided on the clamp tab 26 . It is to be understood that the clamp 24 may be adjustably mounted along the attachment member 21 using any suitable alternative technique which is known by those skilled in the art.
In typical use, the attachment device 30 secures a sliding glass door (not shown) in a closed position in a sliding glass door assembly typically in the same manner as was heretofore described with respect to securing of the sliding glass door 13 in the closed position using the door safety device 1 of FIGS. 1-6 . Prior to use of the attachment device 30 , however, the lock member 32 , which may be a shortened broomstick or the like, for example, is attached to the clamp 24 , typically by inserting the lock member 32 into the clamp interior 24 a of the clamp 24 . Therefore, when positioned in place in a sliding glass door assembly, the door safety device 20 is effective to prevent unauthorized opening of the sliding glass door in the sliding glass door assembly.
While the preferred embodiments of the invention have been described above, it will be recognized and understood that various modifications can be made in the invention and the appended claims are intended to cover all such modifications which may fall within the spirit and scope of the invention.
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A door safety device is disclosed. The door safety device includes a lock member, an attachment member carried by the lock member and an attachment device carried by the attachment member. A method of securing a sliding door in a closed position in a sliding door assembly is also disclosed.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
This application is a division of application Ser. No. 07/472,885, filed Jan. 31, 1990.
BACKGROUND OF THE INVENTION
The present invention pertains to a novel method and apparatus for sinking drill holes in underground rock formations while generating drill cores as rock samples.
The known methods of this type, as described in U.S. Pat. No. 4,518,050 and German Patent DE-C 37 01 914, are intended to optimize the core sample. In these methods, the main drill hole sections follow in the direction of the pilot hole sections and the core shaft section is drilled through the main drilling tool which includes a rotary drill bit corresponding to the rated diameter of the main drilling tool. Once the main drilling tool reaches the base of the core shaft section in the course of this drilling, it is stopped and a nearby core shaft section is drilled for core sampling. The length of the core shaft section is governed by the potentials of the particular tool design and can be quite considerable such as in the design disclosed in German Patent DE-U-88 10 844.
In the known methods, the core drilling unit in the outer housing of the core drilling tool is guided coaxially by a non-rotating guide device. When a core shaft section is drilled, the core tube of the core drilling unit exits coaxially from the outer housing. The outer housing of the core drilling tool thus controls the direction of the advance of the core tube.
SUMMARY OF THE INVENTION
The present invention discloses a method and apparatus which allows for an expanded analysis of ground formations over a larger area through the extraction of drill cores as rock samples.
The present invention discloses a directional core drilling method and a directional core drilling tool which can specify and direct a predetermined core drilling direction which differs from the usually coaxial run of conventional core drilling. The method and apparatus herein disclosed can establish a profile of drill shafts by digressing from the direction of the main drill hole. By using the present method and apparatus, it is also possible to drill from the base of a main shaft section in various directions to create core shaft sections and thus to obtain a number of cores.
BRIEF DESCRIPTION OF THE DRAWINGS
Various designs of the present invention are illustrated in the following figures:
FIG. 1 is a partial vertical cross-section view through the outer housing of a core drilling tool disclosed by the present invention when placed on the base of a main shaft section with the core drilling unit in position for starting core drilling;
FIG. 2 is a cross-section view similar to FIG. 1 where the core drilling tool includes a guide spindle instead of a core drilling unit;
FIG. 3 is a cross-section view similar to FIG. 1 showing the core drilling tool with a finishing drill bit instead of a core drilling unit;
FIG. 4 is a cross-section view similar to FIG. 1 showing a modified design of a core drilling tool as disclosed by the present invention; and
FIG. 5 is a cross-section view of the core drilling tool of FIG. 4 while it is post-drilling a main shaft section under guidance by the core tube of the core drilling unit located in the pre-drilled core shaft section.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The core drilling tool illustrated in FIGS. 1 and 2 is comprised of an outer housing 1 whose upper end (not illustrated) is connectable with a drill string and which has on its lower end a drill bit 2. The core drilling tool is further comprised of a core drilling unit 4 provided with a deep hole motor 3 and braced in outer housing 1. The unit 4 can be raised or lowered as a whole via a cable 5 and has an upper Part 6 which can shift axially and which is secured against rotating in the outer housing 1 by means of a non-rotating guide device 7 formed by an axially multi-wedged shaped part. The upper part 6 of the core drilling unit 4 is provided with reaction surfaces 8 which produce an axially downward directed propulsion force. For a detailed description of this type of core drilling tool refer to German Patent DE-C-37 01 914.
The core drilling unit 4 is further comprised of a lower portion having a core tube 10 driven by the deep hole motor 3 and including a core drilling bit 11 located on its lower end and a rotary-seated inner tube 13 mounted on a bearing 12 and used to hold the drilling core. At its upper end, the core tube 10 is connected with the deep hole motor 3 drive shaft 14 via a tubular, flexible connector 15. An articulated shaft or a similar connector could also be used.
A guide element 16 with guide surface 17 for core tube 10 is provided in the lower region of outer housing 1. This element 16 defines a guide axis 18 which is at an acute angle 20 with the main axis 19 of the outer shaft 1. The guide element 16, as shown in FIGS. 1 to 3, is designed as an outside cylindrical tube which is non-rotatably seated in outer housing 1 as a secured unit, e.g., by a fitting spring (not illustrated). The guide element could also be of an outside cylindrical tubular design as shown in FIGS. 4 and 5 and form a component of the wall of the outer housing 1.
The guide element 16 can be designed as hoistable unit which is also lowerable into outer housing 1 and secured against rotating only in the operating position in outer housing 1. Therefore, it is possible to have differing guide orientations relative to the outer housing 1 and to replace a guide element by one with a differing angular alignment of the guide axis 18, which alignment, if need be, could also run parallel to the main axis 19 of the outer housing 1.
The guide element 16 and the non-rotating guide device 7 for the upper part 6 of the core drilling unit 4 can be combined into a hoistable unit which is also lowerable into the operating position of outer housing 1, e.g., via axial distancing pieces (not illustrated). As a rule, a guide element 16 designed as an installed unit in outer housing 1 will be secured against rotating and against vertical shifting. The guide element 16 or 22 includes a sloped cylindrical guide surface 17 formed by a solid, slope-mounted guide hole which can be provided with an upper, funnel-like inlet 23.
The core drill unit 4 is shown in its starting position in FIG. 1 wherein the core tube 10 extends into the guide hole of guide element 16 and assumes a correspondingly slanted direction. For drilling a core shaft section proceeding from the position shown in FIG. 1, the core drilling unit 4 is lowered along the non-rotating guide device 7 in outer housing 1 and drills out a core shaft section 26 emanating from the base 24 of a main shaft section. The section 26 has a direction corresponding to the angle 20 with respect to the alignment of the outer housing 1 of the core drilling tool. Several core shaft sections 26 can be drilled in differing directions to scout out the formation environ from the same shaft base 24 merely by changing the position of the outer housing 1.
Following the drilling of a core shaft section 26 to obtain a core in the inside tube 13, the core drilling unit 4 can be lifted by cable 5 connected to a catch unit (not shown) and the core removed above ground. For after-drilling the main shaft section 25 along the pre-drilled core shaft section 26, a guide spindle 28 can be placed in the outer housing as shown in FIG. 2. This spindle can be raised and lowered into a working position in outer housing 1. The spindle has an upper support unit 29 employed in the non-rotating guide device 7 of outer housing 1 and a spindle section 30 with a pilot peak 31 protruding downward through the guide element 16. Both parts 29 and 30 are connected by a flexible intermediate connector 32 which allows the spindle 30 to enter the guide element 16 and ensures a slanted alignment in it.
After insertion of the guide spindle 28 into its operating position wherein it is secured against rotation, as shown in FIG. 2, the outer housing 1 is rotated along with the main drill bit 2 from above ground via the drill string. A main shaft section 25 is then drilled along the pre-bored core shaft section 26 whereby the core shaft section 26 is converted into the next main shaft section 25. As soon as the main shaft section 25 is finish-drilled, the guide spindle 28 is withdrawn and a core drilling unit 4 is placed into outer housing 1. A new core shaft section 26 can then be drilled. Once the desired alignment of axis 18 of the guide element 16 or 22 is attained, the direction of the next drilled core shaft section can be specified by a twist of the outer housing 1.
Instead of a guide spindle 28, a hoistable tool 33 as shown in FIG. 3 can be used for the after-drilling of a main shaft section 25. This finishing drill tool 33 can be lowered into an operating position in the outer housing 1. The tool 33 has an upper, tubular support housing section 34 which meshes in its operating position with the non-rotating guide device 7 of the outer housing 1 and which section 34 also includes a deep hole motor 3. The tool 33 further includes a lower bearing housing 35 which meshes into guide element 16 and on which a bit shaft 37 is seated which includes on its end and protruding from the bearing housing section 35 and from the guide element 16 and the outer housing 1 a finishing drill bit 36. A flexible intermediate housing section 38 between the support housing section 34 and the bearing housing section 35 allows the bearing housing section 35 to assume the slanted alignment of guide element 16 as illustrated in FIG. 3. The finishing drill tool 33 is manipulated via a catch mechanism 39 at the upper end of support section 34 and it can include any suitable finishing drill bit 36. The bit 36 is laterally shifted into the pre-drilled core shaft section 26 thereby allowing for a re-drilling of the core shaft section 26.
The design shown in FIGS. 4 and 5 basically corresponds to that shown in FIG. 1 except that the guide element 22 is designed as a tubular component of the wall of the outer housing 1. Furthermore, instead of a single non-rotating guide device 7, a two-part design is provided as shown whereby the outer housing 1 includes a non-rotating section 40 and a guide section 41. The upper section 6 of the core drilling unit 4 is comprised of an upwardly open, tubular housing 42 comprised of anti-magnetic material. This housing 42, when in its operating position, meshes with the non-rotating section 40 and is designed as a holder for a removable orientation-control unit 43. The orientation-control unit 43 can be raised and lowered by a separate cable 44. In its operating position, the unit 43 assumes a non-rotating alignment within the housing 42, for example by means of a fitting spring (not shown). This alignment and information about the alignment of the guide axis of the guide element 22 of the outer housing 1 can be queried from above ground.
In conjunction with this information, the outer housing 1 can be twisted from above ground via the drill string so that the alignment of the guide axis is in the direction corresponding to the direction of the core shaft to be drilled. The housing 42 of the upper part 6 of the core drilling unit 4 is then moved down in carrier segments which consist of bearing section 45, an internal stator 46 for the deep hole motor 3, and a flexible connector 47 on whose lower trunnion 48 the inside tube 13 of core drilling unit 4 is attached. The core tube 10 is connected via a tubular, flexible intermediate pipe section 49 to the rotor 50 of the deep hole motor 3 which is rotatably-seated through an upper tubular extension 51 via bearing device 52 on bearing piece 45.
The directional drilling method performed with the core drilling tool as shown in FIGS. 4 and 5 corresponds to that described in connection with the core drilling tool shown in FIGS. 1 to 3. After the outer housing 1 has been put into the appropriate alignment corresponding to the direction of the core shaft section 26 to be drilled, through turning and locking from above ground, the orientation-control unit 43 is lifted out and the core drilling is performed. For after-drilling a main shaft section 25, the outer housing 1 is driven downward with its main drill bit 2 under the force of the drill string with the core drill unit 4 serving as a guide agent.
As shown in FIG. 5, in order to keep the core drilling bit 11 from being accidentally over-drilled by the main drill bit 2, a separate hoisting valve unit 53 can be placed in the outer housing 1. The valve can be lowered into an operating position and, once the outer housing 1 moves downward relative to housing 42 of the upper section 6, the core drilling unit 4 meshes with the valve thereby blocking the drill mud flow through the housing 42. A pressure increase then occurs which is measured above ground and can be read to indicate that the main drilling tool has reached a specified distance from the core drilling tool.
In the foregoing specification, the present invention has been described with reference to specific exemplary embodiments thereof. It will be evident, however, that various modifications and changes may be made thereunto without departing from the broader spirit and scope of the invention as set forth in the appended claims. The specification and drawings included here are, accordingly, to be regarded in an illustrative rather than in a restrictive sense.
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The present invention comprises a novel method and apparatus for sinking drill holes in underground rock formations while generating drill cores as rock samples. More particularly, the present invention discloses a method and apparatus which allows for an expanded analysis of ground formations over a larger area through the extraction of drill cores as rock samples. The method and apparatus herein disclosed allows one to drill a number of core shaft sections from the base of a main shaft section in various directions in order to obtain a number of sample cores.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to improved methods and apparatus for servicing wells with coiled tubing and coiled tubing components comprised of composite fiber materials. In a preferred embodiment, fiber reinforced coiled tubing, provided as a layered laminate, is used within a wellbore to provide a strong and versatile coiled tubing for wellbore operations. In one embodiment, signals representing data may be transmitted along the length of the coiled tubing to the surface, providing useful information used in monitoring and directing coiled tubing operations. Further, composite disconnects are disclosed for disconnection of coiled tubing from tool strings facilitating retrieval of the coiled tubing from the wellbore.
Using this invention it is possible to vary the section modulus along the length of coiled tubing to improve buckling characteristics. Using intrinsic fibers for data communication is also part of this invention.
2. Description of the Prior Art
Coiled tubing is increasing in popularity as a method of conducting operations in an oil or gas wellbore. Historically, drilling pipe was used for drilling and conducting operations inside a wellbore, usually several hundred or thousand feet under the surface of the ground. However, drill pipe must be assembled in sections and lowered into the wellbore over a long time period of many hours or days. Coiled tubing emerged as a solution by providing a relatively fast and reliable method of conducting operations downhole within a wellbore, without using heavy and cumbersome jointed drilling pipe. Coiled tubing is used as a continuous strand, and therefore is easier and faster to use in many wellbore operations. Technological developments, improved service reliability, and the need to drive down industry costs have contributed to expanded uses for coiled tubing.
Modern coiled tubing operations are used to drill slim hole wells (wellbores of smaller than normal diameter), deploy reeled completions, log high angle boreholes, and deploy treatment fluids downhole. The use of coiled tubing in horizontal wellbores (i.e. wellbores that deviate from vertical) is increasing at a rapid rate.
In some instances, well treatment fluids are pumped downhole through the interior hollow space of the coiled tubing, and then are made available to the subterranean formation.
One of the primary limiting factors in coiled tubing workover applications, particularly in horizontal wells, is the depth to which coiled tubing can be pushed without locking or buckling in the production tubing, casing or open hole. The usefulness of coiled tubing is greatly limited by its inability to proceed farther into horizontal wells without buckling or locking within the wellbore. Coiled tubing is not rotated, but instead is pushed into and out of the wellbore. The frictional forces of the coiled tubing rubbing against the interior of the wellbore eventually overcome the integrity of the coiled tubing, causing buckling and lock up of the tubing in the wellbore. This phenomenon is illustrated in FIG. 4.
Another limiting factor that prevents the use of coiled tubing in deeper wells is the internal strength of the coiled tubing itself. Coiled tubing, when suspended in a wellbore, is subjected to the pull of gravity. Since a length of coiled tubing weighs several thousand pounds, the coiled tubing must have enough internal integrity and strength to withstand this force during operations without separating into two or more pieces. This problem is compounded when additional weight (such as drilling or completion apparatus) is placed on the distal end of the coiled tubing and lowered into the wellbore. Further, if the coiled tubing is restricted due to frictional forces or "hangs" within the wellbore, the additional force necessary to pull the coiled tubing free is added to the weight forces, thereby working to undesirably separate the coiled tubing at its weakest point.
Another criteria for coiled tubing is that it must be capable of being spooled onto a reel for storage, and for transport to the well site. Coiled tubing reels are deployed from trucks for land based wells, and from ships for servicing offshore wells. The most practical way to handle relatively long lengths of coiled tubing is to spool the tubing upon a reel. However, spooling a length of coiled tubing onto a reel subjects the tubing to bending forces that can damage the coiled tubing, and sometimes make it difficult to properly store and deploy the tubing.
The design of coiled tubing is complicated by the fact that the tubing must show sufficient strength to conduct the coiled tubing operations downhole without failure or buckling, while at the same time being flexible enough to be spooled onto a reel after the operation is complete. Unfortunately, coiled tubing that has a high section modulus and is therefore advantageous as to its strength and buckling characteristics downhole is difficult to spool onto a reel. The properties that make tubing work well downhole (i.e. stiffness) also work to disadvantage on the surface of the ground when attempting to spool the tubing.
What has been needed in the industry for some time is a coiled tubing that is stronger and more resistant to the forces encountered within a wellbore, but at the same time is easily spoolable, facilitating tubing operations in deeper wells. A coiled tubing that can be used in deeper wells, and also is capable of extended reach into horizontal wells is needed.
One additional problem encountered in coiled tubing operations is that the amount of real time information available to a coiled tubing operator during coiled tubing operations currently is very limited. A need exists for a reliable method and apparatus for sending signals from the lower portion of the wellbore to the surface. Signals could be converted to data that is used, for example, to monitor the properties of the coiled tubing, events outside and/or inside any length or a particular length of coiled tubing or to monitor the operation of downhole tools mounted upon the distal end of the coiled tubing. In some cases of pumping fluids through the coiled tubing, an apparatus could be used to monitor the leakage from the tubing, or perhaps monitor the integrity of the coiled tubing. This apparatus would be integral to the composite coiled tubing.
In many instances, it is very important to know reliably the exact depth of the coiled tubing in the wellbore, or in some instances, the exact point in the formation that corresponds to the downhole tool or other apparatus mounted on the end of the coiled tubing. There is needed a method or apparatus by which a coiled tubing operator may operate coiled tubing in a manner to know exactly (or within very narrow limits) the location of the tubing in relationship to the subterranean formation for use in isolating zones, providing diverting fluids, etc. to a specific portion of the reservoir.
Another significant problem in coiled tubing operations is the method and apparatus for disconnection of coiled tubing from tool strings during coiled tubing operations. Typically, either mechanical or hydraulic disconnects have been used in coiled tubing applications. However, there are problems with mechanical and hydraulic disconnects.
The disconnects, which are run above the tool string, facilitate release of the tool string by the tubing in the event the tool string becomes lodged in the hole. The alternative would normally result in tensile failure of the tubing close to the well head (near the surface of the ground at the reel end of the tubing), thereby complicating tubing retrieval. A disconnect may also be desirable at a length from the distal end for allowing the lower length to be left in the hole. Thus disconnecting the tool string from the tubing is necessary in many instances.
If is difficult to predict exactly at what load mechanical disconnects will fail. This is because such disconnects typically use a small number of studs or screws that are designed to fail at a pre-set load. A problem with such mechanical disconnects is that the failure load range is fairly broad due to the indefinite tolerances of the failure mechanism.
What is needed in the industry is a disconnect that will fail at a relatively narrow range or exact load rating. Predictability in failure load, and failure at a narrow load range, is desirable. Further, a disconnect that can be activated on demand would be desirable, because it would eliminate the uncertainty associated with known methods of disconnection, and would permit an operator to disconnect on demand.
SUMMARY OF THE INVENTION
The invention comprises several embodiments and combinations. In one form, it comprises composite coiled tubing that resists buckling within the wellbore comprising a substantially cylindrical hollow tube having a reel end and a distal end adapted for insertion into a wellbore.
Several layers may be present, including a cylindrical surface layer and a cylindrical composite fiber layer. The latter is preferably concentrically inside of the surface layer, the composite fiber layer formed by weaving composite fiber in a predetermined pattern whereby the fibers are oriented in relationship to the longitudinal direction of the coiled tubing such as to provide appropriate strength and buckling characteristics to the coiled tubing.
It is advantageous to provide the fibers in an orientation such that the modulus strength of the composite coiled tubing is dependent upon the orientation of the woven fibers, wherein the angle formed by the fiber as compared to the longitudinal direction of the coiled tubing are changing near the reel end of the tubing and the distal end of the tubing.
A cylindrical liner layer typically is concentrically inside the composite fiber layer, said cylindrical liner layer being chemically resistant to abrasive fluids, wherein conductive fibers are provided within the composite coiled tubing, the fibers being adapted to transmit signals representing data.
A composite disconnect on the distal end of the composite coiled tubing may optionally be provided. The disconnect typically would have a plurality of fibers of varying strength and perhaps varying orientation mixed into a fiber blend, wherein the load range at which the composite disconnect fails corresponds to the failure characteristics of the fiber blend, the fiber blend having a predetermined failure limit.
Importantly, one aspect of this invention is that the composite coiled tubing is adapted to resist buckling within the wellbore.
The composite coiled tubing also may advantageously include conductive fibers adapted to transmit signals representing data for many different and varied useful purposes. For example, the data may be used to facilitate monitoring the structural integrity of the coiled tubing, to monitor breakage or leakage of the coiled tubing. Data may also be used for learning the strains at particular location on the coiled tubing.
Fiber optics optionally could be incorporated into the fiber blend layer as well. One embodiment could use fiber optic materials to monitor the coiled tubing by measuring the refraction within optical fibers, and thereby determining the weakest point of fatigue, in the coiled tubing by comparison with previously measured refraction indices for that particular tubing.
A method of disconnecting a tool string from coiled tubing is also provided as one aspect of the invention. This is done to facilitate retrieval of the coiled tubing. In general, the method includes providing a composite disconnect. The disconnect removably interconnects coiled tubing to a tool string, the composite disconnect being adapted for failure at a predetermined load range. At that point, it is feasible to insert coiled tubing into a wellbore, the coiled tubing having a reel end and a distal end, the distal end having attached a tool string secured by a composite disconnect.
It is possible to disconnect the distal end of the coiled tubing from the tool string at a predetermined load range, thereby facilitating retrieval of the coiled tubing from the wellbore. In many cases, it is advisable to provide a composite disconnect comprising a plurality of fibers of varying strength and orientations mixed into a fiber blend, wherein the load range at which the composite disconnect fails corresponds to the failure characteristics of the fiber blend.
The fiber blend may comprise one or more fiber types. Chemical, thermal, or other means of providing for disconnection may include contacting the composite disconnect with acid, thereby degrading the composite disconnect, facilitating release of the tool string from the distal end of the coiled tubing. Other methods of breaking down the fiber connection could be used.
In one aspect of the invention, it is possible to provide gravel packing apparatus for a well comprising a perforated composite gravel packing screen. The gravel packing apparatus could include perforations comprising predetermined leak paths which are chemically removable at will, providing the filtering function to the screen.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The invention is shown in FIGS. 1-29.
FIG. 1 shows the coiled tubing operation of the invention in a typical configuration of a horizontal wellbore;
FIG. 2 shows a more detailed view of the above ground components used to facilitate the coiled tubing operations;
FIG. 3 reveals provides a more detailed observation of the components that directly drive coiled tubing into a well and also the configuration that results in bending events upon the coiled tubing;
FIG. 4 demonstrates the drive mechanism and how it operatively connects to the tubing in such a way that buckling of coiled tubing may occur inside the casing of a wellbore;
FIG. 5a depicts sinusoidal buckling of coiled tubing;
FIG. 5b depicts a cross-sectional view of that shown in FIG. 5a of the casing containing sinusoidally buckled coiled tubing;
FIG. 5c shows helical buckling of coiled tubing;
FIG. 5d is a cross-sectional view of FIG. 5c of the casing containing the helically buckled coiled tubing;
FIG. 6a shows a preferred embodiment of the invention of the composite coiled tubing with a solid liner inner layer and several different fiber layers overlaying the solid liner inner layer;
FIG. 6b demonstrates an alternate embodiment of the composite coiled tubing which uses a weave without an inner mandrel;
FIG. 6c presents yet another alternate embodiment of the composite coiled tubing invention;
FIG. 6d shows a further alternate embodiment of the composite coiled tubing invention;
FIG. 6e depicts a cross section of composite coiled tubing containing conductive wires;
FIG. 7 depicts a sketch of an automated circular braiding machine configuration of the type used to manufacture composite coiled tubing;
FIG. 8 shows a three dimensional solid finite element model of a composite coiled tubing laminate;
FIG. 9 shows a three dimensional solid finite element model of regular steel containing one element;
FIG. 10 depicts axial stress in composite coiled tubing that is wound (and therefore deformed) on an 84 inch circular reel;
FIG. 11 shows axial stress in composite coiled tubing that is wound upon (i.e. deformed) on a 96 inch circular reel;
FIG. 12 demonstrates the axial stress load for case B (case scenario "B" is presented later in the specification);
FIG. 13 demonstrates the axial stress load for hoop stresses for load case B;
FIG. 14 presents radial stress characteristics for load case B;
FIG. 15 depicts axial stress for load case C (case scenario "C" is presented later in the specification);
FIG. 16 shows hoop stresses for load case C;
FIG. 17 demonstrates radial stress for load case C;
FIG. 18 presents hoop stress for load case D (load case scenario "D" is presented later in the specification);
FIG. 19 shows radial stress for load case D;
FIG. 20 presents axial stress for load case E (load case scenario "E" is presented later herein);
FIG. 21 presents hoop stress for load case E;
FIG. 22 shows radial stress for load case E;
FIG. 23 presents hoop stress for load case F (load case "F" is presented later herein);
FIG. 24 depicts radial stress for load case F;
FIG. 25 shows a typical prior art configuration for a downhole connection means to connect coiled tubing to a downhole tool;
FIG. 26 shows one embodiment of the invention of the composite disconnect of this invention;
FIG. 27 reveals a magnetic marking depth calculating configuration of the present invention that serves to calculate depth using magnetic marker materials embedded within the composite laminate of the coiled tubing;
FIG. 28 shows a detailed view of the magnetic nodes that operate to provide depth data in the configuration of FIG. 27;
FIG. 29 depicts an alternate configuration of this invention in which the magnetic detector is located underground and acts to relay depth information to the surface.
In FIG. 1, the operating environment of this invention is shown. Coiled tubing operation 10 is comprised of a truck 11 which supports power supply 12 and tubing reel 13. An injector head unit 15 feeds and directs composite coiled tubing 16 from the tubing reel into the subterranean formation. The configuration of FIG. 1 shows a horizontal wellbore configuration which supports a coiled tubing well trajectory 18 into a horizontal wellbore 19. This invention is not limited to a horizontal wellbore configuration, but is advantageously applied to that configuration. Downhole tool 20 is connected to the coiled tubing, as for example, to conduct flow or measurements, or perhaps to provide diverting fluids.
FIG. 2 represents a coiled tubing unit 26 having a hydraulic operated tubing reel 27 which feeds tubing 29 by way of levelwind 39 and past a depth counter 28. Tubing guide 30 directs the tubing downward into hydraulic (or electric) drive tubing injector 31 and past stripper rubber 32. A depth detector 40 is shown, which may be of the magnetic mark type detector. A tubing monitor 38, which measures the ovality and outer diameter of coiled tubing is provided. The tubing 29 is pushed into the well through blowout preventor stack 33 and through flow tee 35. Injector support 34 supports the injector over the wellbore. A power pack 41 supplies power to control console 37 for operation of the coiled tubing unit.
The forces and strain placed upon coiled tubing when it is used in a coiled tubing unit 44 is apparent from viewing FIG. 3. Coiled tubing undergoes numerous bending events each time it is run into and out of a wellbore. The tubing is plastically deformed on the reel. First, coiled tubing 46 is bent when it emerges from the reel 45. Then, it is bent as it passes over tubing guide 47, and is straightened as it goes into tubing injector 48 for entry into the wellbore of course, each bending event is repeated in reverse when the tubing is later extracted from the wellbore.
These bending events weaken the tubing each time it is used, and tubing use must be counted and tabulated, and tubing discarded, when it has been used beyond an acceptable safety limit. The composite tubing of this invention is designed to monitor tubing condition and even report data to the operator to show the condition of the tubing in real time during use. Cost savings can be achieved by knowing the exact condition of the tubing, and instances of catastrophic tubing failure can be substantially reduced or even eliminated by use of this invention. Cost savings can be realized since the fatigue life of composite coiled tubing will be substantially longer than that of steel. A more detailed description of the use of this invention is set forth below.
Tubing often buckles when it is placed in deep wellbores, causing problems. Buckling is especially pronounced in horizontal and long reach wellbores because the tubing is subject to gravitational forces that cause large amounts of friction between the tubing and the wellbore. When this friction overcomes the forces pulling or pushing the tubing into the wellbore, buckling occurs. First, buckling is of the sinusoidal type, which is akin to a two dimensional wave in the tubing, as seen in FIGS. 5a and 5b. Later, as the tubing proceeds further into the wellbore, helical buckling occurs. Helical buckling is shown in FIG. 5c. Helical buckling is a more serious problem, and it is a "corkscrew" effect represented as three dimensional buckling, which eventually leads to total lock-up of the tubing. Helical buckling causes the tubing to be in contact with the inner surface of the wellbore at many (or even all points) which greatly increases the friction encountered by the tubing. Sensors embedded in the wall of the coiled tubing can be used to ascertain when this occurs. When total lock-up is reached, the tubing no longer can be pushed further into the wellbore, and further coiled tubing operations cannot be performed.
FIG. 5a shows a section 64 of sinusoidally buckled coiled tubing 65. Within wellbore casing 66 the tubing is in a sine-wave two dimensional form wherein it touches the casing at its peaks. Cross section shown in FIG. 5b shows wellbore casing 66 in contact with tubing 65 at its high and low points. A two dimensional sinusoidal buckling is seen in FIG. 5b.
Helical buckling is seen in FIG. 5c, wherein the helically buckled tubing section 68 is characterized by helically buckled tubing 69 in a spiral or "corkscrew" three dimensional configuration within wellbore casing 70.
FIGS. 6a-6e shows various configurations of composite coiled tubing that may be employed in the practice of this invention, although other embodiments are possible. In FIG. 6a, first embodiment composite tubing 75 comprises solid liner 76 upon which is placed longitudinal fiber layer 77. Circumferential fiber layer 78 overlays the longitudinal layer, and weaved fiber layer 79 provides a weave of composite fibers at an angle of preferably about 45 degrees in each direction. However, other angles and orientations are possible to achieve different strength properties of the composite fibers. The composite fiber is formed on an apparatus as seen in FIG. 7, although it is anticipated that there may numerous methods and apparatus capable of forming such a composite tube which are known by those skilled in the art of composites. A suitable resin, such as epoxy resin, is impregnated into the fiber layers as they are formed, as seen later in FIG. 7.
FIG. 6b shows a second embodiment composite tubing 82 which does not have the solid liner, but instead contains an inner weaved layer 83 which contains an overlay of longitudinal fiber layer 84. On top of that layer, a circumferential fiber layer 85 is placed, and finally an outer weaved layer 86 provides the outer protective coating.
A third embodiment in FIG. 6c shows a different arrangement of fiber layers. Third embodiment composite tubing 90 is made of solid liner 91 upon which is placed longitudinal fiber layer 92. First circumferential fiber layer 93 is next, and longitudinal fiber layer 94 provides the next layer. Finally, second circumferential fiber layer 95 provides the outermost layer.
FIG. 6d shows fourth embodiment composite tubing 98 containing solid liner 99 with longitudinal fiber layer 100 on top of said solid liner. Circumferential fiber layer 101 is the next outermost layer, followed by longitudinal fiber layer 103, then circumferential fiber layer 109, followed by weaved fiber layer 102.
There are thousands of different laminates depending on the number of laminas (individual layers), materials and orientation of each lamina. In the specific use of coiled tubing, the desirable traits are contradictory in the two different load conditions (spooled and downhole).
The bending stiffness of the tube is determined by the number of axial fibers, the fibers modulus of elasticity and the location of the fibers in the cross-section. Adding more fibers and/or fibers with high moduli will result in a stiffer tube. More fibers can be used by either increasing the thickness of each lamina or adding more laminas. Placing fibers closer to the outer diameter results in a stiffer tube. These factors are considered in the design process.
Since composite materials typically do not yield before failure, the tubing must remain elastic when spooled on the reel. Therefore, a low bending modulus is desirable in this situation. However, when downhole, the buckling characteristics of the tubing are the controlling factors as to how far the tubing can be pushed downhole. The stiffer the tube, the farther it can be pushed downhole.
Therefore, different designs are beneficial depending on the job requirements. For example, if a large reel can be used the tubing can be extremely stiff and thus treat deeper wells. If small reels are required (imposed by transportation limitations) then only shallower wells can be treated.
FIGS. 6a and 6b illustrate tubing with virtually the same mechanical properties. The only difference is the liner. The liner provides two functions. The first is a mandrel for manufacturing and the second is to prevent leakage through the composite wall. The drawback is that it uses a substantial amount of space which limits the flow area of the tubing. Through experimental testing and manufacturing development it may be possible to replace the plastic liner with another composite lamina, as in FIG. 61b. Both of these tubes have axially stiff laminas which are close to the inner diameter. These tubes would be ideal for spooling on small reels and treating moderate depth wells.
The tubes illustrated in FIGS. 6c and 6d are ideal for treating deeper wells using larger diameter reels. Additional axially stiff laminas are included which are located closer to the outer diameter, thus increasing the tubing stiffness. FIG. 6c is shown without the outer +/-45 degree lamina which is purely used as a damage reduction or sacrificial lamina. It does not significantly affect the overall mechanical properties, but it instead prevents damage to the load bearing laminas.
FIG. 6e shows the coiled tubing arrangement 104 using a solid liner 105 surrounded by composite layer(s) 106. Included is conductive wires 107 and 108 located outside the inner solid liner layer. Any conductive wire may be used, but copper is preferable due to conductivity and low price. Alternate conductors would be inserted depending on the application. These would be thermal couple wires such as Iron Constantan, Chrome Alumel, Graphite, aluminum, nickel cobalt (MP35N) and other types of metals could also be used. Fibers which are magnetic due to proprietary processes or iron impregnation could also serve as a conductive medium. Attaching the wires in a straight axial line is easiest from a manufacturing standpoint. However, the wires will yield when the tubing is spooled onto a reel. This will result in an elongation of the copper wires. When the tubing is unspooled, the wires will be longer than the tubing. The wires will either buckle inside the tubing or protrude from the ends. Either case is undesirable. It would be preferential to attach the wires in a helix to prevent them from yielding.
The wires may be used to either communicate with downhole tools or to receive data from downhole tools, such as pressure gages or to communicate at one or various places in the coiled tubing. The inner solid layer or any other layer could also include a circuit board with processing capability.
FIG. 7 shows a schematic arrangement of the automated circular braider machine 120 that may be used to manufacture the composite tubing of this invention. Braiding machines and methods are known in the art, and the making of composite tubes has been accomplished for purposes other than coiled tubing. For example, composite tubes are known to be made and used for missile silos for ballistic missiles and other applications.
Mandrel 121 provides a form for construction of the composite. The composite fiber is wound or spun onto the mandrel from bobbins 122, 123, 124, and 125. Bobbin spools contain the fiber and prevent fiber entanglement or slippage. The mandrel forms the composite in pulling direction 135, and resin applicator 134 provides a continuous stream of resin impregnation to fill the matrix space existing within the fiber weave once it is formed. First axial 126, second axial 127 and first axial tube 128 and second axial tube 129 cooperate to construct fiber weave 137. The braiding plane 136 is actually circular and rotates as the mandrel proceeds towards the top of FIG. 7 during composite tube manufacture.
Fibers 130, 131 132, and 133 are weaved upon the mandrel by the rotation of the circular braider along braider plane 136.
Typically three different types of manufacturing processes are used to manufacture composite tubes. They are pultrusion, continuous filament winding and braiding.
Pultrusion is similar to the extrusion of plastics and nonferrous metals. The fibers are drawn through a die which has the desired final shape. In pultrusion, the fibers are pulled through the die; conversely, in extrusion, the material is pushed through the die. The resin can be impregnated into the fibers either prior to entering the die or after entering the die under pressure. The resin is rapidly cured in the die using heat. A post-cure module can be added after the curing/forming die.
Continuous filament winding is similar to forming wireline or cables. Spools of fiber are mounted on ring winders which rotate about the workpiece. As the spools rotate, the mandrel moves at a specified speed forming the desired fiber orientation with the axial axis. Multiple winders are used to form the individual laminas with either different materials or different fiber orientations. Resin can be applied by running the fibers through a resin bath prior to winding. Alternatively, prepregged fibers can be used. The resin can then be cured on-line or off-line.
Braiding is similar to filament winding, except the fibers are interwoven onto the mandrel. This is accomplished with a braiding ring which contains spools moving in both a clockwise and counterclockwise direction as well as moving radially which forms the over/under braiding sequence. The resin is cured in the same manner as the continuous filament winding technique.
The steps of the manufacturing process are largely dependent upon the complexity of the machinery. Typically, it is ideal to form all of the laminas in one run. However, this may require several winders/braiding heads which is expensive. Alternatively, multiple runs may be made in which one or two laminas are deposited each time. This method takes more time, but is significantly less expensive. The type of resin is dependent on the design parameters and the cure time for the resin is more dependent on the manufacturing process.
FIGS. 8-24 reveal finite element analysis test results that indicate the advantages of composite tubing in different load scenarios, as set forth below. Detailed discussion of those figures will accompany the discussion of test methodology and finite element analysis, including Examples 1-7 set forth in that portion of this specification.
FIGS. 25-29 relate to downhole composite connection means and apparatus. FIG. 25 shows a typical prior art configuration, while FIGS. 26-29 reveal the invention.
In the prior art, it is known generally to provide disconnecting apparatus to disconnect coiled tubing from downhole tools and the like by separation of shear screws, for example. Prior art downhole connection means 200 is arranged with coiled tubing 201 attached to locking sub 202. Upper screws 203 and 205, and lower screws 204 and 206 provide connection. Threaded connection 208 is screwed onto sleeve 209, and o-ring 210 provides sealing engagement on the coiled tubing. Mandrel 211 connects to threaded hub 212, and lower unit 215 is adjacent to upper body 213. Threaded connection 218 provides connection between downhole tool 219 and the lower body 215. A space 214 is within the string.
Shear screws 216 and 217 shear upon receiving a predetermined degree of force, thereby separating the downhole tool 219 from the coiled tubing. The range of this force sometimes is quite wide, and it is usually not possible to provide a narrow range of force at which such mechanical failure means will separate, releasing the coiled tubing.
The invention shown in FIG. 26 is a composite disconnecting apparatus 231 which shows threaded sub 220 with internal space 222, and upper joinder threads 221 as part of upper threaded joinder 223. Upper threaded joinder 223 connects to the composite fiber pack 224 by a sealing engagement that is made to maximize the surface area of the composite threaded pack upon the upper threaded joinder to increase strength of the connection.
The fiber pack 224 is made so as to provide failure characteristics that are over a relatively narrow load range so that failure may be predetermined at a specific load. Fibers provide a more definite failure mechanism at specific loads than that afforded by metal shearing failure mechanisms. Composite fiber pack 226 is similarly connected to lower threaded joinder 228 which is threadedly or by other means connected by lower threaded joinder threads 229 to downhole tool 230.
FIG. 27 shows one embodiment of the invention of this application including a magnetic marking depth or other means of detecting a specific location on a CT string calculating configuration 235 which uses magnetic mark detector or other type of location detector, gamma ray, light, etc. detector 236 to assist in determining depth of coiled tubing. Wellbore 238 disposed below ground surface 237 contains casing 239 or can be open hole. Coiled tubing 240 is disposed within the casing and is passed along into the wellbore past the detector 236 which serves to record the length or location of tubing that has descended into the well by magnetic or other measurement means. Magnetic or other type of detectable nodes 241, 242, 243, 244, 245, and 246 each sequentially are recognized as they pass the detector 236.
In FIG. 28, a close up view of detection node 244 is shown wherein magnetically active fibers 247 are detectable by detector 236. Such fibers preferably are of the type INCO VaporFab Nickel Coated Fibers, manufactured by INCO SPP at 681 Lawlins Road, Wyckoff, N.J. 07481. However, it is recognized that any number of fibers that are magnetically active, or radioactive or can give signal at a certain location in the coiled tubing could achieve the function of marking tubing depth. A microprocessor also optionally may be provided within the layers of the coiled tubing, in the configuration of FIGS. 27 or 29.
An alternate configuration for determining coiled tubing depth is shown in FIG. 29. Subterranean depth calculating configuration 250 uses magnetic mark or other detectable nodes like radioaction indicator 251 (which may also be a relayer of information) to determine more accurately the depth of coiled tubing in a well. In this configuration, accuracy is improved because the "zero" point for depth calculation is advantageously located hundreds or thousands of feet below the ground surface, facilitating a much more accurate measurement of exact depth of coiled tubing, or perhaps a determination when the tool is exactly adjacent or above a particular subterranean structure that is intended to be modified by the downhole operation.
Magnetic or other detectable nodes 253, 254, 255, 256, 257, 258, and 259 operate to provide a detectable signal when they pass the mark indicator 251, which itself is incorporated into locking hub 260 downhole. This locking hub can be retrievable or permanently attached downhole. The mark indicator can also be part of the tubing, attaching to the outside. Further, a transmitter 252 may relay information uphole in real time manner by inductively sending pulses or other means, acoustic for transmission by conductors or fibers in the CCT wall. The transmitter downhole could also relay information via a conductor attached from the surface to the transmitter. Alternatively, an ultrasonic source could provide high energy pulses that change the property of a fiber optic conductor, which would be detectable at the surface and readable by a coiled tubing operator in real time during a job. Other conductive or detection methods and means are possible using specialized composite coiled tubing with magnetic mark or other indicators and conductive and/or other like acoustic means within the tubing. Further it would be possible to use a subterranean receptor attached different ways downhole and send data up the borehole through a conductor in the casing wall or tubing, rather than using a conductor or fiber in the coiled tubing.
Composite coiled tubing manufactured as set forth above offers several advantages over traditional tubing such as lower weight, better fatigue characteristics, low ovality, and data transmission by way of intrinsic conductors built into the tubing (no more cables in the inside diameter). Composite coiled tubing ("composite coiled tubing sometimes is abbreviated as "CCT"") has been studied to determine how CCT could be designed with better properties than steel coiled tubing ("coiled tubing sometimes is abbreviated herein as "CT").
The results reveal that composite coiled tubing is more advantageous than steel, especially in terms of its strength characteristics. The `final` preliminary design outperformed steel CT in terms of pressure and axial strength, but at the sacrifice of flow area within the interior of the tubing.
The results of the study show that CCT is feasible based upon analytical models, limited environmental testing and production of short (10 foot) samples.
Various environmental conditions must be considered in the design of the composite laminate for coiled tubing. Specifically, exposure to both low and high temperatures (-50° F. and 400° F., respectively) in naturally occurring wellbore fluids is required, including for example selected acid solutions and organic solvents. Other important functional considerations include incorporation of a CCT field splicing technique and end coupling designs as well as the incorporation of communications capability along the CCT length.
Composite laminate design and analysis was performed to create an optimum composite construction which satisfies all of the load cases. The design was based on an optimizing routine and classical laminate plate theory. Since the `plate` is relatively thick, finite element analysis was used to verify/improve the design, as further shown in the FIGS. 8-24. The various hostile environmental conditions currently experienced by the steel coiled tubing during service were considered. After completion of the design and analysis of the composite structure, fabrication of reduced scale tubular sections was completed to support mechanical and environmental testing. In addition, fabrication of full scale, nominal 1.50" OD CT sections were completed to investigate: 1) incorporating a CCT coupling mechanism, 2) intrinsic communication lines and 3) the fatigue life of the proposed CCT design.
Advantages of composite coiled tubing include the ability to treat deeper wells, more buoyancy and improved buckling characteristics, better fatigue characteristics, little increase in ovality during the tubing lifetime, lower fluid friction and less pressure drop for a specified inner diameter. Intrinsic conductors (wire, fiber optics, etc.) in CCT wall are possibilities that provide distinct communication advantages.
Composite coiled tubing has several advantages over steel or alloy coiled tubing for oilfield service. The composite coiled tubing weighs considerably less which allows treatment of deeper wells and also is more buoyant which improves the buckling characteristics.
Steel tubing suffers from severe fatigue limits. Typically the tubing is scrapped because the fatigue limits have been reached. The steel is plastically deformed every time it is spooled off the reel, over the gooseneck, through the chains and the reverse process. It is known that the fatigue resistance of steel is severely degraded when it is plastically deformed. A main advantage of composite coiled tubing, other than the improved fatigue properties of composite materials compared to steel, is that typically it is not plastically deformed, thus its fatigue failure resistance remains high.
Steel coiled tubing also suffers from ovality and ballooning both of which are attributed to cyclic fatigue and result in severely degraded properties. For example, perfectly round 1.5", 0.095" thick steel coiled tubing has a collapse pressure of approximately 10,000 psi. Tubing with a 5% ovality ratio, typically the allowable maximum, has a collapse pressure of about 6,000 psi.
Composite tubing does not plastically deform, hence its ovality will be small. Steel coiled tubing exhibits a fluid resistance coefficient, friction, that approximates "smooth" tubing. As the tubing is used, this value increases which results in a larger pressure drop. The proposed CCT utilizes a plastic liner which should not change appreciably with use. Initially, the steel CT has a 10% to 20% higher pressure drop for a given flow diameter. The pressure drop of the steel CT will increase with time.
The final advantage of composite coiled tubing is related to the utilization within coiled tubing of an intercommunication or "Smart" coiled tubing. Conductors, fiber and/or microprocessors, may be intrinsically manufactured in the composite coiled tubing eliminating many of the problems associated with "Smart tubing" (i.e. cable in the inside diameter of CT). Another property of composite tubing, which could be advantageous or disadvantageous depending on the situation, is that the tubing would be virtually non-conductive. Disadvantages of coiled tubing include lower buckling load in `dry` wells, more stored energy on the reel, higher initial cost, smaller inner diameter for a specified outer diameter, and larger diameter reels (8' minimum drum diameter for 1.5" CCT). Also, a microprocessor could be incorporated into the layers of the coiled tubing facilitating "smart" operations.
The only performance disadvantage currently known in use of composite coiled tubing as compared to steel is the lower bending stiffness of composite materials. One of the major operational characteristics of coiled tubing is the distance it can be run in the hole before the onset of helical buckling and thus lockup. Lockup is defined as the point at which the tubing cannot be pushed farther in the hole. Helical buckling is a function of the tubing modulus of elasticity and the moment of inertia.
Since the composite tubing has a lower modulus, but similar moment of inertia, earlier lockup will occur than steel tubing when running in a dry well. One unknown is the friction of composite coiled tubing. It is feasible to coat the tubing with a low friction coefficient material to improve the lockup properties. However, since the composite tubing is less dense than steel, the tubing will have less effective weight in fluid packed wells which decreases the frictional force and thus increases the distance to lockup.
Currently known CCT designs require a liner to prevent leakage through the wall of the CT. The liner serves no structural purpose, but uses valuable space (approximately 20% of the flow area). The liner also aids in manufacturing by providing a `mandrel` on which to wind the composite material.
DESIGN OPTIMIZATION
Several fibers and matrix materials were considered based on temperature limits and chemical compatibility
Genetic algorithm was used to determine `ideal` laminate properties for various design cases (1000's of lamina combinations)
Six different load cases
Three matrix materials and four fiber materials were considered
Laminate design and analyses were performed using three distinct load cases, Table 1, which were based on the design criteria. Loads were converted into curvatures and/or stress resultants as required for a general laminated plate analysis. The computer program used was provided in conjunction with a combinatorial optimization routine.
This program searched for an optimum design given up to ten laminas (layers, plies, etc.). In a single run, thousands of material, stacking sequence and ply angle combinations were evaluated. Four fiber materials, E glass, S-2 glass, Kevlar 29, Kevlar 49, and three matrix materials, epoxy, polycyanate and siloxirane, were considered.
TABLE 1______________________________________Design Cases for Laminate DesignLoa "Easy" "Medium" "Hard"d Press Press PressCas Spool Axial ure Spool Axial ure Spool Axial uree ed (lbf) (psi) ed (lbf) (psi) ed (lbf) (psi)______________________________________1 X 0 0 X 0 0 X 0 02 X 0 7,500 X 0 11,25 X 0 14,00 0 03 -- 7,500 -- 11,25 -- 14,00 7,500 7,500 0 7,500 04 25,00 7,500 27,50 11,25 30,00 14,00 0 0 0 0 05 -- -- -- -- -- -- 7,500 5,750 7,500 5,750 7,500 5,7506 25,00 -- 27,50 -- 30,00 -- 0 5,750 0 5,750 0 5,750______________________________________
In each load set, the spool diameter was varied to study the trade-off between stresses due to spooling and the other loading conditions. A curvature term for the laminated plate analysis was calculated as follows:
k=e/y where e=y/r (1)
y=distance from neutral axis
r=radius of curvature of neutral axis
For a 1.5" diameter tube on a 6 foot diameter spool:
e=0.75/36.75=0.0204 (2)
k=0.0204/0.75=0.0272 (3)
For a 1.5" diameter tube on a 7 foot diameter spool:
e=0.75/42.75=0.0175 (4)
k=0.0175/0.75=0.0234 (5)
Based on the results of the optimization analysis, a hybrid construction with Kevlar 49 at approximately 85° and S-2 Glass at 0° with a matrix of either epoxy or Siloxirane was selected for prototype fabrication. This design, the lay-up for which is shown in FIG. 8 and tabulated in Table 2, met all three load case sets with a 7' diameter spool. Using a 6' diameter spool, the Kevlar just begins to reach compression failure under the more extreme loading conditions. The predicted longitudinal and transverse stiffness levels for the laminate are 3 msi and 9.6 msi, respectively. For comparison, the CCT samples made previously by US Composites Corporation ("US Composites") for Conoco Oil Company ("Conoco") had a longitudinal and transverse modulus of 1.09 msi. US Composites developed alternate designs, using axial carbon fiber, which have longitudinal moduli values of up to 9 msi, if required to control buckling. Temperature differences were not considered in the optimization analysis. When taken into account (to represent thermal residual stresses) in the optimized design, transverse failures, or micro-cracking, were indicated. Although these are not necessarily critical, they do suggest the need for an impermeable liner and/or layer. FIG. 8 shows composite coiled tubing laminate 110 containing finite elements 111 with a twelve layer finite element matrix (circumferential layers) containing depth lines 113. The ply or layers are numbered as seen in FIG. 10, counting the plies or layers from the outermost to the innermost layers, from outside to inside, and the innermost being layer 12. (See Table 2 below).
Full Scale CCT Test Section
Two full size cross section CCT samples, approximately 10' long, were fabricated. Fabrication of the 10' long sections was completed using the standard epoxy matrix utilized on the first set of 1/4" CCT samples discussed further herein. To facilitate fabrication of the limited length of full size CCT, commercially available stock materials were selected for the mandrel and liner materials. Specifically, standard 13/16" steel tubing was selected for the mandrel and a stock 7/8" ID×1.0" OD PVDF tubing was used as a liner. FIG. 6a shows the liner construction utilized on the these sections.
TABLE 2______________________________________Composite Coiled Tubing Laminate Design Ply Angle CompositePly Number (Degrees) Material Thickness Layer (1-12)______________________________________1 85 Kevlar 49 0.015 first (outer)2 0 S-2 Glass 0.015 second3 -85 Kevlar 49 0.015 third4 0 S-2 Glass 0.015 fourth5 85 Kevlar 49 0.015 fifth6 -85 Kevlar 49 0.015 sixth7 -85 Kevlar 49 0.015 seventh8 85 Kevlar 49 0.015 eighth9 0 S-2 Glass 0.015 ninth10 -85 Kevlar 49 0.015 tenth11 0 S-2 Glass 0.015 eleventh12 85 Kevlar 49 0.015 twelfth (inner)______________________________________
Using a scale up of the 1/4" CCT sample construction, and additional dry fiber wrapping trials over the full size mandrel, the following construction was utilized in fabrication of the full size CCT sections.
Two 10' CCT sections were fabricated, (see FIG. 6a), using the above fiber construction and on-line resin impregnation with the epoxy system. To demonstrate the ability to include communications capability in the CCT, four individual 28 gauge insulated copper wires were installed in the laminate concurrent with the application of the first ply. These conductors were installed longitudinally in the full scale samples for demonstration purposes only and alternate incorporation techniques are being considered for the production CCT.
As discussed above, the resulting outside diameter, using the predicted 12 ply design construction and the undersized stock liner, was expected to fall short of the 1.5" nominal outside diameter. Therefore, to provide a configuration more representative of the desired 1.5" nominal OD, a sample of CCT section was fabricated using a 14 ply construction of alternating unidirectional fiberglass and high angle Kevlar. The average outside diameter of this cured sample was determined to be 1.395" which approaches the predicted 1.410" outsider diameter per the computer generated laminate design over the 1.050" ideal liner. The second 10' section, Sample #2 was fabricated using a 12 ply construction of the same alternating fiber plies and had a resulting average outside diameter of 1.340". Accordingly, a Sample section is more representative of the actual 12 ply design laminate construction tabulated earlier in this report.
TABLE 3______________________________________Composite Coiled Tubing Laminate Design Ply AnglePly Number (Degrees) Material Thickness______________________________________1 0 S-2 Glass 0.0122 -81 Kevlar 49 0.0163 0 S-2 Glass 0.0124 81 Kevlar 49 0.0165 0 S-2 Glass 0.0126 -81 Kevlar 49 0.0167 0 S-2 Glass 0.0128 81 Kevlar 49 0.0169 0 S-2 Glass 0.01210 -81 Kevlar 49 0.01611 0 S-2 Glass 0.01212 81 Kevlar 49 0.01613.sup.1 0 S-2 Glass 0.01214.sup.1 -81 Kevlar 49 0.016______________________________________ .sup.1 Plies 13 and 14 apply to Sample #1 only.
S-2 Glass is believed to be a registered trademark of Owens-Corning and this material may be obtained from Owens Corning. Kevlar 49 is believed to be a registered trademark of Dupont Company, and this material may be obtained from Dupont.
It is also noted that an `on-line` resin curing system is planned for the production CCT cell. This curing method, however, could not be practically incorporated in the prototype manufacturing cell utilized in fabrication of the 10' CCT sections. Alternatively, the 10' sample sections were overwrapped with conventional heat shrink materials and then rotisserie cured in a conventional oven. The heat shrink materials were utilized to provide both laminate consolidation and an acceptable exterior surface appearance. During design and fabrication phases, it was considered that interim staging of the various CCT plies may become necessary to ensure adequate cure and to maintain dimensional stability of the relatively thick wall section.
Sample #1 CCT section was fabricated by applying several layers of wet wrapped fiber, staging of the partial build-up, application of the remaining plies, and, subsequent shrink wrap and curing of the laminate. For comparative purposes, Samples #2 was fabricated by applying all wet wrapped plies to the mandrel, an overwrap of heat shrink tape, and final cure of the laminate. As expected, irregularities of the sample section surface finish resulted from the relatively thick, compliant laminate being over consolidated in localized regions by the heat shrink wrap during cure. As a result, it is anticipated that on-line staging of the production CCT, at select layers in the multiply wall thickness will be required.
BUCKLING OF COMPOSITE COILED TUBING (CCT)
CCT Modulus=3 msi (`best` overall design)
If CCT friction=CT friction then CCT lockups at 60% of CT lockup length
If CCT friction=1/2 CT friction then CCT lockups at 120% of CT lockup length
CCT Modulus=9 msi (stiffest design for buckling resistance)
If CCT friction=CT friction then CCT lockups at 100% of CT lockup length
If CCT friction=1/2 CT friction then CCT lockups at 200% of CT lockup length
Buckling is one of the controlling parameters in coiled tubing operations. The CT buckles downhole as shown in FIG. 4. A cursory buckling analysis was performed based on industry recognized technology. The controlling parameters for a buckling problem (sinusoidal buckling, FIGS. 5a and 5b) are the section modulus (linear relation), weight (linear relation) and length (nonlinear relation). However, for helical buckling, FIGS. 5c and 5d, only the section modulus and weight are of consequence.
The section modulus of the proposed composite coiled tubing is approximately 1/10 that of steel coiled tubing, and the weight of the tubing per foot is approximately 1/2. Both of these parameters are comparable to other companies' CCT designs. The lower section modulus reduces the buckling length but is somewhat offset by the lower CCT weight. The effective weight is dependent on the fluid in the well (buoyancy of the CT string).
A simple governing equation for helical buckling 1! is ##EQU1## where E Modulus of Elasticity
I=Moment of Inertia
w=CT buoyed weight
a=well deviation from vertical
r=radius of outer tubing/casing
Lockup occurs when the friction force required to push the pipe downhole is equivalent to the helical buckling load, thus the tubing can no longer be pushed down hole. The friction force can be calculated using 2! ##EQU2## where F 1 =loading force
b=angle from bottom of outer tubing/casing
The first term is the normal force exerted by the helical buckling, and the second term is the coiled tubing weight. Therefore, the total frictional force can be written as ##EQU3## where f=friction coefficient
L=depth of CT
The depth the CT can be pushed before lockup can thus be approximated as ##EQU4##
The results shown in Table 4 are for a horizontal section only. A casing radius of 4" is assumed. Two different composite moduli are used. The first is the proposed design and the second is the maximum value determined by the design procedure. Also, two different friction coefficients are assumed. The first case uses the same friction as steel CT and the latter assumes 1/2 the friction coefficient. Actual values will have to be determined, but handbooks show plastic laminate/steel friction coefficients as low as 1/2 steel/steel values. Column 4 of Table 4 shows the ratio of the lockup distance of CCT to steel CT. Obviously, the results can be construed to match any viewpoint. The worst case is that CCT will only be pushed half as far as steel CT in horizontal applications and the best scenario is that CCT can be pushed twice as far. Realistically, CCT will exhibit similar lockup distances as steel CT.
TABLE 4______________________________________Comparison of Lockup Depth for CCT Versus CTComposite Axial Friction Lockup Ratio,Modulus (msi) Wellbore Fluid Coefficient, f.sub.c /f.sub.st L.sub.c /L.sub.st______________________________________3 × 10.sup.6 dry 1.0 0.573 × 10.sup.6 water 1.0 0.633 × 10.sup.6 dry 0.5 1.163 × 10.sup.6 water 0.5 1.259 × 10.sup.6 dry 1.0 1.009 × 10.sup.6 water 1.0 1.089 × 10.sup.6 dry 0.5 2.009 × 10.sup.6 water 0.5 2.16______________________________________
FINITE ELEMENT ANALYSIS
21 different load cases were analyzed
1 Axial load
Spooled tubing
Load due to tubing weight
Internal pressure
External pressure
The six most severe cases were studied in detail
Results verify design procedure
Limited modifications are required to meet "hard" specification except for 300° F. temperature limit
The finite element analysis was conducted using ANSYS, which is a computer program written by Swanson Analysis System Incorporated of P.O. Box 65 Johnson Road, Houston, Pa. 15342. Normally, pressurized tubes are modeled using axisymmetric shell or solid elements, depending on the thickness. However, since the problem contains non-axisymmetric loading (bending), these types cannot be used. The next logical choice would be plane stress or plane strain elements. Again, most planar elements, including ANSYS's elements, do not allow this type of loading due to the bending loads, as well as the axial loads. Therefore, three dimensional solid elements must be used.
The coiled tubing is constructed of three-dimensional solid elements with one element along the length and numerous elements radially and circumferentially. A typical model is shown in FIG. 9, the length is greatly exaggerated for a clearer picture. Only one element through the thickness is required since the strain field is constant. The length of the `slice` should be approximately equal to the element length in the radial and hoop directions for well shaped elements. A special layered composite element was used; however, the elements are not easy to use (the orientation of the elements was tedious to construct).
In FIG. 9, a composite coiled tubing finite element model 115 with depth lines 116 and a twelve layer matrix 117 is shown. The elements were formulated to allow several laminas per element, but one element per lamina was used for improved results, as seen in FIGS. 10-24. Better results could be obtained by using more than one element per lamina, the need of which will be demonstrated later. For this preliminary analysis, however, one element per layer suffices. The basic element is an eight node (linear) formulation but allows higher order (parabolic) displacement shapes. There are 12 laminas. The other laminas are +/-85 degrees from the axial (stiff in the circumferential direction).
As discussed previously, only one element is along the length, which is constant strain. Symmetry is not used for two reasons. The first is that 1/4 symmetry cannot be used because of the bending loads (1/2 would have to be used). The second is that since the circumferential laminas are not symmetric, the 1/2 model symmetry is destroyed.
Pressure loads are applied by either pressure applied to the internal surface or external surface. Axial loads are applied by displacing the axial direction a prescribed amount thus providing the applied axial load. The difficulty in defining the loading parameters arises from the debate of plane strain versus plane stress. If the coiled tubing is allowed to move freely in the well (assuming negligible friction) then plane stress occurs; however, if the coiled tubing is fixed at the end (by a tool) and tension is applied, then plane strain occurs. In most cases the plane stain condition is most severe, so that is what is modeled. One end of the tubing is completely constrained while the other end is given a displacement based on the stress level. The problem with this technique is that as external pressure is applied to the tubing, the tubing elongates due to Poisson's ratio thus reducing the effective axial load.
Failure criteria for this analysis are believed to be at levels of about the following:
______________________________________Axially stiff laminalongitudinal stress - tension: 360 ksilongitudinal stress - compression: 124 ksitransverse stress - tension: 11 ksitransverse stress - compression 24 ksiHoop stiff laminalongitudinal stress - tension: 315 ksilongitudinal stress - compression: 45 ksitransverse stress - tension: 12 ksitransverse stress - compression 27 ksi______________________________________
FIG. 10 shows axial stress model 140 with coiled tubing which is spooled and deformed on an 84 inch reel. The layers of this model, and for explanatory purposes, layers generally in this modeling, are numbered, for example here, as first finite element layer 141, second finite element layer 142, third finite element layer 143, fourth finite element layer 144, fifth finite element layer 145, sixth finite element layer 146, seventh finite element layer 147, eighth finite element layer 148, ninth finite element layer 149, tenth finite element layer 150, eleventh finite element layer 151, and twelfth finite element layer 152.
FIG. 10 shows particularly high tension levels in high tension zone 155, while showing high compression levels in high compression zones 153 and 154.
In the axially stiff laminas (layers 2,4,9,11) the axial stress corresponds to the longitudinal strength and the hoop and radial stresses to the transverse stress. For the hoop stiff laminas (1,3,5,6,7,8,10,12) the fibers are oriented at 85 degrees to the axial. Therefore, the radial stress closely corresponds to the longitudinal strength, but the strength at 90 degrees will be lower. The hoop and axial stresses closely correspond to the transverse stress, but the strength will be slightly higher at 0 degrees. The failure properties for the laminas can be specified in ANSYS using either a default failure criteria or a user defined criteria. For this preliminary analysis, neither was used.
Twenty-one different load cases were evaluated for the finite element analysis. The axial loading varied from spooled tubing to tubing in both tension and compression. Internal pressure was varied from 0 psi to 22,500 psi. External (hydrostatic) pressure was varied from 0 psi to 15,000 psi. Safety factors of 2 and 1.5 were used for surface and downhole conditions respectively. The six most severe cases are documented below.
EXAMPLE 1
Load Case A.1: CCT spooled on an 84" drum without pressure. Increasing the pressure reduces the minimum stress and increases the maximum stress which is a less severe case. This case will fail in axial compression. Axial stress is plotted in FIG. 10. Note the low stress in the hoop (circumferential) laminas and the overall bending behavior of the section.
Load Case A.2: CCT spooled on a 94" drum without pressure. Axial stresses are plotted in FIG. 11, which shows axial stress model 158 as existing on a spooled reel. High tension finite element 156 and high compression finite element 157 are visible. In this case axial stresses are close to failure (compression), but manageable through material modifications and/or design modifications.
EXAMPLE 2
Load Case 3: CCT downhole with 15000 psi internal pressure and 30000 lb. axial load. Axial stress, FIG. 12, in a downhole (unspooled) condition with only internal pressure (safety factor of 1.5 on 10,000 psi) along with 30,000 lb. axial load (low safety factor on axial load is generally used). Axial stress model 161 reveals second finite element layer 163 and ninth finite element layer 164 that show axial stresses (pulling) due primarily to gravity since the tubing is in the unspooled state.
FIG. 13 shows the hoop stress for load case B, including hoop stress model 165 (showing internal pressure effects) and twelfth finite element layer 166, which shows high pressure.
Note the very low stress states--approximately 1/2 of failure in the hoop laminas and 1/3 in the axial laminas. The hoop (circumferential) stress is shown in FIG. 18. The stress in the hoop-stiff laminas are low compared to failure; however, the stress in the axial-stiff laminas are at failure (low strength transverse to fiber orientation). FIG. 14 shows the radial stress, the pressure gradient through the element. Radial stress model 168 discloses first finite element layer 169 and second finite element layer 170 and twelfth finite element layer 171. The minimum stress should be 15,000 psi and the maximum stress 0 psi. The actual is -13655 and 133 psi which is an error in mesh refinement. Better refinement will provide better results at the expense of time. For a final design, the analysis would be better refined. The compressive transverse strength of the laminas is twice the tensile, hence this stress is well below failure (approximately 1/2).
EXAMPLE 3
Load Case C: CCT downhole with 7500 psi external pressure and -7500 lb. axial load Axial stress are plotted in FIG. 15 for tubing in a downhole condition with external pressure and -7500 lb. axial load. Axial stress model 173, as expected shows that the axial stresses are very low. Hoop stress are shown in FIG. 16, in hoop stress model diagram 175. Stresses as shown in FIG. 16 are well within maximum and minimum stresses should be 0 and -7500 but are actually -541 and -7374 respectively for the reasons discussed above.
EXAMPLE 4
Load Case D: CCT downhole with 20,000 psi internal pressure Hoop stress for downhole condition with 0 axial load and 20,000 psi internal pressure is plotted in FIG. 18. FIG. 18 contains hoop stress diagram 178, and one may note the stress levels in twelfth finite element layer 179. This loading condition would occur between the gooseneck and reel in high pressure situations, 10000 psi with a safety factor of 2 (surface). The axial stiff laminas would crack in this case, but the hoop stiff laminas are well below (1/3) their failure strength.
FIG. 19 shows the radial stress. Radial stress diagram 180 in FIG. 19 further reveal eleventh finite element layer 181 and twelfth finite element layer 182. Note that stresses are not very close to the pressure at the OD and ID. All stresses are well below the failure stress.
EXAMPLE 5
Load Case E: CCT downhole with 22,500 psi internal pressure, 15,000 external pressure and 30,000 lb. axial load Axial stress are plotted in FIG. 20 for the most severe downhole case with maximum internal pressure, wellbore pressure and axial load. FIG. 20 reveals axial stress condition 184 with areas of relatively high stress shown at fifth finite element layer 185, sixth finite element layer 186, seventh finite element layer 187 and eighth finite element layer 188. Axial stresses are well within limits, again approximately 1/2 or less of failure. FIG. 21 shows the hoop stress. As in FIG. 18, the axial stiff laminas would crack, but both the hoop stiff laminas are approximately 1/4 of their failure stress. Radial stresses are plotted in FIG. 22, as shown by radial stress condition 192. First finite element layer 193 and twelfth finite element layer 194 show that pressures are quite low on the outer layer but relatively higher on the inner layer. Extreme stresses match applied pressure fairly well.
EXAMPLE 6
Load Case F: CCT downhole with 22,500 psi internal pressure, 15,000 external pressure
Similar loading as the previous case but without the axial load. The hoop stress, FIG. 23, is slightly lower, but not much indicating that axial load does not significantly affect this particular CCT design when considering stresses in the hoop direction. Hoop stress condition 196 is shown in FIG. 23. Radial stresses are shown in FIG. 24 (showing radial stress condition 198) which are not much different than FIG. 22.
The finite element analysis load cases were more severe than those used in the computer program. The design load cases are realistic service conditions while the FEA are the most rigorous including 10,000 psi tubing pressure and 7,500 psi hydrostatic pressure with high safety factors. In general the finite element results verify the results from the software program. The CCT design meets the minimum requirements and with some modifications will likely meet the maximum requirements.
THE FOLLOWING LITERATURE REFERENCES ARE INCORPORATED BY REFERENCE
1. Dawson, R., and Paslay, P. R., `Drill Pipe Buckling in Inclined Holes`, Journal of Petroleum Technology, pp. 1734-1738, 1984
2. Chen, Y. C., and Cheatham, J. B., `Wall Contact Forces on Helically Buckled Tubulars in Inclined Wells`, Transactions of the ASME, pp. 142-144, Vol. 112, 1990.
The invention has been described in the more limited aspects of preferred embodiments hereof, including numerous examples. Other embodiments have been suggested and still others may occur to those skilled in the art upon a reading and understanding of the this specification. It is intended that all such embodiments be included within the scope of this invention.
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Products and methods relating to composite materials and their use in coiled tubing is disclosed. The composite tubing is a pressurized structure for conveying fluids downhole in a wellbore. It has a multilayered laminate that resists buckling within the wellbore and is fabricated into a hollow tube. The fibers are oriented in angular relationship to the longitudinal direction of the coiled tubing such as to provide appropriate strength and buckling characteristics to the coiled tubing. Further, the coiled tubing layered laminate may transmit signals representing data from downhole to the surface. In some embodiments, a composite disconnecting structure having a blend of fibers of different types or orientations is shown. The disconnecting structure shows a failure load range corresponding to the failure characteristics of the fiber blend, the fiber blend having a predetermined failure limit.
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FIELD
[0001] The present invention relates generally to the mining valuable mineral and/or metal deposits and particularly though not exclusively to an inflatable cushion used to create and maintain a void during backfill operations.
BACKGROUND
[0002] Valuable metals and minerals are frequently contained in subterranean deposits referred to in the art as “ore bodies”. Such ore bodies are typically located at varying depths in hard or high strength barren rock. Before mining can commence, a number of underground excavations must be developed at a plurality of levels to facilitate access to the ore body at each level.
[0003] Several methods have been developed to mine such ore bodies to recover the valuable metals or minerals, some examples of which are described, in U.S. Pat. No. 6,857,706. During mining operations, each cut or “panel” of ore is removed sequentially by drilling a plurality of vertically extending boreholes, loading explosive charges into each borehole and blasting. The blasted ore or rock material is gathered or “mucked” to a loading or draw point. Thereafter, a cavity referred to in the art as a “stope” is created by removal of the broken ore is backfilled with waste material such as mine tailings, concrete, cement rock fill, or paste fill.
[0004] Once rock is fragmented, the release of pressure causes it to expand therefore occupying a larger volume than before. Using the processes of the prior art, a space or void for receiving the fragmented rock is created by mining an elongated substantially vertical or inclined shaft extending between a lower level and an upper level of the mine, referred to in the art as a “rise”. Developing a rise for every production panel of the stope being mined can be both time consuming and expensive.
[0005] There remains a need for more efficient or economical methods for underground mining.
SUMMARY
[0006] According to one aspect of the present invention there is provided a method of mining a valuable metal or material in an ore body comprising the steps of:
a) placing a collapsible cushion in a stope whereby the cushion creates a void into which fragmented rock can expand during subsequent blasting operations for a second or subsequent panel; and, b) maintaining the void until blasting operations occur whereupon the void is caused to collapse to accommodate fragmented ore generated during blasting operations.
[0009] In one form, the cushion is inflatable which is advantageous in that the cushion can be transported to the stope in a deflated condition and inflated underground. In one form, the cushion is inflated in-situ during step a). In one form, step a) comprises placing the cushion adjacent to an ore body facing wall.
[0010] In one form, the method further comprises the step of backfilling the stope to secure the position of the cushion within the stope during step b). When the cushion is inflatable, the overall shape of the inflated cushion can be modified by only partially inflating the cushion. Thus, in one form, the inflated condition of step b) is a fully inflated condition. In one form, the cushion is partially or completely filled with a compressible fluid and the fluid within the cushion is compressed to occupy a smaller volume as a result of pressure being applied to the cushion by the fragmented ore during blasting operations. Alternatively, the cushion is filled with an incompressible substance and the cushion is punctured or vented to release the incompressible substance during or prior to blasting operations.
[0011] In one form the cushion is capable of withstanding forces of 0.5 to 50 psi (3.5 to 350 kPa) of internal pressure during step b).
[0012] Preferably, the cushion comprises an elongate fluid-tight housing having at least one cavity therein which is isolated from the surrounding atmosphere and is capable of retaining a substance under pressure. To resist damage occurring prior to blasting operations, the housing may be constructed of a tear-resistant material. In one form, the housing is constructed from a woven polypropylene or a woven polyethylene.
[0013] The ore body is accessible via upper and lower spaced-apart access located at different levels. Whilst the cushion may be dimensioned such that the length of the cushion, in use, extends substantially along the full distance between the floor of the upper drive and the ceiling of the lower drive, in one form of the present invention, the cushion is dimensioned such that the length of the cushion is not less than 80%, not less than 85%, not less than 90% or not less than 95% of the distance between the floor of the upper drive and the ceiling of the lower drive. The cushion may be dimensioned such that the width of the cushion, in use, extends substantially across the full width of the second or subsequent panel as measured across a wall of the ore body facing the stope. Alternatively or additionally, the width of the cushion is 5% to 75% of the width of the second or subsequent panel as measured across a wall of the ore body facing the stope. In this form, the cushion may be one of a plurality of cushions arranged in a side-by-side configuration.
[0014] Advantageously, an umbilical line is used to regulate or monitor the pressure within the cushion during step b). In one form, a pressure sensing means is used for providing feedback signals to a controller regarding the internal pressure of the cushion during step b), and wherein the feedback signal is compared with a fluid pressure set point whereby the controller operates to regulate the flow of pressurized fluid through an umbilical line to the cushion to ensure that the pressure within the cushion is maintained above the set point until the blasting operation commences.
[0015] Preferably, the cushion further comprises an elongate fluid-tight inner container. In one form, the inner container is formed from a fluid impervious material capable of retaining a fluid under pressure. When the cushion comprises an inner container, the housing may be a bag, sleeve or other receptacle within which a fluid-tight inner container is placed.
[0016] In one form, the inner container and the housing are dimensioned so that, upon inflation, the inner container fits snugly inside the housing.
[0017] Preferably, the inner container is constructed of a material having low fluid permeability. In one form, the inner container may be constructed of one or more materials selected from the group comprising: plastic materials, rubber or other elastomerics, extrusion grade nylon, polyethylene, polyurethane, polypropylene, latex, reinforced PVC, PVC, coated or co-extruded plastic materials which have suitable strength and suitably low gas permeability. In another form, the inner container is constructed of one or more of the materials selected from the group comprising: density polyethylenes, polyurethanes and co extrusions thereof.
[0018] To provide redundancy in the event of a puncture, the cushion may comprise a plurality of fluid-tight inner containers arranged inside the housing. In one form, the cushion is provided with a surplus of inner containers over and above the number required to fill the volume occupied by a fully inflated housing. Each of the plurality of inner containers may be independently collapsible.
[0019] In one form, each of the plurality of inner containers is an elongated container arrayed side-by-side a single row whereby the overall shape of the cushion is substantially planar. In another form, the plurality of elongated inner containers is arranged randomly within the housing. To assist in effecting a random arrangement of inner containers, the plurality of inner containers may be capable of sliding movement relative to each other such that the overall shape of the cushion can take any shape.
[0020] In one form, the housing wraps snugly around each of the plurality of inner containers to reduce the likelihood of accidental puncture of the housing. In this embodiment, the housing may be formed from a first sheet and a second sheet being joined together to form a plurality of stiffening ribs arranged in rows, each row containing one of the inner containers. The ribs provide increased rigidity to the cushion to assist in deployment during step a).
[0021] An impervious fluid seal may be formed at each of the plurality of ribs to retain fluid in the event of a leak of one of the inner containers.
[0022] In one form, the cushion comprises a plurality of inner containers and each inner container is configured to independently receive fluid from a fluid delivery system. Alternatively, each of the inner containers may be in fluid communication such that fluid supplied to the cavity of one of the inner containers is receivable within the cavity of each of the plurality of inner containers whereby the plurality of inner containers is simultaneously inflatable and collapsible. In one form, the cushion is one of a plurality of cushions positioned within the stope during step a).
[0023] According to a second aspect of the present invention there is provided a cushion for use in the method of mining a valuable metal or material in an ore body according to one form of the first aspect of the present invention.
[0024] According to a third aspect of the present invention there is provided a method of mining a valuable metal or material in an ore body substantially as herein described with reference to and as illustrated in the accompanying drawings.
[0025] According to a fourth aspect of the present invention, there is provided a cushion substantially as herein described with reference to and as illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] In order to facilitate a more detailed understanding of the nature of the invention several embodiments of the present invention will now be described in detail, by way of example only, with reference to the accompanying drawings (not shown to scale), in which:
[0027] FIG. 1 is a side view of the mine showing the location of an ore body, an upper drive and a lower drive and the deployment of a collapsible cushion within the stope adjacent to the ore body facing wall;
[0028] FIG. 2 is a partial cross-sectional view of a first embodiment of the present invention in which the cushion is partially inflated and comprises a single housing, the internal pressure of which is monitored using a pressure sensing means;
[0029] FIG. 3 is a partial cross-sectional view of a second embodiment of the present invention in which the cushion is partially inflated and is provided with a single inner container arranged to fit snugly inside the housing;
[0030] FIG. 4 is an isometric view of a third embodiment of the present invention illustrating the provision of handles for securing the position of the cushion in use;
[0031] FIG. 5 is a partial cross-sectional view of a fourth embodiment of the cushion in which the cushion comprises a plurality of inner containers arranged inside a single housing connected to a pressure sensor, controller and umbilical line;
[0032] FIG. 6 illustrates the cushion of FIG. 5 in a deflated condition for ease of transport;
[0033] FIG. 7 is a partial cross-sectional view of a fifth embodiment showing the plurality of inner containers arranged randomly within the housing; and,
[0034] FIG. 8 is a partial cross-sectional view of a sixth embodiment of the present invention in which the housing wraps snugly around each of a plurality of inner containers to provide the cushion with a plurality of stiffening ribs.
DETAILED DESCRIPTION
[0035] Particular embodiments of the present invention are now described. The terminology used herein is for the purpose of describing particular embodiments only, and is not intended to limit the scope of the present invention. Unless defined otherwise, all technical and scientific terms used herein have the same meanings as commonly understood by one of ordinary skill in the art to which this invention belongs.
[0036] The term “strike” refers to the angle of inclination of the surface of an ore body relative to a horizontal plane. The term “dip” is the direction and angle of inclination of the ore body, measured from a horizontal plane, perpendicular to the strike. The term “stope” is used to refer to an excavation from which ore has been removed in a series of cuts or “panels”. The term “panel” refers to a segment of ore of a pre-defined volume which is designated for removal in a given drilling and blasting operation. The term “rise” is used to refer to an elongated substantially vertical or inclined shaft extending between a lower level and an upper level in a mine. A rise is cut as the first step in creating the stope. The term “drive” is used to refer to an elongated substantially longitudinal passageway in a mine extending generally in the direction of the strike. The term “shaft” is used to refer to a substantially vertical excavation in a mine for the purpose of providing access to an ore body. The term “incline” or “inclined shaft” is used to refer to a sloping excavation or slanting shaft.
[0037] The term “substance” refers to a kind of matter or material that can be a solid, liquid or a gas. The term “fluid” refers to gases and liquids. The term “compressible” refers to something that is capable of being made to occupy a smaller volume by the application of pressure or a similar process. The term “incompressible” refers to something that is not capable of being made to occupy a smaller volume by the application of pressure or a similar process.
[0038] With reference to the mine depicted in side view in FIG. 1 , there is shown an ore body ( 10 ) containing a valuable metal or mineral, whether of igneous, metamorphic, or sedimentary origin. The ore body can be of any shape and is depicted as being substantially planar in cross-section for ease of description of the present invention. The mine is provided with upper and lower spaced-apart access drives (( 12 ) and ( 14 ), respectively) located at different levels. With referent to FIG. 1 , each of the upper drive ( 12 ) and the lower drive ( 14 ) pass through at least a portion of the ore body ( 10 ) and are arranged generally parallel to the strike of the ore body. As will be appreciated, other drives not shown in FIG. 1 can be located at the same or other levels within the mine to divide the ore body into a plurality of mineable segments.
[0039] The upper drive ( 12 ) provides access to excavation equipment ( 16 ) including but not limited to production drilling apparatus, blasting apparatus and services such as sand, water, compressed air and electricity. When each sequence of drilling and blasting operations has been completed, broken ore falls under the influence of gravity towards the lower drive ( 14 ). The lower drive provides access for a haulage system ( 18 ), such as a loader, to load and haul the mined broken ore ( 19 ) to a desired location. As will be appreciated, the haulage system can also be a scraper, a scraper conveyor, a scraper conveyor, a mini-scoop, tracked or rubber-tired haulage vehicles (such as a truck, a shuttle car, or a tractor trailer), water jets, rail cars, a haulage pipeline (such as a hydraulic hoist), and combinations thereof.
[0040] After development of the upper drive ( 12 ) and lower drive ( 14 ) has been completed, mining of the ore body ( 10 ) can commence. As a first step, a first panel ( 11 ) extending between the upper drive ( 12 ) and the lower drive ( 14 ) is excavated to commence creation of a “stope” ( 22 ). By way of example, the first panel ( 11 ) can be excavated by positioning drilling equipment ( 16 ) within the upper drive ( 12 ) and drilling a plurality of boreholes ( 24 ) in sequence into the ore body ( 10 ). Each borehole ( 24 ) extends downwardly from the upper drive ( 12 ) towards, and preferably breaking through into, the lower drive ( 14 ). After drilling of the plurality of boreholes has been completed, suitable explosives are charged within each borehole for detonation to create the void ( 22 ) by removing the first panel ( 11 ). Persons skilled in the art would be familiar with ways of designing specific drilling and blasting sequences and operations to produce chucks of broken ore of manageable size for hauling and further processing.
[0041] Drilling and blasting operations are repeated to progressively remove a second or subsequent panel ( 20 ) of the ore body to increase the size of the stope ( 22 ). In an analogous manner to the excavation of the first panel ( 11 ), drilling and blasting of the second or subsequent panel ( 20 ) is conducted using procedures that are known to persons skilled in the art, which procedures do not form part of the present invention. By way of example, the first rise can be mined in 5-20 m sections, blasting from the bottom up, and using voids provided by reamer holes (not shown) to prevent binding up of the first rise as the fragmented rock expands.
[0042] Using the methods and apparatus of the present invention, a cushion ( 30 ) is positioned within the stope ( 22 ) after the first panel ( 11 ) has been blasted and hauling operations associated with the broken rock generated in excavation of the first panel and stope generation have been completed, but before backfilling operations commence. The cushion ( 30 ) is positioned between the ore body facing wall ( 40 ) and a backfill segment of pre-defined volume which is designated for subsequent backfilling ( 23 ). In general terms, the cushion ( 30 ) is a fluid tight container that is used to create a collapsible void prior to backfilling operations, the void created by the cushion ( 30 ) being maintained during backfilling operations and then collapsed, depending on backfill material selection, either during or just prior to blasting operations.
[0043] With reference to FIG. 1 , the cushion ( 30 ) is positioned after the first panel ( 11 ) has been excavated in such as way as to create a collapsible void or ‘fake rise’ of a controlled size at a pre-determined location. For ease of access to underground mining operations, the cushion may be inflatable. Inflation may occur either before or after the cushion ( 30 ) is positioned within the stope ( 22 ). For example, the inflatable cushion ( 30 ) can be in a rolled or folded configuration for transport underground. After transport underground, the cushion ( 30 ) is positioned against the ore body facing wall ( 40 ) using the deployment system ( 46 ). The cushion ( 30 ) is then secured and inflated in-situ prior to or during backfilling operations. Whilst the cushion ( 30 ) can be placed at any suitable location within the stope ( 22 ), best results are achieved by positioning the cushion ( 30 ) adjacent to the ore body facing wall ( 40 ).
[0044] A first embodiment of a basic implementation of the cushion ( 30 ) is illustrated in FIG. 2 . In this embodiment, the cushion ( 30 ) comprises an elongate fluid-tight housing ( 32 ) formed from a tear-resistant fluid impervious material having at least one cavity ( 34 ) therein which is isolated from the surrounding atmosphere and is capable of retaining a fluid under pressure. Between deployment and blasting, the internal pressure of the cushion ( 30 ) is monitored to ensure that the cushion does not collapse until blasting occurs. Whilst the inflated cushion ( 30 ) is in position against the ore body facing wall ( 40 ), a pressure sensing means ( 66 ) is used to monitor and maintain pressure. The pressure sensing means ( 66 ) may be used for providing feedback signals to a controller ( 68 ) regarding the internal pressure of the cushion ( 30 ). The feedback signal is compared with a fluid pressure set point whereby the controller ( 68 ) operates to regulate the flow of pressurized fluid through the umbilical line ( 52 ) to the cushion to ensure that the pressure within the cushion is maintained above the set point until the blasting operation commences. If desired, the controller ( 68 ) can be programmed to initiate inflation of the cushion as well as monitor the internal pressure after inflation until blasting operations are commenced. Preferably, the controller is a remote controller and the feedback signals are transmitted between the cushion to the controller using the umbilical line ( 52 ). Preferably the cushion ( 30 ) is able to maintain 0.5 to 50 psi (3.5 to 350 kPa) of internal pressure when it is being used to maintain a void before blasting of the second or subsequent panel ( 20 ).
[0045] In a second embodiment illustrated in FIG. 3 for which like reference numerals refer to like parts, the cushion ( 30 ) is provided with an inner container ( 36 ) formed from a flexible fluid impervious material. In this embodiment, a more rigid housing ( 32 ) is used to shield the fluid tight inner container ( 36 ) from waste material used for backfilling operations which might otherwise affect the integrity of the fluid tight inner container ( 32 ), allowing a loss of pressure and a failure to maintain the void as required until blasting commences. The housing ( 32 ) may take a variety of forms, for example a bag, sleeve or other receptacle within which the fluid-tight inner container ( 36 ) is placed. The inner container ( 36 ) and the housing ( 32 ) are dimensioned so that, upon full inflation, the inner container ( 36 ) fits snugly inside the housing ( 32 ).
[0046] The inner container ( 36 ) of the cushion ( 30 ) may be constructed of any suitable material having low fluid permeability. By way of example, the inner container may be fabricated using plastic materials, rubber or other elastomeric materials, extrusion grade nylon, polyethylene, polyurethane, polypropylene, latex, polyvinylchloride (“PVC”), reinforced coated or co-extruded plastic materials, or a combination which have suitable strength and suitably low gas permeability. Polyethylenes, polyurethanes and co-extrusions are preferable to other types of materials. Preferably the inner container is constructed of an elastic material having low fluid permeability.
[0047] The housing ( 32 ) may be constructed of any suitable tear-resistant material to protect the inner container against damage when the cushion is positioned into a rise or during backfilling operations. One suitable tear-resistant material is woven polypropylene, polyester woven cloth, reinforced PVC, Kevlar or woven polyethylene. For best results, the tear-resistant material should also impart rigidity to the cushion whilst still allow for inflation thereof.
[0048] The inner container ( 36 ) and the housing ( 32 ) are sealed by means that are known in the art to be suitable for the materials of construction, for example using heat welding.
[0049] With reference to a third embodiment illustrated in FIG. 4 , the tear resistant housing ( 32 ) may further include one or more strengthening bands ( 33 ) arranged around the girth of the cushion ( 30 ) whereby the main axis of each of the strengthening bands is generally perpendicular to the vertical axis of the inflated cushion ( 30 ), advantageously reducing the risk of local bulging or bursting of the cushion ( 30 ) in use. If the cushion bulges in a local area during inflation, that area is more likely to be damaged during backfilling operations prior to blasting. Where more than one strengthening band ( 33 ) is used, the bands are positioned at spaced apart intervals to encourage even inflation of the cushion ( 30 ) in use.
[0050] The overall dimensions of the cushion can vary depending on such relevant factors as the size and type of ore body, the angle of the strike, the type of backfilling material being used, and the materials of construction of the cushion. In this regard, the overall dimensions of the cushion ( 30 ) may be in the range of 0.3-6 m in diameter when fully inflated or width when deflated or partially inflated and can range from 5-100 m in vertical height. Best results are achieved when the cushion ( 30 ) is dimensioned such that the length of the cushion is not less than 80%, not less than 85%, not less than 90% or not less than 95% of the distance between the floor ( 42 ) of the upper drive ( 12 ) and the ceiling ( 44 ) of the lower drive ( 14 ). For best results, the width of the cushion is from 5% to 75% of the width of the second or subsequent panel ( 20 ) being mined.
[0051] In use, the cushion ( 30 ) is positioned within the stope ( 22 ) using a deployment system ( 46 ). By way of example, the deployment system may include a support cable ( 49 ), a mobile hoist ( 50 ), and an umbilical line ( 52 ). Alternatively, the deployment system ( 46 ) can be located on a drilling rig, on an explosives rig ( 16 ). The umbilical line ( 52 ) is used to regulate or monitor the pressure within the cushion until blasting operations associated with the excavation of the second or subsequent panel ( 20 ) occur. When the cushion ( 30 ) is inflated, the umbilical line ( 52 ) is used to provide fluid to the cushion to allow the cushion to be inflated immediately prior to deployment or in-situ as described in greater detail below. Either way, the cushion ( 30 ) can advantageously be inflated using substances which are provided as services during underground mining, including fluids such as compressed air or water; or other substances such as sand.
[0052] The cushion ( 30 ) is maintained in an upright configuration using the support cable ( 49 ). The cushion ( 30 ) is provided with one or more anchors or handles ( 51 ) to assist in positioning the cushion ( 30 ) within the stope ( 22 ), with the support cable ( 49 ) being releasably attachable to one of the handle(s) ( 51 ) during deployment. In the embodiment illustrated in FIG. 4 , the cushion ( 30 ) has a first proximal end ( 55 ) and a second distal end ( 57 ) and the first end ( 55 ) is provided with one or more of the anchors ( 51 ) to assist in deploying the cushion ( 30 ) using the support cable ( 49 ) as set out above. In this embodiment, the second end ( 57 ) of the cushion ( 30 ) is provided with one or more additional handles ( 51 ) to assist in anchoring the cushion ( 30 ) within the stope ( 22 ) in the direction of the lower drive ( 14 ) to obviate the risk of the cushion rising upwardly during backfilling operations.
[0053] Using the methods and apparatus of the present invention, backfilling of the stope ( 22 ) occurs after positioning and inflation of the cushion ( 30 ). In essence the handles ( 51 ) anchor the cushion ( 30 ) in place within the stope ( 22 ) during backfilling operations. When backfilling of the backfill segment ( 23 ) of the stope ( 22 ) has been completed, drilling equipment ( 16 ) is again positioned within the upper drive ( 12 ) for excavating the second or subsequent panel ( 20 ) in an analogous manner to the excavation of the first rise. When the second or subsequent panel ( 20 ) of the ore body ( 10 ) is excavated using blasting, the volumetric area occupied by the cushion ( 30 ) is caused or allowed to collapse to allow the fragmented ore to expand into and fill the void previously created and maintained by the cushion ( 30 ).
[0054] Fourth and fifth embodiments are illustrated in FIGS. 6 and 7 , respectively, for which like reference numerals refer to like parts. In FIGS. 6 and 7 , the cushion ( 30 ) is shown in its inflated condition for clarity. In both embodiments, the cushion ( 30 ) comprises a plurality of fluid-tight inner containers ( 36 ) arranged inside a single outer protective housing ( 32 ), each of the plurality of inner containers ( 36 ) being independently collapsible. In the embodiment illustrated in FIG. 7 , each of the plurality of inner containers ( 36 ) is an elongated cylindrical container arrayed side-by-side a single row whereby the overall shape of the cushion upon inflation is substantially planar. This arrangement is used for ease of positioning of the cushion ( 30 ) against the ore body facing wall ( 40 ).
[0055] In the embodiment illustrated in FIG. 6 , the plurality of elongated cylindrical inner containers ( 36 ) is arranged randomly within the housing ( 32 ) and the overall shape of the cushion upon inflation would be circular in cross-section if no external pressure was being applied to it. FIG. 5 shows a partial cross-sectional isometric view of the cushion of FIG. 6 prior to inflation. In this embodiment, the plurality of inner containers is capable of sliding movement relative to each other such that the overall shape of the cushion ( 30 ) can take any shape. Using this embodiment, the cushion ( 30 ) may be provided with a surplus of inner containers ( 36 ) over and above the number required to fill the volume occupied by a fully inflated housing ( 32 ). This is done so that if any of the inner containers are punctured prior to blasting operations, one or more of the surplus inner containers is inflated to fill the space previously occupied by a punctured container. This redundancy is built into the cushion ( 30 ) to maintain the overall integrity of the cushion until blasting occurs.
[0056] A sixth embodiment is illustrated in FIG. 8 for which like reference numerals refer to like parts. In this embodiment, the cushion ( 30 ) comprises a plurality of elongate cylindrical inner containers ( 36 ) arranged within an outer protective housing ( 32 ). In this sixth embodiment, the housing ( 32 ) wraps snugly around each individual inner container ( 36 ) to reduce the likelihood of accidental puncture of the housing ( 32 ). The housing ( 32 ) is formed from a first sheet ( 60 ) and a second sheet ( 62 ) being joined together, for example, using stitching or gluing, to form a plurality of seams ( 63 ) delineating a corresponding plurality of compartments ( 64 ) arranged in rows, each compartment containing one of the inner containers ( 36 ). In this way, each of the plurality of seams ( 64 ) has its main axis generally aligned with the main longitudinal axis of the inflated cushion ( 30 ). An impervious fluid seal is formed at each of the plurality of seams ( 63 ) to retain fluid within each of the compartments ( 64 ) in the event of a leak or a puncture of one of the inner containers ( 36 ). If desired, the seams ( 63 ) may be reinforced whereby the cushion ( 30 ) is provided with a plurality of stiffening ribs ( 65 ), advantageously increasing the overall rigidity of the cushion ( 30 ) in use.
[0057] In the embodiment illustrated in FIG. 8 , the plurality of inner container ( 36 ) is configured to receive fluid from a fluid delivery system in the form of a manifold ( 70 ) and a corresponding plurality of fluid delivery tubes ( 72 ). In this embodiment, the controller ( 68 ) is used to independently regulate the distribution of the fluid from the manifold ( 70 ) to each of the inner containers ( 36 ) to control the flow of fluid along each of the fluid delivery tubes ( 72 ).
[0058] In its most basic form, the cushion ( 30 ) is collapsed due to puncture of the cushion by the fragmented ore during blasting. However, various mechanisms for inflating and collapsing the cushions are now described. It is to be clearly understood that these mechanisms can be used for any of the above-described embodiments.
[0059] In its most basic form, the cushion ( 30 ) is inflated by being partially or completely filled with an incompressible substance such as sand or an incompressible fluid such as water. The incompressible fluid is sealed within the cushion and then released immediately prior to or during blasting operations to allow the cushion to collapse. By way of example, the cushion may be deflated during blasting operations as a consequence of broken rock penetrating or puncturing the cushion, resulting in the release of the incompressible fluid from the inner container ( 36 ) of the cushion ( 30 ) resulting in collapse of the cushion.
[0060] In another form, backfilling operations may be conducted using a settable composition capable of retaining its shape when set so that the void is maintained until blasting operations occur. In this form, the void can be maintained after setting of the settable composition has been achieved, even if the cushion is accidently or deliberately deflated. In this form, the cushion may be inflated using a compressible fluid such as air or an incompressible substances such as sand or water. When the cushion is inflated using a compressible fluid and the fragmented ore that is generated during blasting expands to occupy a larger volume during excavation of the second or subsequent panel ( 20 ), the fragmented ore applies pressure to the cushion in excess of its internal pressure, causing compression of the fluid and controlled collapse of the cushion during blasting operations. The fluid within the cushion ( 30 ) is simply compressed to occupy a smaller volume as a result of pressure being applied to the cushion by the fragmented ore. When the cushion is inflated using an incompressible fluid, the cushion can be deflated by releasing the incompressible fluid from the cushion after backfilling operations have been completed and the settable composition has set, allowing the cushion ( 30 ) to be re-used if desired.
[0061] In another form of the invention, the cushion ( 30 ) is placed in a stope ( 22 ) and partially or completely filled with a compressible fluid such as air to create the void into which fragmented rock can expand during subsequent blasting operations for a second or subsequent panel ( 20 ). Sufficient gas is provided to the cushion, for example using the umbilical line ( 52 ), to maintain inflation of the cushion ( 30 ) until blasting operations occur. In this form, the pressure sensing means ( 66 ) is used to monitor and maintain pressure during backfilling operations. A feedback signal is compared with a fluid pressure set point whereby the controller ( 68 ) operates to regulate the flow of pressurized fluid through the umbilical line ( 52 ) to the cushion to ensure that the pressure within the cushion is maintained above the set point until the blasting operation commences.
[0062] To inflate the cushion for use using a compressible fluid such as air directed through an umbilical line ( 52 ), the cushion is provided with a normally closed one-way valve assembly ( 74 ) arranged to open upon application of fluid pressure on the inlet side of the valve. By way of example, the valve assembly may include a fitting adapted for connection to compressed air services provided in the upper drive or the lower drive. By way of example, fluid can be provided to the cushion using a stand-alone diesel compressor or air provided by mine services. The pressure within each inner container ( 36 ) is monitored to ensure that the cushion ( 30 ) remains inflated until the next drilling and blasting operations have been completed.
[0063] Alternatively, to facilitate inflation of the cushion using an incompressible fluid such as water, the cushion ( 30 ) may be provided with a two-way valve that operable in one way to allow fluid ingress into the inner container ( 36 ) to allow the inner container to expand and operable in another way to allow fluid to be expelled out of the inner container ( 36 ) to cause the controlled collapse of the cushion ( 30 ) during blasting. The same result can be achieved using an inlet valve assembly operable to allow fluid to pass into the inner container to allow inflation of the cushion and a separate outlet valve assembly operable to allow fluid to be expelled out of the inner container to cause the controlled collapse of the cushion during blasting.
[0064] When the cushion is provided with a plurality of inner containers ( 36 ) as illustrate in FIGS. 6 , 7 and 8 , each of the inner containers may be in fluid communication such that fluid supplied to the cavity ( 34 ) of one of the inner containers ( 36 ) is receivable within the cavity of each of the plurality of inner containers. In this way, the plurality of inner containers ( 36 ) is simultaneously inflatable and collapsible. In this example, the manifold ( 70 ) may be used to direct the flow of pressurized fluid into the plurality of inner containers ( 36 ) via an inlet valve ( 74 ) associated with one of the plurality of inner containers ( 36 ), with the fluid being distributed to the remaining inner containers ( 36 ) via a corresponding plurality of interconnecting channels ( 76 ). However, for maximum control, each of the plurality of inner containers ( 36 ) is independently inflatable and independently collapsible.
[0065] Now that several embodiments of the invention have been described in detail, it will be apparent to persons skilled in the relevant art that numerous variations and modifications can be made without departing from the basic inventive concepts. The foregoing is not intended to limit the invention to the form or forms disclosed herein. Although 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. For example, whilst it is preferable for ease of deployment to use a single cushion, it is equally possible to deploy a plurality of cushions in side-by-side alignment along the ore body facing wall or randomly distributed within the stope to achieve the same effect. All such modifications and variations are considered to be within the scope of the present invention, the nature of which is to be determined from the foregoing description and the appended claims.
[0066] All of the patents cited in this specification, are herein incorporated by reference. It will be clearly understood that, although a number of prior art publications are referred to herein, this reference does not constitute an admission that any of these documents forms part of the common general knowledge in the art, in Australia or in any other country. In the summary of the invention, the description and claims which follow, 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 method of mining a valuable metal or material in an ore body is described. The method comprises the steps of: a) placing a cushion in a stope whereby the cushion creates a void into which fragmented rock can expand during subsequent blasting operations for a second or subsequent panel; and, b) maintaining the void until blasting operations occur whereupon the void is caused to collapse to accommodate fragmented ore generated during blasting operations.
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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 invention relates to the erection and completion of reinforced concrete building wall structure in which a skeleton reinforcing matrix is first set in place and then concrete or similar material applied thereto, see, for example, U.S. Pat. No. 3,305,991.
2. Description of Prior Art
The structure of U.S. Pat. No. 3,305,991 comprises a modular wire framework panel designed for erection and receipt of concrete to provide a reinforced concrete wall. To facilitate the application of concrete, the structure of U.S. Pat. No. 3,305,991 includes a centrally positioned partition wall of polyurethane foam which affords core insulation and a support against which concrete can be applied from the opposite sides of the wall, the application being most expeditiously accomplished by pressure spraying of the concrete by the well known Gunite process. Plumbing parts and electrical lines may be mounted in the wall framework prior to the application of the concrete and buried therein so long as the plumbing and electrical members are formed to resist the corrosive attack of the concrete. Construction of walls having a completely open dead air space therein is not possible using known prior art structures and techniques, nor is it possible to form or fill the wall core with any of the available variable density insulated concrete or self-supporting plastic insulating materials. Prior art structures have also not been designed for use with form walls for most effectively embedding the reinforcing matrix within the wall being formed and to provide special surface effects which may be sought.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a building form and reinforcing matrix of the character described which may be quickly, easily and precisely erected, followed by expeditious completion of finished concrete walls and which will afford complete freedom of selection of wall core structure, including open dead air space, inclusion of loose insulation material, or filling with a self-supporting plastic insulation mass, and in any and all such core structures, enabling the inclusion of plumbing and electrical lines without requiring any special precaution against the normally expected corrosive attack on these parts of concrete.
Another object of the present invention is to provide a building form and reinforcing matrix of the character described which is specially formed for use in conjunction with form boards and the like to provide specially desired surface effects and ornamentation and which will, at the same time, correctly index the reinforcing matrix for full and most effective embedding in the concrete.
A further object of the present invention is to provide a building form and reinforcing matrix of the character above which will afford improved wall strength without common weakening and disfiguring cracks and finish out to a recognized standard wall thickness for use with conventional hardware, windows, doors, etc.
The invention possesses other objects and features of advantage, some of which of the foregoing will be set forth in the following description of the preferred form of the invention which is illustrated in the drawings accompanying and forming part of this specification. It is to be understood, however, that variations in the showing made by the said drawings and description may be adopted within the scope of the invention as set forth in the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front view of a modular building form and reinforcing matrix panel constructed in accordance with the present invention.
FIG. 2 is a fragmentary enlarged edge elevation of the panel.
FIG. 3 is a fragmentary cross-sectional view of the panel taken substantially on the plane of line 3-3 of FIG. 2.
FIG. 4 is a fragmentary perspective view of the panel.
FIG. 5 is a cross-sectional view of a section of finished wall constructed in accordance with the present invention.
FIG. 6 is a cross-sectional view of another form of finished wall constructed in accordance with the present invention.
FIG. 7 is a perspective view of a modified form of the panel.
FIG. 8 is a fragmentary edge elevation of the panel illustrated in FIG. 7.
FIG. 9 is a bottom view of the panel illustrated in FIG. 7.
DETAILED DESCRIPTION OF INVENTION
The building form and reinforcing matrix illustrated in the accompanying drawing comprises, briefly, a pair of mesh sections 11 and 12; a plurality of sinuous truss members 13 extending between and secured to and supporting sections 11 and 12 in spaced-apart planes, the truss members defining angularly related sides 16 and 17 between sections 11 and 12 and being joined in apexes 18 and being connected to at least one of sections 11 and 12, with apexes 18 projecting outwardly therefrom in spaced relation thereto, as best seen in FIGS. 1-4 of the drawings. In practice, apexes 18 project out about 1/2 inch from sections 11 and 12 so as to form an index of definition for the final wall surfaces 21 and 22, see FIGS. 5 and 6, wherein mesh sections 11 and 12 are fully and completely buried within the finished concrete wall to provide most effective reinforcing of the wall. Construction of the concrete wall is more fully hereafter discussed, but in connection with apexes 18, it may be noted that the latter all lie in a common plane spaced from and parallel to the adjacent wire mesh sections so that form boards and the like may be supported on the apexes for forming of the concrete wall or the dual purpose of providing special surface effects and proper embedding of the reinforcing mesh structure. Where the concrete is applied by a spray-on technique, the concrete is built out to the apexes 18, thus defining the limit of the finished wall and the proper and most effective inclusion of the reinforcing matrix. Sections 11 and 12 may be composed of standard commercially available rectangular wire mesh, including a plurality of substantially parallel, longitudinally extending wires 23 for section 11 and 24 for section 12, which are bonded, as by welding, to a plurality of substantially parallel, transversely extending wires 25 for section 11 and 28 for section 12. A standard 2 inches × 4 inches spacing of 121/2 gauge steel wire is quite satisfactory. The truss members 13 may be composed of 12-gauge steel wire mounted on 4-inch centers in the plane of opposed longitudinally extending wires 23 and 24 of the two mesh sections. The panels are preferably constructed in a standard 4-foot width in lengths typically 6', 8', 9', 10' and 12'.
As will be best observed from FIGS. 2-4, the longitudinal mesh wires 23 and 24 will traverse each pair of angularly related sides 16 and 17 of the trusses in spaced relation to their connected apex 18; and in accordance wtih the present invention, the longitudinal mesh members 23 and 24 are bonded, as by spot welding, to sides 16 and 17 to provide a rigid two-point triangular support for the outwardly projecting apexes 18. Also, as will be observed, the joinder of transverse wires 25 and 28 to longitudinal wires 26 and 27 are at positions spaced from the joinders of the truss members to the longitudinal wires, thereby spacing apexes 18 from any of the transversely extending wires 25 and 28. Moreover, the several truss members are positioned so that the apexes 18 of transversely adjacent truss members are offset longitudinally from each other, with the apexes defining a diamond-shaped pattern, as seen in the front view, FIG. 1.
In accordance with the present invention, one or more partitions 26 and 27 are carried by truss members 13 between sections 11 and 12; and as a feature of the present invention, these partitions may comprise a simple sheet pierced by apexes 18 and mounted interiorly of the adjacent mesh section and supported on adjacent diverging sides 16 and 17 of the truss members. Common building paper may be used for this purpose, the paper sheets being positioned in place on the truss members prior to the welding of the adjacent mesh section thereto. Any desired sheet of frangible material may be used for this purpose. The purpose of the partition sheet is to facilitate the application of the concrete skins which will provide the finished wall and to define the interior core space 31 of the wall.
Normally, the matrix panels of the present invention will be erected on a foundation when they are to define a building wall and secured together over the length of the wall by wiring together, cinching with hog rings and the like. Thereafter, concrete may be applied to the matrix, either by troweling or by spray application, using one of the partitions 26-27 as a backing and the concrete wall built out to the extremity of the apexes 18, thus fully embedding one of the mesh sections 11-12 and forming, typically, about a 1-inch concrete wall 32, as seen in FIGS. 5 and 6. The structure of the present invention provides various alternative techniques for completing the wall. One preferred system is to proceed from the opposite side of wall 32 by using the interior of wall 32 as a support against which to apply, as by spraying, a self-supporting plastic insulating mass 33, which will embed therein plumbing, electrical wiring and the like, and form the core of the wall. Various types of variable density insulated concrete may be used for this purpose. One preferred material is the combination of rock wool and a plastic resin binder cement, such as manufactured by Spray Craft. Other self-supporting plastic insulating masses combining insulating fiber, shredded plastic foam waste, plastic cement and Portland cement may be used. If desired, the core space 31 may be filled with a plastic foam sprayed in place or simply packed with rock wool or the like. Where the core area 31 is filled, as above described and as illustrated in FIG. 5, the opposite concrete wall skin 34 may be applied as by troweling or spraying, using the interior core as a backing support. As in the case of wall section 32, wall 34 is built out to the extremity of apexes 18, thus fully and most effectively embedding mesh section 12 in the wall. Typically, wall 34 will be approximately 1 inch thick, leaving an interior core section 33 of approximately 21/2 inches in thickness. In the foregoing described wall structure, and as illustrated in FIG. 5, only one interior partition sheet 26 need be used, since the interior core structure 33 will provide the backing for supporting the application of the concrete wall 34. If desired, the interior surface of partition sheet 26 may be sealed by a coating applied thereto, as by spraying, from the opposite side of the wall. Liquid tar or other sealer may be used for this purpose. In the wall structure depicted in FIG. 5, insulating core material is used which is inert in respect to plumbing, electrical lines and the like, which may be embedded therein. As will be understood, in the wall constructed as shown in FIG. 5, the steel mesh and truss members carry the tensile load; the concrete skins, the compressive load; and the combination resists shearing forces. The core area is not relied upon for structural strength.
The inclusion of a second interior partition sheet 27, as optionally illustrated in FIGS. 2 and 3, permits the construction of a wall, as seen in FIG. 6, with two spaced-apart concrete skins 32 and 34 with a wholly open dead air space 31 in the core area of the wall. In this construction, concrete wall 32 is laid up against interior partition sheet 26, and wall section 34 is laid up against interior partition sheet 27 by any of the well known concrete-applying techniques. As a further alternative, not illustrated, form boards may be placed on opposite sides of the matrix panel, supported on apexes 18, and the wall poured solid. Other alternatives include the placing of form boards only at one side of the panel against apexes 18 and concrete applied from the opposite side of the panel to form either a thin wall section or a full solid wall. In any of the described structures, additional conventional reinforcing steel may be added.
In the form of the invention illustrated in FIGS. 1-6, the mesh sections 11 and 12 are mounted in substantially parallel planes and the truss members 13 are mounted in spaced parallel planes substantially perpendicular to the planes of sections 11 and 12. Also, the longitudinal truss members 23 and 24 are positioned in the planes of the truss members with the angularly related sides of the truss members bonded thereto, as above described. A modified form of the invention is illustrated in FIGS. 7-9, wherein truss members 13a are offset transversely from their longitudinal dimension at their points of connection to mesh sections 11a and 12a to provide what may be termed as a "double shear structure," that is, a structure which resists shear in two directions. Preferably, truss members 13a are fashioned with pointed apexes 18a at one side of their sinuous form and which may be bonded to longitudinal members 23a of one mesh section 11a. In this form of the invention, however, the trusses 13a do not proceed from apexes 18a in the same plane, but the two angularly related sides 16a and 17a, which extend from apexes 18a, diverge laterally to opposite sides of a symmetrical, central, longitudinal plane of the truss members. Accordingly, the opposite ends 36 of the sinuous truss members are offset from the longitudinal wires 24a of the opposite mesh section 12a and secured, as by welding, to the cross wires 37 of mesh section 12a. In this form of the invention, the two mesh sections may be offset, as seen in FIG. 9, so as to locate the ends 36 on cross wires 37. Preferably, wire ends 36 are flattened, as seen in FIGS. 7-9, to facilitate their location on and welding to cross wires 37. In this structure, the flattened wire ends 36 form truncated broadened foot portions with respect to the diverging truss sides connected thereto, and the foot portions are positioned medially on, and bonded to, one of the transverse wires 37, thus spacing the connected truss sides from the connected transverse wire 37. A partition sheet 26a may be pierced by apexes 18a and mounted on the angularly related sides of the truss members interiorly of the mesh section 11a in the same manner as the first-described embodiment and as is illustrated in FIGS. 7-9. Also, the double bonding of the angularly related sides of the truss members to longitudinal wire 23a adjacent apexes 18a is preferably effected as in the first-described embodiment.
While the matrix of the present invention will be typically used in the erection of concrete walls (including floors, ceilings and roof structures), it may also be used for the holding and reinforcing of other materials, such as, for example, adobe, which may be applied as hereinabove described. In such case, the interior partition seal may be of particularly importance in maintaining the wall integrity and waterproofing upon washing away of the exterior adobe skin. The term "cementitious material," as used herein, is intended to include adobe and like materials.
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A skeleton wall structure providing a form and matrix for building walls (both exterior and interior and including floors and ceilings) for providing a reinforced concrete or similar type structure.
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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 swimming pool wall system and is particularly directed to a novel sectional wall construction permitting quick assembly of wall components into a rigid unitary assembly.
Conventional known swimming pool constructions incorporate a plurality of wall panels secured together by directly joining abutting panel flanges through the use of securing means such as nuts and bolts or screws. Not only does this type of construction require considerable time for alignment and assembly of component parts but also the need for securing means necessitates the handling of a multiplicity of parts at the time of installation.
STATEMENT OF INVENTION
The present invention substantially obviates the foregoing disadvantages of conventional systems by providing a connector for joining together wall panels which aids the alignment of component parts and which is amenable to partial preassembly without the need of a great number of ancillary securing means. The connector assembly additionally provides the advantages of imparting lateral rigidity to the assembly, in order to counter lateral forces created by the water load contained in a swimming pool, if above ground, and to counter lateral forces from earth walls, if below ground, while providing support for a coping or deck structure.
In general, the sectional wall construction of my invention comprises in combination: a plurality of rectangular wall panels each having top and bottom edges and parallel side edges, a longitudinal flange formed along each side edge defining an acute angle with the plane of the panel, whereby said flanges diverge from each other to form an angle with each other when said panels are in alignment with or perpendicular to each other, and an elongated connector defining a pair of opposed converging faces adapted to receive said diverging flanges in abutment whereby said panels are rigidly connected together.
More particularly, the aforesaid connector can comprise an elongated post member having a pair of diverging slots formed along one side thereof adapted to form said opposed converging faces for receiving said flanges in abutment or a pair of elongated members each having an arcuate section and a planar section whereby said arcuate sections form opposed converging faces upon abutment of said planar sections upon each other for receiving said diverging flanges in abutment.
The wall construction includes novel aluminum or plastics copings adapted to seat on the wall top edge and to detachably secure a pool liner thereto.
BRIEF DESCRIPTION OF THE DRAWINGS
The construction of my invention is described in the accompanying drawings, in which:
FIG. 1 is an exploded perspective view, partly cut away, of an embodiment of my invention showing a first version of a coping;
FIG. 2 is a section through line 2--2 of FIG. 1;
FIG. 3 is a vertical transverse section of the connector shown in FIG. 1 illustrating another version of coping;
FIG. 4 is a perspective view of a wall incorporating the connector of FIG. 1;
FIG. 5 is a perspective view of another embodiment of connector of the invention;
FIG. 6 is a perspective view of the connector of FIG. 5 with corner coping members;
FIG.7 is a section of another version of coping;
FIG. 8 is a perspective view of a gusset; and
FIG. 9 is a section of still another version of coping.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference now to FIGS. 1-4 of the drawings, the embodiments of the wall construction of my invention illustrated comprise a plurality of wall panels 10 each having flanges 12 formed at each end defining an acute angle of about 30° to about 60°, preferably about 45°, to the plane of the wall panel, as shown most clearly in FIG. 2. Panels 10 are maintained in alignment in a common plane and are secured together by a connector 14 which comprises in the embodiment illustrated an elongated post member which may be rectangular in cross-section having a pair of diverging slots 16 formed along one side thereof at an angle of from about 120° to about 60°, preferably about 90°, with each other adapted to receive flanges 12 therein.
Panels 10 conventionally are formed of galvanized steel. Post members 14 can be formed of structural foam, such as of styrene or polyurethane by molding, or from extruded plastics such as polyvinyl chloride or acrylonitrile butadiene styrene.
A reinforcing gusset 18 formed integral with post 14 or separate from post 14 and secured thereto by rivets or screws 15 through flanges 20 provides lateral support and rigidity to post 14 and to the wall panels 10 secured thereto to accommodate the lateral loading from water contained in the swimming pool or from earth outside the swimming pool. The top edge of gusset 18 has T-flange 19 to receive a coping, to be described. Gusset 18 can be formed of roll-formed steel, aluminum or structural foam.
The top edge 21 of panel 10 can be slit 22 at equal intervals of about 15 cm and alternating sections 23 offset to form a projected recess 24 with remaining sections 25. Recess 24 can be used to receive front flange 26 of metal cap 28 adapted to seat on the top T-flange 19 of gussets 18. Rear flange 30 of cap 28 encloses the rear edge of gusset 18.
FIG. 1 illustrates a version of coping 32 which comprises an elongated extrusion of aluminum or a rigid plastics material such as polyvinyl chloride having a planar base 34, downwardly depending front flange 36 adapted to lap edge section 23, an arcuate section 38 depending upwardly from base 34 defining a recess 40 with base 34 for receiving the beaded edge 42 of vinyl liner 44, and a pair of opposed elongated ribs 46, 48 formed on base 34 and section 38, respectively, for receiving inter-connecting member 50 at spaced intervals along the length of coping 32 to provide rigidity thereto.
Coping 32 is secured to cap 28 by securing means such as screws or rivets 52.
FIG. 3 illustrates another version of coping 54. An aluminum or rigid plastics extrusion 56 having a planar base 58 is adapted to seat on cap 28 with downwardly depending front flange 60 adapted to lap edge section 23. Upwardly extending section 62 has forwardly depending ribs 64, 66 which define recesses 68, 70 respectively for receiving the beaded edge 42 of vinyl liner 44 in recess 68 and edge 72 of coping 54.
Coping 54 comprises an elongated extrusion of aluminum or rigid plastics having a rearwardly-inclined portion 74 with rounded front 76 and downwardly depending rear flange 78 adapted to overlie flange 30 of cap 28. A pair of ribs 80, 82 depending downwardly from the underside of top portion 74 abut cap 28 to provide rigidity to coping 54. Conventional securing means such as screws 84, 86 join coping 54 to cap 28 and to gusset 18. Screws 86 are seated in longitudinal recess 88 which is closed by strip 90 snap-fitted thereinto.
FIG. 4 shows a corner connection 92 in which corner panels 11 have oblique flanges 94 joined together by bolts 96 with flange 98 of arcuate member 100 welded perpendicular thereto gripped therebetween. Arcuate member 100 provides a rounded inner corner for support of the pool vinyl liner.
FIG. 5 illustrates a preferred embodiment of my invention in which panels 10 are connected together in planar alignment by connector 102 which consists of elongated metal member 104 having a planar section 106 and an integral arcuate section 107 with a reverse flange 108 formed along its free edge. Co-operating metal member 110 has a planar section 112 with arcuate section 114 and reverse flange 116 formed along its free edge. Members 104 and 110 are joined together by bolts 118 along planar sections 106, 112 whereby arcuate sections 107, 114 form opposed converging faces 120, 122 which engage diverging flanges 12 of panels 10. Panels 10 thus are locked together in planar alignment by converging faces 120, 122 engaging flanges 12 and reverse flanges 108, 116 abutting the outer surfaces of panels 10.
The corner connection is essentially established in like manner by connector 122 which comprises elongated metal member 124 having a planar section 126 and integral arcuate section 128. Co-operating metal member 130 having a planar section 132 and arcuate section 134 is secured to member 124 by bolts 136 whereby arcuate sections 128, 134 form opposed converging faces 138, 140 which engage diverging flanges 12 of panels 10. Panels 10 thus are locked together at right-angles to each other at the corner of the wall construction.
With reference now to FIG. 6, a corner cap 142 is illustrated for joining abutting copings together. Cap 142, formed of aluminum or a rigid plastics material, has a square outer corner 144 and a rounded inner corner 146 which is coextensive with arcuate member 100. Wings 150, 152 underlie the ends of adjoining copings and are secured thereto by bolts, not shown. A corner gusset 154 has a top flange 156 to which cap 142 is secured by bolts, not shown.
FIG. 7 illustrates another embodiment of coping 157 extruded from aluminum or a rigid plastics material. A pair of spaced flanges 158, 160 depending from the front edge of planar base 162 defines recess 164 which is adapted to receive the upper edge 166 of panel 10. If coping 157 is made of aluminum, a strip formed of an inert material such as polyvinyl chloride, not shown, should be inserted over edge 166 to preclude corrosion between steel panels 10 and the aluminum coping.
A recess 168 defined by upwardly extending arcuate section 170 with planar base 162 is adapted to receive the beaded edge 42 of a vinyl liner 44. Gusset 172 secured to post member 102 provides vertical support to coping 157. The coping embodiments of my invention shown in FIGS. 1 and 7 are intended to be used with concrete decks about in-ground installations.
FIG. 8 is a perspective view of the metal gusset 172 wherein main planar portion 190 is adapted to be secured to section 106 of member 104 by bolts or the like 103 and diagonal web 192 depending therefrom supports top flange 194.
FIG. 9 shows still another embodiment of coping 173 in which a pair of downwardly depending spaced flanges 174, 176 from planar base 178 define recess 180 which receives the upper edge 166 of panel 10. A recess 182 defined between upwardly extending arcuate section 184 and the front edge of planar base 178 is adapted to receive the beaded edge 42 of vinyl liner 44. Coping 173 is secured directly to gusset 186 by securing means such as screws, rivets or bolts 188.
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A swimming pool sectional wall construction having connectors permitting quick assembly of wall components into a rigid, self-aligning structure. Panels comprising wall components have longitudinal flanges formed along each side edge defining an acute angle with the plane of each panel whereby flanges on adjacent panel edges diverge from each other. A connector, having a pair of opposed converging faces adapted to receive said diverging flanges, secures the adjacent panels in tight-fitting abutment.
Novel copings seated on the wall top edge permits detachable securement of a post liner thereto.
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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 an original cover closing device employed for closing an original cover for use in a copy machine, a printing machine, or the like.
2. Related Art
In recent years, moldings of synthetic resins (plastic) are used as parts in every industrial machinery. The synthetic resins have so-called creep characteristics such that (1) when a predetermined force is continuously applied, deformation is advanced with elapse of time, and even if the force is stopped, the molding is not returned to the original state, (2) when a predetermined deformation occurs continuously, its repulsion is decreased with elapse of time, and (3) when time is further elapsed, the molding is destroyed. Among the synthetic resins, since zircon (polyacetal copolymer) has excellent mechanical characteristics including a creep resistance characteristic, it is used in various fields.
Consequently, zircon is also used for an original cover closing device. The following device using zircon is known.
There is an original cover closing device comprising: a supporting member made of zircon attached to the device body side; a spring case provided integrally with the supporting member; a slider housed in the spring case slidably to a cam part; and compression means constructed by a compression spring compressedly provided between the slider and the bottom of the spring case so as to press the slider to the cam side.
The attaching member and the supporting member made of zircon can be produced cheaper than those produced by press working iron plates and have an advantage that the members can be made in various forms. Although zircon has a high creep resistance characteristic among synthetic resins, when the members are used for many years, the following problems occur. A crack occurs especially on the bottom of the spring case and the bottom is fell out. The spring case is broken when a force is applied and broken pieces spread, and the like.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a closing device for an original cover, in which a spring case is not cracked or broken during use even when zircon by which especially the spring case can be cheaply manufactured and which has excellent mechanical characteristics is used.
In order to achieve the object, according to the invention, there is provided a closing device for an original cover, comprising a spring case made of a synthetic resin provided for either an attaching member attached to a machine body or a supporting member for holding an original cover rotatably connected to the attaching member via a hinge pin, and for controlling the rotation moment of the original cover attached to the supporting member by using the compression force of compression coil springs housed in the spring case, wherein a reinforcing frame member made of a metal for reinforcing the spring case which consists of a base plate portion for covering a bottom portion of the spring case, side plate portions bent from both ends of the base plate portion into a direction away from a plane of the base plate portion for covering both side portions of the spring case, and attaching holes opened at the side plate portions for connecting to the hinge pin. Thus, the reinforcing frame member is fastened to the spring case by inserting the hinge pin into the attaching holes.
According to the invention, there is also provided a closing device of an original cover, characterized by comprising: an attaching member attached to a machine body; a cam part mounted on the attaching member; a supporting member made of a synthetic resin which faces the cam part and supports an original cover rotatably connected to the attaching member via a hinge pin; a spring case made of a synthetic resin integrally formed with the supporting member and having a bottom portion and both side portions; a slider housed in the spring case slidably toward the cam part; a compression spring compressedly provided between the slider and the bottom of the spring case in order to press the slider toward the cam part; and a reinforcing frame member made of a metal for reinforcing the spring case and consisting of a base plate portion for covering a bottom portion of the spring case, side plate portions bent from both ends of the base plate portion into a direction away from a plane of the base plane portion for covering both side portions of the spring case, and attaching holes opened at the side plate portions for connecting to the hinge pin. Thus, the reinforcing frame member is fastened to the spring case by inserting the hine pin to the attaching holes.
According to the invention, there is further provided a closing device of an original cover, characterized by comprising: an attaching member serving as a leg to be attached to a machine body, provided in an upper part of a spring case made of a synthetic resin; a supporting member for supporting an original cover rotatably connected to the attaching member via a hinge pin; a cam part provided for the supporting member; a slider slidably housed in the spring case so as to face the cam part; a compression spring compressedly provided between the slider and the spring case in order to energize the slider to slide toward the cam part; and a reinforcing frame member made of a metal for reinforcing the spring case and consisting a base plate portion for covering a bottom portion of said spring case, side plate portions bent from both ends of the base plate portion into a direction away from a plane of the base plate portion for covering both side portions of the spring case, and attaching holes opened at the side plate portions for connecting to the hinge pin. Thus, the reinforcing frame member is fastened to the spring case by inserting the hinge pin to the attaching holes.
Other and further objects, features and advantages of the invention will appear more fully from the following description
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of an original cover closing device according to the invention;
FIG. 2 is a plan view of the original cover closing device shown in FIG. 1;
FIG. 3 is a side view of a partial cross section of the original cover closing device shown in FIG. 1;
FIG. 4 is a cross section taken on line 4--4 of the original cover closing device shown in FIG. 3;
FIG. 5 is a perspective view of a reinforcing frame member;
FIG. 6 is a side view showing another embodiment of the original cover closing device according to the invention;
FIG. 7 is a plan view of the original cover closing device shown in FIG. 6;
FIG. 8 is a sectional side view of the original cover closing device shown in FIG. 6;
FIG. 9 is a cross section taken along line 9--9 of the original cover closing device shown in FIG. 8; and
FIG. 10 is a perspective view of another embodiment of the reinforcing frame member.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following drawings show an embodiment of an original cover closing device A according to the invention. In FIGS. 1 to 5, reference numeral 1 denotes an attaching member having a leg 2. By detachably inserting the leg 2 into an insertion hole 3a opened in a rear upper end of the body of, for example, a copy machine shown by imaginary lines, the closing device is mounted on the machine body 3. Although a use example of the leg 2 is not shown in the diagram, for example, when an original is a thick original such as a book, by lifting the position of the insertion hole 3a to allow an original cover 4 shown by imaginary lines to cover the top face of the thick original in a horizontal state, it can be prevented as much as possible that external light enters an optical system of the machine body 3 and that internal light leaks to the outside. The attaching member 1 including the leg 2 are formed of a synthetic resin such as zircon and a cam part 5 is integrally formed on the attaching member 1.
Reference numeral 6 denotes a supporting member for supporting the original cover 4 having one end rotatably connected to the attaching member 1 via a hinge pin 7. The supporting member 6 is made of a synthetic resin such as zircon in a manner similar to the attaching member 1 and is formed integrally with a spring case 8 in a position facing the cam part 5. In the spring case 8, a slider 9 is slidably housed and a lever pin 10 attached to an end of the slider 9 comes into contact with the cam part 5. Compression means 13 comprising small and large coil springs 11 and 12 are compressedly provided between the slider 9 and the inner side of the bottom 8a of the spring case 8 to thereby always press the slider 9 to the cam part 5 side.
A reinforcing frame member 14 having an almost U- letter shape in cross section especially shown in FIG. 5 is attached to the outside of the spring case 8 so as to cover the outside of the bottom 8a. are coupled to the hinge pin 7. The reinforcing frame member 14 is made of a base plate portion 14a, side plate portions 14b, 14b bent from both ends of the base plate portion 14a to a direction away from a plane of the base plate portion and attaching holes 14c, 14c are opened in each end portions of the side plate portions 14b, 14b. In the member 14, a part which is in contact with the bottom 8a of the spring case 8 is made wider than the other parts to be adapted to a shape of the bottom 8a so as to cover the bottom 8a, an attaching hole 14d. The side plate portions 14b, 14b are fit on both side portions 8c, 8c of the spring case 8 and fastened or coupled to the hinge pin 7 by inserting the hinge pin 7 to the attaching holes 14c, 14c. A vis can be also used for this part.
The original cover closing device A according to the embodiment can be used by attaching the rear end of the original cover 4 to the supporting member 6 and by inserting the leg 2 of the attaching member 1 into the insertion hole 3a opened in the upper rear end of the machine body 3 as shown by imaginary lines in FIGS. 1 and 3. When the original cover 4 is opened/closed, the supporting member 6 rotates around the cam part 5 by using the hinge pin 7 as a fulcrum. Simultaneously, by a cooperative action of the cam part 5 and the slider 9 sliding on the circumferential face of the cam part 5 in a pressure contacting state, the original cover 4 is stably stopped and held at an intermediate open angle and is not naturally closed. As shown by the imaginary lines in FIG. 3, the original cover 4 is opened until the lever pin 10 of the slider 9 comes into contact with a stopper member 15.
When the original cover 4 is closed, the slider 9 which is in press contact with the cam part 5 slides in the direction of compressing the compression means 13. By the repulsion of the compression means 13, although the original cover 4 is not suddenly closed, the original cover 4 is energized in the closing direction. Consequently, the closing state of the original cover 4 is stable and occurrence of so-called a floating phenomenon which tends to occur when such compression means 13 is used can be prevented. The problem of the crack, coming off, and the like which tends to occur with long time of use on the bottom 8a of the spring case 8 is solved by reinforcing the spring case 8 by the reinforcing frame member 14 covering the outside of the bottom.
FIGS. 6 to 10 show another embodiment of the invention. In an original cover closing device B according to the embodiment, as an attaching member 21 is especially shown in FIGS. 6 and 8, for example, the leg attached to a machine body 22 side also serves as a spring case 23. A slider 24 is slidably housed in the spring case 23 and compression means 27 constructed by small and large coil springs 25 and 26 is compressedly provided between the slider 24 and the inner bottom of the bottom part 23a of the spring case 23.
Reference numeral 28 denotes a supporting member which is rotatably connected to the upper part of the attaching member 21 by a hinge pin 29. The supporting member 28 has a cam part 30 and the cam part 30 is in press contact with the slider 24. Reference numeral 35 is a lever pin which is actually in press contact with the cam part 30.
In the original cover closing device B according to the embodiment, as shown in FIGS. 6 to 8, the rear end of an original cover 31 shown by imaginary lines is attached to the supporting member 28 and a reinforcing frame member 32 having an almost U-letter shape in cross section is fit to the outside of the spring case 23 so as to cover the bottom 23a. The reinforcing frame member 32 is made of, for example, stainless steel. The reinforcing frame member 32 is made from a base plate portion 32a, side plate portions 32b, 32b bent from both ends of the base plate portion 32a to a direction away from a plane of the base plate portion, attaching holes 32c, 32c are opened in each end portions of the side plate portions 32b, 32b, and an attaching hole 32d is opened in a part covering the bottom portion 23a.
Both side plate portions 32b, 32b of the reinforcing frame member 32 are inserted into insertion holes 23c, 23c opened on both side portions 23b, 23b of the spring case 23. The base plate portion 32 fixed to bottom portion 23a of the spring case 23 by an attaching vis 36 through the attaching hole 32d. The side plate portions 32b, 32b is fit on side portions 23b, 23b of the spring case 23 and fastened or coupled to the hinge pin 29 by inserting the hinge pin 29 to the attaching holes 32c, 32c.
When the original cover 31 is opened, the supporting member 28 rotates around the hinge pin 29 as a fulcrum and the original cover 31 is stably stopped and held at an intermediate open angle by a cooperative action of the cam 30 and the slider 24 which slides in a press contact state to the cam part 30. The end 28a of the supporting member 28 comes into contact with a stopper member 33 attached to the upper part of the attaching member 21 by an attaching vis 34, thereby regulating the maximum open angle of the original cover 31.
In case of closing the original cover 31 as well, the original cover 31 is not suddenly closed by the cooperative action of the cam part 30 and the slider 24. The crack and breakage occurring on the bottom of the spring case 28 by the compression member 27 which repeats expansion and contraction with repetition of the opening/closing operation of the original cover 31 is prevented by the reinforcing frame member 32.
Having described our inventions as related to the embodiment shown in the accompanying drawing, it is our intention that the invention be not limited by any of the details of description, unless otherwise specified, but rather be construed broadly within its spirit and scope as set out in the accompanying claims.
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In order to provide a closing device for an original cover in which a spring case is not cracked or broken during use even if zircon by which the spring case can be cheaply manufactured and which has excellent mechanical characteristics is especially used, the closing device has the spring case made of a synthetic resin provided for either an attaching member attached to a machine body or a supporting member for holding the original cover rotatably connected to the attaching member via a hinge pin and the rotation moment of the original cover attached to the supporting member is controlled by using a compression force of a compression coil spring housed in the spring case, wherein a reinforcing frame member made of a metal for reinforcing the spring case is attached to the spring case.
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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 security devices and, more particularly, to a plug for blocking transmission through a door viewer from a light source.
2. Description of Related Art
For security purposes, and, more particularly, to determine the identity of a person seeking to enter a building, door viewers of various types have been developed. These door viewers generally include a lens system for providing to a person on the inside a wide angle view to the outside. Thereby, the person on the inside has an opportunity to view and identify a person(s) seeking entry prior to permitting entry by opening the door. Generally, the commercially available door viewers for this purpose are adequate in providing the results sought.
The lens system in commercially available viewers does not permit a person outside to view with any clarity a person or features of the room inside the door. However, the door viewer does transmit light from the inside to the outside. If there is no light source optically aligned with the door viewer, ambient light is transmitted through the door viewer from the inside to the outside. In such event, the intensity of the light transmitted is essentially unaffected by a person on the inside looking through the viewer from a short distance removed therefrom. However, if a light source is optically aligned with the door viewer, any blockage of light from such light source to the door viewer will reduce the intensity of the light transmitted through the door viewer. Thus, a person on the outside can readily determine, by the change in light intensity emanating from the door viewer, that a person is present inside in proximity to the door viewer. While it is impossible for the inside person to be recognized due to the optics of the door viewer, the person on the outside will know that a person is inside the building. This information can be used by a thief or burglar as part of the decision making process of whether to burglarize or break into the building. There have also been reported instances of a thief or burglar injuring the person on the inside by driving an icepick or the like through the door viewer when the person on the inside was looking through it, as would be evident by the change in light intensity emanating from the door viewer.
There are available lenses which can be used in conjunction with a conventional commercial door viewer that permit a person from the outside to view with clarity the surroundings on the inside of the door. Thus, the privacy intended by a commercially available viewer is compromised. Such compromise and effect thereof is of particular concern in commercial establishments, such as motels and hotels which have door viewers and wherein the occupants are generally viewable as their activities are normally conducted within the room into which the door opens. Moreover, for a person with criminal intentions the opportunity to view and assess the nature of the occupants prior to committing a criminal act may be of significant benefit and to the detriment of the occupants.
Conventional commercially available door viewers permit transmission of light from the exterior to the interior space of a room into which the door opens. This light transmission will vary from intermittent, partial or complete blockage of light entering the door viewer as persons walk by on the outside. The resulting flickering seen on the inside of a door viewer may be particularly disturbing to a motel or a hotel guest who has turned out the lights and is trying to sleep.
SUMMARY OF THE INVENTION
The present invention is directed to a portable or permanently installed blockage for precluding light transmission through a door viewer from the inside to the outside. Furthermore, during daylight conditions, removal of the blockage for purposes for of using the viewer will not provide an indication of whether a viewer on the inside is looking through the door viewer.
It is therefore a primary object of the present invention to provide a portable blockage for precluding light transmission through a door viewer.
Another object of the present invention is to provide a demountable blockage for a door viewer which is attached to the door viewer.
Still another object of the present invention is to provide a selectively usable blockage attached to a door viewer for selectively blocking light transmission through the door viewer.
Yet another object of the present invention is to provide an inexpensive portable or permanently mounted plug for use with a door viewer.
A further object of the present invention is to provide a selectively removable plug for use with a conventional door viewer.
A still further object of the present invention is to provide a plug removable from the inside of a door viewer which does not signal use of the door viewer to a person on the outside.
A yet further object of the present invention is to provide a method for selectively controlling light transmission through a door viewer.
These and other objects of the present invention will become apparent to those skilled in the art as the description thereof proceeds.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be described with greater specificity and clarity with reference to the following drawings, in which:
FIG. 1 illustrates the present invention attached to a conventional door viewer mounted in a door;
FIG. 2 is a partial cross-sectional view of the present invention mounted in a door viewer; and
FIG. 3 illustrates use of the present invention while precluding an indication to a person on the outside that the door viewer is being used by a person on the inside.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring jointly to FIGS. 1 and 2, there is shown a conventional door viewer 10 mounted within a door 12 . Usually, the door is the front door of a dwelling or the door to a hotel or motel room. The door viewer has essentially three components. The first component is a cylinder 14 having an annular flange 16 for abutting engagement with outside surface 18 of door 12 . The interior of cylinder 14 includes a lens system 20 , representatively depicted by lenses 21 and 22 . The lens system provides a wide angle view of the area outside of door 12 and essentially distorts the view through the door viewer from the outside into the space behind the door. A sleeve 30 including an annular flange 32 is essentially hollow. The interior of sleeve 30 includes threads 34 for threaded engagement with threads 36 on the exterior of cylinder 14 . With such threaded engagement between the cylinder and the sleeve, a range of widths of door 12 can be accommodated.
A plug 40 , which may be in the shape of a truncated cone, as illustrated, is demountably mounted within hollow end 42 of door viewer 10 . Following such mounting, transmission of light through the door viewer from a location outside of door 12 is precluded. As particularly shown in FIGS. 1 and 3, plug 40 is readily mounted in or demounted from engagement with the door viewer.
To insure accessibility of plug 40 and to minimize the likelihood of loss or misplacement, the plug may be attached to the door viewer through a lanyard 44 or the like. As shown, the lanyard may be a chain 46 of metallic material or of manmade material. The lanyard may be attached to a cap 48 , which cap receives and retains one end of plug 40 .
The other end of lanyard 44 may be attached to door viewer 10 by use of attachment means, such as a cord or a wire 50 , secured to and extending from the lanyard. As discussed above, sleeve 30 is in threaded engagement with cylinder 14 . To assist in threading and unthreading the sleeve, a pair of diametrically opposed slots 52 , 54 may be formed in annular flange 32 . These slots can be engaged by a coin or the like to provide a grip for rotating the sleeve. Upon rotation of the sleeve in one direction, such as counterclockwise, the sleeve will be urged to translate away from the door and provide a space between annular flange 32 and interior surface 38 of the door. By wrapping a section of the attachment means, such as wire 50 , about the sleeve adjacent annular flange 32 , and thereafter rotating the sleeve in a clockwise direction, wire 50 will become captured between annular flange 32 and surface 38 of the door. Thereby, plug 40 and its attached lanyard 44 will remain in proximity with door viewer 10 when the plug is not engaged with the door viewer and loss or misplacement is essentially eliminated. Because of this simple mode of attaching plug 40 , it can be temporarily attached at temporary abodes of the user, such as hotel room and motel room doors. To disengage plug 40 and its attached lanyard 44 , the above described process can be reversed to release wire 50 from between annular flange 32 and surface 38 of door 12 .
One of the optical characteristics of a conventional door viewer of the type illustrated in FIGS. 1 and 2 is that blockage of a source of light transmitting light directly through the door viewer can be detected by a person outside of the door. However, when ambient light interior of the door is the only light transmitted through the door viewer, no or little change in intensity of the light transmitted is detectable if a person were to place one's head in position to look through the door viewer from the inside to the outside.
As shown in FIG. 3, it is assumed that a source 60 of light would transmit light directly through door viewer mounted within door 12 . In such event, if a person 62 were to look through the door viewer, the transmission of light from source 60 would be blocked. The resulting change in intensity of light detectable by a person 64 outside of door 12 would provide an indication of the presence of person 62 .
The present invention is particularly suited to avoid such indication of the presence of a person 62 . When a person 62 decides to look through door viewer 10 , the person would block direct light transmission from source 60 through the door viewer and only ambient light would be available for transmission through the door viewer. When in such position, person 62 would remove plug 40 from the door viewer. The resulting light transmitted through the door viewer would not change as a function of movement of person 62 unless such person's movements would result in transmission of light directly from source 60 . That is, only ambient light would be transmitted through the door viewer and the intensity of such ambient light would remain essentially constant despite some movement of person 62 . Thus, a person 64 on the outside of door 12 would not be aware of whether person 62 was or was not looking through the door viewer and hence the presence of person 62 would be unknown.
While the invention has been described with reference to several particular embodiments thereof, those skilled in the art will be able to make the various modifications to the described embodiments of the invention without departing from the true spirit and scope of the invention. It is intended that all combinations of elements and steps which perform substantially the same function in substantially the same way to achieve the same result are within the scope of the invention.
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A conventional commercial door viewer includes a lens at one end for providing a wide angle view and a hollow end through which a person would look. A truncated cone shaped plug fits within the hollow end to block light transmission through the door viewer. The plug is readily manually removable to use the door viewer and includes a removable lanyard to tether the plug in proximity to the door viewer.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
The invention relates to a system for securing a rail to a level solid ground, including a guide plate, for providing lateral support for the rail to be secured, a spring element supported on the guide plate and having at least one spring arm exerting an elastic retaining force on the base of the rail, and tensioning means for tensioning the spring element, a support angle being provided, which is connectable to the solid ground and which has a bearing surface against which the guide plate rests on the side facing away from the rail base. Such a system is known from WO 2007/082553 A1.
Solid ground, like base plates, concrete railroad sleepers or ties or the like, on which systems according to the invention are mounted is also referred to as “slab track systems”. Unlike a railway superstructure formed from loose ballast, they normally do not have any inherent compliance. Slab track systems are typically formed by concrete slabs, onto which sleepers also cast from concrete may be laid, which in turn support the rails.
Lateral support of the rails on such a solid ground is, as a rule, provided by means of support facilities positioned on both sides of the rail base between the rail base and respective stops which are each positioned at a lateral distance from the rail base. To this end, the stop is commonly moulded on to the respective solid ground in the form of a support shoulder or the like.
Thus, the concrete sleepers typically used for securing rails to a permanent railway include, as a rule, lateral stop shoulders against which the guide plates intended for laterally guiding the respective rail come to bear. These guide plates are directly fastened either to the solid ground or to the respective sleeper by means of suitable fastening elements, as a rule, screw-bolts. In practice, a system of this kind is known under the designation “System 300”.
Usually, the fastening elements are additionally used for tensioning a spring element which exerts a retaining force onto the rail base of the rail to be secured, which is oriented in the direction of the solid ground. Depending on the shape of the ground and the fastening means used, additional spacer and fastening means for a correct orientation and retention of the rails are required.
On railway surfaces which are formed to be level, i.e. do not provide any stop shoulders for laterally supporting the guide plates, fastening systems of the kind described above can not be used.
According to the state of the art disclosed in WO 2007/082553 A1 this problem has been solved in that a support angle is provided for the lateral support of the guide plate required in each case for laterally guiding the rail, which support angle may be bolted to the solid ground and has a bearing surface, against which the guide plate is supported on the side facing away from the rail base. In operation, the support angle will receive the transverse forces emanating from the rail and transmitted by the guide plate. Thus, the support angle enables a fastening system to be mounted on a level surface in a simple manner, without there having to be formed a special stop shoulder or the like. However, in practical use it turns out rather laborious to assemble the support angles which as a rule are made from a steel material.
SUMMARY OF THE INVENTION
Against this background, it is the object of the invention to provide a system for securing rails, which allows an optimally secure support of the rail on level solid ground, whilst being easy to handle.
According to the invention, this object is achieved by means of a system characterised as set out in claim 1 . Advantageous embodiments of this system are set out in the claims dependent on claim 1 .
According to the invention the support angles used in a system as referred to in the outset and disclosed in WO 2007/082553 A1 are manufactured from a plastic material. Surprisingly it turns out that although support angles made from a plastic material have a lower capacity for absorbing forces such support angles suffice to support a guide plate against the transverse forces emanating during practical use.
The support angles provided according to the invention allow a transmission of the forces occurring during operation, which is particularly kind to the material, via the respective fastening into the solid ground. In addition to that by the use of support angles made from plastic it can be avoided that current linkages occur between the rail and the solid ground on which the rail is fixed. Moreover, the use of a plastics material for manufacturing the support angle allows a considerable weight reduction to be achieved.
As a plastic material for the manufacture of support angles for example a polyolefin or a polyamide may be used.
The support angle may be provided with reinforcement ribs able to safely receive the forces occurring during operation.
The strength of the support angle manufactured of plastic material in accordance with the invention may be further enhanced if the plastics material includes reinforcement fibres.
A particularly good transmission of the forces received by the respective support angle onto the solid ground may be achieved, without any particular preparation of the ground being required for this purpose, by integrally forming into the contact surface of the support angle, which is associated with the surface of the solid ground, a grooved rough structure. The rough structure may preferably be formed to have a serrated cross-section, in order to transmit the respective transverse forces into the ground in a particularly safe manner. To this end, linear indentations extending parallel to the bearing surface may be integrally formed into the contact surface of the support angle.
Alternatively or additionally to a purposeful roughening of the contact surface of the support angle, which is associated with the solid ground, an intermediate layer may be provided, which is positioned between the contact surface of the support angle and the surface of the solid ground and which enhances the friction coefficient between the contact surface of the support angle and the surface of the solid ground. In order to simplify its mounting operation as much as possible, the intermediate layer may be firmly connected to the contact surface of the support angle already during prefabrication of the support angle.
For bolting the support angle to the solid ground, the support angle may include a through-opening for a fixing bolt. A particularly simple mounting procedure, which can preferably be carried out automatically, may be achieved by providing a tensioning element made from an elastic plastics material, which in the mounting condition exerts a return force on the bolt inserted in the through-opening, which return force acts against the clamping force applied by the bolt. This tensioning element is preferably retained in a captive manner directly in the respective through-opening. If such a tensioning element is used, the spring washers which are usually used for tensioning the elements of the known fastening systems and which are often cumbersome to handle, are no longer necessary.
In order to be able to adapt the position of a support angle used according to the invention to the position of the rail or to the guide plate usually present between the rail and each support angle in a simple manner, means may be provided on the support angle, which allow the support angle to be fastened in a position relative to the rail to be secured, in which the bearing surface of the support angle is oriented at an angle to the longitudinal axis of the rail. These adjustment means may be formed by two through-openings integrally formed in the support angle, through each of which a fixing bolt may be inserted such that the distance of one bolt from the bearing surface of the support angle is different to that of the other bolt.
Also, in order to allow a simple adaptation of the position of a support angle used according to the invention to the respective position of the rail or the guide plate, it may be advantageous to provide the support angle with means for adjusting its position in a direction normal to the bearing surface. In practice, these means may be realised for example as an eccentric bush or a toothed disk, which may each be made from plastics.
Another possibility for compensating any manufacturing or mounting inaccuracies of the alignment between the support angle and the rail or the guide plate, which is particularly suitable in practice, is to support the guide plate against the bearing surface of the support angle via a wedge element tapered in the longitudinal direction of the rail to be secured. The provision of such a wedge element between the guide plate and the support angle allows even larger misalignments between the support angle and the guide plate to be compensated, without a specially adapted guide plate being required for this purpose. Rather, in this embodiment of the invention, compensation is carried in each case solely by displacing the wedge element.
In this regard, an essential advantage of the invention is that the guide plate may be fabricated consistently having a uniform wall thickness. This not only results in a minimum weight, but also allows a particularly uniform transmission of the forces received by the guide plate into the wedge element and from there onto the support angle. As a result of this uniform loading, the guide plate may be designed with a particularly small size and with a reduced weight.
In order to ensure an optimal bearing of the support angle and the guide plate on the wedge element, the wedge element should have a first bearing surface associated with the guide plate and a second bearing surface associated with the support angle, which second bearing surface forms an acute angle with the first bearing surface.
Practical experiments have shown that a particularly good effect of a wedge element used according to the invention may be achieved if the bearing surfaces form an angle of 5° to 15°.
Secure retention of the wedge element in the position set in each case during the mounting operation may be achieved if the bearing surface associated with the guide plate has at least one projection and/or recess which may be positively coupled with at least one correspondingly shaped projection and/or recess formed on the bearing surface of the guide plate, which is associated with the respective bearing surface of the wedge element. Preferably, more than one projection and/or recess is provided on the bearing surface associated with the guide plate. By mounting the guide plate and the wedge element in a positively meshing manner whilst tightening the guide plate against the solid ground, the positive coupling of the wedge element and the guide plate is combined with the connection effected by the tensioning force exerted on the wedge element by the guide plate, so that any inadvertent release of the connection between the wedge element and the guide plate is prevented.
In this connection, particularly favourable properties of use of a system according to the invention are achieved if in the mounting condition of the wedge element, the projections and/or recesses extend parallel to the top surface of the level solid ground.
The effectiveness of applying the retention force transmitted by the guide plate onto the wedge element may be enhanced by providing the guide plate with a projection resting, in the mounting position, on the free top surface of the wedge element.
If a positioning of the rail at a certain angle is required for the safe guidance of the respective rail vehicle on the rail to be secured by means of the system according to the invention, then this may be realised with the system according to the invention by means of providing a base plate, by means of which the rail to be secured may be supported on the solid ground, this base plate being provided with a bearing surface associated with the solid ground and a support surface associated with the bottom surface of the rail base of the rail to be secured, and the support surface is oriented, viewed in cross-section, inclined at an angle relative to the contact surface.
Particularly in the case where a base plate is provided, a projection may be formed on that side of the guide plate, which is associated with the rail to be secured, which projection engages with the base plate or the rail base, when in the mounting condition. This projection prevents in a particularly safe and yet simple manner a lifting off of the guide plate under unfavourable operating conditions. In the case where an elastic intermediate layer is provided, on which the base plate rests in the fully mounted condition of the system according to the invention, a recess may be formed on the intermediate layer for this purpose, which in the mounting position is engaged by the projection.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be explained in more detail by means of drawings showing an embodiment example, wherein:
FIG. 1 shows a top view of a system for securing a rail;
FIG. 2 shows a partially sectioned front view of the system shown in FIG. 1 ;
FIG. 3 shows a top view of a support angle used in the system shown in FIG. 1 ;
FIG. 4 shows a partially sectioned perspective view of the support angle according to FIG. 3 ;
FIG. 5 shows an enlarged view of section A of FIG. 2 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
System 1 for securing a rail 2 on solid ground 3 formed by a concrete slab comprises an elastic intermediate plate 4 resting directly on the continuously plane surface 5 of the solid ground 3 .
On the intermediate plate 4 lies a base plate 6 made from steel, which covers the intermediate plate 4 and distributes in practical operation the loads acting on the base plate 6 via the rail 2 , which are caused by a rail vehicle (not shown) driving over the rail 2 , onto the intermediate plate 4 .
A further intermediate plate 7 is placed on the base plate 6 , the width of which corresponds at most to the width of the rail base 8 of the rail, which stands with its bottom surface on top of the intermediate layer 7 .
In order to adjust any required inclination of the rail 2 relative to the plane surface 5 of the solid ground 3 , the base plate 6 may have a wedge-shaped cross-section, with the top surface associated with the rail base 8 forming an acute angle with the bottom surface of the base plate 6 , which is associated with the intermediate plate 4 .
To provide lateral support for the rail 2 against transverse forces occurring whilst a vehicle travels thereon, a guide plate 9 , 10 is provided on either side of the rail base 8 . Each of the guide plates 9 , 10 has a support surface 11 bearing against the rail base 8 and stands through corresponding support portions 11 a on the plane surface 5 of the solid ground 3 .
On its bottom portion adjacent to the surface of the solid ground 3 , a cam-type projection (not shown here) may be formed onto the support surface 11 of the guide plates 9 , 10 , which projects into a correspondingly shaped recess (also not shown here) of the elastic intermediate plate 4 and engages behind the base plate 6 . In this way, the respective guide plate 9 , 10 is positively retained in a vertical direction, so that any lifting off of the guide plates 9 , 10 from the ground 3 is securely prevented even in the case of any in this respect adverse longitudinal forces FL or transverse forces FQ occurring.
On their free top surfaces, the guide plates 9 , 10 have forming elements shaped in a manner per se known, each of which form a guide for one w-shaped tensioning clamp 12 , 13 , respectively, serving as a spring element for tensioning the rail 1 to the solid ground 3 . For tensioning the tensioning clamps 12 , 13 , tensioning means in the form of bolts 14 , 15 are provided, which are screwed into a dowel (not shown here) inserted into the solid ground 3 . During this process, the bolts 14 , 15 bear, via the bolt head, on the centre portion of the tensioning clamps 12 , 13 in a manner per se known, so that the tensioning clamp 12 , 13 exerts the required spring-elastic retention force onto the rail base 8 via the free ends of its arms, which rest on the top surface of the rail base 8 .
The lateral support of the guide plates 9 , 10 is effected by means of a wedge element 16 , 17 against a support angle 18 , 19 , respectively.
Each of the wedge elements 16 , 17 has, viewed from the top, basically a triangular shape and in the mounting position, their bearing surface 20 extends parallel to the rail 2 forming an acute angle α 1 (viewed from the top) of 5 to 15° with that bearing surface 21 that is associated with the respective support angle 18 , 19 .
At the same time, the bearing surface 20 is inclined relative to the vertical in such a way that the bottom contact surface 22 associated with the solid ground 3 is wider than the free top surface 23 of the wedge elements 16 , 17 .
Associated with the bearing surface 20 of the wedge elements 16 , 17 is in each case a bearing surface 24 of the respective guide plate 9 , 10 , which is oriented parallel to the rail 2 and is inversely inclined. The bearing surface 20 of the wedge elements 16 , 17 and the bearing surface 24 of the guide plates 9 , 10 each have formed therein indentations 25 , 26 and projections 27 , 28 , which respectively correspond to each other and which extend linearly across the width of the respective surfaces 20 , 24 in such a way that the projections 27 of the respective wedge element 16 , 17 engage in the indentations 26 of the respective guide plate, and vice versa.
In this way, a positive coupling of the wedge elements 16 , 17 with the respective guide plate 9 , 10 is achieved. The friction created in the area of this positive coupling due to the clamping forces exerted on the guide plates 9 , 10 by the respective bolt 14 , 15 is so great that self-locking occurs and any inadvertent movement of the wedge elements 16 , 17 out of their mounting position will be securely prevented even in the presence of great transverse forces.
Clamping of the guide plates 9 , 10 against the respective wedge element 16 , 17 is further enhanced in each case by a loading section 29 projecting in the direction of the respective wedge element 16 , 17 , which loading section 29 is formed on the respective guide plate 9 , 10 in the area of the transition from its bearing surface 24 to its top surface. The loading section 27 is formed and designed in such a way that, in the case of fully mounted and clamped guide plates, it exerts a compression force P on the respective wedge element 16 , 17 .
In order to simplify the correct orientation of the wedge elements 16 , 17 relative to the guide plates 9 , 10 associated therewith, markings 28 are provided on the wedge elements 16 , 17 and the guide plates 9 , 10 , which facilitate easy reading of the respective relative position.
The support angles 18 , 19 are in each case made in one piece from a fibre-reinforced plastics material. They have a support surface 31 resting against the bearing surface 21 of the wedge element 16 , 17 respectively associated therewith, the height of which is greater than the height of the wedge elements 16 , 17 . The support surface 31 is formed on the free front side of a support portion 32 of the support angles 18 , 19 , which is oriented at a right angle to a base portion 33 of the support angle 18 , 19 , which rests on the surface 5 of the solid ground 3 .
Opposite the base portion 33 , the support portion 32 is supported against the base portion 33 by means of three triangular (in a lateral view) stiffening portions 34 , 35 , 36 extending therefrom essentially at right angles, the free top surface of which extends from the top surface of the support portion 32 obliquely downwards. Of the stiffening portions 34 , 35 , 36 , one each is formed on either outer edge, respectively, and the other is formed in the centre of the support angles 18 , 19 .
In the area of the free spaces remaining between the stiffening portions 34 , 35 , 36 , a through-opening 37 , 38 , respectively, is formed in the base portion 33 of the support angles 18 , 19 . The distances of the centre points of these through-openings 37 , 38 from the support surface 31 of the support angles 18 , 19 are so different from each other that the connecting lines of the centre points of the through-openings 37 , 38 form an acute angle α 2 (viewed from the top) with the support surface 31 , which has the same dimension as the angle α 1 formed by the bearing surface 21 and the bearing surface 20 of the wedge elements 16 , 17 . In this way, the respective support angle 18 , 19 may be readily secured by means of two dowels (not shown here) inserted into the solid ground 3 and positioned along a line extending parallel to the rail 2 , in such a way that its support surface 31 bears positively against the bearing surface 21 of the respective wedge element 16 , 17 , which is associated therewith.
The contact surfaces of the support angles 18 , 19 , which are respectively formed on the bottom surface of the base portion 33 , are each coated with a friction resistance-enhancing layer 39 . This may be made from a rubber material which may be vulcanised directly onto the base portion 33 , in order to simplify the mounting operation as much as possible, or may be placed as a loose intermediate layer between the respective support angle 18 , 19 and the solid ground 3 as late as during the mounting operation itself.
Each of the through-openings 37 , 38 has associated therewith a socket 40 which is circular as viewed from the top and which is integrally formed into the top surface of the base portion 33 and the centre point of which is in alignment with the centre point of the through-openings 37 , 38 . Each of the sockets 40 accommodates a ring serving as a tensioning element 41 , 42 , which is made from a spring-elastic plastics material. The height of the rings 41 , 42 is dimensioned such that in the pre-mounted condition, the rings project beyond the perimeter of the respective socket 40 .
For mounting the support angles 18 , 19 , one bolt 43 , 44 , respectively, is inserted in the through-openings 37 , 38 and is screwed into the dowels (not shown here) beneath. As soon as the bolt head rests on the elastic rings 41 , 42 , any further screwing in will result in the rings 41 , 42 being compressed, so that they exert an elastic return force acting against the clamping force exerted by the respective bolt 43 , 44 . This ensures secure retention of the bolts 43 , 44 and the support angles 18 , 19 even under adverse conditions.
In order to securely fill the space present between the respective guide plate 9 , 10 and the support surface 31 of the support angle 18 , 19 respectively associated therewith, the wedge elements 16 , 17 which are each located between the respective support angle 18 , 19 and the respective guide plate 9 , 10 may be displaced along the rail 2 . To this end, the bolt 14 , 15 clamping the respective guide plate 9 , 10 against the solid ground 3 is released to such a degree that the self-locking in the area of the positive coupling of the respective wedge element 16 , 17 and the respective guide plate 9 , 10 is released and the respective wedge element 16 , 17 may be displaced. As soon as it rests positively on both sides against the bearing surface 31 of the respective support angle 18 , 19 and the bearing surface 24 of the respective guide plate 9 , 10 , the respective fixing bolt 14 , 15 is re-tightened, until the respective tensioning clamp 12 , 13 exerts the required retention force onto the rail base 8 and—in connection therewith—the self-locking condition between the respective wedge element 16 , 17 and the respective guide plate 9 , 10 is restored.
In this way, a particularly simple adaptation of the fastening system 1 to the respective relative position of the rail 2 and the support angles 18 , 19 may be achieved without having to dismantle the system 1 into its individual components.
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The invention relates to a system for securing a rail, including a guide plate for providing lateral support for the rail to be secured, a spring element supported on the guide plate and having at least one spring arm exerting an elastic retaining force on the base of the rail, and tensioning means for tensioning the spring element. Such a system allows an optimally secure support of the rail even in the case of a level ground having no indentations or stop shoulders, whilst being easy to handle and having only a small number of components to be mounted in each case, by providing a support angle which may be connected to the solid ground and which has a bearing surface against which the guide plate rests on the side facing away from the rail base. According to the invention the support angles are made from a plastic material, in order to facilitate assembly and improve the function of the support angles in practical use.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
[0001] A recent development in the oil and gas exploration and production industry has been the adoption of expandable bore-lining tubing. This involves running tubing into an open section of bore and then expanding at least a portion of the tubing to a larger diameter. Typically, the upper end of the tubing will overlap the lower end of existing bore-lining casing or liner. In a number of proposals, the upper end of the tubing is expanded initially to create a tubing hanger which serves to fix the tubing in the bore so that the tubing may be disengaged from the running string used to carry the tubing into the bore. Other operations, such as cementing the tubing, or expanding other portions of the tubing, may then take place.
[0002] The present applicant has identified that there are certain difficulties involved in creating the initial anchor, particularly in previously cemented tubing. A number of existing proposals suggest the use of radially extendable members for radially extending circumferentially spaced portions of the tubing, to bring the outer surfaces of these portions into engagement with the surrounding casing. However, in any such deformation of metallic tubing, there is a degree of elastic recovery of the tubing once the deforming force has been removed. Thus, the desired degree of engagement between the tubing and the casing may not be achieved.
Field of the Invention
[0003] This invention relates to tubing anchors. In particular the invention relates to an apparatus and method of anchoring one tubing within another, most particularly at a downhole location.
SUMMARY OF THE INVENTION
[0004] According to a first aspect of the present invention there is provided a method of anchoring tubing in a bore, the method comprising:
[0005] providing tubing having a section having outer surface portions defining a tubing profile, the outer surface portions configured to describe an outer diameter less than a first diameter;
[0006] locating the tubing within a bore having an internal diameter equal to the first diameter, and defining a bore profile; and
[0007] reconfiguring the tubing section such that the tubing profile engages with the bore profile.
[0008] Preferably, the tubing profile defines a radially extending surface and the bore profile defines a cooperating radially extending surface. The tubing profile may be a radial projection and the bore profile a radial recess.
[0009] Preferably, the tubing profile is defined by a plurality of radial projections and the bore profile a one or more of radial recesses. Alternatively, the tubing profile may be a circumferential rib.
[0010] In an alternative embodiment the bore profile may be defined by one or more radial projections and the tubing profile by one or more radial recesses. Conveniently, the bore profile may be a circumferential rib and the tubing profile a circumferential channel.
[0011] When the tubing section is reconfigured, the outer surface portions are moved radially outwardly such that the tubing profile may engage with the bore profile, securing the tubing in the bore. Further reconfiguration of the tubing section may bring further parts of the outer surface portions into contact with the bore, which will further assist in securing the tubing in the bore.
[0012] The method of the invention thus provides a convenient method of creating a coupling between a tubing and a surrounding bore wall, which coupling may be utilised to fix the tubing relative to the bore, both axially and rotationally, to facilitate subsequent operations, such as further reconfiguration or deformation of the tubing, or cementation of the tubing in the bore. The outer surface portions of the tubing may be circumferentially spaced, and most preferably are regularly spaced around the circumference of the tubing. Alternatively, the outer surface portions may be defined by a substantially continuous arc or segment. The tubing may initially be circular and in this initial form preferably has an outer diameter at least as large as the first diameter. Portions of the initially circular tubing wall may be reconfigured to a generally planar form such that the tubing is then substantially polygonal, most preferably defining a pentagon or hexagon. The tubing may then be further reconfigured such that the planar tubing wall portions become convex, and are located between the outer surface portions, which describe the tubing maximum diameter, which is less than said first diameter. The tubing may then be passed into the bore. Alternatively, one or more indents may be formed in the tubing wall, to create one or more convex wall portions such that the tubing defines an outer diameter less than said first diameter. Of course the tubing may be initially created in this form, if desired.
[0013] If a radially outwardly directed force is then applied to the one or more convex wall portions, which will typically describe the tubing section minimum diameter, the outer surface portions are urged radially outwards to assume a configuration in which at least the tubing profile and the bore profile can engage.
[0014] The provision of one or more convex wall portions facilitates passage of fluid between the tubing section and the surrounding bore, both before and after reconfiguring the tubing section, and even after the tubing section is restrained in the bore, which may be particularly useful if the first tubing is to be cemented in the bore. If desired, the tubing may subsequently be sealed to the bore wall by, for example, reconfiguring the tubing section to a form corresponding to the bore wall or, most preferably, by configuring another section of the tubing to a form corresponding to the bore wall. Most preferably, sealing the tubing with the bore wall is achieved by expanding a section of the tubing, which section may include a peripheral seal member. Preferably, the expansion is achieved by means of a rotary expander, that is an expander which is rotatable in the tubing and preferably includes at least one rotating member in rolling contact with the tubing inner wall.
[0015] The bore may be a drilled or otherwise formed bore, a section of tubing or pipe, or a combination of both. Preferably, the bore is at least partially defined by downhole bore-lining tubing, such as casing or liner. The bore-lining tubing will typically be unexpandable, for example if the bore-lining tubing has been cemented; the method of the present invention allows the tubing to be located in such bore-lining tubing while avoiding the difficulties that are inherent in locating tubing by expansion within an unexpandable larger tubing. However, in other embodiments of the invention the bore-lining tubing may experience a degree of expansion, elastic, inelastic or both.
[0016] The radially outwardly directed force is preferably created by passing a tubing expander, which may be of conical or tapered form, through the tubing. Preferably, the tubing expander comprises an expansion cone, and most preferably the expander comprises a seal for sealingly engaging the bore wall, such that fluid pressure may be utilised to drive the expander through the tubing section. The expander may have a first configuration in which fluid may pass through or around the expander, and a second configuration in which the expander creates a barrier to fluid flow through the bore. The second configuration may be achieved by locating a ball or plug in a suitable shoe or profile in the expander. The expander may further be adapted to assume a third configuration in which fluid may again flow through or around the expander. The third configuration may be achieved by rupturing a disc, diaphragm or the like, which may be provided in the plug, or by shearing out a ball or plug shoe.
[0017] The tubing may itself serve as a hanger, or may be coupled, by any appropriate means, to a hanger to be set following the reconfiguration of the tubing.
[0018] A further length of tubing, which may or may not be expandable, may be coupled to the tubing.
[0019] The tubing may include a profile for co-operating with a corresponding profile on a running string to allow the string to support the tubing as the tubing is being run into the bore. Preferably, the profile is provided on an upper portion of the tubing, above a notch in the tubing. The area of tubing including the notch may be subject to expansion utilising a rotary expander, which it has been found results in the tubing shearing or otherwise parting at the notch, allowing the portion of tubing defining the profile to be pulled out of the bore, leaving the remainder of the tubing in the bore.
[0020] According to a second aspect of the present invention there is provided apparatus for use in anchoring tubing in a section of a bore having an internal first diameter and defining a bore profile, the apparatus comprising:
[0021] tubing including a section with a non-circular wall, the wall having an outer surface portion defining a tubing profile, the wall configured such that the outer surface portion describes an outer diameter less than the first diameter;
[0022] means for engaging a running tool for running the tubing into the bore; and
[0023] a first expander for diametrically expanding the tubing section wall such that the tubing profile engages with the bore profile.
[0024] Preferably, the apparatus further comprises a second expander for expanding a section of the tubing into sealing contact with the bore wall.
[0025] According to a further aspect of the present invention there is provided a method of anchoring tubing in a bore, the method comprising:
[0026] providing tubing having a section with outer surface portions defining a profile, the section configured such that the outer surface portions describe an outer diameter less than a first diameter;
[0027] locating the tubing within a bore having an internal surface defining a profile, the bore having an internal diameter corresponding to said first diameter; and
[0028] reconfiguring said section such that said outer surface portions are biased to describe an outer diameter greater than said first diameter but are restrained to said first diameter by said bore, and such that said tubing profile engages the bore profile.
[0029] According to a fourth aspect of the present invention there is provided a method of anchoring tubing in a bore, the bore having an internal first diameter, and defining a bore profile, the method comprising:
[0030] providing tubing having a section with outer surface portions defining a tubing profile, the outer surface portions configured to describe an outer diameter greater than the first diameter, at least one of the tubing and the bore comprising an elastically deformable material; and
[0031] axially translating the tubing relative to the bore to locate the tubing within the bore such that the tubing profile engages with the bore profile.
[0032] Preferably, the tubing comprises elastically deformable material. Alternatively, the bore comprises elastically deformable material.
[0033] The method of the invention thus provides a convenient method of creating a coupling between a tubing and a surrounding bore wall, which coupling may be utilised to fix the tubing relative to the bore, both axially and rotationally, to facilitate subsequent operations, such as further reconfiguration or deformation of the tubing.
[0034] The bore profile may be formed in bore-lining tubing, such as casing or liner. The profile may be formed in the bore-lining tubing prior to the tubing being run into the bore. Alternatively, the profile may be formed after the bore ling tubing is located in the bore. The profile may be formed by any appropriate means, including a rotary profiling tool, as described in application GB 2346909, the disclosure of which is incorporated herein by reference. This permits the profile to be located to suit conditions in the bore.
BRIEF DESCRIPTION OF THE DRAWINGS
[0035] These and other aspects of the present invention will now be described, by way of example, with reference to the accompanying drawings, in which:
[0036] [0036]FIG. 1 is a perspective view of an expandable section of tubing incorporating a lip in accordance with an embodiment of the invention;
[0037] [0037]FIG. 2 is a perspective view of an expandable section of tubing incorporating a lip in accordance with an alternative embodiment of the invention; and
[0038] FIGS. 3 to 6 are schematic illustrations of steps in a method of anchoring tubing in a bore, in accordance with an embodiment of a first aspect of the present invention; and
[0039] [0039]FIGS. 3 a , 4 a and 6 a are sectional views on lines 3 a - 3 a , 4 a - 4 a and 6 a - 6 a of FIGS. 3, 4 and 6 , respectively.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0040] Referring firstly to FIG. 1, this shows a perspective view of an expandable section of bore-lining tubing, generally indicated by reference numeral 100 , incorporating a lip, in accordance with a preferred embodiment of the invention. This section may be part of an otherwise circular section tubing of diameter slightly less than the bore with which the tubing is intended to be located.
[0041] The crinkled, expandable section 100 includes six concave wall portions, 101 to 106 . Between each concave wall portion are lips 111 to 116 , intended for engaging with cooperating recesses in a bore wall (not shown).
[0042] At least this crinkled section of the tubing 100 comprises an elastically deformable material and the lips 111 to 116 describes a diameter slightly greater than the bore internal diameter. The tubing is forced into the bore and the crinkled section 100 deforms to allow the lips 111 to 116 to pass down through the bore. When the lips 111 to 116 reach the complementary profile in the bore, the lips 111 to 116 will spring out to engage with the profile.
[0043] [0043]FIG. 2 shows a perspective view of an expandable section of tubing 120 incorporating a lip, in accordance with an alternative embodiment of the invention. In this case the lip 122 is in the form of a continuous rib, for engaging with a cooperating channel in the bore.
[0044] Reference is now made to FIGS. 3 to 6 of the drawings, which illustrate steps in the method of anchoring tubing, according to a second aspect of the present invention, and subsequently cementing and sealing the tubing. Elements of the method described with reference to FIGS. 3 to 6 , such as for cementing and sealing the tubing, are equally applicable to the method of anchoring described with reference to FIGS. 1 and 2. The tubing is in the form of liner 20 , in the lower end of a drilled bore 22 . In this embodiment the liner 20 describes a diameter less than the bore 22 diameter. In FIG. 3, the liner 20 is shown in the run-in position, with the upper end of the liner 20 overlapping the lower end of existing cemented casing 24 . The remainder of the liner 20 is located in unlined, or open bore.
[0045] The liner 20 is coupled to a running string 26 , formed of drill pipe, by means of co-operating profiles 28 . Below the liner profile 28 , which is located at the upper end of the liner 20 , the liner wall defines a notch 30 , the purpose and function of which will be described in due course.
[0046] Mounted to the lower end of the string 26 , within the liner 20 , is a running tool 31 and a rotary expansion tool 32 . The expansion tool 32 comprises a hollow body 34 in fluid communication with the string 26 , the body 34 accommodating three piston-mounted rollers 36 . As will be described, supplying fluid at elevated pressure to the interior of the body 34 tends to urge the rollers 36 radially outwardly, and by then rotating the tool 32 within the liner 20 the internal and external diameters of the liner may be increased. A cement plug catcher 40 is mounted via shear pins to the lower end of the expansion tool 32 .
[0047] A drillable cone and seal assembly 48 is initially located within a section of the liner 20 a below the plug catcher 40 , which liner section 20 a has been formed to provide a corrugated or crinkled wall profile, as may be seen from FIG. 3 a of the drawings. In addition the liner includes a radially projecting tubing lip 21 , similar to the lips shown in FIGS. 1 and 2. The casing includes a profile 23 , in the form of a radial recess. Other than the liner section 20 a , the liner 20 is of a circular form and has an outer diameter slightly smaller than the inner diameter of the casing 24 , to provide sufficient clearance for the liner 20 to be run in through the casing 24 . However, the liner section 20 a has been first shaped into a polygonal form in a forming die and the planar wall portions then further deformed to a concave form such that the outer diameter of the liner section 20 a is described by six outer surface portions 50 . The minimum inner diameter of the section 20 a is defined by the midpoints of the concave wall portions 51 .
[0048] The cone and seal assembly 48 comprises a hollow upper cone 52 , and a reduced diameter tubular portion 56 extends from the cone 52 to a larger diameter stabiliser collar 58 . The collar 58 has an external circumferential seal 54 for engaging the inner wall of the liner 20 and defines an internal ball seat 59 . Initially, the assembly 48 is located in the liner 20 as illustrated in FIG. 3, that is with the cone 52 and collar 58 respectively located above and below the crinkled section 20 a , and the tubular portion 56 extending through the section 20 a.
[0049] The lower end of the liner 20 is provided with a drillable cement shoe 60 .
[0050] In use, the liner 20 is run into the bore 22 to the position as illustrated in FIG. 3, with the liner profile 21 lining up with the casing profile 23 . If desired, fluid may be circulated through the liner 20 , and the liner 20 may be rotated within the bore 22 as the liner 20 is run in. Pre-flush fluid may then be pumped from surface down through the running string 26 , followed by a ball 62 (FIG. 4) and a volume of cement 64 . The ball 62 lands on the seat 59 and closes the throughbore defined by the collar 58 . Fluid pressure then acts on the area defined by the seal 54 , and urges the collar 58 , and of course the remainder of the assembly 48 , down through the crinkled section 20 a . The diameter and profile of the cone 52 are selected such that the cone contacts the inner faces of the concave wall portions 51 , which has the effect of moving the outer surface portions 50 radially outwards causing the liner profile 21 to engage with the casing profile 23 . A pressure drop will be evident at surface when the cone 52 clears the lower end of the section 20 a , and further pumping of cement 64 will continue to push the assembly 48 through the liner 20 until the collar 58 engages the shoe 60 .
[0051] The gaps 76 (FIG. 4 a ) that remain between the casing inner wall and the polygonal liner section 20 a allow for fluid circulation.
[0052] The volume of cement 64 is followed by a wiper plug 66 and water spacer 68 . The plug 66 engages and shears out the plug catcher 40 , which is then pushed through the liner 20 until the catcher 40 engages the cone 52 . Prior to this, a pressure increase will have been applied to shear out the ball seat 59 , such that the seat 59 and ball 62 land out within the float shoe 60 , allowing the cement 64 to circulate into the annulus 70 between the liner 20 and the open bore 22 .
[0053] Weight is then applied to the liner 20 to check the integrity of the thus-formed hanger, before releasing the running tool 31 from the liner 20 .
[0054] Referring to FIG. 5, the expansion tool 32 is then lowered into the liner 20 , which is now axially fixed relative to the casing 24 by the liner profile 21 being engaged with the tubing profile 23 , until the tool 32 is located above the section 20 a at a liner seal section 20 b . Elevated fluid pressure applied through the string 26 to the tool 32 then acts to extend the rollers 36 , such that rotation of the string 26 and the activated tool 32 will diametrically expand the liner section 20 b into sealing contact with the casing 24 . Fluid is then pumped through the running string 26 to circulate out cement residue, and the thus-formed hanger is then subject to a pressure test.
[0055] The expansion of the liner 20 is then continued over the notch 30 , and the expansion at the notch causes the liner 20 to separate. The tool 32 , and the short length of liner 20 above the notch 30 , may then be pulled out of the bore on the running string 26 , as shown in FIG. 6.
[0056] In other embodiments of the invention, a profiled liner section may be subject to expansion by a cone and seal assembly or the like while positioned within the lower end of the casing. The outer surface portions of the expanded liner section, if unrestrained by the surrounding casing, would assume a larger diameter. Accordingly, the restraint provided by the casing results in the liner section outer surface portions engaging the casing, allowing the liner to be hung from the casing while providing gaps between the liner and casing to permit fluid circulation.
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A method of anchoring tubing in a bore comprising: providing tubing having a section with outer surface portions defining a tubing profile, and configured to describe an outer diameter less than a first diameter. The tubing is located within a bore having an internal diameter equal to the first diameter and defining a bore profile. The tubing is then reconfigured such that the tubing profile engages with the bore profile, anchoring the tubing within the bore.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
The present invention relates to systems and methods for the construction of underground structural concrete walls.
It is often necessary to provide concrete walls below grade, for example in the construction of railroad or highway tunnels, underground parking garages, foundation walls and retaining walls. These underground walls are commonly formed by excavating a trench and pouring concrete into the trench, i.e., casting the wall in place. The physical properties of cast-in-place slurry walls tend to vary depending upon the composition of the concrete, the weather, and other variables present when the concrete is poured.
SUMMARY OF THE INVENTION
The present invention provides an improved method of constructing underground structural concrete walls, using pre-cast concrete panels. Preferably, the panels are also pre-stressed to provide the walls with high strength and resistance to bending moments, e.g., exerted by soil pressure against the wall. Advantageously, the concrete walls have a smooth, finished surface that is substantially free of defects such as inclusions. Moreover, the method of the invention may require less manpower than the construction of conventional cast-in-place slurry walls. Finally, the pre-cast concrete panels can be manufactured under carefully controlled conditions and subjected to quality control, and, if desired, a predetermined preload may be applied to the panels, allowing excellent control over the physical properties of the finished concrete wall.
In one aspect, the method includes: (a) providing, e.g., by casting in place, a pair of parallel, opposing, underground guide walls spaced a predetermined distance apart; (b) excavating a trench, using the guide walls to guide the excavation tool, the trench having a predetermined width substantially equal to the space between the guide walls; (c) pouring a footing at the base of the trench; and (d) lowering a pre-cast panel into the trench in a desired orientation relative to the trench walls.
Preferred embodiments of the invention include one or more of the following features. The footing formed in step (c) is formed of concrete, and is poured into the trench using the tremie method. The method further includes (e) pumping an excavating slurry containing a thickening agent, e.g., bentonite or polymer, into the trench during step (b) to prevent the walls of the trench from collapsing. The method further includes (f) pumping a soil replacement material, e.g., a cement/thickening agent slurry, into the space between the panel and trench walls. This soil replacement material provides support and resists movement of the panels relative to the trench walls when the panel is loaded, and also provides a waterproof barrier. Preferably, each slurry contains from about 3 to 6% bentonite as the thickening agent, and the cement/thickening agent slurry contains cement and bentonite in a ratio of from about 3:1 to 5:1, more preferably 4:1.
In a preferred embodiment of the invention, the guide walls are constructed to support the weight of the panel, and the method further includes the step of suspending the panel from a pair of beams placed transversely across the guide walls and trench opening. The panel is suspended by providing the panel with threaded inserts extending vertically from the upper edge of the panel into the panel, inserting a threaded rod into each of the threaded inserts, passing the threaded rod through an aperture (e.g., a through hole) in the beam, and securing the threaded rod, e.g., with a threaded nut. The elevation of the panel in the trench can then be readily adjusted by raising the panel to unweight the threaded nut and changing the position of the threaded nut on the threaded rod.
In preferred embodiments, the wall is formed of a plurality of pre-cast panels placed side by side in the trench, and the method further includes joining the panels along their adjoining edges. Preferably, the panels are joined by engagement of corresponding interlocking members. Preferred interlocking members include, on one of the adjoining edges, a channel, and, on the opposite edge, a member dimensioned to be received by the channel. It is particularly preferred that the channel and member be keyed for interlocking engagement to provide a secure connection between adjoining panels.
In a particularly preferred embodiment, each of the adjoining edges includes a slot, the slots being positioned so that when the interlocking members are engaged the slots align to define a common slot, and the method further includes introducing into the common slot a liquid, e.g., a polymer, that is curable to form an elastomeric rubber material. Preferably, the elastomeric material is water-swellable. The presence of the elastomer-filled common slot prevents leakage of water through the interface between the panels.
Preferably, when the wall is formed of a plurality of panels, the trench into which the panels are lowered is excavated incrementally, i.e., the entire length of the trench is not excavated prior to placing the panels, but instead a first length of trench is excavated, one or more panels are positioned in this trench, then a further trench is excavated adjacent the first trench. Preferably the entire length of the guidewalls is formed initially, prior to beginning excavation of the trench.
In another aspect, the invention features a method of constructing an underground tunnel. The method includes (i) forming a pair of spaced, opposed vertical walls by the method described above, (ii) excavating to a predetermined roof level, (iii) casting the tunnel roof in place between the vertical walls, (iv) excavating the tunnel to an elevation suitable for the base slab, and (v) casting the base slab in place between the vertical walls.
Preferably, the method further includes (vi) scraping the cement/bentonite slurry (from step (f), above) off of the exposed side of the vertical walls to expose the surface of the precast panel. This step provides the exposed side of each vertical wall with a smooth, finished surface.
The invention also features methods of forming retaining and foundation walls by forming a wall according to a method of the invention and excavation a region adjacent the wall to expose a surface of the wall.
Other features and advantages of the invention will be apparent from the description of preferred embodiments thereof, taken together with the drawings, and from the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top schematic view of the vertical walls of a tunnel, formed according to one embodiment of the invention. FIG. 1a is a side view in elevation of one of the vertical walls.
FIG. 2 is a cross-sectional view of a pre-cast panel, taken along line 2--2 in FIG. 3. FIG. 2a is a detail view showing the engagement of the interlocking members joining two pre-cast panels.
FIG. 3 is a cross-sectional end view of a tunnel formed according to one embodiment of the invention.
FIGS. 4-4g are schematic diagrams illustrating the steps of a method according to one embodiment of the invention.
FIGS. 5 and 5a are top plan and side cross sectional detail views, respectively, showing the manner in which the panel is suspended in FIG. 4g.
FIG. 6 is a top plan view of adjoining panels according to the invention, showing a common slot containing a water-swellable polymer.
FIG. 7 is a front view of a panel according to an alternate embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
As shown in FIG. 1, a tunnel 10 includes two opposing vertical walls 12, 14. Each of the opposing walls includes a plurality of pre-cast panels 16 arranged side by side, as shown in FIG. 1a.
Referring to FIG. 2, each pre-cast panel 16 includes a plurality of prestressing strands 18 imbedded in concrete 20. The material used for prestressing strands 18, and the preload applied, may be selected to suit a particular application, as would be understood by a person skilled in the art. In a preferred embodiment, prestressing strands 18 are 7-wire (0.6" diameter) low relaxation strands conforming to ASTM A416 and having an ultimate tensile strength of 270,000 psi. The preload is applied by tensioning the strands to a desired tension prior to pouring the concrete, and releasing the tension from the strands when the strength of the concrete reaches 4000 psi during curing. In the tunnel application described herein a preload of about 2 million pounds was desired due to design considerations. By way of example, to provide this preload, 38 strands were each tensioned to about 44,000 pounds. The strands can typically be tensioned to about 75% of their total yield strength. The total preload can be varied by changing the number of strands used, or the material used to form the strands.
Each pre-cast panel 16 also includes a first interlocking member 22 on one of its longitudinal edges and a second interlocking member 24 on its opposite longitudinal edge. In a preferred embodiment, the first interlocking member includes a channel 26 having a substantially diamond-shaped cross-section, and the second interlocking member includes a rod 28 having a substantially round cross-section and being dimensioned to be received in the channel by sliding the rod downwardly through the upper opening of the channel (see FIG. 2a). Rod 28 is mounted on the panel by an elongate member 25. The rod 28 preferably includes two coaxially arranged rod portions that each have a length that is much smaller than the length of the panel. The diamond-shaped cross-section of the channel 26 is preferred over other shapes because it has been found to have good resistance to breakage during and after engagement of the interlocking members. The channel may be formed of angle iron or any other suitable high-strength material. Similarly, the elongate member 25 and rod 28 may be formed of any suitable high strength, rigid material.
Preferably, the interlocking members also include a tongue 27 and groove 29 which interlock in tongue and groove fashion. The combination of the keyed channel and rod and the tongue and groove engagement provides a particularly stable, secure connection between panels, providing dimensional stability to the wall when the wall is placed, positioned and loaded.
Referring to FIG. 6, in preferred embodiments the pre-cast panels further include a slot 31 extending along each of the vertical edges of the panel. These slots align when the panels are in place, defining a common slot 33 extending vertically between each pair of adjoining panels. A liquid that is curable to form an elastomeric material is poured into the common slot and allowed to cure to form a gasket-like seal 35 between the panels. A suitable liquid is a liquid rubber commercially available from Asahi Denka under the tradename ADEKA ULTRA SEAL® (Product No. A-50), a water-swelling rubber sealing material. This preferred rubber, after curing, has a tensile strength of more than 47 kg/m and an elasticity of greater than 1000%. Importantly, this seal provides a secondary waterproofing barrier against water leakage between the adjoining panels in addition to the barrier formed by the soil replacement material.
In addition, each panel includes a plurality of vertical through holes 30 extending through the interior of the panel. These through holes act as a relief, allowing the concrete at the base of the trench and the bentonite slurry in the trench, displaced by the volume of the panel, to flow into the through holes rather than cause the panel to be buoyed up in the trench. The panels may also include transverse through holes (not shown) through which tie-backs (soil anchors) may be inserted to further stabilize the finished vertical wall, as is well known in the art.
One side of a finished tunnel 10 is shown in FIG. 3. In addition to vertical walls 14, the tunnel includes a roof slab 32 and a base slab 34. Threaded steel bar inserts 36, 38 are provided at the intersection of the roof slab and vertical wall and base slab and vertical wall, respectively. These inserts assure the structural continuity of the tunnel structure.
A preferred method of installation of the pre-cast panels is illustrated in FIGS. 4-4g. FIGS. 4-4b illustrate the initial steps used to form the guide walls 40. First, as shown in FIG. 4, a relatively wide (e.g., 7-8 ft.), shallow (e.g., 4-6 ft.) trench 42 is excavated and formwork 44 and rebar 46 are placed on each side of the trench. Then concrete 47 is poured into each side of the formwork 44 and allowed to cure (FIG. 4a), and the formwork is removed (FIG. 4b), leaving a pair of opposed guide walls 40 spaced a predetermined distance (the width of the formwork 44) apart. Once the guide walls have been completed, a narrow (e.g., 1 to 3 ft.), deep trench 48 is excavated using the guide walls to guide the excavation bucket, as shown in FIG. 4c. During this excavation step, a bentonite slurry 50 is continuously pumped into the trench 48 to prevent the walls of the trench from collapsing. Preferably, the bentonite is a high swelling, Wyoming type, sodium based bentonite consisting mainly of montmorillonite, and the slurry contains a concentration of from about 3 to 6% bentonite in water. The concentration of bentonite will vary depending upon the type of ground to be excavated, as is understood in the art. The slurry is formed by mixing bentonite and water at high shear, as is well known. When excavation has been completed, i.e., when the depth of the trench is substantially equal to the desired height of the vertical wall, the trench bottom is cleaned. The trench preferably has a depth substantially equal to the height of the wall to be formed. Then, concrete footing 51 is placed in the bottom of the trench, preferably using the tremie method as shown in FIG. 4d, to a depth at which a small portion (e.g., 1 to 3 ft.) of the bottom edge of the pre-cast panel will be embedded in the concrete when the panel is in place in the trench. Before the concrete has set, pre-cast panels 16 are then inserted into the trench, e.g., by a crane (not shown), one at a time, as shown in FIG. 4e, the position of each panel being adjusted until the panel is plumb and level. Each panel is suspended from the upper surface of the guide walls 40, e.g., by a pair of structural steel box beams 52 (FIG. 4f). As shown in detail in FIGS. 5 and 5a, each panel includes two pairs of threaded inserts 60. A threaded rod 62 is inserted into each of the threaded inserts, and each threaded rod is inserted through apertures in box beam 52 and retained in this position by threading a nut 64 onto each rod above the beam 52. The elevation of the panel is then adjusted by raising the panel sufficiently to unweight the threaded nuts and then adjusting the position of each threaded nut 64 on the threaded rod.
As subsequent panels are placed, the second interlocking member 24 on the panel being placed is engaged with the first interlocking member 22 on the adjoining, previously placed panel (see FIG. 2a), to securely join the panels together. Finally, a soil replacement material 54, e.g., a cement/bentonite slurry, is pumped into the area between the panels and the trench walls (FIG. 4g) to provide support to the panels and resist movement of the panel relative to the trench walls when the panel is loaded. Preferred soil replacement materials, such as the cement/bentonite slurry, also provide a barrier to infiltration of water or moisture from the soil through the wall or between the panels.
To construct a tunnel as shown in FIG. 3, panels are installed as shown in FIGS. 4-4g, to form a first vertical wall, and installed in similar manner to form a second vertical wall spaced a predetermined distance from the first vertical wall and substantially parallel thereto. Then, the area between the vertical walls is excavated to the design level of the lower surface of the tunnel roof, and the roof slab is cast in place. Next, the tunnel is excavated, under the cured roof slab, to the level of the lower surface of the base slab, and the base slab is cast in place.
Other embodiments are within the claims. For example, although the method has been described above in the context of tunnel construction, the method is useful in many other underground wall applications.
Moreover while a preferred method of prestressing the pre-cast panels has been described, other prestressing techniques could be used, as would be understood by a person skilled in the art.
Further, while preferred interlocking members are illustrated herein, other interlocking arrangements can be used, e.g., the channel and/or the rod may have a different cross-sectional shape.
Additionally, while the precast panels have been illustrated as being suspended from the guide walls so that their upper edge is slightly below grade level, the panels could be placed so that a portion of the panel extends above grade level, or suspended in a manner that would allow the upper edge of the panel to be further below grade level, if desired.
If desired, the concrete that is placed in the bottom of the trench prior to insertion of the panel may instead be placed in the bottom of the trench after insertion of the panel, e.g., by providing a vertical through hole through the interior of the panel having a sufficient diameter to allow the concrete to be tremied through the panel.
While bentonite has been described as the preferred thickening agent for use in both slurries, either slurry can include a different thickening agent. Other suitable thickening agents, e.g., polymers, for excavating slurries are well known in the oil drilling art.
Moreover, other soil replacement materials could be used instead of a cement/bentonite slurry. Suitable materials are those that could be pumped into the space between the panel and trench walls and that would provide support equal to or greater than that of soil, e.g., lean concrete, cement/atapulgite slurry and flowable fill.
Moreover, rather than using two slurries, an excavating slurry and a soil replacement slurry, a single, thickening agent/concrete slurry can be used for both steps. Alternatively, a curing additive can be added to the thickening agent/water slurry, after insertion of the panel, to cause the slurry to solidify.
The pre-cast panels need not be rectangular, as shown. For example, as shown in FIG. 7, in an alternate embodiment the precast panel includes a pair of "arms" 102 that allow the upper edge of the panel to be placed below grade level. These arms may be cut off after the panel is in place, allowing the soil above the upper edge of the panel to be excavated after the wall has already been formed.
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The present invention provides a method of constructing underground structural concrete walls, using pre-cast, preferably pre-stressed, concrete panels, including: (a) casting in place a pair of parallel, opposing, underground guide walls spaced a predetermined distance apart; (b) excavating a trench, using the guide walls to guide the excavation tool, the trench having a predetermined width substantially equal to the space between the guide walls; (c) pouring a footing at the base of the trench; and (d) lowering a pre-cast panel into the trench in a desired orientation relative to the trench walls.
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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 boomstick, more specifically, the present invention relates to a synthetic boomstick for replacement of conventional boomsticks or the like.
BACKGROUND OF THE PRESENT INVENTION
In conveying or storing of logs in water in the form of log booms or the like, the boundary of the log boom is formed by a plurality of so-called boomsticks. Boomsticks are normally made of wood, i.e. relatively large logs in the order of about 66 feet in length and 2 feet in diameter. The boomsticks are coupled together at their ends by chains or other interconnecting means interconnecting the hooks.
The cost of these boomsticks is relatively high since each contains a substantial amount of generally high value wood that is subject over their period of uses amongst other things to physical abuse, rot, decay, infestation by organism, i.e. sea-worms (teredos) etc. each or which may have a significant influence the life of a boomstick, and its recoverable value.
Attempts have been made to produce synthetic boomsticks to replace the natural or wooden boomstick. For example, U.S. Pat. No. 5,006,014 issued April 1991 to Greenough, discloses a synthetic boomstick formed from old used tires secured together by reinforcing rods and filled with light weight concrete or the like. This system never reached commercial acceptance.
It is also known to use inflated rubber tires on rims that are joined together in side by side relationship to form an elongated barrier (similar or equivalent to boomstick). This system also has not received any significant degree of commercial success. (See Offenlegungsschrift German patent 25 32 255 issued Feb. 3, 1977 to Lochel.)
U.S. Pat. No. 4,378,749 issued Apr. 5, 1983 to Leblanc et al. discloses a barge bumper formed by a plurality of axially-lined tires mounted in side by side relationship on an axially extended pipe.
The use of rubber tires to provide the surface of the boomstick or the like, at first glance, appears to be ideal in that the used tires have tread surfaces which make gripping by caulks on the bottom of the shoes of the workman more easy and provide at least a temporary disposal for used tires. However, it will be apparent that the coefficient of friction of rubber, even though it is wet, is relatively high, and thus, any rubbing action between the periphery or surface of the rubber tires and adjacent logs or the like induces a relatively high strain which in many cases is very detrimental to the operation. Also, the use of rubber tires as the surface of the boomstick inherently limits the ability to apply stabilizers or ballast in the form of axially extending projections and/or a keel to stabilize the boomstick in the water.
BRIEF DESCRIPTION OF THE PRESENT INVENTION
It is an object of the present invention to provide a synthetic boomstick from a coated tubular body.
Broadly, the present invention relates to a boomstick comprising an elongated, hollow ridged cylindrical body section having a longitudinal axis, partition means dividing said body section into a plurality of compartments, an end cap sealing each axial end of said body portion, ballast means fixed to and extending axially of said body portion in a position to orient said body portion with said ballast means submerged and a longitudinally extending tread area uppermost, a coating of a wear and abrasion resistant, water proofing material completely encasing said boomstick, said coating having a coefficient of friction with logs to permit slippage there between, said coating being sufficiently thick to protect said body portion and to receive caulks on boots of workmen walking thereon without damaging said body portion.
Preferably, said coating will be polyethylene.
Preferably, a pair of axially extending stabilizers will be symmetrically positioned on opposite sides of said body portion relative to said ballast means.
Preferably, each of said stabilizers will comprise a hollow, cylindrical section having its cylindrical axis extending longitudinally of said body portion substantial parallel to said longitudinal axis of said body section.
Preferably, said tread area is defined in said polyethylene coating.
Preferably, said ballast means will be formed by material secured to the outside of said body portion and shaped in cross-section to form a keel extending axially of said body portion.
Preferably, said coating will have a minimum thickness of at least 5 mm.
Preferably, said coating will comprise high density polyethylene.
BRIEF DESCRIPTION OF DRAWINGS
Further features, objects and advantages will be evident from the following detailed description of the preferred embodiments of the present invention taken in conjunction with the accompanying drawings in which;
FIG. 1 is an isometric schematic illustration of a boomstick constructed in accordance with the present invention.
FIG. 2 is a partial axial section along the length of the boomstick taken on line 2--2 of FIG. 3.
FIG. 3 is a section along the line 3--3 of FIG. 2.
FIG. 4 is a view similar to FIG. 3 but showing a more easily constructed boomstick without a keel.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
As shown in FIG. 1, the boomstick 10 is in the form of an elongated cylindrical having an upper tread surface 12, a lower keel 14, a pair of stabilizers 16 and 18 (see FIG. 3), and a pair of end caps 20 and 22, each provided with its respective eye 24 and 26.
As illustrated in FIGS. 2 and 3, the boomstick 10 is formed from a hollow, cylindrical tube-like body member 28 which may be composed of a plurality of axially aligned tubes 28A, 28B, etc. that are welded together at partitions, such as the partition 30 via circumferential welds indicated at 32. Generally the pipe used to form the body member 28 will have an outside diameter of between 20 and 36 inches, preferably 24 to 30 inches.
A 33 foot long boomstick may be formed with between four to ten sections A, 28B, etc., with each pair of adjacent sections welded together by weld 32 separated from the next adjacent section by its respective partition 30. Thus if desired each tube section 28A, 28B, etc. may form its own air tight floatation compartment.
End closing partitions 34 (only one shown) close off the axial ends of the cylindrical body section 20 and convex or domed end caps 36 (only one shown) are welded or otherwise secured to the tubular body section 28 to provide a convex domed cap, one at each axial end of the boomstick 10.
In the illustrated arrangement, the eyes 24, 26 are each formed by a U-bolt 38 that passes through holes in the end cap 36 and is welded to the end cap as indicated at 40.
A longitudinally extending ballast forming member 42 has been shown welded to the bottom of body member 28, along substantially the full length of the body member 28. The member 42 is preferably an angular member having its apex 47 extending axially of the hollow body member 28 and having its opposite sides 44 and 46 welded or otherwise secured to the body 28 along substantially the full axial length of the body 28. This ballast forming member 42 also functions as keel.
The use of a ballast forming member 42 as above indicated provides a keel for the boomstick. However, a keel is not absolutely essential to the operation of the device and the provision of the keel renders coating as will be described herein below more difficult. It is thus preferred to use as a ballast a settable material such as concrete or the like as indicated at 43 in FIGS. 3 and 4 wherein the concrete material 43 is positioned within each of the cylindrical body members 28 and is held in proper position, i.e. at a fixed position relative to body section 28 to define the bottom. Concrete is a settable material and thus may be anchored in position by suitable reinforcing rods or the like schematically illustrated at 45 that are welded or otherwise secured to the inside surface of the cylindrical body member 28.
It will be apparent that the ballast 43 (plus the stabilizers 16 and 18) orient the boomstick 10 in the water, where the keel 42 is provided, it may also be desirable to incorporate an appropriate amount of ballast 43 to obtain the required degree of submergence of the boomstick.
The stabilizers 16 and 18 both are essentially the same and are formed, in the illustrated arrangement, by a major (larger diameter) tube member 48 and a pair of smaller tube members 50 and 52 position one above and one below the tube 48. These tubes or pipes 48, 50 and 52 all extend substantially axially along substantially the full length of the body section 28. These tubular members 48, 50 and 52 are all welded together and welded or otherwise secured to the body member 28 and are closed or sealed off by end partitions (not shown).
The longitudinal axes of the stabilizers 16 and 18 are symmetrically positioned on opposite sides of the keel 14 and are preferably positioned at 90° to a longitudinally extending vertical plane passing through the apex 45 of the keel 14.
It will be noted that the pipe 48 is significantly larger in diameter than the pipes 50 and 52 i.e. at least twice that of pipes 50 and 52 and that the pipes 50 and 52 normally will have essentially the same outside diameters. The diameter of the pipes 48 will normally be in the range of about 2 to 4 inches.
This whole unit as above described is then coated with a relatively thick coating 56, generally in the order of at least 5 mm and generally not more than about 15 mm thick. This coating 56 extends over all of the elements above described to completely encase or seal the components of the boomstick 10. The material used will be a wear and abrasion resistant water proofing material having a coefficient of friction with logs to permit slippage there between under normal operating condition. Preferably, the coating material will be an olivinic-type plastic having suitable characteristics and will normally comprise polyethylene, preferably what is known in the trade as high density polyethylene. Preferably, the coefficient of friction of the coating material with logs will not exceed that of polyethylene.
In the illustrated arrangement, the polyethylene coating completely coats the eyes 24 and 26 to completely surround the U-shaped members 38. However, because of the way these U-shaped members are used in conjunction with chains and the like, the coating relatively quickly wears off, but luckily the coating on these U-shaped members 38 is not particularly important.
The upper surface of coating 56 remote from the keel 14, i.e. the tread surface area as indicated at 12 which extends over a significant portion of the circumference of the boomstick 10 expose above the water line L will be suitably treated to provide a tread surface for cooperation with the caulks on a workman's boots. This may be accomplished by striating the plastic or embossing or moulding a suitable pattern into the plastic in the tread area 12, for example to texture the plastic to simulate the bark of a tree or a wood surface so that the workman will be comfortable in walking along the upper tread surface 12 of the boomstick 10 and the cooperation of the caulks and plastic coating in the tread surface area will not increase the hazard of walking on the boomstick to be higher than that of the conventional boomstick.
In the illustrated arrangements, this tread surface 12 is shown to extend substantially the full axial length of the boomstick 10 and over an area occupying over about 50% of the area of the boomstick above the water line under normal conditions and has a circumferential length as indicated by the dimension C in FIG. 3 generally equal to at least about 20% of the circumference of the boomstick.
The body member 28, ballast forming member 42 and the pipes or hollow cylindrical members 48, 50 and 52, forming the stabilizers, may be formed from suitable materials such as steel with the cylindrical sections 28A, 28B, etc., each being formed, for example, from lengths of pipe and with the tubular sections 48, 50 and 52, each being formed of a pipe.
The ballast forming member 42 is preferably in form an angle or the like made from metal such as steel and is welded as above indicated to the body member 28.
These partitions 30 and 34, preferably formed of disks of the same material as the body 28, such as steel, and are welded in place at the same time as the adjacent sections such as sections 28A and 28B of the body 28 are welded together. These partitions, being made of steel, provide reinforcements axially spaced along the length of the boomstick 10 to reduce possibility of the boomstick 10 being deformed.
Rather than having isolated compartments formed by the partitions 30 and 34, the partitions 30 and 34 may be opened (they will still provide the required reinforcing) and the interior free space of the hollow body member 28 be filled with a suitable floatation material 60, for example, a light-weight foam material to provide buoyancy even if there is a puncture in the body 28.
While a conventional boomstick is normally about 66 feet long, it is intended to produce the synthetic boomstick 10 of the present invention about one half of the conventional length and to couple two such synthetic boomstick together to replace a single boomstick as used by the prior art.
Having described the invention, modifications will be evident to those skilled in the art without departing from the scope of the invention as defined in the appended claims.
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A boomstick is formed from an elongated hollow cylindrical body divided into plurality of compartments by axially spaced traversed partitions and enclosed at its end by sealing end caps. Preferably, an axially extending keel forming ballast will be provided to orient the boomstick and axially extending stabilizers will be symmetrically spaced on opposite sides of the body portions spaced from the ballast. The whole boomstick is coated with a polyethylene coating sufficiently thick to protect cylindrical body and to receive the caulks of workmen without damaging the body portion while providing a good retention between the caulks and the coating to better ensure the comfort and safety of the workmen.
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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 generally to liquid drainage systems used on site for footings, open trenches, or nitrification fields used as discharge points for septic tanks, and more particularly to a novel flexible preassembled drainage line unit which is an improvement over the flexible preassembled drainage line units illustrated in FIGS. 2 and 3 of U.S. Pat. No. 5,015,123 (the “'123 patent”, owned by the assignee of this invention), the disclosure of which is incorporated herein by reference in its entirety.
[0002] The preassembled drainage line unit illustrated in FIG. 2 of the '123 patent constitutes loose aggregate in the form of lightweight materials such as polystyrene beads provided in surrounding relationship to a perforated conduit and bound thereto by a perforated sleeve member such as plastic netting. These units, used in combination with preassembled units illustrated in FIG. 3 of the '123 patent which do not include the perforated pipe, provide a storage chamber or area for example for effluent from a septic tank until it can be absorbed by the surrounding soil as illustrated in FIGS. 4 b and 4 c of the patent and replaces the conventional gravel drainage system illustrated in FIG. 1 of the patent. Drainage systems employing the preassembled drainage line units of the '123 patent represent a substantial improvement over prior conventional gravel systems for reasons set forth in the '123 patent and have enjoyed substantial commercial success.
[0003] While those preassembled drainage line units have enjoyed commercial success, in certain applications problems have presented themselves. For example depending on the type of fill soil placed on top of the preassembled units, solids such as sand or dirt may pass downwardly through the netting into the void area between adjacent aggregate, clogging that area and causing an undesirable reduction in liquid flow through the aggregate. In other applications it is sometimes desirable that the pre-assembled units which are normally very flexible along their length possess greater rigidity along that length and still in other applications it is sometimes beneficial to provide structure as part of those units which promotes the growth of microorganisms within the drainage units.
[0004] The improved drainage products of the invention as described hereinbelow have been developed to overcome the problems associated with the units described in the '123 patent and to fulfill the needs described above.
SUMMARY OF THE INVENTION
[0005] Accordingly, a primary object of the invention is to provide a preassembled drainage line unit in which loose aggregate in the form of lightweight materials is contained within and bounded by a perforated conduit such as a plastic mesh tube of construction netting and wherein a barrier material overlies at least a portion of the aggregate to prevent solids from passing through the netting and entering the storage area defined by the aggregate.
[0006] Another object of the invention resides in the provision of the above novel preassembled drainage unit which further includes a perforated conduit wherein the loose aggregate surrounds the conduit and is bounded thereby by the perforated sleeve member.
[0007] Depending upon the type of drainage application in which the novel preassembled units are to be used, the material from which the barrier is constructed may vary. For example, it may be paper, cloth, geo-textile such as nylon, or any other suitable pliable sheet material that can be inserted between the netting and the aggregate. The thickness of the sheet material can be varied. For example the thickness of the material may be thin so as to conform to the preferred cylindrical shape of the units or may be thicker to provide rigidity along the length of the units. In addition, the barrier material may extend around the aggregate through an angular distance of about 10 degrees through full coverage of 360 degrees.
[0008] The provision of the barrier material within the above described novel preassembled drainage units can be tailored to block the infiltration of outside media such as sand, dirt and soil through the net into the aggregate, to provide rigidity to the drainage units along their length and to provide structure which promotes the growth of microorganisms within the drainage unit.
[0009] It is also an object of the invention to provide a method and apparatus for manufacturing the novel drainage units.
[0010] Further objects and advantages of the invention will become evident from the reading of the following detailed description of the invention wherein reference is made to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] [0011]FIG. 1 illustrates a preassembled drainage line unit constructed according to the invention which includes a plurality of lightweight aggregate surrounding a perforated conduit and bounded thereto by an outer perforated sleeve member, with a barrier material overlying at least a portion of the aggregate to prevent outside media such as sand, dirt or soil from infiltrating into the liquid storage area defined by the aggregate;
[0012] [0012]FIG. 2 is a cross-sectional view of the unit taken along line 2 - 2 of FIG. 1;
[0013] [0013]FIG. 3 illustrates a preassembled drainage line unit similar to FIG. 1 with the perforated conduit removed;
[0014] [0014]FIG. 4 is a cross sectional view of the conduitless unit taken along line 4 - 4 of FIG. 3;
[0015] [0015]FIG. 5 is a cross-sectional schematic view illustrating an alternative construction of the unit illustrated in FIG. 1.
[0016] [0016]FIG. 6 is a fragmentary front perspective view of apparatus for manufacturing the novel drainage units of the invention;
[0017] [0017]FIG. 7 is a side view of the apparatus of FIG. 6 illustrating the manner in which the rolls of barrier material are supported on the mandrel.
DETAILED DESCRIPTION OF THE INVENTION
[0018] Referring now to the drawings, the longitudinally extending, flexible preassembled drainage line unit 20 illustrated in FIG. 1 includes a corrugated PVC perforated vent pipe 10 encased by an outer perforated sleeve member 22 of tubular nylon netting or mesh which is filled with an aggregation of discrete water impervious crush resistant lightweight plastic elements 21 and is secured to the pipe ends 24 and 25 by means of suitable conventional wires or tie fasteners 26 which prevent the escape of the loose aggregates 21 .
[0019] Unit 20 as described thus far corresponds to the drainage unit illustrated in FIG. 2 in U.S. Pat. No. 5,015,123 and the detailed description set forth therein is incorporated herein by reference.
[0020] As mentioned hereinabove, in some applications employing the flexible drainage line units illustrated in the '123 patent, outside media solids such as sand, dirt or local soil placed on top of the units can penetrate into the units and thereby reduce the void space between the aggregates 21 , clogging the units and reducing the fluid flow through the units.
[0021] To alleviate this problem a liquid or water permeable barrier material 28 is placed between aggregates 21 and netting 22 , the barrier 28 extending longitudinally along unit 20 between ends 24 and 25 of the pipe and being secured at its ends to the pipes by fasteners 26 along with the netting 22 .
[0022] As shown n FIG. 2 the barrier 28 extends through a predetermined desired angular distance across the top portion of unit 20 and depending upon the application it may extend through an angular distance within the range of 10 degrees to a complete 360 degrees of the unit.
[0023] Barrier 28 may be constructed of any suitable pliable water permeable sheet material such as paper or cloth, but is preferably a geo-textile material such as nylon having a fine weave to block the passage of the sand or dirt but sufficiently open to permit the passage of water therethrough.
[0024] Preferably barrier 28 is very thin so as to readily conform to the shape of the flexible unit 20 which is preferably generally cylindrical but it may be thickened as desired to provide rigidity to the unit if desired.
[0025] In operation water collected at one end of pipe 10 passes into the pipe and outwardly through the perforations of the pipe into the chamber defined by aggregates 21 and barrier 28 blocks infiltration of sand or dirt placed on top of units 20 into the void space containing the aggregates.
[0026] Referring now to FIG. 3 the generally cylindrical drainage unit 30 is the same as unit 20 described in FIG. 1 except that it has no conduit passing therethrough. The end of the netting 22 and barrier 28 are tied together at the ends of unit 30 to hold aggregates 21 in place within the units. The units illustrated in FIG. 3 in this application containing the barrier 28 constitute an improvement over the conduitless units illustrated in FIG. 3 of the '123 patent and described therein.
[0027] [0027]FIG. 5 an alternative construction to that illustrated and described above with respect to FIG. 1. In the FIG. 5 embodiment, a pipe 10 a is surrounded by aggregate 21 a which is bounded to the pipe by a first perforated net 22 a , with this structure described so far being essentially identical to the prior art unit illustrated in FIG. 2 of the '123 patent. A barrier 28 a extends longitudinally along the length of the unit outside of net 22 a and around the unit through a predetermined angular distance and is fastened thereto by suitable means such as a second outer tubular nylon net or mesh 40 fastened at its ends along with the ends of barrier 28 a to the ends of pipe 10 in the same manner as the unit of FIG. 1. Instead of the tubular net 40 , barrier 28 a may, for example, be fastened to the outside surface of net 22 a by rope or cord at various locations along the length of the unit.
[0028] Another embodiment constructed according to FIG. 5 but without the conduit 10 a may be provided as an alternative to the conduitless unit illustrated in FIGS. 3 and 4.
[0029] From the description herein above it is apparent that the provision of the barrier 28 in the preassembled drainage line units advantageously prevents the passage of outside media such as sand, dirt or soil into the void space defined by the lightweight plastic aggregates; the barrier provides structure for the growth of microorganisms within the drainage unit; and the barrier may be constructed to provide rigidity to the unit when desired. The flexible pliable barrier material may extend a varying angular distance around the unit. For example, it may extend through a small angular distance of about 10 degrees to full circumferential coverage of 360 degrees of the unit depending upon the application in which the unit is to be used.
[0030] The apparatus shown in FIGS. 6 and 7 is of the type illustrated and described in detail in U.S. Pat. No. 6,173,483 which is owned by the assignee of this application, and the disclosure of U.S. Pat. No. 6,173,483 is incorporated herein by reference in its entirety. The apparatus is used to make both of the units of FIGS. 1 and 2.
[0031] Briefly, the apparatus includes a tubular mandrel 50 having an inner bore or cavity, a rear opening, a front opening, and an upper opening, with each opening communicating with the inner cavity.
[0032] A pipe feeder is positioned for feeding a predetermined length of perforated length pipe through the inner cavity of the mandrel 50 in a direction of manufacture from the rear opening to the front opening and therethrough. As it is fed into the mandrel 50 the vent pipe is positioned within the inner cavity so as to define a void space between the pipe and the inner wall of the mandrel.
[0033] A hopper assembly containing the plastic aggregate bodies is connected via conduit 52 to the upper opening in the mandrel to feed the plastic aggregates into the cavity.
[0034] A blower 54 is positioned in communication with the inner cavity of the mandrel for producing the sufficient air flow therethrough for moving the aggregate from conduit 52 through the inner cavity to substantially fill the void space between the vent pipe and the wall of the mandrel so that the pipe is surrounded by the aggregate as it emerges from the from opening of the mandrel.
[0035] A sleeve feeder is connected to the front end of the mandrel for feeding a continuous sleeve of netting 22 over the plastic aggregate and the vent pipe emerging through the front opening of the mandrel. As it is fed the continuous sleeve of netting 22 substantially encases the plastic aggregate around the vent pipe thereby forming a drainage unit.
[0036] The apparatus operates substantially the same for producing the conduit units of FIG. 3 but with no perforated vent pipe being fed through the unit.
[0037] For a more detailed description of this type of apparatus, reference is made to the specification of U.S. Pat. No. 6,173,483.
[0038] In accordance with the invention one or more rolls 56 of barrier sheet material 28 are mounted on top of mandrel 50 , the leading end 58 of which is located underneath the netting 22 in contact with the mandrel and is fed with the netting over the plastic aggregate and is fastened with the netting around the vent pipe for manufacturing the units of FIG. 1, or is simply tied together with the end of the netting for producing the conduitless units of FIG. 3. The apparatus as illustrated in FIGS. 6 and 7 is producing conduitless units. When drainage units larger in diameter for example, 10 inches, 12 inches, 14 inches, etc. are being produced instead of using a single roll 56 of barrier material it is better to use a plurality of rolls which are angularly offset as shown in FIGS. 6 and 7 with overlapping side edges so that the barrier material is able to extend for a larger angular distance, for example approximately 180 degrees in the unit shown in FIG. 6.
[0039] The operation illustrated in FIGS. 6 and 7 produces the units of FIGS. 1 and 2 and FIGS. 3 and 4 wherein the barrier material 28 is placed between netting 22 and aggregates 21 .
[0040] To produce the embodiments illustrated in FIGS. 5 and 6, the operation of FIGS. 6 and 7 may be modified by placing the leading edges of barrier material 28 on top of the netting 22 on mandrel 50 and then placing a second netting 40 around barrier 28 and the first netting 22 and continue the operation as described above.
[0041] The invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.
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A pre-assembled drainage line unit includes a flexible longitudinally extending perforated sleeve member and a loose aggregation of lightweight elements contained within the sleeve member. A pliable, water permeable barrier material extends along the sleeve member and overlies at least a portion of the aggregation to prevent the passage of solid materials, such as sand and dirt, into the aggregation.
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PRIORITY
[0001] This application is a continuation-in-part of U.S. patent application Ser. No. 12/958,761, filed Dec. 2, 2010, now pending, which claims benefit from U.S. Provisional Application No. 61/265,988, filed Dec. 2, 2009, now expired. The complete disclosures of both applications are incorporated herein by reference.
TECHNICAL FIELD
[0002] This disclosure relates to excavation tools, and more particularly to bucket type excavation tools, for excavators, backhoes, and wheel, crawler and skid-type loaders.
BACKGROUND
[0003] Excavation tools of the types described herein are typically mounted to conventional excavators of the type having a backhoe, or mounted to a conventional loader with a pair of boom arms. The backhoe version includes a dipper stick, and the tool is mounted on the outboard end of the dipper stick. The loader version would include boom arms of wheel loaders, crawler loaders and skid steer loaders where the tool is mounted to the outboard end of the boom arms. These tool types are employed for excavation of medium packed substrate, e.g. substrate between the category of loose soil or loose gravel and the category of substrate requiring a ripper or hammer. Medium packed substrate does not usually require special tools or rippers to be excavated; however, conventional buckets that have teeth horizontally aligned do not excavate efficiently. Loose soil or gravel can be excavated with a conventional bucket, but a conventional bucket is generally not efficient in hard packed substrate. Solid rock excavation generally requires a hydraulic hammer, but a hydraulic hammer is not efficient for excavating hard packed substrate because it is slow and requires an additional bucket to remove the material. Intermediate substrate excavation generally requires a ripper, but a ripper may not be efficient for excavating hard packed substrate because it requires an additional bucket to remove the material. Intermediate substrate excavation also generally requires a ripper bucket combination, e.g., similar to that described in Horton, U.S. Pat. No. 7,322,133, entitled “Multi-Shank Ripper”, the complete disclosure of which is incorporated herein by reference, but a ripper bucket combination is considerably more expensive and may not be efficient for excavating hard packed substrate because it generally has a small capacity and it is not flat on the bottom for easily forming flat trench bottoms. Excavation projects generally require that the bottom of the excavated hole or trench be flat. Attempts have been made to develop tools that are effective, inexpensive, and efficient in excavating hard packed substrate while making the trench bottom flat. Simply stated, there has been one general approach, i.e. the spade nose bucket approach, e.g. as described in Evans et al., U.S. Pat. No. 5,992,062, entitled “High Penetration Bucket Arrangement,” and replaceable versions, e.g. as described in Grant, U.S. Pat. No. 7,266,914, entitled “Wear Plate Assembly,” and versions thereof, the complete disclosures of which are incorporated herein by reference. Evans et al. describes a forward center tooth that makes penetration engagement with the soil prior to the side teeth and side teeth assemblies that will engage the material at the same time. This arrangement provides for good penetration and efficiency when the first center tooth engages; however, as soon as the two outer tooth assemblies engage with the soil, the efficiency drops and the soil resistance becomes dramatically higher. Grant also described a spade nose type bucket for a loader; however, the front leading edge contains a replaceable spade nose wear portion. This design also provides good penetration when the first center tooth engages; however, as soon as the subsequent multiple side teeth engage, the efficiency drops dramatically as the teeth engage in pairs. These teeth also align with each other when viewed from the side. Each of these approaches has been found to have drawbacks.
SUMMARY
[0004] According to a first aspect of the disclosure, a staggered edge excavation tool for use mounted to an arm of an excavation machine and having an axis of rotation relative to the arm comprises a body mounted for rotation from the arm, a pair of generally flat, side leading edge plates mounted to the body, a formed back sheet mounted to said body and to the side leading edge plates, and a planar plate having a staggered front leading edge, the planar plate being mounted to span the region of the staggered edge bucket between the side leading edge plates, and attached to the formed back sheet and the side plates, to define, together, a staggered edge bucket volume for receiving material excavated from a hard packed substrate during excavation action. Also included is a set of two of more teeth mounted along the staggered front leading edge of the planar plate, wherein each tooth of the set of two or more teeth defines a forward surface non-aligned with the forward surfaces of all other teeth of the set of two or more teeth and thereby disposed for individual, sequential initial engagement with the hard packed substrate during excavation action, and the set of two or more teeth defines a flat plane that is generally parallel to the planar plate. Each tooth of the set of two or more teeth defines an excavation angle measured between a surface of the tooth and the axis of rotation, and the excavation angle of each tooth of the set of two or more teeth is different from the excavation angles of all other teeth of the set of two or more teeth.
[0005] Preferred implementations of the disclosure may include one or more of the following additional features. The staggered front leading edge of the planar plate defines scalloped front leading edge segments between teeth of the set of two or more teeth. The set of two or more teeth comprises at least three teeth, with each tooth equally spaced along the staggered front leading edge of the planar plate from every adjacent tooth. The front leading edge defines multiple edge portions, the multiple edge portions being disposed at contrasting angles relative to the direction of substrate engagement motion, e.g., the front leading edge is a staggered edge having two edge portions. The front leading edge defines a single multiple edge portion, the single portion being disposed at a predetermined angle relative to the direction of substrate engagement motion.
[0006] Preferred implementations of this aspect of the disclosure may also or instead include one or more of the following additional features. The excavation teeth are replaceably mounted to the tool. The excavation teeth are integral with the tool. The body portion comprises a body upper portion and a body tubular cross brace portion. Each excavation tooth comprises a weld-on adapter. Each excavation tooth has a top cutting surface and a bottom surface. Each excavation tooth terminates in a tip, and the first excavation tooth top cutting surface is disposed at a predetermined angle to the line through the arm pivot. The predetermined angle is between about 20° and about 50° from the tangent. The excavation teeth can be any standard or special style of excavation teeth. A tip radius dimension between the dipper stick pivot and each excavation tooth tip is about the same as a tip radius dimension of a conventional bucket.
[0007] Preferred implementations of this aspect of the disclosure may also or instead include one or more of the following additional features. The first excavation tooth is linearly advanced relative to the second excavation tooth in a direction of substrate excavation motion, whereby the first excavation tooth is engaged for excavating the substrate before the second excavation tooth is engaged for excavating the substrate. The tool further comprises additional teeth, for excavation engagement with a substrate, each additional tooth being laterally spaced from each other shank along the axis of rotation of the staggered edge excavation tool relative to the arm, and the excavation tooth of each additional tooth being linearly spaced from the excavation tooth of each other of the additional shanks in a direction of excavation motion. The excavation tooth is replaceably mounted to the tool. The excavation tooth is integral with the tool.
[0008] Preferred implementations of this aspect of the disclosure may further or instead include one or more of the following additional features. A front leading edge is staggered spanning both laterally at an angle, and connecting the forward side leading edge and tooth to the rearward side leading edge and tooth. Additional teeth are spaced along the front leading edge. All of the teeth and the front leading edge are positioned generally on a flat plane, providing a flat bottom on the excavation tool that is parallel to the angle of rotation. The forward tooth is set to the optimum excavation angle relative to the axis of rotation.
[0009] Preferred implementations of this aspect of the disclosure may still further or instead include one or more of the following additional features. The rearward side leading edge is shaped to support the front leading edge while also limiting side spillage, thus providing for maximum capacity of excavated material.
[0010] Preferred implementations of this aspect of the disclosure may include the additional feature of the staggered front leading edge plate including non-aligning teeth mounted thereto.
[0011] According to another aspect of disclosure, a method for excavation of a substrate employing a staggered edge excavation tool mounted to an excavation machine comprises the steps of: engaging a first excavation tooth of the staggered edge excavation tool with the substrate surface to be excavated and applying excavation force only to the first excavation tooth to cause the first excavation tooth to penetrate the substrate in excavation action, thereafter, engaging a second excavation tooth of the staggered edge excavation tool with the substrate surface being excavated and applying excavation force to the second excavation tooth to cause the second excavation tooth to penetrate the substrate in excavation action, and thereafter engaging, in succession, succeeding excavation teeth of the staggered edge excavation tool with the substrate surface being excavated and applying excavation force to the succeeding excavation teeth, in succession to cause the succeeding excavation teeth, in succession, to penetrate the substrate in excavation action.
[0012] Preferred implementations of this aspect of the disclosure may include one or more of the following additional features. The method comprises the further steps of, as the first excavation tooth penetrates the substrate surface to break out material from the substrate surface, allowing the tool and dipper stick to nosedive until a second excavation tooth engages the substrate surface with full cylinder force; and, as the second excavation tooth penetrates the substrate surface to break out material from the substrate surface, allowing the tool and dipper stick to nosedive until a third excavation tooth engages the substrate surface with full cylinder force. The method may further comprise the step of, as each succeeding excavation tooth, in succession, penetrates the substrate surface to break out material from the substrate surface, allowing the tool and dipper stick to nosedive until a still further succeeding excavation tooth, in succession, engages the substrate surface with full cylinder force.
[0013] According to yet another aspect of the disclosure, a method for excavation of a substrate employing a staggered edge excavation tool mounted on a dipper stick of an excavation machine comprises the steps of: (a) extending the dipper stick to full extent forward of the excavation machine and pivoting the excavation tool at the end of the dipper stick back to full extent; (b) lowering the dipper stick until a first excavation tooth of the excavation tool engages the substrate; (c) drawing the excavation tool toward the excavation machine to cause the first excavation tooth to penetrate the substrate surface in excavation action; (d) simultaneously pivoting the excavation tool forward until a second excavation tooth of the excavation tool engages the surface of the substrate being ripped; (e) drawing the excavation tool toward the excavation machine to cause the second excavation tooth to penetrate the substrate surface in excavation action; and (f) repeating steps (d) and (e) for each succeeding excavation tooth of the excavation tool, in succession.
[0014] According to yet another aspect of the disclosure, a method for excavation of a substrate employing a staggered edge excavation tool mounted on a dipper stick of an excavation machine comprises the steps of: (a) extending the dipper stick to full extent forward of the excavation machine and pivoting the excavation tool at the end of the dipper stick back so that the flat bottom is parallel to the ground; (b) lowering the dipper stick until the flat bottom of the excavation tool engages the substrate; (c) drawing the excavation tool toward the excavation machine to cause all of the teeth to shave substrate surface in excavation action; (d) simultaneously pivoting the excavation tool rearward thus keeping the bottom flat to the surface of the substrate being excavated; (e) drawing the excavation tool toward the excavation machine to cause the teeth to shave the substrate surface flat in excavation action.
[0015] The staggered edge bucket excavation tool described herein outperforms prior art tools, e.g. as described by Evans, et al., because no two teeth are in alignment. Each tooth of the disclosed excavation tool engages the hard packed substrate at different times, thus creating a smooth, higher force concentration as the bucket engages the material. None of the prior excavation tools is as efficient and effective for excavation of hard packed substrate as the staggered edge bucket described herein.
[0016] One advantage of the staggered edge excavation tool of this disclosure is realized when working with a top frost layer condition. Since the teeth engage one at a time, the staggered edge excavation tool has the ability to simplify excavation of a top layer of frozen ground due to the concentration of the breakout force on one tooth at a time. Once the top layer is removed, the soft soil underneath can be excavated easily and quickly with the large capacity of this tool. Other ripper/bucket combinations that might function similarly would be on the order of, e.g., four times as expensive, and typically would not have as large a capacity.
[0017] A further object of the disclosure is to provide excavation tools and systems that apply maximum working force to the working tooth for efficient and effective excavation of hard packed substrate.
[0018] It is another object of the disclosure is to provide excavation tools and systems with smooth operation and minimum stress on an excavating vehicle as it efficiently and effectively excavates hard packed substrate.
[0019] It is a further object of the disclosure to provide excavation tools and systems capable of easily forming a flat bottom in the trench or excavated formation of hard packed substrate.
[0020] It is a further object of the disclosure to provide excavation tools and systems capable of high quality, large capacity and low cost manufacture, with long and useful service life and, minimum of maintenance.
[0021] Drawbacks experienced with the prior art devices have been obviated in a novel manner by the present disclosure. It is, therefore, an outstanding object of the present disclosure to provide excavation tools and systems that efficiently and effectively excavate hard packed substrate.
[0022] The details of one or more implementations of the disclosure are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the disclosure will be apparent from the description and drawings, and from the claims.
DESCRIPTION OF DRAWINGS
[0023] FIG. 1 is a perspective view of a first implementation of a staggered edge excavation tool of the present disclosure having a front leading edge with multiple portions, the multiple portions being disposed at contrasting angles relative to the direction of substrate engagement motion, i.e., a staggered edge, in this case having two edge portions.
[0024] FIG. 2 is a top view of a portion of the excavation tool of FIG. 1 .
[0025] FIG. 3 is a right side view of a portion of the excavation tool of FIG.
[0026] FIG. 4 is a front view of the excavation tool of FIG. 1 .
[0027] FIG. 5 is a perspective view of a second implementation of a staggered edge excavation tool of the present disclosure having a front leading edge with only a single portion, the single portion disposed at a predetermined angle relative to the direction of substrate engagement motion, i.e., a staggered edge having a single edge portion.
[0028] FIG. 6 is a top view of the staggered edge excavation tool of FIG. 5 .
[0029] Like reference symbols in the various drawings indicate like elements.
DETAILED DESCRIPTION
[0030] Referring to FIGS. 1-4 , a staggered edge excavation tool 100 having a staggered or non-symmetrically angled, multiple portion edge has a body 120 for mounting from an arm (not shown), e.g., a dipper arm or a boom arm, and a set of first and second side leading edge plates 130 , 131 mounted to the body. The body 120 consists of two plates 121 that form a tube spanning between the side leading edge plates 130 and 131 . Each side leading edge plate 130 , 131 is perpendicular to an axis of rotation, R, of the tool, and each side leading edge is connected by a front leading edge plate 150 positioned for engagement with a substrate. Referring to FIG. 2 , the front leading edge plate 150 has an irregular, non-symmetrically angled (or staggered) front leading edge 151 with two edge portions at contrasting angles in the directions of substrate engagement motion. The front leading edge plate 150 connects the first side leading edge 132 to the second side leading edge 133 shown in FIG. 1 . The staggered front leading edge plate 150 shown in the drawings has mounted teeth 161 ; however, other implementation may or may not have mounted teeth. The side leading edge plates 130 , 131 and teeth 161 are laterally spaced apart along the axis of rotation relative to the arm, and the teeth are positioned in a direction of substrate engagement motion. The first side leading edge 132 and second side leading edge 133 are spaced apart in the direction of bucket motion, and a first tooth 161 A positioned foremost in the direction of substrate engagement motion is separated from a rearmost tooth 161 D by distance, D′, e.g., 11 inches for an 30-inch wide bucket or 15 inches for a 40-inch wide bucket, as shown in FIG. 3 . Additional teeth 161 (e.g. 161 B and 161 C as shown in FIG. 2 ) may be intermediately spaced along the front leading edge 151 of the front leading edge plate 150 . All of the teeth 161 and the front leading edge 151 are positioned generally on a flat plane, S, as shown in FIG. 3 , providing a flat bottom on the excavation tool that is generally parallel to the path of rotation. The top of the forward tooth 161 A can be set to the optimum excavation angle B, e.g. about 30°, relative to the axis of rotation, R, to provide maximum penetration in the substrate. The front leading edge plate 150 is configured to support tooth adapters 160 (to which teeth 161 are mounted, e.g. by pins), while also limiting side spillage, thus providing for maximum capacity of excavated material. The front leading edge 151 is scalloped to help slice through the hard packed substrate, e.g., as shown in FIG. 2 . The scallop segments generate a non-uniform, irregular pattern such that each tooth 161 is positioned at a different distance from the rear of the front edge plate 150 .
[0031] A curved back plate 140 as shown in FIG. 1 is mounted to span a region between the side leading edge plates 130 and 131 , and the side plates 141 , providing a bucket volume, V, of predetermined capacity, e.g. 1.2 cubic yards, for receiving material excavated from the substrate. The tip radius and the width of the staggered edge bucket may be similar to conventional buckets in order to maintain capacities that are also similar. As shown in FIG. 2 , the teeth 161 arranged on the tooth adaptors 160 may or may not be directly aligned in the direction of substrate engagement, e.g., perpendicular to the axis of rotation R′ or to the rear of the front leading edge plate 150 . By way of example, the midpoints of teeth 161 C and 161 D have non-perpendicular angles 163 C and 163 D, respectively, which are greater than 90 degrees.
[0032] The staggered edge bucket 100 of FIG. 1 improves the efficiency of excavating hard packed substrate, e.g., as compared to prior art tools, by focusing the breakout force one tooth at a time, while the flat bottom, as shown in FIG. 3 , simplifies the operation of forming a flat bottom in the trench. When the operator is excavating hard packed substrate, the bucket is rolled away from the operator, and then lowered, such that the first tooth 161 A engages the material first. The concentration of machine breakout force on one tooth provides a concentration of the forces that are high enough to easily break up hard packed substrate. As the bucket is rolled toward the operator and lowered, the second tooth, e.g., the tooth 161 B adjacent to tooth 161 A, engages the substrate. Looking only at the second tooth, because the second tooth is closer to the arm bucket pin location of rotation (axis, R′), the force on this tooth will be relatively higher, i.e. than the force on the first tooth, and also because the teeth are positioned in a flat plane, the angle, B′, as shown in FIG. 3 , for the second tooth, e.g. 32°, is relatively larger than the angle, B, for the first tooth, e.g. the angle for the first tooth is about 30°. This relatively larger angle, B′, creates a greater material slicing effect than the smaller angle, B, on the first tooth. Looking at the first and the second tooth together, the first tooth engages with the hard packed substrate with full breakout force. When the second tooth engages the substrate, some of the load is shared with the first tooth. As the bucket continues to be rolled forward the third tooth 161 C also adjacent to tooth 161 A engages the substrate. As the rolling motion continues, the fourth tooth 161 D immediately adjacent to the second tooth 161 B and closest to second side leading edge plate 131 engages the substrate. When all of the teeth have engaged with the substrate, the efficiency is only slightly better than a conventional bucket. Throughout a good portion of the digging of the hard packed substrate, the bucket will have all teeth engaged; however, when the material becomes difficult to dig the operator will know to position the bucket so that relatively fewer teeth are engaged, thus providing relatively higher forces for simplifying the excavation of the hard packed substrate.
[0033] The bucket volume, V, of the staggered edge bucket 100 fills and empties easily, permitting the operator to scoop all excavated materials. When the operator has excavated to the bottom of the trench to where he/she would like to produce a flat bottom, the staggered edge bucket can be positioned flat, similar to FIG. 4 , and can be forced laterally using the machine hydraulics, to shave the trench bottom material to produce a perfectly flat bottom. This technique is similar to the technique used with a conventional bucket.
[0034] Referring to FIGS. 5-6 , in a second implementation of a staggered edge excavation tool 200 , a front leading edge has only a single portion, with the single portion disposed at a predetermined angle relative to the direction of substrate engagement motion, i.e., a staggered edge having a single edge portion. The arrangement of the staggered edge bucket 200 allows an operator to own a relatively inexpensive bucket while being able to more efficiently excavate hard packed substrate, and also being able to easily shave the bottom of the trench flat, without requiring a tool change or machine change as required in order to use another style bucket. The staggered edge excavation tool 200 has a body 220 for mounting from an arm (not shown), e.g. a dipper arm or a boom arm, and a set of first and second side leading edge plates 230 , 231 mounted to the body. The body 220 consists of two plates 221 that form a tube spanning between the side leading edge plates 230 and 231 . Each side leading edge plate 230 , 231 is perpendicular to an axis of rotation, R′, of the tool, and each side leading edge is connected by a front leading edge plate 250 positioned for engagement with a substrate. The front leading edge plate 250 has a single edge portion that is angled laterally by angle, A ( FIG. 6 ), e.g. about 10° to about 35°, and connects the forward side leading edge 232 to the rearward side leading edge 233 shown in FIG. 5 . The staggered front leading edge plate 250 shown in the drawings has mounted teeth 261 . (Other implementations of the staggered edge excavation tool 200 may or may not have teeth mounted thereto.) The side leading edge plates 230 , 231 and teeth 261 are laterally spaced apart along the axis of rotation relative to the arm, and the teeth are positioned in a direction of substrate engagement motion, thus providing a forward side leading edge 232 and tooth 261 F ( FIG. 5 ) and a rearward side leading edge 233 and tooth 261 R ( FIG. 5 ) that are spaced apart in the direction of bucket motion by distance (e.g., a distance D′, e.g., 11 inches for an 30-inch wide bucket or 15 inches for a 40 -inch wide bucket) As shown in FIG. 5 , additional teeth 261 may be intermediately spaced along the front leading edge 251 of the front leading edge plate 250 . All of the teeth 261 and the front leading edge 251 are positioned generally on a flat plane, S, providing a flat bottom on the excavation tool that is generally parallel to the path of rotation.
[0035] The top of the forward tooth 261 F is set to the optimum excavation angle, B, e.g. about 30°, relative to the axis of rotation, R′, to provide maximum penetration in the substrate. The rearward side leading edge plate 231 is shaped to support the front leading edge plate 250 and tooth adapters 260 (to which teeth 261 are mounted, e.g. by pins 262 ), while also limiting side spillage, thus providing for maximum capacity of excavated material. The front leading edge 251 is scalloped to help slice through the hard packed substrate, e.g. as shown in FIG. 6 . The front leading edge 251 is disposed at angle A, as shown in FIG. 6 . Ideally, angle A ranges between about 10 ° and about 35°, but other angles may be employed. A curved back plate 240 as shown in FIG. 5 is mounted to span a region between the side leading edge plates 230 and 231 , and the side plates 241 , 242 , providing a bucket volume, V, of predetermined capacity, e.g. 1.2 cubic yards, for receiving material excavated from the substrate. The tip radius and the width of the staggered edge bucket may be similar to conventional buckets in order to maintain capacities that are also similar.
[0036] The staggered edge bucket 200 of FIG. 5 improves the efficiency of excavating hard packed substrate, e.g. as compared to prior art tools, by focusing the breakout force one tooth at a time, while the flat bottom simplifies the operation of forming a flat bottom in the trench. When the operator is excavating hard packed substrate, the bucket is rolled away from the operator, and then lowered, such that the first tooth 261 F engages the material first. The concentration of machine breakout force on one tooth provides a concentration of the forces that are high enough to easily break up hard packed substrate.
[0037] As the bucket is rolled toward the operator and lowered, the second tooth, i.e. the tooth 261 next adjacent to tooth 261 F, engages the substrate. Looking only at the second tooth, because the second tooth is closer to the arm bucket pin location of rotation (axis, R′), the force on this tooth will be relatively higher, i.e. than the force on the first tooth, and also because the teeth are positioned in a flat plane, the angle, B″′ for the second tooth, e.g. 32°, is relatively larger than the angle, B″, for the first tooth, e.g., the angle for the first tooth is about 30°. This relatively larger angle, B″′, creates a greater material slicing effect than the smaller angle, B″, on the first tooth. Looking at the first and the second tooth together, the first tooth engages with the hard packed substrate with full breakout force. When the second tooth engages the substrate, some of the load is shared with the first tooth, and as subsequent teeth engage with the hard packed substrate, the load is shared between each subsequent tooth until all of the teeth have engaged with the substrate. When all of the teeth have engaged with the substrate, the efficiency is only slightly better than a conventional bucket. Throughout a good portion of the digging of the hard packed substrate, the bucket will have all teeth engaged; however, when the material becomes difficult to dig the operator will know to position the bucket so that relatively fewer teeth are engaged, thus providing relatively higher forces for simplifying the excavation of the hard packed substrate.
[0038] The bucket volume, V′, of the staggered edge bucket 200 fills and empties easily, permitting the operator to scoop all excavated materials. When the operator has excavated to the bottom of the trench to where he/she would like to produce a flat bottom, the staggered edge bucket can be positioned flat and can be forced laterally using the machine hydraulics, to shave the trench bottom material to produce a perfectly flat bottom, G. This technique is similar to the technique used with a conventional bucket.
[0039] A number of embodiments of the invention have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. For example, the side leading edge plates 30 , 31 , of the staggered edge bucket 10 may be fitted with replaceable bolt-on or weld-on side cutters for severe applications. Also, the front leading edges could be a separate bolt-on or weld-on aftermarket assembly for existing buckets. Also, the excavation tool of the disclosure could be used on wheel-type, crawler-type and skid steer-type loaders or shovels. Additionally, teeth 161 A- 161 D can be arranged to engage the substrate in a sequence different than sequence described above, for example in the order of 161 A, 161 B, 161 D, 161 C. Accordingly, other implementations are within the scope of the following claims.
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A staggered edge bucket excavation tool has a body formed by side-leading edge plates, a back sheet, and a plate with a front leading edge spanning a region of the bucket between edge plates. The tool defines a volume for receiving material excavated from a hard packed substrate. Two or more teeth may be mounted along the front leading edge, with each tooth defining a forward surface non-aligned with forward surfaces of all other teeth, thereby disposed for individual, sequential initial engagement with the substrate during excavation. The teeth define a flat plane generally parallel to the planar plate. Each tooth defines an excavation angle between a surface of the tooth and the axis of rotation, and the excavation angle of each tooth being different from excavation angles of all other teeth. In implements, the front leading edge defines multiple edge portions or defines a single multiple edge portion.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND
[0001] The invention generally relates to a gas lift valve.
[0002] A well typically includes a production tubing string for purposes of communicating well fluid to a surface of the well through a central passageway of the string. Due to its weight, the column of well fluid that is present in the production tubing string may suppress the rate at which the well fluid is produced from the formation. More specifically, the column of well fluid inside the production tubing string exerts a hydrostatic pressure that increases with well depth. Near a particular producing formation, the hydrostatic pressure may be significant enough to substantially impede the rate at which the well fluid is produced.
[0003] For purposes of reducing the hydrostatic pressure and thus, enhancing the rate at which fluid is produced, an artificial-lift technique may be employed. One such technique involves at various downhole points in the well, injecting gas into the central passageway of the production tubing string to lift the well fluid in the string. The injected gas, which is lighter than the well fluid displaces some amount of well fluid in the string. The displacement of the well fluid with the lighter gas reduces the hydrostatic pressure inside the production tubing string and allows the reservoir fluid to enter the wellbore at a higher flow rate. The gas to be injected into the production tubing string typically is conveyed downhole via the annulus (the annular space surrounding the string) and enters the string through one or more gas lift valves.
SUMMARY
[0004] In one example, a gas lift valve assembly includes a housing that includes a first passageway that is substantially concentric with the central passageway of a string to communicate well fluid and a second passageway that is eccentrically disposed with respect to the central passageway to communicate a second fluid to lift the well fluid. The gas lift valve assembly includes a valve that is disposed in the second passageway and includes a ball valve to regulate communication of the second fluid.
[0005] In another example, a method includes providing a gas lift valve that includes a ball valve element and operating the ball valve element to regulate fluid communication through the gas lift valve.
[0006] In yet another example, a system includes a string that includes a central passageway to communicate well fluid to the surface and gas lift valve assemblies. At least one of the gas lift valve assemblies includes a ball valve to regulate communication of a gas lift fluid into the central passageway of the string.
[0007] Advantages and other features of the invention will become apparent from the following drawing, description and claims.
BRIEF DESCRIPTION OF THE DRAWING
[0008] FIG. 1 is a schematic diagram of a well according to an example.
[0009] FIG. 2 is a schematic diagram of a gas lift valve assembly according to an example.
[0010] FIG. 3 is a flow diagram depicting an artificial lift technique according to an example.
[0011] FIG. 4 is a perspective view of a ball valve according to an example.
[0012] FIG. 5 is a cross-sectional view of the gas lift valve of FIG. 2 according to an example.
DETAILED DESCRIPTION
[0013] In the following description, numerous details are set forth to provide an understanding of the present invention. However, it will be understood by those skilled in the art that the present invention may be practiced without these details and that numerous variations or modifications from the described embodiments are possible.
[0014] As used here, the terms “above” and “below”; “up” and “down”; “upper” and “lower”; “upwardly” and “downwardly”; and other like terms indicating relative positions above or below a given point or element are used in this description to more clearly describe some embodiments of the invention. However, when applied to equipment and methods for use in wells that are deviated or horizontal, such terms may refer to a left to right, right to left, or diagonal relationship as appropriate.
[0015] Referring to FIG. 1 , a subterranean well 10 includes a wellbore 11 that extends downhole into one or more subterranean formations. As depicted in FIG. 1 for purposes of example, the wellbore 11 is vertical. However, the techniques and systems that are disclosed herein may likewise be applied to lateral or highly deviated wells. Additionally, the wellbore 11 may or may not be cased by a casing string 12 , which is depicted in FIG. 1 . Furthermore, the well 10 may be a terrestrial subterranean well or may be a subset well, as many variations are contemplated and are within the scope of the appended claims.
[0016] As depicted in FIG. 1 , a production tubing string 14 extends downhole into the wellbore 11 . The production tubing string 14 communicates well fluid to the surface of the well. For purposes of enhancing the rate at which well fluid is produced, an artificial-lift technique may be employed in which a lifting gas (provided by a surface-disposed lift gas source 12 , for example) is injected into the production tubing string 14 to displace well fluid in the string 14 with the lighter gas to enhance the production of the well fluid. In general, the gas is communicated downhole via an annulus 15 of the well 10 and enters the production tubing string 14 at various controlled access points along the string 14 .
[0017] More specifically, as an example, the production tubing string 14 may include several side pocket gas lift mandrels 16 (gas lift mandrels 16 a , 16 b and 16 c , being depicted as examples in FIG. 1 ), which contain flow control devices to control the communication of gas from the annulus 15 into the central passageway of the string 14 . More specifically, each of the gas lift mandrels 16 includes an associated gas lift valve 18 (gas lift valves 18 a , 18 b and 18 c , being depicted as examples in FIG. 1 ) for purposes of establishing one way fluid communication paths from the annulus 15 into the central passageway of the production tubing string 14 .
[0018] As described herein, the gas lift valves 18 are injection pressure operated (IPO) valves. In general, an IPO valve opens when the annulus pressure exceeds the production tubing string pressure by a certain threshold. The pressure thresholds of the gas lift valves 18 may be separately configured, which permits the gas lift valves 18 to be opened in a certain sequence. It is noted that the production tubing string 18 may contain more or less than the three gas lift valves 18 that are depicted in FIG. 1 . Furthermore, the production tubing string 14 may contain one or more gas lift valves that have designs different than the design of the gas lift valve 18 .
[0019] As described herein, the gas lift valve 18 includes a ball valve 19 , which is constructed to be operated such that when the pressure of the annulus 15 near the gas lift valve 18 exceeds a certain threshold, the ball valve 19 opens to permit communication between the surrounding annulus and the central passageway of the production tubing string 14 . The ball valve 19 is further constructed to automatically close when the annulus pressure near the gas lift valve 18 decreases below the threshold.
[0020] Due to the use of the ball valve 19 to control the flow through the valve 18 , the valve 18 may be used in a barrier application. As a comparison, a conventional gas lift valve may use a check dart-type valve element for purposes of preventing a reverse flow through the gas lift valve when closed. However, these valve elements may deform when the element is used over a relatively wide pressure range, and this deformation may cause leakage. As such, conventional gas lift valves may not be suitable for a barrier application, which needs to seal over a wide range of pressures. In contrast, the ball valve design is capable of sealing over a wide range of pressures and thus, is suitable for use as a barrier device.
[0021] Referring to FIG. 2 in conjunction with FIG. 1 , as an example, the side pocket gas lift mandrel 16 is a sub, or assembly, of the production tubing string 14 , which houses the gas lift valve 18 and provides ports that permit communication between the annulus 15 and central passageway of the production tubing string 14 . The gas lift mandrel 16 includes a tubular housing 17 that contains a central passageway 35 that is concentric with the longitudinal passageway 120 of the mandrel 16 and forms a corresponding section of the central passageway of the production tubing string 14 . The housing 17 also includes a smaller diameter offset, or eccentrically-disposed, passageway 32 that is generally parallel with but is eccentric with respect to the longitudinal axis 120 . As depicted in FIG. 2 , the gas lift valve 18 is disposed inside the eccentrically-disposed passageway 32 .
[0022] As shown in FIG. 2 , the passageways 32 and 35 are generally parallel to each other, and the housing 17 includes at least one radial port 36 to establish fluid communication between the longitudinal passageways 32 and 35 when the gas lift valve 18 is open. The side pocket mandrel 16 further includes one or more radial ports 38 for purposes of establishing communication between the annulus 15 and one or more inlet ports 58 of the gas lift valve 18 . In this regard, the gas lift valve 18 includes upper 60 and lower 61 seals (o-ring seals, v-ring seals or a combination of these seals, as non-limiting examples) that circumscribe the outer surface of the housing of the gas lift valve 18 . These seals contact the inner wall of the passageway 32 to form a sealed annular space for receiving fluid from the annulus 15 .
[0023] In general, the gas lift valve 18 controls fluid communication between the annulus 15 and the central passageway of the production tubing string 14 in the following manner. As long as the annulus pressure is below a certain threshold, the ball valve 19 of the gas lift valve 18 remains closed to block fluid communication between the inlet port(s) 58 and an outlet port 52 of the gas lift valve 18 . Thus, when the ball valve 19 is closed, fluid communication does not occur through the gas lift valve 18 . When the annulus pressure exceeds the threshold, as described further below, the ball valve 19 opens to permit fluid communication between the inlet port(s) 58 and the outlet port 52 . When the ball valve 19 is open, fluid thus is communicated between the annulus 15 , into the inlet port(s) 58 , through the ball valve 19 , through the outlet port 52 , through the port(s) 36 and into the central passageway of the production tubing string 14 .
[0024] It is noted that the gas lift valve 18 may be installed and/or removed from the production tubing string 14 by a wireline operation (as a non-limiting example). In this regard, as a non-limiting example, the gas lift valve 18 may include a latch 62 , which is engageable by a tool at the end of a wireline for purposes of securing the gas lift valve 18 inside the passageway 32 , as well as releasing the gas lift valve 18 from the side pocket mandrel 16 for purposes of retrieving the valve 18 to the surface of the well 10 .
[0025] Referring to FIG. 3 , in accordance with embodiments of the invention, a technique 80 that is depicted in FIG. 3 may be used in conjunction with a gas lift valve. Pursuant to the technique 80 , the gas lift valve is run into a well, pursuant to block 82 . The annulus pressure is regulated, pursuant to block 84 , to selectively open and close a ball valve of the gas lift valve to control fluid communication through the gas lift valve.
[0026] Referring to FIG. 4 , as a non-limiting example of a possible design for the ball valve 19 , the valve 19 may include a ball element 100 that rotates about an axis 102 between open and closed positions. In this regard, the axis 102 is generally transverse to the longitudinal axis 120 of the production tubing string 14 , and pivot points extend from the ball element 100 into corresponding recesses of the housing of the ball valve 19 to confine the ball element 100 to rotate about the axis 102 .
[0027] The ball element 100 includes a central passageway 104 , which is aligned with the central passageway of the production tubing string 14 in the open state of the ball valve 19 . In the closed state of the ball valve 19 , the ball element 100 is rotated so that the passageway 104 is no longer aligned with the central passageway of the production tubing string 14 , but rather, for this orientation of the element 100 , the solid portion of the element 100 blocks fluid communication through the valve 19 .
[0028] The angular orientation of the ball element 100 about the axis 102 is controlled by a yoke 106 and a pin 110 . The pin 110 is located near a lower end of the yoke 106 and resides in a slot 105 of the ball element 100 . In general, the free end of the pin 110 resides in a longitudinal slot inside the housing of the gas lift valve 18 and is confined by the slot to move along the longitudinal axis 120 with the longitudinal translation of the yoke 106 . Due to the eccentric positioning of the pin 110 with respect to the axis 102 of the ball element 100 , upward movement of the yoke 106 causes the ball element 100 to rotate about the axis 102 to its closed position. Conversely, downward travel of the yoke 106 causes an opposite rotation of the ball element 100 for purposes of returning the ball element 100 to its open position (as depicted in FIG. 4 ). As also depicted in FIG. 4 , in general, the yoke 106 includes a longitudinally extending operator 112 that is connected to an actuator (as further described below) for purposes of longitudinally translating the yoke 106 and thus, transitioning the ball valve 19 between its open and closed states.
[0029] FIG. 5 depicts a non-limiting example of a possible implementation of the gas lift valve 18 . For this example, the actuator for the ball lift valve 19 includes a metal bellows diaphragm 150 . More specifically, the ball valve 19 is located inside an outer housing 130 of the gas lift valve 18 . The outer housing 130 includes a longitudinal slot in which the pin 110 slides and also includes the radial ports 58 that are constructed to receive well fluid from the annulus 15 (see FIGS. 1 and 2 , for example). The ball valve 19 controls fluid communication between the ports 58 and the lower port 52 of the valve 18 , which is also formed in the housing 130 .
[0030] The well fluid that enters the radial ports 58 exerts a pressure on a lower surface of the bellows 150 to form a corresponding upward force on the bellows 150 . This upward force, in turn, is countered by a downward force that is created by a stored gas charge. The bellows 150 is connected to the operator 112 of the yoke 106 so that upward and downward movement of the bellows 150 induces a corresponding longitudinal translation of the yoke 106 and thus, controls the open and closed state of the ball valve 19 .
[0031] A force that is created by gas in a pressurized upper gas chamber 160 of the gas lift valve 18 exerts a downward force on the opposite side of the bellows 150 . In general, the gas pressure inside the chamber 160 biases the yoke 106 downwardly, thereby biasing the ball valve 19 to rotate to a position to form a fluid blocking seal against a valve seat 177 to close the valve 19 . This biasing force, in turn, is overcome when the pressure that is exerted by the annulus fluid exceeds a predefined threshold. When this occurs, the upward force on the bellows 150 exceeds the downward force exerted by the gas in the chamber 160 to cause upward movement of the bellows 150 and yoke 106 , thereby transitioning the ball valve 19 to its open state and permitting fluid communication through the ball valve seat 177 and port 52 .
[0032] The annulus pressure required to open the ball valve 19 is set by the pressure charge inside the chamber 160 . As depicted in FIG. 5 , as a non-limiting example, the threshold may be established by adjusting the pressure of the gas charge. The gas may be introduced into the chamber 160 at an inlet fill port 170 in the outer housing 130 .
[0033] In general, when the ball valve 19 is open, fluid is communicated between the inlet ports 58 and the outlet port 52 of the gas lift valve. As depicted in FIG. 5 , as an example, the gas lift valve 18 may include a venturi 182 that is located between the ball seat 177 and the outlet 52 . In general, the venturi housing 182 includes a venturi orifice 186 , which minimizes turbulence in the flow of gas from the well annulus to the central passageway of the production tubing string 15 .
[0034] In accordance with a non-limiting example, the gas lift valve 18 may include energized seal assemblies 200 (T-seal assemblies, V-seal assemblies, chevron assemblies, o-ring assemblies, etc.) to seal the ball element 110 against the ball valve seat 177 . The energized seal assemblies 200 relax the tolerance requirements for the ball valve 19 and permit ease of operating the ball valve 19 , especially in the case of high annulus pressures.
[0035] While the present invention has been described with respect to a limited number of embodiments, those skilled in the art, having the benefit of this disclosure, will appreciate numerous modifications and variations therefrom. It is intended that the appended claims cover all such modifications and variations as fall within the true spirit and scope of this present invention.
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A gas lift valve assembly includes a housing that includes a first passageway that is substantially concentric with the central passageway of a string to communicate well fluid and a second passageway that is eccentrically disposed with respect to the central passageway to communicate a second fluid to lift the well fluid. The gas lift valve assembly includes a valve that is disposed in the second passageway and includes a ball valve to regulate communication of the second fluid.
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BACKGROUND OF THE INVENTION
In many parts of the country home swimming pools are very popular. A home pool can provide a place of exercise, entertainment and relaxation for the user. One of the drawbacks of owning a pool is the need to keep it clean. Although a pool filter removes contaminants suspended in the water, a film of dirt forms on the bottom and sides of the pool and leaves and other debris collect along the bottom. It is necessary to periodically clean the pool surfaces to remove the surface film and the bottom debris.
Manual pool cleaners typically are based upon a suction principle and are connected to the pool skimmer inlet. However, these manual systems require that the user spend a significant amount of time each week cleaning the pool. Thus, automated systems for pool cleaning have been developed.
One type of automated system, which can be termed a water jet system, uses a buoyant power head connected to a high-pressure water source. One such pool cleaner, disclosed in U.S. Pat. No. 3,291,145 to Arneson, includes a pair of flexible hoses extending downwardly from the buoyant power head. The hoses have nozzles through which high-pressure water streams are ejected. As the buoyant power head moves about the surface of the pool, the cleaner hoses sweep the dirt film from the bottom and sides of the pool and the debris on the bottom of the pool towards the main drain at the pool's lower end. Waterlogged leaves and large debris, collected in one place, can then be removed from the pool. Floating leaves and other material are driven to the edge of the pool where they are removed by the pool skimmer.
Although this type of pool cleaner does a fine job cleaning the pool, a currently available pool cleaner of this type requires that water be delivered to the buoyant power head at about 50 p.s.i. However, the maximum water pressure developed by conventional pool filter pumps is about 20-25 p.s.i. Therefore a booster pump is required to use this type of pool cleaner. The need for two pumps increases the purchase and installation costs of the pool cleaner. Operating two pumps is necessarily less efficient than operating a single pump.
A second type of automatic pool cleaner uses a suction principle. These pool cleaners are typically connected to the skimmer inlet so that no booster pump is needed. Operating this type of pool cleaner does create an additional resistance to flow requiring the filter pump to work harder, and use more energy, compared to the amount it would use without the pool cleaner. One type has a suction head which attaches itself to the bottom and sides of the pool and moves about the pool in little steps. As it does so it sucks up the dirt along the pool surface. Although this type eliminates the need for a separate booster pump, it suffers from the same disadvantage common to most suction-type pool cleaners. That is, all the dirt, waterlogged leaves and other debris removed by the pool cleaner is sucked into the pool filter. This causes the filter to clog up faster so that the filter must be backwashed more often. This is a particular disadvantage when a lot of leaves or other debris collect in the pool. Therefore, if a suction type of pool filter is left unattended for a sufficiently long period, such as can occur during a vacation, the filter may well become so filled with dirt that it becomes ineffective.
SUMMARY OF THE INVENTION
The present invention is directed to a pool cleaning system using an improved water jet type of pool cleaner including a buoyant housing containing a drive unit which delivers water under pressure to one or more flexible, depending hoses which clean the pool. Water from the outlet of the main pool filter passes through an in-line filter before passing through a flow director valve. The director valve is used to direct a fraction of the water from the main filter to a poolside cleaner connection and the remainder along the return line to the main outlet at the pool. A supply hose connects the poolside cleaner connection to the inlet of a fluid distribution manifold on the drive unit. The buoyant housing is powered about the pool by forward and reverse programmed driving nozzles so that the entire pool becomes clean. The dirt and debris is gathered at the low point on the bottom of the pool, typically at the leaf strainer covering the bottom drain. Floating debris is directed to the pool edges where it is collected by the pool skimmer.
Pressurized water is directed to the forward and reverse nozzle units through a rotary valve. The rotary valve is rotated by a drive gear train connected to the turbine wheel. The rotary valve is supplied pressurized water from the manifold. Depending upon the rotary orientation of the rotary valve, water is directed through the rotary valve to either the reverse or forward nozzle units. The forward nozzle unit is rotated along with the rotary valve so the orientation of the forward nozzle changes. The forward nozzle unit includes a nozzle angled relative to the direction in which the supply hose extends from the manifold inlet. The forward and reverse nozzles drive the buoyant power head about the pool in a manner similar to that disclosed in U.S. Pat. No. 3,291,145, the disclosure of which is incorporated by reference.
A primary feature of the present invention is the provision of the manifold to provide the pressurized cleaning fluid, typically water, to the forward and reverse nozzles, to the cleaner hoses and to the turbine wheel at substantially the same pressure. This eliminates the pressure drop which occurs when water passes through the turbine wheel of the prior art water jet type of pool cleaner. In addition, the turbine wheel has been configured to minimize turbulence and windage thus reducing drag. The net effect is that a standard pool filter pump can drive a pool cleaner made according to the present invention without the need of a booster pump. Thus the present invention achieves the cleaning effectiveness of the prior art water jet pool cleaner with the ease of installation, the lower cost and the energy efficiency of suction-type pool cleaners.
The director valve can be of two different types--manually operated or automatic. For both types a pressure gauge is used between the director valve and the poolside cleaner connection to monitor the water pressure at the poolside connection. The user periodically adjusts the manual valve using the pressure gauge as a guide to achieve the proper pressure at the poolside connection. The pressure gauge is also used to determine when the pool filter needs to be backwashed.
The automatic director valve adjusts the flow paths between the poolside connection and the main outlet by monitoring the pressure at an inlet of the director valve and adjusting a variable restriction to the flow path to the main inlet. The pressure gauge is used with the automatic director valve to initially set the valve and to monitor the condition of the main filter for the need to backwash.
The in-line filter is used to trap particles passing from the main pool filter to ensure proper operation and long life for the various pool cleaner components. The in-line filter is specially constructed to provide a very low pressure drop for maximum system efficiency. The in-line filter can be cleaned by merely removing a plug which allows water to flush out the cylindrical filter element. The filter body housing the filter element can be easily removed from a rigid line by backing off a pair of threaded rings which secure the filter body to the ends of the pipes.
Other features and advantages of the present invention will appear from the following description in which a preferred embodiment has been set forth in detail in conjunction with the accompanying drawings.
DETAILED DESCRIPTION OF THE DRAWINGS
FIG. 1A is a schematic representation of the pool cleaning system of the invention.
FIG. 1B is an enlarged schematic representation of the director valve of FIG. 1A.
FIG. 2 is an exploded perspective view of a pool cleaner made according to the present invention.
FIG. 3 is a perspective view of the manifold used with the pool cleaner of FIG. 2.
FIG. 4A is a front view of the manifold and forward nozzle unit of FIG. 3.
FIG. 4B is a top view of the manifold and forward nozzle of FIG. 3 shown mounted to the drive unit housing.
FIG. 4C is a cross-sectional view of the manifold and forward and reverse nozzle units taken along line 4C--4C of FIG. 4A.
FIG. 5 is an enlarged partial side view of the turbine wheel of FIG. 2.
FIG. 6 is a front view of the inside of the rear cover of the manifold of FIG. 4C.
FIG. 7 is a side cross-sectional view of the forward nozzle unit and rotary valve of FIG. 4C.
FIG. 8 is a cross-sectional view taken along line 8--8 of FIG. 7.
FIG. 9 is an end view of the rotary valve of FIG. 7.
FIG. 10 is a cross-sectional view of an in-line filter of FIG. 1A.
FIG. 11A is a cross-sectional view of an automatic flow director valve.
FIG. 11B is a plan view of the valve of FIG. 11A.
FIG. 11C is a sectional view taken along line 11C--11C in FIG. 11B.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1A, a pool cleaner system 1 includes generally a pool cleaner 2 moving about a pool P. Pool P includes a water drain D, a skimmer inlet S and a main outlet 0. Drain D and skimmer inlet S are connected to an inlet of a filter pump 3 through a valve 5, used to proportion the water flow to the filter pump from drain D and skimmer inlet S. The outlet of filter pump 3 is connected to a main filter 7. Pool P, drain D, skimmer inlet S, main outlet O, valve 5, filter pump 3 and filter 7 are all conventional.
A low pressure drop, in-line filter 9 is connected to main filter 7 and an inlet 11 of a flow directing valve 15. Valve 15, shown also in FIG. 1B, has a first outlet 17 connected to main outlet O by a return line 19. Valve 15 includes a second outlet 21 connected to a poolside cleaner connection 23 by a line 25. Pool cleaner 2 is provided with pressurized water from pump 3 at connection 23. The pressure along line 25 is indicated by a pressure gauge 27 connected to line 25 adjacent second outlet 21.
Turning now to FIG. 2, a water jet type of pool cleaner 2 is shown. Cleaner 2 includes a top shell 4, a bottom shell 6, a float 8 and a drive unit 10. Float 8 and drive unit 10 are mounted between top and bottom shells 4, 6. A pair of tires 12 are mounted to a pair of outwardly extending flanges 14 on bottom shell 6. The general configuration of pool cleaner 2 is essentially the same as that sold by Arneson Products, Inc. of Corte Madera, Calif. as Pool Sweep I. It is also similar to the pool cleaner disclosed in U.S. Pat. No. 3,291,145. Therefore, only those features which form a part of or are relevant to the present invention will be described in more detail below.
The primary distinction between the Arneson Pool Sweep I and the pool cleaner of present invention is the use of a novel water distribution assembly 16, shown in FIG. 4C. Assembly 16 includes a manifold 18 having front and rear covers 20, 22 and a main water inlet 24 formed within front cover 20. Water entering main inlet 24 passes into a hollow interior 26 within manifold 18.
Hollow interior 26 houses a part of a forward valve unit 28 and a rotary valve 30 within a cylindrical portion 32 of rear cover 22. See also FIG. 6. Forward valve unit 28 and rotary valve unit 30 are molded as a unitary structure 34 but may be made from separate components, if desired.
Rotary valve 30, as seen in FIGS. 7, 8, and 9, includes two peripheral regions 38, 40 which fluidly connect a throat region 36 in cover 22 with either a forward nozzle 42, formed within forward nozzle unit 28, or a reverse port 44, formed within one end 46 of rotary valve 30. One end 46 has a square cross-sectional shape and extends through a bore 48 in rear cover 22 for engagement within a correspondingly shaped opening 50 formed within an end 52 of a reverse nozzle unit 54 as shown in FIGS. 2 and 4C. Unit 54 is housed within the casing 56 of drive unit 10 and includes a central bore 58 through which water can pass from throat 36, past region 38, through port 44 and into bore 58 for discharge through a reverse nozzle 60. Together manifold 18, forward valve unit 28, rotary valve 30 and reverse nozzle unit 54 comprise water distribution assembly 16.
Reverse nozzle unit 54, and forward nozzle unit 28 and rotary valve 30 therewith, is rotated by a drive train 62 as described below. Water passing through main inlet 24 and into interior 26 passes directly into drive unit 10 through a bore 64 in rear cover 22. Bore 64 is directly aligned with main inlet 24 in front cover 20 and also with a housing inlet 66 formed in casing 56 of drive unit 10. Water passes through a nozzle 67 in drive unit 10 and is directed against an impulse turbine wheel 68 housed between casing 56 and a cover 70. This is accomplished in a manner similar to that used with the Pool Sweep I. However, to accommodate the lower pressure water, a larger diameter orifice in nozzle 67 is used to direct the water against the blades 72 of turbine wheel 68.
Turbine wheel 68 differs from the prior art turbine wheel in that the blade profile, shown in FIG. 5, is triangular. Each blade 72 has a flat, radially extending forward face 74 and a rearwardly inclined rear face 76 which intersects the base 78 of the forward face 74 of the adjacent blade. Thus blades 72 occupy a greater volume than the relatively thin, flat blades used with the turbine wheel of the Pool Sweep I. This reduces the volume of water carried about between the blades 72 so to reduce turbulence and windage and thus increase the efficiency of the unit. This increase of efficiency is very important because of the limited water pressure available from the filter pump, not shown, for powering drive unit 10.
As is standard with the Pool Sweep I, the impulse turbine wheel 68 includes a first worm 80 which engages a first worm gear 82 on a vertical drive shaft 84. A second worm 86 on shaft 84 engages a second worm gear 88 mounted to reverse nozzle unit 54. See FIGS. 2 and 4C. Water passes through main inlet 24 and bore 64 in manifold 18, through housing inlet 66 and nozzle 67, and past turbine wheel 68 and into the interior of drive unit 10 at a turbine exit 91, thus powering drive train 62. This results in the rotation of second worm gear 88 and reverse nozzle unit 54, to which it is mounted.
Water passes along direct pathways 104, 106 from interior 26 through a region 108 defined between front and rear covers 20, 22, through openings 110, 112 in front cover 20, and through rigid fittings 114, 116 for passage through flexible cleaner hoses 100, 102.
Water which enters housing inlet 66 exits the housing in two ways. Water passes through a lateral bore 90 in vertical drive shaft 84 and into an axial bore in the upper end 92 of shaft 84. This water then passes out through a tile rinser 94 mounted to the tip of upper end of shaft 84. With the prior art Pool Sweep I, water from within unit 10 would also pass through openings 96, 98 for passage into cleaner hoses 100, 102. With the present invention, since there is no need to supply water to the cleaner hoses from the housing, opening 98 is a blind hole. A circular post 118 on rear cover 22 extends into opening 98 when manifold 18 is mounted to drive unit 10 so that opening 98 and post 118 act as positioning aids. Opening 96 is left open to allow the flow of water from turbine wheel 68, out of unit 10 through opening 96, as indicated by arrow 103 in FIG. 4C, and into the pool.
Water is supplied to main inlet 24 by a supply hose 120 similar to that used with the Pool Sweep I. Supply hose 120 includes a first, rigid pipe section 122, a flexible section 124 and a float 126 mounted about the intersection of rigid and flexible sections 122, 124. Rigid section 122 and rigid fittings 114, 116 pass through appropriately placed openings 128, 130, 132 in top shell 4. Such openings are aligned with openings 110, 112 and inlet 24 respectively and permit threadable engagement of fittings 114, 116 and section 122 with their respective openings 110, 112 and inlet 24. An opening 134 is also formed within top shell 4 to accommodate forward valve unit 28.
In use, supply hose 120 is connected to a source of pressurized water, typically from the pool filter pump. Although the present invention may be used with many different sources of pressurized fluid, one of the advantages of the invention is that it can be used with water at the pressures produced by substantially all swimming pool filter pumps. This eliminates the need and cost of obtaining and running a special booster pump. Pressurized water is introduced into manifold 18 through supply hose 120 and main inlet 24 for distribution to rotary valve 30, cleaner hoses 100, 102 and turbine wheel 68 and at substantially equal pressures. This parallel fluid connection eliminates the pressure drop associated with the prior art water jet type pool cleaners in which the water was delivered to the forward and reverse nozzles and to the cleaner hoses only after passing the turbine wheel.
Rotating turbine wheel 68 causes drive train 62 to rotate reverse nozzle 54 and thus rotary valve 30 and forward nozzle unit 28 therewith. As shown in FIG. 8, water is forced through forward nozzle 42 for more than 50 percent of the time and through reverse nozzle 60 for less than 50 percent of the time. Reverse nozzle unit 54 ejects water in a reverse direction 136, which is generally parallel to rigid section 122. Water is ejected through forward nozzle 28 at an angle of about 15° to forward direction 138, that is in the direction of forward nozzle axis 140. As axis 140 precesses about direction 138, it also changes direction with respect to the horizontal and vertical. This precessional motion causes pool cleaner 2 to move in a manner similar to Pool Sweep I and to the cleaner disclosed in U.S. Pat. No. 3,291,145.
Turning now to FIGS. 1A and 10, in-line filter 9 includes a cylindrical body 142, entrance and exit coupling members 144, 146 and a cylindrical filter element 148 mounted within body 142 and between coupling members 144, 146. Water flowing through entrance member 144 passes into the interior 150 of in-line filter 9, flows along flow paths 152 through filter element 148 and through exit coupling member 146. Since the flow through in-line filter 9 is primarily axial, filter 9 exhibits a very small pressure drop. Central portion 153 of exit member 146 seals the far end 154 of filter element 148 so that all flow from entrance member 144 to exit member 146 must pass through filter element 148. Filter element 148 is cleaned by removing a plug 156 in exit member 146 allowing the water flowing in through entrance 144 to flush out all contaminants from filter element 148.
Occasionally it may be necessary to remove filter body 142 and filter element 148 therein for replacement or thorough cleaning. This is easily accomplished with in-line filter 9. Body 142 is mounted between coupling members 144, 146 by a pair of threaded rings 158, 160. By backing off rings 158, 160 allows filter body 142 and filter element 148 to be removed laterally from between entrance and exit members 144, 146.
Referring now to FIG. 1B, flow director valve 15 can be a manually operated three-way valve as schematically indicated at FIG. 1B, such as that sold by Ortega Valve and Engineering Co. of Westminster, Calif., as part no. G65028. With this valve the user manually adjusts the proportion of flow passing through outlets 17 and 21 until the pressure indicated by pressure gauge 27 falls within a desired operating range, typically between about 16 and 21 psi. This range may be indicated by making that segment of the gauge face green. If the gauge reads above 21 psi the user is to adjust director valve 15 to reduce the pressure along line 25. If the pressure drops below 16 psi and adjusting valve 15 does not raise the pressure above 16 psi, it is time to clean main and in-line filters 7 and 9.
In lieu of manual flow director valve 15, an automatic flow director valve 164, shown in Figs. 11A-11C, can be used. Automatic valve 164 includes an inlet 166, a first, pool outlet 168 and a second, cleaner outlet 170. Pool outlet 168 is fluidly connected to main outlet O by return line 19 while cleaner outlet 170 is fluidly connected to poolside cleaner connection 23 by line 25. Valve 164 includes a transversely positioned cylinder 172 within which a spool valve 174 is positioned. Valve 174 is biased in the direction of arrow 176 by a spring 177.
Under low pressure conditions, that is when the pressure at the inlet 166 is much less than the chosen minimum operating pressure, for example 16 psi, spool valve 174 will be in its fully forward position of FIG. 11A. When in this position water entering opening 178 and passing into annular chamber 180 surrounding spool valve 174 cannot pass through outlet opening 182 because spool valve 174 is too far in the direction of arrow 176. However, when the water pressure at inlet 166 is at or above the minimum operating pressure, an adjustable pressure ball check valve 184, shown in FIG. 11C, allows water from within the interior 186 of director valve 164 to flow through a passageway 188, past ball check valve 184 and into a region 190 above the face 192 of spool valve 174. This pressurized water forces valve 174 in the direction opposite arrow 176. The distance valve 174 moves is determined by the pressure within interior 186 and thus region 190. This in turn determines to what extent outlet opening 182 is uncovered by spool valve 174. By properly sizing the various components and openings, the flow path between inlet 166 and outlet 168 can be properly constricted to provide water to connection 23 at the proper pressure. A needle valve 194 allows any water trapped within region 190 to slowly and controllably bleed off to pool outlet 168 along a passageway 196 connecting region 190 and pool outlet 168.
Use of automatic director valve 164 eliminates the periodic adjustment which is needed with manual valve 15 as a result of filter 7 becoming filled with dirt. However, it is still preferred to use a pressure gauge 27 along line 25 to monitor the condition of filters 7 and 9.
As has been discussed above, the primary emphasis with pool cleaning system 1 is the elimination of or the minimizing of pressure drops along the flow paths. Director valves 15, 164 are configured to provide changing orifice sizes along the flow paths to main outlet O and poolside cleaner connection 23. Inefficient throttling type of flow controllers are not used. The losses associated with valves 15 and 164 are only of the orifice type thus minimizing pressure drop.
The present invention has been described relative to an embodiment in which a commercially available pool cleaner has been modified by mounting a manifold to the outside of the casing, replacing its valved drive jets with forward nozzle unit 28, rotary valve 30 and reverse nozzle unit 54, and modifying the shape of the blades on the turbine wheel. This embodiment makes it possible to manufacture the pool cleaner of the present invention as an adaptation of the commercially available pool cleaner with minimal tooling changes. The present invention may also be provided in the form of a kit for modifying existing water jet type pool cleaners.
Other modification and variation can be made to the disclosed embodiment without departing from the subject of the invention as defined in the following claims. For example, the particular configuration of manifold 18 can be changed so long as fluid from main inlet 24 is supplied directly, that is in parallel, to rotary valve 30, turbine wheel 68 and cleaner hoses 100, 102. Forward nozzle unit 28 may be made stationary with more than one forward nozzle, each fluidly connected to interior 26 according to the orientation of the rotary valve. Also, manifold 18 may be incorporated into a drive unit modified to provide a common fluid reservoir and parallel fluid paths to the forward and reverse nozzles, the cleaner hoses and the turbine wheel according to the present invention.
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An improved water jet pool cleaner system includes a pool cleaner with a buoyant housing powered about the pool by forward and reverse driving nozzles so dirt and other debris is gathered at the low point on the bottom of the pool by the action of depending cleaner hoses. Water from the filter pump enters a fluid reservoir from which it flows along parallel flow paths to the forward and reverse driving nozzles, to a turbine, and to the cleaner hoses. Pressurized water is directed to the forward and reverse nozzles through a rotary valve which is rotated by the drive train connected to the turbine. The parallel flow paths permits water to be provided to the driving nozzles, to the turbine and to the cleaner hoses at pressures substantially equal to the fluid reservoir pressure. The system uses a flow diverter downstream of the main pool filter to divert the proper amount of water to the cleaner. Manual and automatic flow diverters and a novel in-line filter are also disclosed.
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RELATED APPLICATIONS
[0001] The present application claims the benefit of U.S. Provisional Applications 61/262628 and 61/319114, the disclosures of which are hereby incorporated by reference.
TECHNICAL FIELD
[0002] The present invention relates generally to tiles for covering surfaces, and more specifically to composite tiles with the composite elements mechanically connected together, and improved methods for manufacturing said tiles.
BACKGROUND
[0003] Tiles have been used to cover different surfaces for a long time. They are used in different environments to provide different functions, for example as a hard wearing surface, decoration or water proofing. The size, shape, material and surface finishing of each tile installed in a tiling array can all be varied according to the use requirements. A tiling array as defined herein is an array of tiles in various shapes, sizes and materials that fit together to continuously cover a surface.
[0004] One type of installation is where a surface is covered in a tiling array composed of the same general type of tile, although certain characteristics such as the colour and size may be varied to produce visually appealing decorative patterns. Precise alignment of the tiles is required to achieve the visual effect.
[0005] Another type of installation is where a tile is installed as a decorative insert in another floor covering array, such as hardwood flooring or parquets where adjacent flooring planks are connected together with an interlocking tongue and groove system. Currently it is difficult to install certain types of tile, such as stone or metal tiles, as decorative inserts because such types of tiles lack coupling regions.
[0006] Traditional tiles are typically affixed to surfaces by a labour-intensive method in which each tile is individually placed on the surface and affixed thereto using adhesive between an underside of the tile and the surface. This process is repeated until the surface is covered in an array of tiles. As these traditional tiles do not have an integral positioning mechanism, the alignment process depends on the skill of the installer, who can optionally use spacing inserts or other tools. Significant time, usually at least one day, is required to allow the adhesive to harden before any grout application process can start, such that the total time is at least 2 days. This has made the installation cost high for small jobs.
[0007] A further complication arises during installation because traditional tiles have significant dimensional variance: 2 mm is not unusual, and in some cases up to 5 mm. To accommodate the variance, installers have to leave space between the tiles. The gap between the tiles is filled in a manual labour-intensive process with a material known as grout, which hardens after application. The final appearance depends on the skill of the installer applying the grout, and installation by a non professional is tedious and prone to producing an unappealing finish. The composition of the grout is varied according to the use requirement, for example in wet environments the grout provides water proofing to prevent permeation of water to the underside of the tile. The grout is usually flexible enough to accommodate any thermal expansion.
[0008] If additional layers, such as cushioning or underlay layers, need to be installed then each tile will have to be connected to the layer, which further lengthens the installation process.
[0009] There is therefore a need to manufacture a tile which can be easily and quickly installed by a non-professional and which overcomes the above drawbacks.
[0010] Various attempts have been made to produce a tile which can be readily installed in a reduced amount of time, with minimal need for manual alignment of each tile.
[0011] One example is the Snapstone® tiling system (disclosed at www.snapstone.com) produced by the Snapstone Co. LLC. This utilizes a porcelain tile which is glued to a substrate having a push fit interlocking mechanism arranged along its edges which locks adjacent tiles together. After installing the Snapstone® tiles on a floor in a floating tile installation, the gaps between the interlocking tiles are filled with grout manually.
[0012] Although an improvement on traditional tiles, the Snapstone® tiling system is a partial solution because the installation process still requires the grouting step. Additionally, the Snapstone® tile also requires the use of adhesive to fasten the tile to the substrate. This is a significant drawback because the adhesive compound can fail in use, especially through moisture damage.
[0013] Another partial solution is disclosed in U.S. patent application Ser. No. 11/701,777, the contents of which are hereby incorporated by reference. A substrate which is formed in an injection moulding process, preferably Reaction Injection Moulding (“RIM”), is attached to a pre-formed tile to form a laminated groutless tile. The means of attachment is by bonding between the substrate and tile, such as by use of an adhesive. The edges of the substrate of the resulting laminate tile are then linear milled parallel to the edges of the tile to produce coupling members.
[0014] Manufacturing a tile using reaction injection moulding is relatively slow, taking between 10 and 20 minutes to make a single tile. Additionally, use of RIM results in the dimensions of the end product varying from the designed dimensions due to dimensional changes during curing. This and the material used result in any sealing effect with adjacent substrates being sub-optimal.
[0015] The process of milling after moulding disclosed in U.S. patent application Ser. No. 11/701,777 increases the manufacturing cost and time, wastes material and space, and places restrictions on the precision and types of coupling members that can be made.
[0016] In use, the tile of U.S. patent application Ser. No. 11/701,777 suffers from substrate-to-tile debonding due to failure of the adhesive.
[0017] The invention as claimed herein overcomes some or all of the above mentioned drawbacks and provides an improved method of manufacture with lower production cost.
SUMMARY
[0018] It is an objective of the presently claimed invention to provide an improved method of manufacturing a mechanically-held tile wherein the process of directly mechanically connecting a substrate to a tile occurs during an injection process. Preferably the process of forming an interlocking system for engagement with other tiles also occurs during the injection process. The tiles thus manufactured can be placed on a subfloor in a floating tile array which can be readily removed and reused, such as an interconnecting tile array.
[0019] Herein is disclosed a method of manufacturing a mechanically-held tile, comprising providing a tile having a durable surface, an underside and an anchoring region, locating the tile in a mould, providing a substrate in the mould, and injecting a first flowable material into said mould which flows into contact and mechanically engages with the anchoring region, the said first flowable material solidifying into a retaining member which exerts a holding force on the tile and the substrate.
[0020] Tile is defined herein as a piece of material with a definite size that is usable to cover surfaces for aesthetic and/or functional purposes. It can be made from any material, for example ceramic, porcelain, natural stones of all kinds, marble, granite, limestone, sandstone, slates, artificial stone of all kinds, made with cement base or resin base, wood, plastic of all kinds, fiber board, cement, laminates, metal, glass, resin, leather, etc.
[0021] The claimed tile of the invention can have any size or shape provided it can form continuous covering of a surface when arranged together with others in a tiling array, including for example tiles in the same geometric shapes, squares, rectangles, hexagons, or any other shapes that complement each other.
[0022] A wide variety of coupling regions on the substrate may be used that facilitate connection with the coupling regions of other tiles or surface-covering materials. The coupling region is preferably provided on at least one lateral side of the substrate. The coupling region can also be partially enclosed within an underside of the substrate, facilitating easy insertion of separate coupling members. The coupling region should preferably vertically and horizontally connect a tile to an adjacent tile.
[0023] In exemplary embodiments, the coupling regions comprises cooperating male and female members, such as hook and lock, tongue and groove, interlock and snap buttons. Either or each type of members can be located along all, some or just one of the edges of the substrate in a distribution determined by the tiling system. In other embodiments such as temporary tiling arrays which are frequently re-used, only female members are provided, with removable double ended male members being inserted into some of the female members after manufacture according to the claimed invention. The above examples are just exemplary embodiments and it will be understood that a wide variety of alternative embodiments can be used. In other embodiments, the coupling members may not be formed: the composite or self-grouting tile produced will be readily layable with other similar tiles. In all cases, the tiles of the claimed invention can be laid in a floating array or affixed to the subfloor.
[0024] In exemplary embodiments, the injection system used is the insert moulding system wherein one or more components of the tile are located within the mould prior to injection in the positions relative to each other that these components will adopt in the mechanically-held tile.
[0025] In certain embodiments, providing the substrate is achieved by injecting a first flowable material, which solidifies to form said substrate integrally with said retaining member, said substrate further comprising an integral coupling region for connecting the mechanically-held tile with an adjacent coupling region.
[0026] In other embodiments, the substrate having a coupling region is provided in the mould, and the injecting comprises injecting a first flowable material into the mould which both engages an engagement region provided on the substrate and the anchoring region, and solidifies to form the retaining member. The substrate may be made of any suitable material including for example plastic, resin, metal, wood and laminates.
[0027] In yet other embodiments, the substrate is provided by injection of a second flowable material into the mould which flows into the mould forming the substrate and integral coupling region, and further comprising substantially concurrent or consecutive injection of a first flowable material to engage the anchoring region, thus mechanically anchoring the substrate to the tile by the retaining member.
[0028] The first flowable material is preferably a single common thermoplastic that is molten when heated. Preferably it sets quickly, during which it substantially maintains its volume so that shrinkage is minimized. Other materials such as resin that solidifies in by a chemical reaction in a process called Reaction Injection Molding may be alternatively used as the first flowable material. The material will flow into and fill space left in the mould.
[0029] Preferably the first flowable material is a relatively soft material capable of tightly mechanically holding the tile and substrate together. Even more preferably, when the first flowable material forms a retaining member that also functions as a grout gasket, it is waterproof and compressible but resilient when hardened, thus forming a waterproof seal between adjacent tiles when in a tiling array. The surface of the grout gasket may be patterned in the mould.
[0030] The first flowable material in certain embodiments involving concurrent injection is more than one material, so that the different desired components can have different properties and behaviors. The second flowable material where used may also have different material properties when hardened, so that different components have different properties and behaviours. For example, the first flowable material may be relatively compressible after it is set to form a grout gasket; the second flowable material may be relatively less compressible when used to form the supporting substrate. The supporting substrate provides strength and in certain embodiments connects other components such as the underlay. Preferably where a separate material is used to make the supporting substrate it is made of a low cost material. Other substantially concurrent or consecutive injections can be performed using other flowable materials to form functional layers or regions with different properties.
[0031] The material of the substrate may be one of the following thermoplastics: acrylonitrile butadiene styrene (ABS), polyethylene (PE), polypropylene (PP). Other plastics that on hardening are relatively rigid and can support the tile may be equally alternatively selected and employed by one skilled in the art without exercising any inventive activity.
[0032] The material of the grout gasket may be thermoplastic rubber (TPR). Other plastics that on hardening are relatively soft may be equally alternatively selected and employed by one skilled in the art without exercising any inventive activity.
[0033] Disclosed herein is providing the anchoring region of the tile by a surface or a step that extends from and is located generally inwardly from an outer edge of the tile. Many tiles have a suitable surface to act as the anchoring region from the original manufacturing process.
[0034] Most natural or artificial stone tiles come with a “chamfer” on all edges when they are manufactured; the original purpose is to smooth the “jagged” edges formed when stone is cut. If the tile comes with this “chamfer”, then that chamfer will constitute the anchoring region as material will flow onto the chamfer, overlapping all or a portion of the periphery of the durable surface and mechanically anchoring the substrate to the tile.
[0035] Most ceramic or porcelain tiles are made by firing pressed clay; when such clay is pressed in a pressing mold, the top of the tile is usually smaller than the base of the tile; such difference in dimension is called “rebate” which allows the pressed clay to be released from the press mold. If the tiles comes with such “rebate”, nothing need to be done as material will flow onto the rebate.
[0036] In the event that the tile does not have the chamfer or rebate when it is originally manufactured, artificial surfaces can be made on the upper surface of the tile to form the anchoring region in lieu of the chamfer or rebate. Where there is a chamfer or rebate but it is insufficient, it can be modified to provide a suitable anchoring region.
[0037] Also disclosed herein is an anchoring region of the tile provided by machining the outer edge of said tile or machining a recess in the underside of the tile.
[0038] In certain embodiments the anchoring region is formed by cutting a step or an angle on at least two or all sides of the tile by cutting tools. This method is also used if the tile is cut from a bigger tile or slab as the cut tile will naturally lack a chamfer or rebate on some or all sides. Various types of angles and steps can be employed that extend inwardly from the edge of the tile and provide a sufficient surface for the flowable material to mechanically grip. The anchoring region may have a horizontal component of about 1 mm measured from the tile edge, and the total width of the grout gasket may be about 2 mm, such that about 1 mm of the grout gasket overlays the 1 mm extent of the anchoring region. The extent of the anchoring region is selected based on the materials used to provide sufficient fixing, balanced against aesthetic considerations of the visible extent of the grout gasket in plan view. Preferably the anchoring region extends continuously around the whole periphery of the tile.
[0039] When the periphery of the durable surface is not accessible, for example when a grout gasket is not required, the anchoring region is machined or molded during tile formation in an accessible area such as the underside of the tile. Various types of recess can be employed that extend generally away from the plane of the underside and provide a sufficient surface for the flowable material to mechanically grip. This has the advantage that the tile can be securely attached mechanically, and may be optionally employed where additional mechanical anchoring is required. The size of each anchoring region on the underside is minimized in order to minimize any effect on the tile's strength. More anchoring regions on the underside may be provided when greater mechanical anchoring is needed.
[0040] In certain embodiments where the tile is disposed directly on the substrate, the substrate is provided with engagement regions that the flowable material flows into and engages with such that on solidifying to form the retaining member it mechanically holds the substrate and tile together. The engagement regions can take several forms. At the simplest, an underside of the substrate may constitute the engagement region. In other embodiments, spaced protrusions extending towards the underside of the tile and generally perpendicular to a plane of the substrate may constitute the engagement region. In other embodiments, one or more through-channels in the substrate provide access to engagement regions on an underside of the substrate. Surface gripping features may be provided on the engagement region to enhance the mechanical engagement. Preferably a plurality of through-channels are provided on the substrate so that the flowable material can flow into the channels and join up to form an interconnected structure disposed on and preferably flush with the underside of the substrate. The areas where the interconnected structure contacts the underside may comprise the engagement regions. The interconnected structure in some embodiments is an underlayment layer, which may be resilient to provide cushioning. The interconnected structure may have a grid arrangement. Preferably the channels are provided in a peripheral zone of the substrate and the first flowable material flows around a peripheral region of the tile to form a grout gasket. Preferably the interconnected structure when formed grips the substrate across a substantial portion of the underside of the substrate.
[0041] In some embodiments the substrate may be provided with a lip around its periphery extending substantially perpendicularly away from the plane of the substrate in one or both substantially perpendicular directions. The through-channels may be formed in said lip. The tile may be directly arranged on the substrate so that the flowable material flows around a vertical portion of the edge of the tile to form a rim and onto an anchoring region of the tile, but ingress between the tile and substrate is restricted. Preferably where protrusions or a lip is provided the protrusions or lip mechanically hold the tile at a minimum number of fixing points to restrict lateral movement, such as at each corner of the tile. All of the arrangements of the aforesaid engagement regions may be combined in compatible forms.
[0042] It is a further objective to provide an easy to install tile that eliminates the need for grout during installation.
[0043] It is a further objective to manufacture a tile with a very high dimensional reproducibility and reduces the need for subsequent calibration or machining.
[0044] By locating the tile in the mould and injecting a material which surrounds the periphery of the tile the dimensional variance is substantially reduced. The dimensional variance of a tile may exist in one, two or three dimensions corresponding to the width, length and thickness, and may vary across the tile as well as from tile to tile. Each can be compensated separately, depending on the position of the tile and design of the mould. For example, the thickness variation can be compensated without compensating the width and length by arranging for no flowable material to flow around the periphery of the tile. A tile with thickness compensated will have a substrate of variable thickness but the resulting composite tile will have a uniform height and can be laid flat with other tiles presenting a substantially co-planar surface. By compensating the variation to produce uniform tiles, the tiles may be aligned and spaced quickly on a surface, and form an array of level tiles.
[0045] Herein is disclosed a grout gasket formed from the first or second flowable material extending outwardly from one or more sides of the durable surface. The retaining member may function as the grout gasket.
[0046] Herein is further disclosed a grout gasket formed from the first or second flowable material which at least partially encapsulates the lateral sides and the anchoring region of the tile.
[0047] Use of a grout gasket also eliminates the need for precise positioning of the tile within the mould, provided that the flowable material can mechanically engage with the anchoring region.
[0048] In certain embodiments, one or more additional components selected from the group of strengthening ribs, a cushioning layer, a ventilation layer, a conduit layer, an underlayer and an acoustic layer are provided and fixed to the tile whilst the tile is in the mould. These functional layers may be located where required, such as on the underside of the durable surface or substrate. To prevent the tile from sounding hollow when used in a floating installation, it is preferred to provide an acoustic layer such as a layer of silicone gel on the underside of the durable surface. The functional layers may be attached by any means, but are preferably mechanically held in place by a force exerted between the durable surface and substrate by the retaining member.
[0049] Herein is further disclosed a mechanically-held composite tile comprising a tile having a durable surface, an underside and an anchoring region, a substrate disposed proximal to or in close contact with the underside, and a looping member as a grout gasket extending around a periphery of the tile and mechanically engaging the anchoring region, with at least a portion of the looping member extending into contact with an engagement portion of the substrate to exert a holding force on the substrate and tile.
[0050] The substrate may have an integral coupling region for connecting the tile with an adjacent coupling region. Tiles having such a coupling region are also referred to herein as interconnectable tiles. Tiles without an integral coupling region will also have high dimensional precision and have a grout gasket, and as such may be placed directly together or attached to a surface by known methods such as with adhesive or mounting adhesive pads.
[0051] An acoustic layer may be disposed directly on the underside of the tile. Other layers may be also provided between tile and substrate.
[0052] Preferably the looping member is formed in an injection process, and is made of a compressible but resilient material, capable of mechanically gripping and holding the tile and substrate together by itself
[0053] The anchoring region of the tile may be provided as discussed above.
[0054] The engagement region may be provided by an underside of the substrate accessed by through-channels in the substrate.
[0055] The looping member may have portions which comprise an interconnected underlayment structure in engagement with the engagement region, which mechanically grips the substrate.
[0056] Herein is also disclosed a self-grouting tile for a self-grouting tile system, each self-grouting tile comprising a tile portion having design dimensions of a width x, a length y, and a thickness z, and actual dimensions of a width x+δ x , a length y+δ y , and a thickness z+δ z , where δ x , δ y , and δ z each represent a manufacturing deviance from x, y, and z, respectively, and δ x ranges from −0.01x to 0.01x, δ y ranges from −0.01y to 0.01y and δ z ranges from −0.05z to 0.05z, the self-grouting tile further including a mechanical anchoring region formed therein; a tile support structure surrounding all edges of the tile portion to create a tile self-grouting portion, the tile self-grouting portion integrally formed with a tile base support portion, the tile self-grouting portion having a design width and length of t x and t y respectively such that, in the x-y horizontal plane of the tile portion the design self-grouting tile dimension is x+t x and y+t y , and due to the manufacturing deviance of the tile, the actual self-grouting portion width in the x direction is t x −δ x and the actual length in the y direction is t y −δ y , the tile base support portion of the tile support structure having a vertical design thickness of t z , and an actual thickness of t z −δ z such that the self-grouting tile design dimensions in the x, y, and z directions are substantially achieved regardless of any manufacturing deviance of the tile portion; and the tile support structure self-grouting portion or the tile base support portion mechanically engaging with the tile through the mechanical anchoring region in the tile.
[0057] The tile support structure of the self-grouting tile may further include coupling regions as discussed above for facilitating interconnection with adjacent self-grouting tiles.
[0058] Other aspects of the invention are also disclosed.
[0059] The claimed method of the invention thus produces a tile as claimed faster than a tile produced by existing methods. It does not require adhesive to affix the composite parts of the tile together, nor does it need to be milled, reducing the number of post-processing steps.
[0060] The claimed tile also has greater dimensional uniformity due to the compensation of the tile's intrinsic variation in one or more dimensions, and can thus be laid fast and accurately.
BRIEF DESCRIPTION OF DRAWINGS
[0061] Embodiments of the invention are described in more detail hereinafter with reference to the drawings, in which:
[0062] FIG. 1 shows the manufacturing steps of the prior art in U.S. patent application Ser. No. 11/701,777;
[0063] FIG. 2 shows the manufacturing steps according to an embodiment of the claimed invention;
[0064] FIG. 3 shows the manufacturing steps according to another embodiment of the claimed invention;
[0065] FIG. 4 a - 4 d show different views of an embodiment of an interconnectable tile made according to the claimed invention;
[0066] FIGS. 5 a and 5 b illustrate an alternative embodiment of a tile according to the claimed invention.
[0067] FIG. 6 shows different exemplary embodiments of forming the anchoring region on a tile according to the claimed invention;
[0068] FIG. 7 a - 7 e show different exemplary embodiments of coupling regions that can be employed with the claimed invention;
[0069] FIGS. 8 a and 8 b illustrate a method used to manufacture an interconnectable tile; FIG. 8 c illustrates an example of a finished tile according to the claimed invention; FIGS. 8 d and 8 e illustrate a method used to manufacture an interconnectable tile according to a further embodiment; FIG. 8 f illustrates a tile made by the method of FIGS. 8 d and 8 e.
[0070] FIGS. 9 a and 9 b illustrate a tile according to the claimed invention installed as a decorative insert and as a parquet respectively
[0071] FIG. 10 a and b illustrate the plan and cross-sectional views respectively of a tile dimensionally compensated according to the claimed invention.
DETAILED DESCRIPTION
[0072] Improved methods of making a mechanically-held tile in an injection process using a pre-formed component are disclosed herein.
[0073] In the following description, the methods of manufacture of the mechanically-held tile and the like are set forth as preferred examples. It will be apparent to those skilled in the art that modifications, including additions and/or substitutions may be made without departing from the scope and spirit of the invention. Specific details may be broadly described so as not to obscure the features of the invention; however, the disclosure is written to enable one skilled in the art to practice the teachings herein without undue experimentation.
[0074] FIG. 1 shows four steps of a prior art method of manufacturing a tile with an interconnecting mechanism. Firstly, a standard tile is located 100 in a mould with its durable surface flush against one of the surfaces of the mould. Then, a flowable material is injected 105 into the mould, flowing around the tile and into spaces left in the mould between tile and mould walls to form the substrate and an oversized surrounding lip. The tile and substrate are joined by non-mechanical methods. Thirdly the tile with substrate is removed from 110 the mould and finally a flange is milled 115 in the substrate where it protrudes from the sides of the tile to form an interconnecting mechanism.
[0075] FIG. 2 shows an improved method according to the current invention, which has a reduced number of steps. A tile with anchoring region is located 200 first in a mould, with the durable surface flush against a surface of the mould. This is followed by injection 205 of a flowable material into the mould, flowing around the tile and into spaces between the tile and mould to form the substrate. The mould walls have a shaped surface corresponding to a negative profile of a desired coupling region, such that the flowable material flows into and abuts against the shaped surface to form the coupling region during injection. The flowable material during injection 205 flows around gaps between the mould wall and tile, into engaging contact with an anchoring region of the tile to mechanically engage it and self-anchor the substrate and tile together. The gap is about 1 mm around the periphery of the durable tile. The tile can be removed 210 from the mould when the flowable material has sufficiently hardened to form a retaining member.
[0076] Referring to FIG. 3 , an alternative embodiment of the method in which both a tile is located 300 in a mould and a substrate with a coupling region is also located 305 in the same mould. The locating 300 , 305 steps are shown at an equivalent position in time because depending on the configuration of the mould the order of placing in the mould can be varied, or carried out simultaneously. Once arranged in the mould such that the anchoring regions are fluidly accessible, a flowable material is injected 310 into the mould, flowing into the fluidly accessible regions and into engaging contact with the anchoring region on the tile and the engagement region on the substrate. The tile can then be removed 315 from the mould when the flowable material has sufficiently hardened.
[0077] FIG. 4 a shows a plan view of a square tile with a durable surface 400 , having a grout gasket 405 formed by injection of a fluid material. The grout gasket 405 surrounds all of the edges of the durable surface of the tile. A pair of protruding male members 410 is disposed at a spaced interval on the substrate 415 ( FIG. 4 b ) on two adjacent sides of each tile. The male members 410 are for cooperation with female members 420 ( FIG. 4 b ) in the substrate.
[0078] FIG. 4 b shows an underside of the tile of FIG. 4 a but omits the tile.
[0079] In section views FIGS. 4 c and 4 d it can be seen that the grout gasket 405 extends upwardly from the substrate to cover all of each lateral edge of the tile. FIG. 4 d is an enlarged view of an edge of 4 c, in which an inwardly sloping surface on the upper edge of the tile forms the anchoring region 425 .
[0080] FIG. 5 a shows an exploded layered view of an alternative embodiment of the tile according to the claimed invention. Tile 500 is disposed for fluid-tight contact on a substrate 505 , which has a lip 510 around its periphery. Through-channels 515 are provided in the periphery of the substrate and extend through the lip. In the embodiment shown the through-channels 515 are open on one side. A grout gasket 520 forms a looping member around a peripheral region of the tile 500 . Spaced protrusions 525 extend downwardly from all sides of the grout gasket 520 , into and through the through-channels 515 . Extending in a plane across an underside of the substrate 505 from each of the protrusions 525 is an interconnected grid structure 530 , formed during the injection process.
[0081] FIG. 5 b shows a view of the underside of the finished tile of FIG. 5 a. The interconnected structure 530 is disposed tightly on the underside 535 of the substrate. The interconnected structure generally comprises a grid, having evenly spaced intersecting lines arranged at approximately 45 and 90 degrees to each other. Reinforcement is provided where the lines intersect. A peripheral line closest to and parallel with the edges of the substrate has discontinuities where the underside 535 of the substrate has a recess, such as coupling regions 540 in the form of arrow-headed female members. A replaceable double-headed male member (not shown) can be inserted into two opposing female members on two adjacent interconnectable tiles to connect the tiles. The intersecting lines may be wholly or partially received in guideways (not shown) in the underside of the substrate. Areas of the underside of the substrate away from the guideways may be relatively recessed to minimize material usage.
[0082] The embodiment of FIG. 5 a, b is made by placing the substrate 505 , which has the through-channels, and coupling regions 540 in the mould in sequence with the tile 500 , the tile's durable surface being flush against a surface of the mould, but with its edges being spaced from the mould walls. A first flowable material plastic is then injected into the closed mould. The flow of the plastic material will vary depending on the mould design, but it will flow on a portion of the underside 535 of the substrate, and via guideways (not shown) will join up to form the interconnected grid structure 530 . The regions where the interconnected structure 530 contacts the underside 535 comprise all or part of the engagement regions. The guideways may be provided in the mould wall or in the underside of the substrate. The plastic also flows through the through-channels towards the tile, and towards the sides of the tile to form the grout gasket 520 . The plastic will also flow to the anchoring regions on the durable surface of the tile, and will mechanically anchor everything together after solidifying into a single piece.
[0083] Referring now to the top three illustrations of FIG. 6 , various examples of anchoring regions 600 on an upper edge of the tile are shown. A sloping surface extending over a partial (such as a natural chamfer) or a full height (such as made by a cutting saw) of the edge or an inward step can be used, and other non-shown variants will be realizable by the skilled user. The 4 th illustration of FIG. 6 shows a tile where the anchoring region is a rebate 605 drilled or molded during tile formation into an underside of the tile. The lateral extent on the underside, distribution and depth can be varied, as can the shape and size of the rebate 605 . The rebate 605 has a pinch point located towards the underside of the substrate such that once fluid material has flowed into the rebate and solidified, the solidified material cannot be removed.
[0084] FIGS. 7 a, 7 b and 7 d are side views illustrating different exemplary male 700 and female 705 coupling members for functioning as cooperating coupling regions. In FIG. 7 d internal detail of a coupling region is also shown in dotted lines. They show hook and lock, tongue and groove, and interlock respectively. FIGS. 7 c and 7 e are bottom views. FIG. 7 c shows snap buttons, whereas FIG. 7 e shows coupling members comprising two female members and a double headed male insert as connector.
[0085] FIG. 8 a shows the first step of a method according to the invention: locating the tile in a shaped mould. Tile 800 has a chamfer 805 around its periphery. Anchoring regions in the underside (not shown) may also or alternatively be used. The tile is located in the lower half of a mould 810 with the durable surface flush against a floor of the mould 810 . Space is provided around the sides of the tile 800 . The upper half of the mould has the female profile 815 of the desired substrate and integral coupling region.
[0086] In FIG. 8 b the two halves of the mould are fluid tightly joined, and flowable material is injected to form a one-piece substrate 820 and grout gasket 825 around the tile. FIG. 8 c shows an interconnectable tile after the injection process of FIG. 8 b has terminated. In the exemplary embodiment of FIGS. 8 a - 8 c, a tongue-and-groove coupling region is formed; however, it is understood that other coupling geometries, including, but not limited to, the coupling configurations of FIGS. 7 a - 7 e can be formed by the process of FIGS. 8 a - 8 b by selection of a corresponding mould configuration.
[0087] FIGS. 8 d and 8 e depict a molding method for forming a tile with a substrate portion and a further molded portion such as the tile of FIG. 5 . The tile 800 with the chamfered portion 805 is placed in the first half of the mould. Substrate 840 , substantially corresponding to substrate 505 of FIG. 5 , is placed behind tile 800 or alternatively is molded to tile 800 in a separate molding step. Substrate 840 includes through-channels 845 through which a polymeric material can flow. Flowable polymeric material 820 is injected into the mold to create gasket/grout portion 825 and the interconnected regions depicted in FIG. 5 (not visible in the cross-sectional views of FIGS. 8 d and 8 e ). The finished tile of FIG. 8 f is substantially similar to that of FIG. 5 b. While the tile of FIG. 5 b is configured to receive a double-headed male interconnecting element, it is understood that the process of FIGS. 8 d and 8 e can be used to form other interconnection structures, either male or female, through selection of the appropriate mould shape.
[0088] For different applications, the interconnectable tile can be installed in combination with other covering materials that already have a connecting system, for example solid and engineered wood planks, parquet systems and so on. In such cases, the coupling regions of the interconnectable tile should be capable of cooperating with those of the other covering materials to form a mating couple. Examples of other covering materials include wood planks and parquet, laminate, bamboo, etc. that come with interconnecting systems such as tongue and groove. FIG. 9 a shows an interconnectable tile 900 in a floor covering of tongue and groove wooden planks 905 . FIG. 9 b shows an interconnectable tile 900 in a parquet array 910 . Although the same reference numeral is used to refer to the tile, the tile may have various configurations and coupling regions.
[0089] FIG. 10 a shows a plan view of a self-grouting tile 1000 which has nominal dimensions of x and y in the length and width dimensions and manufacturing deviations δ x , δ y , in the x and y dimensions respectively. Typically, δ x ranges from −0.01x to 0.01x and δ y ranges from −0.01y to 0.01y The nominal design thickness of the grout is t x and t y respectively, such that, in the x-y horizontal plane of the tile portion, the nominal design self-grouting tile dimension is x+t x and y+t y . However, due to the manufacturing deviance of the tile, the actual self-grouting portion width in the x direction is t x δ x and the actual length in the y direction is t y −δ y . Thus the actual tile dimensions are compensated by the surrounding tile self-grouting portion 1005 such that the width is x+(t x −δ x ) and the length is y+(t y −δ y ) resulting in a length and width of the tile plus self-grouting portion substantially equal to the design dimensions regardless of the actual dimensions of each individual starting tile.
[0090] Similarly, the tile base support portion of the tile support structure has a vertical design thickness of t z , and an actual thickness of t z −δ z such that the thickness is z+(t z −δ z ).
[0091] The tile self-grouting portion 1005 formed integrally with the tile base support portion 1010 ( FIG. 10 b ) constitutes the tile support structure. The dimensions shown in FIG. 10 are representative only and not to scale. In a typical tile, the variation in the x and y directions is about 3 mm (1%). In the z direction it may be up to +/−0.4 mm (5%). Although not shown, the deviation may vary across the tile and therefore so will the compensation.
[0092] Thus in a particular example, if a tile of 305 mm×305 mm×8 mm, being the length, width and height respectively, the tile will come with manufacturing deviances as shown in Table 1 below.
[0093] After compensation by the tile support structure the self-grouting tile will have substantially reduced dimensional variance as shown in Table 1, with figures rounded to nearest significant place.
[0000]
TABLE 1
Tile actual
%
Compensated
%
Dimension
dimensions/mm
variation
dimensions/mm
variation
X
305 +/− 3
1
307 +/− 0.1
0.04
Y
305 +/− 3
1
307 +/− 0.1
0.04
Z
8 +/− 0.4
5
11 +/− 0.1
0.01
[0094] The injection process substantially compensates whatever dimensional variation of the decorative body, resulting in this example in a substantially reduced dimensional variance of 0.1 mm in all three dimensions.
[0095] FIG. 10 b illustrates how a manufacturing deviations δ z of the tile in the z dimension can be compensated by the tile base support portion of design thickness t z.
[0096] The anchoring region of the tile and coupling regions are not shown but are as discussed above with reference to other embodiments.
[0097] The foregoing description of embodiments of the present invention is not exhaustive and any update or modifications to them are obvious to those skilled in the art. Reference is made to the claims for determining the scope of the presently claimed invention.
INDUSTRIAL APPLICABILITY
[0098] The claimed invention is suitable for use in the tile manufacture and installation industry, particularly in the manufacture of interconnecting tiles in a one-step thermoplastic injection process. It is also suitable for use in providing tiles that can be used with a wide variety of interlocking materials that provide coverage of surfaces, such as wooden flooring systems and as a decorative insert.
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A method of making a mechanically-held tile is disclosed by providing a tile having a durable surface, an underside and an anchoring region, locating the tile in a mould, and injecting a polymer into the mould to form a substrate with an integral coupling region. Alternatively, a substrate can be provided in addition to the tile; the injected material mechanically anchors the substrate to the tile. A surrounding grout gasket can also be formed during injection. Injections can be consecutive or concurrent to tailor the properties of the substrate, grout gasket and other layers or regions. Also disclosed is a multi-part tile made by such a process, and a tile with intrinsic manufacturing deviations compensated by a grout gasket. The tile can be interconnected via the coupling regions with other surface-covering materials.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
The present invention is based on the problem of creating a directional drilling tool that improves directional drilling behavior and increases drilling progress.
BRIEF DESCRIPTION OF THE INVENTION
The design disclosed herein of a drilling tool with an impact device acting on its bit shaft allows for a drilling operation with a much reduced static compressive force on the drill bit which results in correspondingly reduced lateral force components on the drill bit which, in an ordinary design, act as interference forces on the desired directional behavior of the drilling tool. The smaller deflections of the drilling tool due to the reduced lateral forces are compensatable with lower radial control forces and the reduction in deviations combined with the reductions in the control forces increase the efficiency of the rock destruction process at the drill bit and allow for considerable increases in the rate of drilling progress. The drilling tool disclosed herein can be used with particularly favorable results in hard or brittle rock and in soil conditions with layers unfavorable to direction control.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows one embodiment of the present invention in a cut-away, partially broken off side view;
FIG. 2 shows another embodiment of the present invention in a cut-away, partially broken off side view.
DETAILED DESCRIPTION OF THE INVENTION
The drilling tool disclosed herein and illustrated schematically in FIG. 1 is shown in drill hole 1 and is connectable at its upper end via connectors, e.g., screw threads (not shown), to a drill string 2 and comprises a torsion resistant tool housing having an upper housing unit 3 that is provided at its lower region with stabilizer fins 4 and a lower housing unit 5 whose upper region is provided with stabilizer fins 6 and whose lower region is provided with four energizers 7 designed as lateral pressure elements capable of moving radially inwardly and outwardly. When in contact with the wall of the drill hole 1, energizers 7 determine the alignment of the drilling tool and thus the heading of the drill bit 10 and the eventual drill hole.
The drilling tool also comprises a bit shaft 8, rotatably mounted in the upper housing unit 3, rotatably extending through the lower housing unit 5, and bearing a drill bit 10 on its lower end 9 protruding from the lower housing unit 5. The bit shaft 8 is designed as a hollow shaft which surrounds a central, longitudinal channel 11 that forms a continuation of the interior of the drill string 2 and that ends at an opening in the region of the drill bit 10. An impact device or hammer assembly 12 is included as a component of the bit shaft 8 between the upper and lower housing unit 3 and 5, respectively.
The impact device or hammer assembly 12 can have any known or suitable design driven by means of the drilling fluid to generate axial vibrational forces in the lower unit 13 of the bit shaft 8 that are superimposed on a small static axial force and impart a pressure component of a threshold characteristic upon the drill bit 10. The upper end of the bit shaft 8 is linked with a rotary drive 14 located in the upper housing unit 3 and indicated schematically in FIG. 1. The drive 14 sets the drill bit shaft 8 into a preferably slow rotation which in turn gives the drill bit 10 a rotational motion.
The lower housing unit 5, which is of a tubular design like the upper housing unit 3, includes a control device 15, schematically illustrated in FIG. 1, which includes sensors used to determine the drill hole parameters, i.e., the particular position of the boring tool and especially its inclination, a processing means to evaluate the acquired data, and a transducer unit to issue control commands to the pressure operated energizers 7, of which there are at least four distributed along the perimeter of the lower housing unit 5 positioned radially in predetermined positions. The sensing, evaluating, and transducer units are not specifically shown in FIG. 1 but are generally indicated by control device 15 and can consist of various such units well known in the drilling art.
The sensing, evaluating, and transducer units of the control device 15 can control the directional profile of the drill hole 1 according to a specified program and can be equipped with a separate power source (not shown). Nevertheless, they can also be linked to an above-ground controller (not shown) via a connector cable 16 for a continual data exchange as shown in FIGS. 1 and 2. A power supply to the control device 15 can be provided via the connector cable 16 which should generally run inside the drill string 2 and then, for at least a part of its length, in the annulus of the hole 1 drilled by the drilling tool.
Compressed air is preferred as the drilling fluid or agent for the drilling tool disclosed herein, especially for drilling in mining or in construction where, frequently, depths of only a few hundred meters are needed. Use of compressed air as the drilling fluid also improves removal of fines in hard formations. Furthermore, when compressed air is used as the drilling fluid, other electrical transmission elements can be used, e.g., slip ring transferors or transformational couplings (not shown) in place of the connector cable 16. When a liquid drilling fluid is used, however, information is obtained from sequential pressure changes in the drilling fluid column, as is common in deep drilling. The design of the overall system operated by the drilling fluid, such as the specific rotary drive and impact device, is generally tailored to the particular drilling fluid used.
FIG. 2 illustrates a design of the invention disclosed herein where a shock absorber 17 acts upon the bit shaft 8 above the impact device 12. This shock absorber 17 is a component of the bit shaft 8 and is located in the region between the housing units 3 and 5, where the impact device 12 is located in FIG. 1. The impact device 12 of FIG. 2 is located in the region of the bit shaft 8, where the housing unit 5 is located in FIG. 1.
Accordingly, in the embodiment shown in FIG. 2, the control device 15 is located in the lower region of the housing unit 18 and at the level of the energizers 7. This control device 15 is also linked to an above ground control unit via a connector cable 16. The shock absorber 17 braces the threaded connectors under occurring axial shock stresses so that the amplitude of the axial force vibrations can be readily increased without effecting the threaded connections (not shown) or the components of the measuring and evaluation units of the control device 15. This, in turn, allows for an increase in the drilling rate.
In the foregoing specifications, this invention has been described with reference to specific exemplary embodiments thereof. It will, however, be evident that various modifications and changes may be made thereunto without departing from the broader spirit and scope of the invention as set forth in the appended claims. The specification and drawings included herein are, accordingly, to be regarded in an illustrative rather than in a restrictive sense.
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The present invention discloses a drilling tool apparatus and method for sinking drill holes in underground rock formations while using a selectable direction profile for the drill hole.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND
[0001] The present invention relates to gripper blocks installed in coiled tubing injection equipment used in the oil and gas production industry. More specifically, the present invention relates to a gripper block designed to better accommodate lengths of coiled tubing with varying outside diameters.
[0002] Reeled or coiled tubing has been used for many years for performing certain downhole operations, including but not limited to completions, washing, circulating, production, production enhancement, cementing, inspecting, and logging. There are a number of patents issued on coiled tubing injectors and related equipment. Such injectors generally use a pair of opposed endless gripper chains mounted in a common plane. The gripper chains are normally made up of links, rollers, and gripper blocks. Opposed gripper blocks on the endless chains engage the tubing as to firmly grasp the tubing in such a way that the gripper blocks will force the tubing into or out of a wellbore when the gripper chains are driven. Upon setting the gripper chains into motion and upon each opposing pair of gripper blocks releasing their hold on the tubing, another pair of opposed gripper blocks grippingly engage the tubing and the cycle continues until a desired amount of tubing has been inserted into or withdrawn from the wellbore, or until the gripper chains are no longer driven.
[0003] Over the years, a variety of gripper blocks have been developed to improve the performance of coiled tubing injector units. Such improvements include designs directed to increasing the load carrying capability of gripper blocks, thus eliminating or limiting scarring and distortion of the tubing caused by gripper block engagement; providing the ability to accommodate differing tubing diameters without having to change gripper blocks; reducing the weight of gripper blocks; and reducing the manufacturing costs of gripper blocks. Such prior art gripper blocks are disclosed in U.S. Pat. No. 5,094,340 to Avakov, issued Mar. 10, 1992; U.S. Pat. No. 5,853,118 to Avakov, issued Dec. 29, 1998; and U.S. Pat. No. 6,230,955 B1 to Parks, issued May 15, 2001; each of these patents being assigned to the assignee of the present invention and the details of each of these patents being incorporated herein in its entirety by reference.
[0004] In the past, coiled tubing has had a constant cross section. However, maintaining a constant diameter for the tubing can present some problems under certain circumstances. For example, it may be desirable to reduce the weight of the string or to reduce the amount of drag in the wellbore by reducing the diameter of the tubing. Additionally, small diameter tubing is preferable if the size at the treatment area is particularly small or confined. However, it is also noted that smaller diameter tubing tends to buckle more readily than large diameter tubing and that smaller diameter tubing also presents significant pressure drop problems in longer tubing strings. It is notable that each of these problems with both large and small constant diameter tubing may be addressed by allowing the use of larger outside diameter tubing at the top of the string and a smaller outside diameter tubing at the bottom of the string proximate to the treatment zone. One convenient way of linking or connecting coiled tubing having varying outside diameters utilizes one or more tapered connectors in the tubing string. Such a tapered connector generally comprises at least a first tubular portion having a first tubing outside diameter, a second tubular portion having a second tubing outside diameter which is different than the first, and a tapered portion disposed between the first and second tubing portions. One such tapered connector for a tubing string is disclosed in U.S. Pat. No. 6,367,557 B1 to Rosine et al., issued Apr. 9, 2002; this patent being assigned to the assignee of the present invention and the details of this patent being incorporated herein in its entirety by reference.
[0005] The tapered connector, according to Rosine et al., and the improved gripper block designs, according to Avakov and Parks, make it possible to insert coiled tubing into a well using a twin carriage coiled tubing injector apparatus as known in the art. One example of a twin carriage tubing injector apparatus is shown in U.S. Pat. No. 5,553,668 to Council et al., issued Sep. 10, 1996; this patent being assigned to the assignee of the present invention and the details of this patent being incorporated herein in its entirety by reference. Although it is possible to stop the injector apparatus to adjust the spacing between the moveable gripper chains to accommodate varying outer tube diameters, it would be desirable to have an improved gripper block to accommodate abrupt changes in the outer diameter of jointed tubulars and tapered strings without costly stoppages to make adjustments or modifications. Accordingly, there is a need for an improved gripper block capable of not only engaging the surfaces of tubing having changing outer diameters but to conform rapidly to these changing geometries and reduce the number of stoppages for adjustment or modification required in standard twin carriage tubing injector apparatus.
SUMMARY
[0006] The gripper block of the present invention will address these needs and provide other desirable properties by creating modified V-style gripper blocks that quickly conform to variable outer diameter elongated objects (e.g. cable, plastic, wire, or pipe). This may be accomplished by designing a V-style gripper block comprising a block body being connectable to a gripper chain in an injector apparatus, a gripper plate having arcuate and/or angled gripping surfaces for engaging tubing of various outer diameters, and a flex layer of elastomeric material disposed between the gripper plate and the block body to allow a gripping surface of the gripper block to move relative to the block body to which it is attached. This relative movement allows the gripping surface of the gripper block to rapidly conform to a changes in the outer diameter of coiled tubing. It is believed that a gripper block that rapidly conforms to changes in diameter will be less likely to bind, crimp, or damage the coiled tubing and will also be able to better accommodate fittings, including tapered connectors.
[0007] The elastomeric material located between the gripper plate and the block body is strategically placed within the gripper block to allow the gripping surface to move without damage to the tubular material. In one embodiment the elastomeric materials may be of various polymeric compounds or blends including natural or synthetic rubber. Moreover, it is also possible to encapsulate a gel or liquid within a flexible membrane to achieve the same function of the elastomeric material. In yet another embodiment, the function of the elastomeric material may be achieved through various mechanical means, such as springs which extend between the block body and the gripper plate and allow the gripper plate to move relative to the block body as the outer diameter of the flexible tubing changes.
[0008] It is believed that a gripper block constructed in accordance with the present invention will allow operators to run tubulars having changing outer diameters without interruption. Specifically, a gripper block constructed in accordance with the present invention will allow twin carriage tubing injectors as known in the art to accommodate abrupt changes in outer diameter, joint tubulars, and tapered strings without costly adjustments or modifications.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The present invention will be better understood in view of the detailed description in conjunction with the following drawings in which like reference numbers refer to like parts in each of the figures and in which:
[0010] [0010]FIG. 1 is an exploded perspective view of a first embodiment of a gripper block with a cushion flex layer constructed in accordance with the present invention;
[0011] [0011]FIG. 2 is an exploded cross-sectional view of the gripper block with a cushion flex layer as shown in FIG. 1;
[0012] [0012]FIG. 3 is an assembled cross-sectional view of the gripper block with a cushion flex layer as shown in FIG. 1;
[0013] [0013]FIG. 4 is an exploded perspective view of a second embodiment of a gripper block with a spring flex layer constructed in accordance with the present invention;
[0014] [0014]FIG. 5 is an exploded cross-sectional view of the gripper block with a spring flex layer as shown in FIG. 4; and
[0015] [0015]FIG. 6 is an assembled cross-sectional view of the gripper block with a spring flex layer as shown in FIG. 4.
DETAILED DESCRIPTION
[0016] Referring now to FIGS. 1-3, a first embodiment of a gripper block 10 constructed in accordance with the present invention is shown. As best seen in FIG. 1, viewed along the longitudinal axis, the upper portion of a gripper plate 100 features a generally V-shaped channel 110 adapted to receive, for example, elongated objects such as coiled tubing. The topmost portion of the gripper plate 100 has a gripping portion 120 for engaging elongated objects. The gripping portion 120 further comprises a pair of opposed gripping surfaces 130 extending perpendicularly from the longitudinal axis. The opposed gripping surfaces 130 are generally inclined or slanted inward toward each other and form an angle of not greater than about 120°. In one embodiment, the opposed gripping surfaces 130 may be inclined at about 90° to each other. The opposed gripping surfaces 130 further feature a series of ridges 140 formed by alternating crests and roots. The ridges 140 permit the opposed gripping surfaces 130 to better engage the surface of coiled tubing as it is moved into or out of a wellbore. Note that the generally V-shaped profile of the gripper plate 100 is well suited to accommodate coiled tubing and other elongated objects having varying outer diameters.
[0017] Still referring to FIGS. 1-3, it is also possible to incorporate a curved gripping surface 150 into the gripping portion 120 of the gripper plate 100 . The curved gripping surface 150 may further comprise ridges, not shown, formed by alternating crests and roots. In one embodiment, the curved gripping surface 150 has a particular radius of curvature designed to accommodate an elongated object having a predetermined minimum outer diameter. For objects exceeding this particular outer diameter, the opposed gripping surfaces 130 will come into play and allow the gripper plate 100 to engage the object. In most embodiments, the radius of curvature for the curved gripping surface 150 should sweep and angle of not more than about 150°. The use of both curved gripping surface 150 and opposed gripping surfaces 130 allow for the gripper plate 100 to achieve better fit and conformity with the elongated object. In yet another embodiment, the opposed gripping surfaces 130 may extend outwardly from the endpoints of the curved gripping surface 150 to form ridges having a rather unique V-shape with a rounded bottom. This particular ridge design for the gripping portion 120 of the gripper block 10 is set forth and described in greater detail in U.S. Pat. No. 6,230,955 B1 to Parks.
[0018] Referring now to FIG. 2, a cross-sectional view of the gripper plate 100 is shown. The gripper plate 100 is usually constructed by casting, forging, or machining a single metal ingot formed of steel, titanium, or other suitable metal alloys. Note that the gripper plate 100 is shown to have an upper portion 102 with a generally V-shaped profile when viewed along the longitudinal axis and a lower portion 104 which is generally more box-like in shape and adapted to fit into an opening or recess 220 in the upper portion of block body 200 . It is understood that, although a box-like lower portion 104 is shown as fitted into a rectangular recess 220 , a number of alternative shapes and geometries may be used such as fitting a hemispherical lower portion into a cup-like recess. Again, the ridges 140 formed of alternating crests and roots that comprise the opposed gripping surfaces 130 of the gripper plate 100 are clearly visible.
[0019] Referring still to FIGS. 1-3, one embodiment of the block body 200 adapted to support the gripper plate 100 will be set forth and described. As shown here, the block body 200 has a form of tongue and groove design which allows the gripper blocks 10 to be connected end-to-end. By linking a number of these gripper blocks 10 together in series, it is possible to form a caterpillar-like chain which may be used as a gripper chain in a device for moving elongated objects, including coiled tubing, suitable for use in oil and gas applications. Although it is to be understood that the block bodies 200 may have any number of embodiments and be connected together in a number of different ways, this particular design allows the block bodies 200 to be easily fitted together and held one to another by two pins, not shown. The pins are fitted through openings 210 which extend laterally or transversally across the block body 200 near leading edge 202 and trailing edge 204 of the block body 200 . As with the gripper plate 100 , the block body 200 is generally formed of a single metal ingot which is cast, forged, or machined of steel, titanium, or other suitable metal alloys.
[0020] Referring still to FIGS. 2-3, a cross-section of the block body 200 is shown. The cross-sectional views permit a better look at the details of the generally rectangular recess 220 located in the central top portion of the block body 200 . The recess 220 , as shown here, features three smaller recesses or slots 230 extending downward into the block body 200 . Of course, the number and geometry of the slots 230 may be varied to suit differing applications or to address particular needs.
[0021] In use, the gripper plate 100 may be fitted into the recess 220 on the block body 200 and multiple block bodies 200 may be linked together by fitting pins through the openings 210 to form a gripper chain. However, in accordance with the present invention, the gripper block 10 will further comprise a flex layer 250 disposed between the block body 200 and the gripper plate 100 . In one embodiment, the flex layer 250 may be a polymeric elastomer such as rubber or the like which is fitted into the recess 220 on the top of the block body 200 prior to attaching the gripper plate 100 . This layer of rubber or elastomer may be about 5 to about 20 millimeters thick and will usually allow the gripper plate 100 to flex or move relative to the block body 200 in use. Of course, the amount of relative movement between the gripper plate 100 and the block body 200 and the amount of force required to induce this movement may be varied by controlling the mechanical properties and the choice of material used to create the flex layer 250 .
[0022] Typically, it is desirable to facilitate a relative movement between the gripper plate 100 and the block body of up to about 10 millimeters in any one direction. Although the magnitude of this movement would appear to be quite small, it is believed that this should be sufficient to reduce crimping or damaging coiled tubing as it varies in diameter and also to better accommodate fittings such as tapered connectors. As best seen in FIG. 3, the slots 230 at the bottom of the recess 220 formed in the block body 200 serve to provide voids into which the flex layer 250 may be forced or guided as loads are applied to the gripper plate 100 . In FIG. 3, the gripper plate 100 is rocked or tilted away from its neutral or resting position to show deformation of the flex layer 250 and the movement of an elastomer or an encapsulated fluid into the slots 230 .
[0023] In one embodiment, the flex layer 250 may actually serve to attach the gripper plate 100 to the block body 200 by selecting a polymeric adhesive compound having the requisite elastomeric properties, such as a natural or synthetic rubber based compound. It is noted that in various alternative embodiments it is possible to create a flex layer 250 with the desired elastomeric properties using a compressible or incompressible fluid which has been properly encapsulated. This may be carried out by disposing a layer of fluid between the gripper plate 100 and the block body 200 and then sealing it in place with a flexible seal about the perimeter of the gripper plate 100 and the recess 220 of the block body 200 .
[0024] Another alternative embodiment would be to create a flex layer 250 by encapsulating a fluid that is substantially incompressible within a flexible polymer membrane to create a small flexible cushion. In use, as loading is applied to the gripper plate 100 , it will tend to force the fluid into the slots 230 of the block body 200 thereby allowing the gripper plate 100 to flex or move slightly in any direction relative to the block body 200 . As noted earlier, small movements of the gripper plate 100 permit the gripper block 10 to engage elongated objects such as coiled tubing and to adapt to changes in the diameter without damaging the elongated object as it is handled. In this particular embodiment, the gripper plate 100 essentially floats atop the encapsulated fluid cushion of the flex layer 250 and is allowed to rock slightly forward, backward, or side-to-side relative to the block body 200 to which it is attached.
[0025] Referring now to FIGS. 4-6, a gripper block 20 similar to that shown in FIGS. 1-3 has been modified for use in an alternative gripper block design. The gripper plate 300 has a generally V-shaped channel 310 when viewed along the longitudinal axis and has a gripping portion 320 further comprising a pair of opposed gripping surfaces 330 along its top surface. The pair of opposed gripping surfaces 330 are provided with a number of ridges 340 formed by alternating crests and roots. As before, the opposed gripping surfaces 330 are sloped or inclined toward each other at an angle of not greater that about 120°. Also, as noted above in regard to FIGS. 1-3, it is possible to have a curved gripping surface 350 to better accommodate small diameter elongated objects. In most embodiments, the curved gripping surface 350 will have a radius of curvature that sweeps though an angle of not more than about 150°.
[0026] As best seen in FIG. 5, the gripper plate 300 has an upper portion 302 for engaging elongated objects and a lower portion 304 having a generally rectangular box-like design to be fitted into a recess 420 on block body 400 . However, in this particular embodiment, the gripper plate 300 has two cylindrical bores or openings 306 formed in its lower portion 304 and extend upward into the gripper plate 300 . The openings 306 are intended to accommodate a pair of mechanical springs. Although shown here as a pair of cylindrical bores 306 intended to accommodate a pair of generally cylindrical coil springs 450 , it is understood that a number of other mechanical solutions are possible involving various numbers and configurations of coil springs and the use of flat or leaf-type springs as well.
[0027] The block body 400 is similar to that shown in FIGS. 1-3, although the recess 420 in the block body 400 has been changed. The three slots or voids 230 which were previously intended to accommodate flowable liquids or movement of elastomeric materials have been removed and replaced by two cylindrical depressions or openings 430 extending downward into the block body 400 . The openings 430 may be used to accommodate the pair of springs 450 . The springs 450 serve to act as a functional equivalent to the flex layer 250 of various elastomeric materials or fluids described earlier in regard to the embodiments shown in FIGS. 1-3. The block body 400 has a form of tongue and groove design which allows the gripper blocks 20 to be connected end-to-end. By linking a number of these gripper blocks 20 together in series, it is possible to form a caterpillar-like chain which may be used as a gripper chain in a device for moving elongated objects, including coiled tubing, suitable for use in oil and gas applications. Although it is to be understood that the block bodies 400 may have any number of embodiments and be connected together in a number of different ways, this particular design allows the block bodies 400 to be easily fitted together and held one to another by two pins, not shown. The pins are fitted through openings 410 which extend laterally or transversally across the block body 400 near leading edge 402 and trailing edge 404 of the block body 400 .
[0028] Similarly, the materials used and the stiffness of the springs 450 as well as other physical characteristics may be selected to provide sufficient stiffness to hold the gripper plate 300 in place atop the block body 400 yet, under the application of applied loads, allow the gripper plate 300 to move or deflect up to about 10 millimeters in any one direction. Although this amount of deflection seems rather small in magnitude, it is sufficient to allow the gripper plate 300 to deflect quickly and accommodate changing outer diameters in coiled tubing better than unitary prior art gripper blocks. It is believed that by incorporating the springs 450 it is possible to reduce crimping and other damage to coiled tubing and also better accommodate fittings such as tapered connectors. Additionally, it is believed that gripper blocks having a separate gripper plate and block body with a flex layer placed therebetween will also result in less stoppages to adjust gripper chains and tubing injector apparatus settings when varying diameter coiled tubing is used in oil and gas operations.
[0029] While a number of preferred embodiments of the invention have been shown and described herein, modifications may be made by one skilled in the art without departing from the spirit and the teachings of the invention. The embodiments described herein are exemplary only, and are not intended to be limiting. Many variations, combinations, and modifications of the invention disclosed herein are possible and are within the scope of the invention. Accordingly, the scope of protection is not limited by the description set out above, but is defined by the claims which follow, that scope including all equivalents of the subject matter of the claims.
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An improved V-style gripper block to better accommodate a variable outer diameter material (e.g. cable, plastic, wire, or pipe). The gripper block comprises a block body being connectable to a gripper chain in an injector apparatus, a gripper plate having arcuate and/or angled gripping surfaces for engaging tubing of various outer diameters, and a flex layer disposed between the gripper plate and the block body to allow the gripping surface of the gripper plate to move relative to the block body to which it is attached. This relative movement allows the gripping surface of the gripper block to rapidly conform to changes in the outer diameter of coiled tubing. In various embodiments, the flex layer may be formed of elastomeric materials including natural or synthetic rubber; an encapsulated gel or liquid within a flexible membrane; or mechanical means such as springs.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
[0001] This application is a continuation-in-part of application Ser. No. 08/970,196, filed Nov. 14, 1997, which application is based in part upon Disclosure Document No. 373320 dated Mar. 8, 1995 and Provisional Patent Application, Serial No. 60/030,914, filed on Nov. 14, 1996.
FIELD OF THE INVENTION
[0002] The present invention relates to monolithic in situ field-applied roofing surface membranes. Preferably, the surface membrane is a fabric or fiberglass imbedded low rise polyurethane adhesive covered by a waterproof and ultraviolet resistant coating, such as a silicone coating.
[0003] The present invention also relates to a new and useful method and industrial robotic device for applying coatings or other spray coated layers, in uniform thicknesses and at appropriate angles of pitch, in field applications, such as roofing applications or pavement applications.
BACKGROUND OF THE INVENTION
[0004] In the roofing applications, flat roofs are often made of polyurethane foam layers, which may be covered by various coatings, such as elastomeric coatings, such as silicone. It is difficult to maintain a uniform thickness when applying a foam or elastomeric material, which by its nature rises when applied to achieve a thickness above a roof base.
[0005] Furthermore, the faster that a foam applicator passes over a surface, the less volume of foam is applied, resulting in less of a thickness of the applied foam. To achieve thicker foam layers, a spray applicator is slowed down in velocity as it passes over the roof bases, so that more foam material is discharged per square unit of space of roof base being passed over by the spray applicator.
[0006] Various attempts have been made to apply foam uniformly, such as from an applicator moving at a uniform speed along a carriage track. However, at the end of each pass of an applicator over a portion of a roof base, the discharged foam is applied twice, i.e. once at the end of the pass to the edge, and again as it starts over above the previously applied foam, until the carriage can adjust to an unsprayed area.
[0007] Field applied roofing foam surface membranes are rigid polyurethane foam surface membranes, such as manufactured by Stepan Company of Pennsylvania under the trade name STEPANFOAM®.
[0008] Stepan Company also manufactures a roofing product known as “low rise polyurethane adhesive”, brand name number RS 9514B, which is a concentrated polyurethane foam type adhesive often used to adhere solid rubber roof substrates to flat roof substrate structures.
[0009] However, it has not been known to imbed a low rise polyurethane adhesive with a woven polyester fabric or fiberglass layer and coat the formed substrate with silicone to create a monolithic integral roofing surface membrane for flat roofs, without the need for attaching a prefabricated roofing sheet, such as of vulcanized rubber, to the underlying roof substrate.
[0010] Furthermore, Dow Corning Corporation of Midland, Michigan manufactures silicone-based roofing coatings for weatherproofing reasons and for resisting the effects of ultraviolet light, such as the POLYCOAT® R-4000 silicone roof coating. Other prior art coatings are described in U.S. Pat. No. 3,607,972 of Kiles, et al, assigned to Dow Corning corporation, such as a room temperature vulcanizable siloxane-based block copolymer.
[0011] U.S. Pat. No. 5,253,461 of Janoski, assigned to Tremco, Inc. describes a cold-process built-up roofing system, which includes a curing adhesive with tarpaper and asphalt. The adhesive in its uncured state is substantially flowable, comprising asphalt and a compatibilizer and optionally a filler, dispersed in a curable polyisocyanate prepolymer. However, in Janoski '461 the adhesive takes up to 10 hours to cure, unlike spontaneously cured polyurethane-based foams.
[0012] Among prior art devices for applying coatings include U.S. Pat. No. 5,381,597 of Petrove which describes a wheeled robotic device for installing shingles on roofs. While it does not concern spraying of urethane foam upon a flat roof, it does describe a movable, wheeled carriage for use upon a roof.
[0013] U.S. Pat. No. 5,620,554 of Venable, assigned to Carlisle Corporation of Syracuse, N.Y. describes an apparatus for making a composite roofing material, including a reel support for reels of prefabricated vulcanized rubber sheets, a polymeric film and fleece matting, wherein rollers advance the solid rubber sheet from its reel, which heat and stretch the rubber, binding it to the polymeric film and fleece matting.
[0014] However, in Venable '554, there must first be a reel of a prefabricated solid rubber sheet, not an spontaneously formed monolithic roofing surface membrane.
[0015] Moreover, U.S. Pat. No. 5,872,203 of Wen describes a polyurethane adhesive for bonding polymeric roofing sheets to flat roof decks, which includes a two-component curable mixture, such as a polyurethane prepolymer and a polyol.
[0016] In addition, British patent application GB 2,055,326A of CCG Roofing Contractors, Limited describes a prefabricated polymer board that includes two layers with a fabric mesh therein. However, the fabric mesh is mechanically imbedded between the two layers during fabrication forming, and does not describe imbedding a fabric spontaneously within a polyurethane foam as the spray-applied foam rises up and through the fabric.
[0017] U.S. Pat. No. 5,248,341 of Berry concerns the use of curved walls to accommodate spray paint applicators for curved surfaces, such as aircraft.
[0018] U.S. Pat. No. 5,141,363 of Stephens describes a mobile train which rides on parallel tracks for spraying the inside of a tunnel.
[0019] U.S. Pat. No. 5,098,024 of MacIntyre discloses a spray and effector which uses pivoting members to move an armature which holds a spray apparatus.
[0020] U.S. Pat. No. 4,983,426 of Jordan discloses a method for the application of an aqueous coating upon a flat roof by applying a tiecoat to a mastic coat.
[0021] U.S. Pat. No. 4,838,492 of Berry discloses a spray gun reciprocating device, wherein parallel tracks are used wherein each track is square in cross section, but further wherein each track guides a plurality of rollers thereon.
[0022] U.S. Pat. No. 4,630,567 of Bambousek discloses a spray system for automobile bodies, including a paint booth, a paint robot apparatus movable therein, and a rail mechanism for supporting the apparatus thereat.
[0023] U.S. Pat. No. 4,567,230 of Meyer describes a chemical composition for the application of a foam upon a flat roof.
[0024] U.S. Pat. No. 4,167,151 of Muraoka discloses a spray applicator wherein a discharge nozzle is moved transversally upon a frame placed adjacent and parallel to the surface having the foam being applied thereto. However, the applicator of Muraoka '151 does not solve the problem of excess foam being applied at the end of each transverse pass of the discharge nozzle.
[0025] U.S. Pat. No. 4,209,557 of Edwards describes a movable carriage for a nozzle applying adhesive to the back of a movably advancing sheet of carpeting. Similarly, Australian Patent no. 294,996 of Keith describes a movable carriage for a nozzle applying a polyurethane foam coating to a movably advancing sheet.
[0026] U.S. Pat. No. 4,016,323 of Volovsek also discloses the application of foam to a flat roof.
[0027] U.S. Pat. No. 3,786,965 and Canadian Patent no. 981,082, both of James, et al, describe a self-contained trailer for environmentally containing a dispenser for uniformly dispensing urethane foam upon a terrestrial surface, wherein the problem of “skewing” occurs at the completion of each pass at the boundary edges of the surface to which are urethane foam is being applied. James '965 employs self-enclosed gantry robots to move the fluid discharge nozzle over the terrestrial surface.
[0028] U.S. Pat. No. 3,667,687 of Rivking discloses a foam applicator device.
[0029] U.S. Pat. No. 1,835,402 of Juers describes an apparatus for spraying glass from a nozzle transversely along a flat surface and U.S. Pat. No. 3,027,045 of Paasche discusses a coating machine where the nozzle moves by a pivot arm.
[0030] U.S. Pat. No. 3,096,225 of Carr discloses a hand-held spray nozzle for depositing a continuous stranded material, such as glass.
[0031] U.S. Pat. No. 2,176,891 of Crom discloses an apparatus for applying coatings over curved surfaces, such as within ditches or other curved surfaces. Moreover, U.S. Pat. No. 4,210,098 of Harrison also discloses an apparatus for spraying insulation or other coatings upon curved surfaces.
[0032] Other related art includes U.S. Pat. No. 2,770,216 of Schook for a pivotable spray nozzle, U.S. Pat. No. 3,548,453 of Garis for a transverse spray apparatus, U.S. Pat. No. 3,705,821 of Breer for a transverse spray apparatus, U.S. Pat. No. 3,867,494 of Rood, et al, also for a transverse spray apparatus, U.S. Pat. No. 3,885,066 of Schwenniger for a spray apparatus with a plurality of nozzles and U.S. Pat. No. 3,923,937 of Piccoli, et al, for a centrifugally moving spray nozzle.
[0033] U.S. Pat. No. 3,954,544 of Hooker describes a method of applying a membrane covered rigid foam and a method of bonding a sheet or web, and U.S. Pat. No. 4,659,018 of Shulman discloses an orbiting nozzle apparatus.
[0034] U.S. Pat. No. 4,474,135 of Bellafiore discloses an apparatus for spraying a coating upon a spherical object supported by a post, which apparatus includes a curved track for providing orbital movement of a spray applicator about the exterior spherical surface of the sphere to be coated. While they are curved in nature, the curved tracks thereof are provided for orbital movement about the sphere, not to change the speed, tilt and direction of a linearly moving nozzle.
[0035] Another attempt to solve the problem of “double spraying” at a pass edge has been described in U.S. Pat. No. 4,333,973 of Bellafiore, which describes a similar spray applicator, such as that of Autofoam® Company. This spray applicator includes a wheeled, self-movable vehicle having a carriage portion with a horizontal linear track thereon. The spray applicator moves from one end of the track to the other, opposite end of the track at the end of one pass, of the applicator, above a portion of a roof base, and then the applicator reverses direction upon the track.
[0036] However, to avoid the “double spraying” problem noted above, the Autofoam® device has an on-off switch which turns the applicator off at an appropriate time at the end of a pass while the applicator is reversing direction, and re-starts the applicator a short time later when the applicator has started to move in the opposite direction.
[0037] Moreover, there are severe problems with this approach, as the constant “on-off” starting and re-starting of the applicator causes fatigue to the metal or other material parts of the applicator, and a detrimental effect to the end product. In addition, the Bellafiore '973 and Autofoam® devices are bulky and complicated to use.
[0038] In addition, while monolithic field applied, spontaneously sprayed polyurethane foam roofing surface membranes are convenient, they use up considerable amount of material in creating the roofing surface membrane.
OBJECTS OF THE INVENTION
[0039] Therefore, the objects of the present invention are as follows:
[0040] It is an object of the present invention to provide a monolithic, unitary integral roofing surface membrane from a combination of a low rise polyurethane adhesive, a reinforcing mesh and a weather proofing and ultraviolet resistant coating.
[0041] It is also an object of the present invention to provide a thin monolithic reinforced roofing surface membrane which cures spontaneously.
[0042] It is also an object of the present invention to provide a thin but durable reinforced roofing surface membrane for roofs.
[0043] It is yet another object of the present invention to provide a method of applying a fabric or fiberglass mesh within an spontaneously curved polymer roofing surface membrane while the polymer is being spontaneously cured at a roofing field application.
[0044] It is further an object of the present invention to provide a method and apparatus for providing monolithic fabric and/or fiberglass reinforced roofing surface membranes.
[0045] It is another object of the present invention to provide a spray applicator for foam roofing which applies a coating of elastomeric foam of uniform thickness.
[0046] It is also an object of the present invention to provide a single yet efficient spray applicator for foam roofing.
[0047] It is also an object of the present invention to provide a spray applicator that can be disassembled into a few major parts for easy transport and reassembly on a roof without resorting to the use of a crane.
[0048] It is yet another object of this invention to provide a method for covering a large area of a roof with foam roofing using a continuous spray.
[0049] It is also an object of the present invention to provide a spray applicator with a nutating nozzle mount to minimize variations in coating thickness.
[0050] It is a further object of the present invention to provide a hand-held remote control to enable the spray applicator vehicle to operate without an on-board operator.
[0051] It is an object of the present invention to provide a method for continuous adhesive spraying and application of elastomeric sheet roofing material of large strip areas of a roof.
[0052] It is a further object of the present invention to provide accessories for the spray applicator vehicle to permit its use for applying elastomeric sheet roofing material from a roll.
[0053] It is also an object of the present invention to improve over the disadvantages of the prior art.
SUMMARY OF THE INVENTION
[0054] In keeping with these objects and others which may become apparent, and to solve the problems inherent in the Bellafiore '973 and Autofoam® spraying devices, the present invention uses one or more track rails, such as a double linear track of round cross section, as shown in the drawings herein, to continuously apply monolithic polyurethane roofing surface membranes.
[0055] In one embodiment, there is an arcuate uphill end portion of the track at each side, so that the spray applicator, which moves along the one or more linear tracks, will accelerate in speed and tilt the discharge nozzle outward as it rolls up the curved uphill portion, thereby reducing the amount of foam applied to the edge portion of the roof at the end of a pass of the applicator.
[0056] To obviate the complicated mechanisms of the Autofoam® device, the present invention uses simple mechanics to move the spray applicator. For example, a transverse linear movement means, such as, a radially extending swinging arm, is provided for the sideways movement of the applicator along the track. To eliminate arcuate movement of the pivoting arm, the transverse linear movement means may have a telescoping mechanism or other gear assembly, so that the spray applicator moves linearly, instead of arcuately. For example, the swinging arm moves about a pivot fulcrum point.
[0057] Other transverse movement mechanisms may be used, such as rack and pinion devices.
[0058] To further insure uniform thickness, the present invention further comprises various speed controls, so that an appropriate thickness can be applied for each pass.
[0059] For example, a rheostat controls the speed of the movement of the spray applicator, and an LED readout tachometer has a display dial with appropriate readings for appropriate speeds for corresponding desired thicknesses. Since the rate of flow of foam-producing material emanating from the nozzle is fixed, the ground movement speed of the applicator determines the weight of the coating per unit area applied. This, in turn, determines the thickness.
[0060] When a slope is desired on a flat roof, such as toward a drainage line, the ground speed of the foam applicator can be reduced on each successive pass away and parallel to the drainage line. This will result in a stepwise slope approximating the desired contour.
[0061] It has been found that a nutating nozzle holder, which tilts the nozzle a small amount cyclically as it traverses the track, can be used to minimize the variations in foam thickness (in the form of rounded ridges) due to the hollowcone pattern of the nozzle.
[0062] Accessories can be added to the spray applicator so that it can be adapted for spraying adhesive on a roof or for automatically laying an elastomeric sheet covering such as Sure-Seal™ Fleece Back 100 EPDM made by Carlisle SynTec Incorporated of Carlisle, Pa. over a polyurethane foam substrate. Accessories can also be added for imbedding reinforced fabric within the polyurethane foam substrate.
[0063] In one embodiment, the primary roofing surface membrane is a polyurethane foam, such as STEPANFOAM® of Stepan Corporation. In this embodiment, the average thickness of the deposited foam is about two inches in thickness.
[0064] However, in the preferred embodiment, instead of a standard polyurethane foam roof surface membrane of about 2 inches in thickness, the preferred monolithic roof surface membrane is much thinner, rising to a thickness of about one quarter (¼) inch in thickness.
[0065] This is because, instead of using standard polyurethane foam such as STEPANFOAM®, what is used is what is known in the trade industry as a “low rise polyurethane adhesive”, such as brand name number RS9514B, also manufactured by Stepan Corporation.
[0066] Previously, low rise polyurethane adhesives have only been used to act as an adhesive to adhere prefabricated roofing, such as vulcanized rubber sheets, to roof deck surfaces.
[0067] These low rise polyurethane adhesives have not previously been used as a component of a monolithic roofing surface membrane itself.
[0068] The combination of low rise polyurethane adhesive with a reinforcing mesh and a silicone-based coating obviates the need for a thick polyurethane foam base of about two inches.
[0069] Therefore, the present invention includes a field applied, monolithic roofing surface membrane, which includes a combination of a low rise polyurethane adhesive with a fabric or fiberglass mesh adding reinforcement thereto, such as a woven polyester, i.e., what is known as a 6 or 10 ounce fabric mesh.
[0070] The mesh is applied to the low rise polyurethane adhesive from a rolling reel and is embedded within the polyurethane adhesive by virtue of the rising, spontaneously cured polyurethane adhesive contacting and rising through the recess spaces between the fabric or mesh structural fibers, thus encasing the mesh within the polyurethane adhesive during the curing of the polyurethane adhesive.
[0071] In the preferred embodiment of the present invention, a subsequent application of a silicone-based coating is applied also by spray nozzle over the already-deposited and mesh reinforced low rise polyurethane adhesive surface membrane.
[0072] This silicone coating adds a seal for weather proofing the underlying mesh reinforced polyurethane adhesive layer and for resisting damage from ultraviolet light. A typical silicone coating is POLYCOAT 4000 of Dow Corning Corporation, or as described in U.S. Pat. No. 3,607,972 of Kiles, et al, assigned to Dow Corning Corporation.
[0073] When the silicone coating is applied, it has a thickness of about 20 mils. The thickness of the reinforcing mesh layer and the silicone coating together is about 30-100 mils. The total thickness of the preferred monolithic roofing surface membrane, including the silicone coating and the mesh-reinforced polyurethane adhesive, is about one quarter (¼) inch in thickness, which is significantly thinner than the two (2) inch thickness of a spray applied foam roofing substrate.
[0074] While the invention has been described for use in applying roofing materials on roofs, it is also usable for spray applications at ground level such as for pavement painting or sealing applications.
DESCRIPTION OF THE DRAWINGS
[0075] The present invention can best be described in conjunction with the accompanying drawings, in which:
[0076] [0076]FIG. 1 is a top plan view of a spray applicator vehicle of the present invention;
[0077] [0077]FIG. 2 is a side elevation of a spray applicator vehicle of the present invention;
[0078] [0078]FIG. 3 is a side cross section detail of a transverse rail and carriage;
[0079] [0079]FIG. 4 is an end elevation of a transverse rail and carriage;
[0080] [0080]FIG. 5 is a block diagram of a spray applicator electrical system;
[0081] [0081]FIG. 6 is an end cross section of a coated roof with a central drain ridge;
[0082] [0082]FIG. 7 is a block diagram of a spray applicator electrical system using a hand-held remote control;
[0083] [0083]FIG. 8 is a nozzle spray pattern and resultant foam cross section;
[0084] [0084]FIG. 9 is a nutating spray nozzle feature with details thereof; wherein FIG. 9A is a side elevation of a nozzle holder and an actuator cable; and, FIG. 9B is a top plan view of a cam and cam follower;
[0085] [0085]FIG. 10 is a side elevation of a spray applicator as adapted for laying elastomeric sheet roofing material; and, FIG. 11 is a side elevation of a spray application vehicle as adapted for applying fabric or mesh reinforced foam coating.
[0086] [0086]FIG. 12 is a cross-sectional view of a monolithic field-applied, mesh-reinforced polyurethane foam roofing surface membrane of the present invention; and
[0087] [0087]FIG. 13 is a cross-sectional view of a monolithic field-applied, mesh-reinforced low rise polyurethane adhesive and silicone-coated roofing surface membrane of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0088] As shown in FIGS. 1 - 2 , spray applicator 1 is used for applying polyurethane foam coatings or other spray coated layers, such as low rise polyurethane adhesives, in uniform thicknesses in field applications, such as roofing applications or pavement applications.
[0089] As shown in FIGS. 1 and 2, spray applicator vehicle 1 includes frame 2 , operator seat 5 , steerable powered single wheel 50 , two unpowered side wheels 4 , swinging boom 18 , transverse rail subassembly 23 and various associated parts of nozzle 62 attached to carriage plate 26 . Motor 6 drives sprocket 52 of chain 8 through gear reduction box 7 to provide vehicle motion via wheel sprocket 51 . The operator steers the vehicle 1 by steering wheel 9 , which moves steering linkage bar 57 , thereby rotating wheel flange 58 . Boom 18 is continuously reciprocated from pivot point 20 on tower 55 by crank arm 16 which is cyclically moved by reduction gear box 13 powered by motor 12 , via adjustable linkage arm 14 . Linkage arm 14 is attached to output shaft 17 and is rotated at a constant speed as determined by settings in control box 11 . Slot 15 permits adjustment of the lateral movement limits of telescoping end 19 of boom 18 . Rails 24 and 25 constrain the movement of carriage plate 26 to a linear path transverse to frame 2 . Other transverse movement means may be used, such as rack and pinion gear assemblies.
[0090] Control box 11 also sets the ground speed of vehicle 1 . Hose 35 , which may consist of two or more separate hoses or individual lumens, carries liquid materials, such as polyurethane foam or low rise polyurethane adhesive, for spraying through nozzle 62 from a remote pressurized source.
[0091] For polyurethane foam, or low rise polyurethane adhesive, two chemicals supplied from separate hoses 35 are mixed at the nozzle 62 just prior to discharge. The two liquids interact chemically causing an exothermic foaming and hardening reaction.
[0092] Hose 35 is retained in boom bracket 37 and may also be attached in one or more places by hook and loop straps 36 . In normal use, a second (non-riding) work person guides hose 35 . Solenoid 38 , actuated by a switch in control unit 11 , operates the discharge valve at nozzle 62 .
[0093] It can be appreciated that vehicle 1 rolling at a constant speed with transverse movement means, such as boom 18 , reciprocating continuously, is able to spray a continuous strip of coating on a surface. If the discharge rate at the nozzle is held constant, the amount of product sprayed on a surface per unit of sprayed area can be set by selecting ground speed.
[0094] Since the transverse movement means, such as a boom or other assembly, changes direction at the distal ends of its swings, a method is employed to limit the amount discharged to prevent “double coating” at the edges.
[0095] As noted before, prior art systems, such as described in Bellafoire '973 and of Autofoam® Company, shut the nozzle off at these portions of the cycle. However this action causes several problems.
[0096] For example, the on/off cycling has detrimental effects on spray material consistency from a chemical reaction point of view. The on/off cycling also causes mechanical wear and induces metal fatigue on brackets that must react to cyclic pressure loading.
[0097] In contrast to the devices of Bellafoire '973 and of the Autofoam® Company, the present invention uses a geometric arrangement and constant and continuous liquid product flow to prevent pattern edge build-up.
[0098] For example, FIG. 3 shows a cross section of rails 24 and 25 in the middle of the transverse sweep. carriage plate 26 , driven by end bushing 27 on telescoping extension 19 , is shown with brackets 65 and 66 attached. Brackets 65 secure top rollers 29 with concave “hourglass” contours. Similarly contoured bottom rollers 53 are secured by brackets 66 . Thus rollers 29 and 53 capture rails 24 and 25 constraining plate 26 to roll along these rails. Plate 26 also supports nozzle holder assembly 34 (not shown in this figure).
[0099] [0099]FIG. 4 shows an end view of one embodiment of rail subassembly 23 . While rails may be flat, preferably both rails 24 and 25 are curved at their distal ends in a constant radius. Nozzle assembly 34 is shown in a flat vertical spray location at “A” and at an oblique spray location at the extreme limit of travel on the curved portion at “B”. Top rollers 29 and bottom rollers 53 are offset from each other to facilitate easy rolling without binding on the curved portions. If the transverse movement means, such as boom 18 or other gear assembly, is reciprocated at an essentially constant rate, the carriage assembly is accelerated at the ends of travel due to the greater distance traveled per unit time on the curved end contour as well as the change in direction. Furthermore, the angle of nozzle 62 is tilted outward at the end so that the coverage area “BB” is larger than that of “AA”. These end factors combine to reduce the thickness of the sprayed layer so that the “double layering” at the edge of each applied band of polyurethane foam or low rise polyurethane adhesive can be controlled to result in an edge thickness essentially the same as that of the center portion of a pass. This can be adjusted empirically based on the particular batch, temperature and other field conditions. The adjustment is the end limit position of nozzle 62 relative to the track end curve as determined by the adjustment of crank arm 16 in slot 15 of linkage arm 14 .
[0100] Spray vehicle 1 is designed to be easily disassembled into four subassemblies for easy transport to the roof of a building on an elevator or by using a winch. Prior art systems require a crane. Booms 18 and 19 can be lifted off as a unit by removing spring pin 22 from upright link 54 , spring pin 21 from pivot shaft 20 and spring pin 28 from carriage plate 26 coupling.
[0101] A front subassembly including of track subassembly 23 with uprights 3 can be removed by removing two spring pins 30 from frame member 2 .
[0102] Central frame 2 subassembly including wheels 4 can be separated from the driven wheel subassembly (including seat 5 and steering wheel 9 ) by removing large spring pin 60 from socket member 59 on the frame subassembly. Then back chassis 10 can be lifted free. Electrical connections tying the various subassemblies have connectors which must be disconnected. The four subassemblies can then be reassembled on the rooftop.
[0103] [0103]FIG. 5 shows a block diagram of the electrical system largely housed in control box 11 . The spray applicator vehicle 1 is electrically operated by connection to standard AC mains (typically 115 VAC at 60 HZ) via plug 40 and extension cord 39 . A portable engine operated generator can supply this power as an alternative. Although two separate modular AC/DC converters 76 and 83 are depicted, a single converter can supply current to all DC loads.
[0104] An AC power switch 75 controls power to the entire spray applicator vehicle 1 . Converter 76 supplies DC to a unidirectional speed control 77 with digital speed indicator 78 and speed set control 79 . For maximum consistency of application, speed control 77 is preferable a PID type of feedback servo control which maintains output speed of motor 12 (for moving the transverse movement means, such as via the swinging of boom 18 or otherwise,) constant via feedback from encoder 80 mounted on motor 12 .
[0105] Switch 81 controls power to a solenoid 82 which opens the discharge valve at nozzle 62 . Converter 83 supplies DC power to a bidirectional PID speed control 84 with digital speed indicator 85 and speed set control 86 . This control accurately and repeatedly maintains the ground speed in either direction of spray applicator vehicle 1 as set even under varying load conditions by virtue of feedback encoder 87 mounted on motor 6 .
[0106] This operation is used during the spraying operation and determines the thickness of the resulting sprayed layer.
[0107] Control switch 89 determines the direction of movement as forward or reverse.
[0108] A second manual bidirectional speed control 90 is used to quickly select the desired ground speed via alternate manual control 91 when it is desired to maneuver spray applicator vehicle 1 prior or after a spray application.
[0109] In this manner, the carefully selected “automatic” setting for spraying is not altered. Either automatic speed control 84 or manual speed control 90 is actively enabled at any one time via selector switch 88 .
[0110] The repeatable application of a desired amount of coating per pass permits the type of roof foam or low rise polyurethane adhesive surfacing depicted in FIG. 6. This is an exaggerated cross section of the end of a roof 61 surface with a central drain 96 ditch with grate cover 95 . If the roof 61 had a flat pitch, it would be desirable to create a pitch toward the drainage ditch for more effective drainage. This can be approximated by a stepped foam or low rise polyurethane adhesive layer as shown, starting from lowest strip “A” and rising in thickness to strip “E” of the thickest cross section farthest from central drain 96 . These strips can be applied in a single pass or in multiple passes by spray applicator vehicle 1 where the ground speed for layer “A” is fastest and the speed is reduced for each successive layer “B”, “C”, “D” “E” and “F”.
[0111] For safety reasons, federal OSHA occupational safety regulations stipulate that a powered vehicle cannot be ridden by a workperson within ten feet of the edge of a roof. Also, a workperson is required to guide hose 35 while the operator rides and guides spray applicator vehicle 1 . For these reasons, it would be desirable to operate spray applicator vehicle remotely. In this manner, a single workperson controls spray applicator vehicle 1 and guide hose 35 .
[0112] [0112]FIG. 7 shows such a remote control configuration. Control box 11 is replaced by a hand-held remote control box 100 with a face plate and several vehicle mounted functional units. Since the operator is no longer physically on spray applicator vehicle 1 , electric steering ram 102 replaces the steering wheel. Electric steeling ram 102 is controlled by positional steering control 101 , which sets the position of steered wheel 50 to match that of steering control wheel 106 on remote control box 100 .
[0113] Communications between remote control box 100 and spray applicator vehicle 1 is via coiled cable 105 , although a fail-safe radio communications channel can be used as well. To limit the number of individual conductors in cable 105 , a multiplexor/demultiplexor module 103 and 104 is used at each end of cable 105 to facilitate the two way communications. The function of similarly numbered components is the same as that explained above in reference to FIG. 5.
[0114] Hollow-cone nozzle 62 sprays a pattern 110 of polyurethane foam or low rise polyurethane adhesive that impinges on the ground as shown in FIG. 8. As this pattern is swept sideways in a single pass, it will lay material that is denser toward the top and bottom edges resulting in a cross section with ridges 111 and valley 112 in the “Y” direction from roof surface 61 .
[0115] While multiple sweeps by boom 18 mitigate this effect somewhat, ridges in the final sprayed surface still persist. This problem is eliminated by nutating or cyclically rocking the nozzle mount 34 slightly at right angles to rails 24 and 25 several times during each sweep to even out the coverage of hollow-cone nozzle 62 over multiple sweeps.
[0116] [0116]FIG. 9 shows optional modifications to accomplish this. The detail of FIG. 9A shows modified bracket 120 with pivot 121 holding nozzle mount 34 . Bracket 120 is fastened to carriage plate 26 . A push-pull cable assembly including armored housing sleeve 123 with cable 122 within is used to actuate the cyclic motion illustrated by the phantom representation (shown in broken lines) of nozzle holder 34 at the extreme outward position. The detail of FIG. 9B shows the powering end of cable 122 . Bracket 126 , attached to the frame of vehicle spray applicator 1 in the vicinity of gear box 13 , retains sleeve 123 . Cam follower 130 is pivoted at pivot point 128 within adjustment slot 127 and is biased toward multiple lobe cam 131 by spring 129 . The stroke of wire 122 (and therefore the amount of cyclic tilt of nozzle holder 34 ) is determined by the dimensions and geometry of cam follower 130 and the depth of lobes on multiple lobe cam 131 .
[0117] The proper centering of the motion of holder 34 is adjusted by moving pivot 128 within slot 127 . Multiple lobe cam 131 is attached to the output shaft of gear box 13 under arm 14 . It can be appreciated that cable wire 122 is cycled by each cam lobe as multiple lobe cam 131 rotates.
[0118] By moving cam follower 130 out of contact with multiple lobe cam 131 and tightening it in a locked position, to defeat the pivoting, nozzle holder 34 can be locked in a vertical position to defeat the nutating feature.
[0119] Alternatively, a separate small gear motor and crank coupling (not shown) mounted right on bracket 120 can be used to actuate the nutating action without need of cable 122 .
[0120] Spray applicator vehicle 1 is easily modified to adhesively bond sheet elastomeric roofing material. As shown in FIG. 10, side arms 141 are pivoted at pivot point 140 from side extensions (not shown) which are attached to frame 2 . These arms 141 have telescoping extensions 142 which are locked with hand screws 143 . A roll of elastomeric sheet 144 is pivoted at the end of arms 142 at pivot point 148 , with sheet end 145 trailing roll 144 as vehicle spray applicator 1 moves in the direction of arrow 149 . Also pivoted at pivot point 148 are side arms 146 which trail a weighted roller 147 , which weighted roller 147 applies even pressure to sheet layer 145 . Nozzle 62 sprays a layer of bonding adhesive which bonds sheet 145 to roof surface 61 .
[0121] Alternately, roll 144 can be adjusted to apply a skin coating of rolled material over the solidified foam layer applied from nozzle 62 to a surface, such as a roof.
[0122] Adjustment of extensions 142 determine the distance X between the sheet contact and the sprayed roof surface a fixed distance from the center of the spray cone. Since the vehicle moves at a predetermined constant speed, distance X can be used to match the optimal delay from adhesive application to contact of the sheet roofing material.
[0123] A method for applying reinforced foam or polyurethane adhesive roofing involves the use of a reinforcing fabric or open fabric mesh. The fabric can be manufactured of a variety of fibers such as nylon, fiberglass, aramid, etc. The method involves spraying a foaming mixture and immediately imbedding the reinforcing fabric in the mixture before the foam rises so that the reinforcing fabric rises with the foam and is embedded in the foam layer.
[0124] [0124]FIG. 11 shows modifications of the spraying applicator vehicle 1 for accomplishing this task. Side arms 160 are rigidly attached to frame 2 and uprights 3 ; they flare out at the distal end to lie outside of the spray pattern on each side. Roll 164 of lightweight reinforcing fabric is pivotally attached at the end of arms 160 . The free end of fabric 165 is fed under light roller 162 , which contacts surface 61 just at the edge of the foam adhesive spray pattern. Spring plunger 161 supported by brace 163 forces roller 162 into contact with roof surface 61 . Foam spray 168 , prior to rising, is contacted with fabric 165 , which rises with foam 166 to embed itself in the foam layer as shown by the broken line.
[0125] [0125]FIGS. 12 and 13 show cross sectional views of portions of roofing substrates provided in the present invention.
[0126] For example, while a monolithic polyurethane foam-based roofing surface membrane is at least 1-2 inches in thickness to provide a strong base, the preferred roofing surface membrane including a mesh-reinforced low rise polyurethane adhesive under a silicone coating can have a thickness of only about one quarter (¼) inch. This saves considerably in the amount and cost of material deposited.
[0127] In FIG. 12, polyurethane foam layer-based 168 is imbedded with mesh 165 and covered by silicone coating 175 . This provides a roofing surface membrane of about 1-2 inches in thickness.
[0128] In contrast, as shown in FIG. 13, a preferred embodiment of a much thinner monolithic roofing surface membrane of from about one quarter (¼) inch in thickness is provided with a base layer 178 of low rise polyurethane adhesive having mesh layer 165 therein and coated by silicone coating 175 for weatherproofing and for resisting the effects of ultraviolet light. Therefore, a substantial savings of material and cost is achieved without compromising the structural and sealing characteristics of the monolithic roofing surface membrane.
[0129] It is further noted that other modifications may be made to the present invention without departing from the scope as noted in the appended claims.
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A uniformly applied monolithic roofing surface membrane at appropriate thickness and pitch is field applied upon a surface. The surface membrane may be field applied from a spray applicator foam dispenser moving between two parallel tracks. The uniform application of foam at each pass is assured, by accelerating the speed of the foam dispenser at the end of each pass, by providing continuous movement of the spray applicator upon the tracks. The monolithic roofing surface monolithic thus formed includes a spontaneously curable polymer, such as low rise polyurethane adhesive or polyurethane foam, having a mesh such as of fabric or fiberglass therein, with a silicone coating thereon.
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FIELD
[0001] The invention relates to a chisel having a chisel head and a chisel shaft, wherein the chisel shaft has in the region of the end thereof facing away from the chisel head a thread portion having a thread, wherein the chisel head carries a chisel tip comprising a hard material and wherein the chisel head is provided with a support face in the region of the side facing the chisel shaft.
BACKGROUND
[0002] Such cutting chisels are generally used on cutting rollers of ground processing machines, in particular road construction machines, mining machines or the like.
[0003] The cutting rollers of road milling machines, mining machines or the like are usually provided with chisel holder changing systems. In this instance, base portions of the chisel holder changing systems can be connected to the surface of a cutting roller pipe, in particular welded or screwed thereto. In this instance, the base portions are positioned relative to each other so that helical loading members are produced on the surface of the cutting roller. Chisel holders are connected to the base portions, wherein the chisel holders may be screwed, welded or otherwise retained with respect to the base portion, for example, clamped. In the simplest case, the chisel holders may also be directly connected to the surface of a cutting roller pipe. The chisel holders have a chisel receiving member. The chisels described above can be mounted therein so as to be able to be replaced. During use of the machine, the chisels strike with the chisel tips thereof the substrate which is intended to be removed and cut into it. In this instance, the ground material is broken up. The material which has been removed in this manner can be transported, for example, via the helical broaching and loading members toward the center of the cutting roller and conveyed out of the operating region of the cutting roller at that location by means of ejectors. The material can then be transported away using appropriate devices, for example, transport belts. The chisels are provided with chisel tips, which comprise hard material and which bring about the cutting engagement. They are consequently subjected to an abrasive attack and must therefore comprise a suitable hard material in order to achieve the longest possible service-life. From the prior art there are known chisels in which the chisel tip comprises hard metal. In order to be able to generate uniform wear at the periphery with such chisels, the chisels are generally rotatably arranged in chisel receiving members of the chisel holders.
[0004] There are also known chisels which are provided in the region of the chisel tips thereof with a “superhard material”. For example, the chisel tips have a coating of polycrystalline diamond or another material which has a hardness which is comparable with diamond. Such a chisel is known from US 2012/0080930 A1. Such chisel tips have an extraordinarily long service-life and exhibit hardly any wear during operational use. It is therefore not absolutely necessary to fix these chisels in a rotatable manner in the chisel holders. US 2012/0080930 A1 therefore proposes providing the chisel shaft of the chisel with a thread and clamping the chisel securely to the chisel holder by means of a nut. If after a specific operating time wear appears on the chisel, the nut can be released, the chisel can be rotated slightly and the nut can then be retightened.
[0005] The chisel is supported with a support portion of the chisel head on a correspondingly formed counter-face of the chisel holder. In this instance, the support portion is constructed in a frustoconical manner and tapers from the chisel head in the direction toward the chisel shaft. During the cutting engagement of the chisel, the cutting force which acts on the chisel varies not only with regard to the value thereof, but also with regard to the force direction. In this instance, it may be the case inter alia that stresses which act in an impact-like manner act on the chisel in the case of uneven surface quality. Those loading situations may result in the support face of the chisel or the corresponding counter-face of the chisel holder being deflected and then the thread connection between the chisel and the chisel holder becoming loose. The chisel can then break or become lost.
BRIEF SUMMARY
[0006] An object of the invention is to provide a chisel of the type mentioned in the introduction with which an improved operational reliability and service-life can be achieved.
[0007] This object is achieved in that the support face of the chisel head is curved.
[0008] The curvature of the support face allows an increased surface with respect to a frustoconical construction for the same construction space. This results in smaller surface pressures and therefore in a construction method which is optimized in terms of loading. Furthermore, in conjunction with a counter-face of the chisel holder, which counter-face is curved in accordance with the support face, a type of “ball-and-socket joint” can be constructed. Such a bearing can react particularly well to the changing force directions which occur during the cutting process and can discharge those forces uniformly and reliably into the chisel holder. Tension peaks which occur in particular in the case of impact-like loads are thereby minimized. The term “curved” is intended to be understood according to the invention to be support face geometries in which the support face is constructed to be spherically convex or correspondingly concave, in particular constructed to be spherical, ellipsoid-like, etc. Spherical or ellipsoid-like geometries can be readily produced and in particular allow the above-mentioned ball-and-socket type construction.
[0009] According to a preferred construction variant of the invention, there may be provision for the chisel head to have a tool receiving member. By means of this tool receiving member, the chisel can be gripped from the front chisel side with a screwing tool and screwed to the chisel holder. The chisel is readily accessible in the region of the chisel head and has a diameter which is greater than the chisel shaft. In this instance, the tool receiving member can then also be constructed with a large effective cross-section in order to be able to better introduce the necessary tightening torques for clamping the chisel.
[0010] In a particularly preferable manner, the tool receiving member is constructed as an outer polygonal member, in particular as an outer hexagonal member, so that screwing is possible with conventional fixing tools. It is also conceivable for one or more recesses which act as tool receiving members to be formed round the chisel head, such as, for example, bores. They can be orientated substantially axially, that is to say, therefore, parallel with the longitudinal center axis of the chisel according to the invention or substantially radially, that is to say, therefore, orthogonally to the longitudinal center axis. Tools can then be inserted therein and a rotation of the chisel brought about. An advantageous aspect of a through-hole in a radial direction is the fact that the tool receiving member is also retained when the chisel head is worn to a very great extent.
[0011] A preferred variant of the invention is such that a concave discharge face of the chisel head directly or indirectly adjoins the tool receiving member and is arranged in the region between the chisel tip and the tool receiving member. The discharge face discharges the ground material which is substantially cut away by the chisel tip away from the tool receiving member and therefore prevents or at least reduces the wear in the region of the tool receiving member. In this regard, the discharge face forms a type of deflector.
[0012] In that the discharge face discharges the cut material outward, wear to the chisel holder is also prevented.
[0013] In a particularly preferred manner, there may also be provision for the maximum cross-section, in particular the diameter, of the chisel head to be greater than the cross-sectional region of the chisel holder adjoining the chisel head in order to protect it from wear.
[0014] In order to be able to bring about a chisel construction which is as compact as possible, there may be provision for a receiving member in which the chisel tip is inserted to be formed in the region of the chisel head forming the discharge face.
[0015] The chisel tip preferably has an operating portion which is formed from a superhard material. Such a material may be formed from a material which has a similar hardness to diamond. It is particularly conceivable to use polycrystalline diamond, natural diamond, synthetic diamond, vapor-deposition diamond, silicon-bonded diamond, cobalt-bonded diamond, thermally stable diamond, cubic boron nitride, a diamond-infiltrated material, a diamond-tipped matrix, a diamond-impregnated carbide or a similar material. This is not a conclusive listing and it is clear to the person skilled in the art that the advantages of the present invention are produced with a large number of different chisel tips and the materials used therein.
[0016] A particularly preferred variant of the invention is such that the chisel shaft has an expansion portion in the region between the thread and the chisel head. That expansion portion is used to form relatively high resilient deformations during the tensioning of the chisel by means of the thread thereof and accordingly a pretension in the chisel shaft. Accordingly, the expansion portion acts as a type of spring. If the chisel strikes the hard substrate to be processed, as a result of the tension direction the pretensioning force is relieved and a residual clamping force is produced. The resilient deformation in the expansion portion ensures that the residual clamping force is not completely eliminated. If the chisel is then out of engagement with the ground again, the pretension in the expansion portion is again produced. The thread connection of the chisel is thereby prevented from becoming loose even in the event of impact-like loads. Furthermore, the resilient deformation in the expansion portion ensures that an adequate pretension and therefore also a residual clamping force is maintained in spite of the unavoidable setting losses. A durably reliable chisel fixing action is thereby achieved. This is particularly advantageous during the use of the above-mentioned superhard materials and the associated high running times of the chisels.
[0017] In order to be able to form a sufficiently effective expansion portion in this instance with conventional road milling applications, the expansion portion is intended to extend at least 20 mm and a maximum of 50 mm in the direction of the longitudinal center axis of the chisel shaft.
[0018] The expansion portion may have a portion with uniform cross-section, in particular a cylindrical cross-section and/or a cross-section which changes in the direction of the longitudinal center axis of the chisel shaft. In the case of changing cross-sections, the expansion rate of the expansion portion can be adjusted in a selective manner.
[0019] A preferred variant of the invention is such that the shaft cross-section does not taper from the chisel head in the direction toward the thread portion and the thread portion does not have a substantially smaller diameter than the transition region which is formed between the chisel head and the thread portion, and such that a nut is retained on the thread. If the improbable case of a chisel breakage occurs, wherein the chisel head breaks off the chisel shaft, then the chisel shaft remaining in the chisel holder can be pulled backward out of the chisel holder with this construction.
[0020] Another variant of the invention is such that the chisel head has a peripheral recess and/or a peripheral projection in the region of the support face.
[0021] As already mentioned above, the forces acting on the chisel change during the cutting process. The curved support face of the chisel can react to those changing force directions particularly well, as explained above. The chisel is retained with the chisel shaft thereof in a chisel receiving member of the chisel holder or the like. If a particularly powerful pulse-like transverse force acts on the chisel, the axial portion thereof is discharged into the chisel holder via the support face. The radial portion instead attempts to pivot the chisel head with respect to the chisel holder; furthermore, the chisel shaft is thereby also stressed in terms of flexion. Finally, a tensile stress is also further introduced into the chisel shaft via the threaded connection. Consequently, a disadvantageous, multi-axis tension state can be produced in the region of the chisel shaft. In order to be able to achieve a configuration of the chisel which is optimized in terms of loading in this instance, there is provision according to a variant of the invention for the chisel head to have in the region of the support face a peripheral recess and/or a peripheral projection. Accordingly, a corresponding projection or a corresponding recess may be arranged in the region of the counter-face of the chisel holder. If, for example, a recess is arranged in the chisel head, a projection of the chisel holder engages therein. That engagement results in a connection geometry which allows improved discharge of forces and which reduces the tensions in the chisel shaft.
[0022] Furthermore, such a construction of a chisel makes it possible to compensate for production tolerances between the curved face of the chisel and the chisel holder. If, for example, a recess is formed in the chisel head, there are formed at both sides of the recess defined abutment regions which always ensure a sufficiently reliable surface contact between the chisel and the chisel holder. For this functionality, there does not have to be provision, for example, for a projection of the chisel holder to engage in a recess of the chisel, or, if a projection is arranged on the chisel, for that projection to engage in a recess of the chisel holder. In order to compensate for the surface tolerances, it is instead simply necessary for a recess to be provided in the chisel and/or in the chisel holder. For example, it is also conceivable for the chisel holder and/or the chisel to be constructed so as to have recesses, in which a peripheral sealing element is introduced. That peripheral sealing element, for example, a copper ring, an O-ring or the like, then prevents introduction of dirt into the region of the chisel shaft. The above-mentioned tooth arrangement in which a projection and a recess of the chisel or the chisel holder engage in each other, may also perform such a sealing action to a given extent in the form of a labyrinth-like seal.
[0023] There is provision in a particularly preferable manner for the recess and/or the projection to extend concentrically round the chisel shaft.
[0024] As already mentioned, the thread of the chisel may carry a nut. That nut may be provided with a sealing portion. That sealing portion prevents dirt from being introduced into the chisel holder in the region of the chisel shaft.
[0025] The nut preferably has a securing portion having blocking faces at the peripheral side. The securing portion adjoins with the blocking faces thereof support faces of the chisel holder and consequently forms in the peripheral direction of the thread a positive-locking fixing of the nut with respect to the chisel holder. When the chisel is tensioned, therefore, the nut does not have to be retained with a counter-tool. Furthermore, the nut is fixed to the chisel holder in a state protected from abrasive attack. A construction of the nut in a tension-optimized manner is produced when there is provision for the blocking faces to be constructed in a concave manner and preferably to merge into each other via convex transition portions. Such a geometry is further also simple to produce.
[0026] A further preferred variant of the invention may be such that the chisel is constructed as a forged component.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] The invention is explained in greater detail below with reference to embodiments illustrated in the drawings, in which:
[0028] FIG. 1 is a side view and a partially sectioned view of a chisel,
[0029] FIG. 2 is a perspective view of the chisel according to FIG. 1 ,
[0030] FIG. 3 is a plan view of the chisel according to FIGS. 1 and 2 ,
[0031] FIGS. 4 and 5 are perspective views of a nut,
[0032] FIG. 6 is a plan view of the nut according to FIGS. 4 and 5 ,
[0033] FIG. 7 is a line of section indicated VII-VII in FIG. 6 ,
[0034] FIGS. 8 and 9 are perspective views of a chisel holder,
[0035] FIG. 10 is a side view of the chisel holder according to FIGS. 8 and 9 ,
[0036] FIG. 11 shows a line of section indicated XI-XI in FIG. 10 ,
[0037] FIG. 12 is an exploded view of a chisel holder changing system,
[0038] FIG. 13 is a side view and sectioned view of the chisel holder changing system according to FIG. 12 ,
[0039] FIG. 14 is a side view of a chisel,
[0040] FIG. 15 is a perspective view of a milling roller of a road milling machine,
[0041] FIG. 16 is a side view and partially sectioned view of a chisel,
[0042] FIG. 17 shows a detail indicated in FIG. 16 ,
[0043] FIG. 18 is a sectioned view of a chisel holder,
[0044] FIG. 19 is a section detail taken from FIG. 18 ,
[0045] FIGS. 20 and 21 show another alternative construction of a chisel,
[0046] FIG. 22 is a section through a chisel holder changing system,
[0047] FIG. 23 is a side view and partially sectioned view of a chisel holder according to FIG. 22 ,
[0048] FIGS. 24 to 27 are side views of different versions of chisel holder changing systems.
DETAILED DESCRIPTION
[0049] FIG. 1 shows a chisel 10 having a chisel head 11 on which a chisel shaft 17 is integrally formed. The chisel head 11 has at the end thereof facing away from the chisel shaft 17 a receiving member 12 which is constructed in this instance in the form of a blind-hole-like bore. A chisel tip 20 is inserted into this receiving member 12 . The chisel tip 20 has a connection portion 23 which may comprise hard metal. The connection portion 23 has at the end thereof facing away from the chisel shaft 17 a receiving member in which a carrier member 22 is inserted. The carrier member 22 comprises a hard material, for example, hard metal. It is provided at the free end thereof with a hard material coating 21 . The hard material coating 21 is in this instance formed by a superhard material. In this instance, it is, for example, possible to use a material which has a similar hardness to diamond. In particular, the hard material coating 21 may comprise polycrystalline diamond. The carrier member 22 is connected to the connection portion 23 by means of a suitable connection. For example, a solder connection may be provided. The connection portion 23 may be connected to the chisel head 11 in the chisel receiving member 12 by means of a suitable connection. For example, a solder connection may be selected. The construction of the chisel tip 20 , comprising the connection portion 23 and the carrier member 22 which is connected thereto with a hard material coating 21 can be produced in a simple manner. The spatially smaller carrier member 22 may be coated in a suitable coating installation with the hard material coating. The connection portion 23 of wear-resistant material is structurally larger than the carrier member 22 and therefore has a high capacity for wear.
[0050] It is also conceivable for the entire chisel tip 20 to be constructed integrally. The chisel tip could then comprise, for example, hard metal. It is further conceivable for the chisel head 11 itself to be provided with a hard material coating which forms the chisel tip and which is preferably of superhard material. The component complexity can thereby be considerably reduced.
[0051] Alternatively, it is also conceivable for the hard material coating 21 to be applied directly to the connection portion 23 with the carrier member 22 being omitted.
[0052] Alternatively, the connection portion 23 could also be constructed integrally with the carrier member 22 , which would lead to a similar chisel tip, as in the preceding example, only the interface would be different.
[0053] The portion of the chisel head 11 forming the receiving member 12 has a discharge face 13 which expands from the chisel tip 20 in the direction toward the shaft 17 . That discharge face 13 may in particular be constructed in a concave manner, as clearly shown in FIG. 1 . Adjacent to the discharge face 13 , the chisel head 11 forms a tool receiving member 14 . This is constructed in this instance as an external hexagonal member, as shown in FIG. 3 . The external hexagonal member has a conventional wrench width for fitting a commercially available tool. Adjacent to the tool receiving member 14 , the chisel head 11 forms a support face 15 . The support face 15 is curved in a spherical manner. In the present embodiment, a simple-to-produce, convex ball contour is used as a spherical curvature. The chisel shaft 17 is formed centrally on the support face 15 so that the support face 15 extends in a uniform manner about the longitudinal center axis M of the chisel shaft 17 . The coupling of the chisel shaft 17 to the chisel head 15 is carried out in a tension-optimized manner via a transition 16 which is formed by a rounded portion. The chisel shaft 17 has a cylindrical region, which forms an expansion portion 17 . 1 . In the region of the free end of the chisel shaft 17 , a thread 19 is cut on the chisel shaft 17 . A recess 18 is provided between the thread 19 and the chisel shaft 17 .
[0054] Via the thread 19 , the chisel can be screwed to the nut 30 shown in FIGS. 4 to 7 . As these drawings show, the nut 30 has a sealing portion 31 in the form of a cylindrical attachment. In the outer periphery of the sealing portion 31 there is formed a groove which can clearly be seen in FIG. 7 . This groove serves to receive a seal 32 which is constructed in this instance as an O-ring. A securing portion 33 adjoins the sealing portion 31 . The securing portion 33 has blocking faces 34 which are constructed in a concave-curved manner. The blocking faces 34 merge into each other via convex transition portions 35 . As shown in FIG. 6 , the nut 30 has five blocking faces 34 which are arranged so as to be distributed in a uniform manner with the same angular spacing over the outer periphery of the nut 30 . The thread 36 extends through the nut 30 . In a state adjacent to the thread 36 , the nut 30 has in the region of the sealing portion 31 a radial impact face 37 .
[0055] FIGS. 8 to 11 show a chisel holder 40 for receiving the chisel 10 shown in FIGS. 1 to 3 . The chisel holder 40 has a base portion 41 which has a cylindrical outer contour. At the upper end thereof, the chisel holder 40 has a cylindrical attachment 42 . The cylindrical attachment 42 may include, in a non-limiting example, at least one surface contour 43 such as at least one of a peripheral projection and a peripheral recess arranged on the base portion 41 . In this instance, the diameter of the cylindrical attachment 42 is selected to be slightly larger than the diameter of the base portion 41 . The cylindrical attachment 42 forms a counter-face 44 which is constructed so as to be curved in a spherical manner and concave. The chisel holder 40 merges in a manner adjacent to the counter-face 44 into a chisel receiving member 45 which is constructed as a bore in this instance. In a state facing away from the counter-face 44 , the chisel receiving member 45 opens in a sealing portion 46 which is constructed in a bore-like manner as an inner cylinder. A seal receiving member is introduced in the wall region delimiting the sealing portion 46 . The seal receiving member may, as illustrated in this instance, be constructed as a peripheral groove 46 . 1 .
[0056] The chisel holder 40 has at the end thereof facing away from the cylindrical attachment 42 a holder receiving member 47 . FIGS. 8 and 11 allow the structure of the holder receiving member 47 to be seen more clearly. As can be seen from these illustrations, the holder receiving member 47 is constructed as an internal receiving member in the chisel holder 40 . It is delimited by five retention faces 47 . 1 which are curved in a convex manner. The retention faces 47 . 1 merge into each other via concave transition portions 47 . 2 . The curvature of the retention faces 47 . 1 and the transition portions 47 . 2 is constructed to be adapted to the curvature of the blocking faces 34 and the transition portions 35 of the nut 30 . Accordingly, the nut 30 can be guided from the rear end of the chisel holder 40 with the sealing portion 31 through the region of the holder receiving member 47 and pushed into the region of the sealing portion 46 . The insertion movement of the nut 30 is blocked by means of the impact face 37 which comes to rest on a stop 46 . 2 of the sealing portion 46 . In this assembly state, the seal 32 engages in the groove 46 . 1 of the sealing portion 46 so that the transition region between the outer contour of the nut 30 and the inner contour of the sealing portion 46 is sealed. The blocking faces 34 are arranged opposite the retention faces 47 . 1 . The transition portions 35 and 47 . 2 are also opposite each other. In this manner, a non-rotatable arrangement of the nut 30 in the holder receiving member 47 is achieved. Since the seal 32 is retained in a manner clamped between the nut 30 and the chisel holder 40 , the nut 30 is retained in a non-releasable manner.
[0057] FIG. 12 is an exploded view of a chisel holder changing system in which the chisel holder 40 is secured in a suitable manner to a lower portion 50 , for example, welded. The lower portion 50 has for this purpose a securing portion 51 which in accordance with the cylindrical contour of the base portion 41 of the chisel holder 40 has a concave recess. The securing portion 51 is formed by a carrier portion 52 of the lower portion 50 . The carrier portion 52 is formed integrally on a base portion 54 by means of a transition portion 53 . The base portion 54 has a lower support face 55 . With the support face 55 , the chisel holder 40 can be placed on the outer face of a cutting roller pipe and can be secured thereto in a suitable manner, for example, welded.
[0058] FIG. 13 shows the above-described assembly position of the nut 30 in the holder receiving member 47 . The chisel 10 can be inserted with the chisel shaft 17 thereof past the counter-face 44 into the chisel receiving member 45 . In this instance, the expanding counter-face 44 facilitates the introduction movement of the chisel 10 . When the thread 19 of the chisel 10 strikes the nut 30 , the chisel 10 can be screwed with the thread 19 thereof into the thread 36 of the nut 30 . This screwing-in movement can first be carried out by hand until the support face 15 comes to rest on the counter-face 44 . Subsequently, a suitable tool can be placed on the tool receiving member 14 . The chisel 10 can then be rotated with the tool and, in this instance, the threaded connection between the thread 19 and the thread 36 can then be tensioned. In order to ensure reliable fixing of the chisel 10 during the processing operations which are intended to be carried out, a high tightening torque has to be selected. In this instance, the support faces 15 and the counter-face 44 press each other. As a result of this pressing action, a seal between the chisel head 11 and the counter-face 44 is brought about in such a manner that no contamination can be introduced. Via the high torque, the expansion portion 17 . 1 of the chisel shaft 17 is resiliently deformed. This resilient deformation portion, in the event of loads acting on the chisel tip 20 in an impact-like manner, prevents the threaded connection between the nut 30 and the chisel shaft 17 from being able to be released. The selected geometry of the concave blocking faces 34 and the convex retention faces 47 . 1 enable increased force transmission regions with respect to conventional, elongate surface portions, as are conventional with nuts. Of course, the retention faces 47 . 1 may also be curved in a concave manner and the blocking faces 34 may accordingly be curved in a convex manner.
[0059] The convex/concave pairings selected prevent for the selected high tightening torques a plastic deformation of the blocking faces 34 or the retention faces 47 . 1 from being able to be produced. Consequently, in particular the holder receiving member 47 remains in the desired form and during the chisel change a new nut 30 can be inserted in a reproducible manner.
[0060] During the tool engagement, the chisel tip 20 strikes the substrate which is intended to be cut and cuts into it. In this instance, the material cut slides off the chisel tip 20 . As a result of the large forces present in the region of the chisel tip 20 , a great abrasive attack is brought about in this instance. This attack is taken into account by the structure of the chisel 10 with the connection portion 23 , which comprises hard material, for example, hard metal. After the material removed has passed the connection portion 23 , it reaches the region of the discharge face 13 . It has then already lost a large proportion of its abrasive nature and can be safely guided further by the discharge face 13 . In this instance, it is guided radially outward from the discharge face 13 and discharged from the tool receiving member 14 and the chisel holder 40 so that where possible it is not subjected to wear or is subjected only to slight wear.
[0061] Since the chisel 10 cannot rotate, it is first worn away at one side. This is permissible up to a specific wear limit. Then, the chisel 10 is released by means of the appropriate tool which engages on the tool receiving member 14 . Subsequently, the nut 30 can be pulled from the holder receiving member 47 and inserted therein again in a rotated state. As a result of this rotation, the thread intake in the thread 36 is also arranged in a rotated position with respect to the chisel holder 40 . When the same chisel 10 is again screwed to the nut 30 , wherein the same tightening torque is again preferably intended to be selected, then the chisel head 11 , and consequently the chisel tip 20 opposite the chisel holder 40 , moves into abutment in a correspondingly rotated position. The processing side of the chisel 10 is then formed by a non-worn chisel tip location.
[0062] In the present embodiment, 5 blocking faces 34 which are arranged in a state distributed in a uniform manner with respect to each other are provided on the nut 30 . Accordingly, the chisel 10 may also be secured at five mutually rotated locations to the chisel holder 40 . It has been found that such an arrangement is particularly advantageous when the chisel 10 is used for the purpose of fine-milling of road surfaces. When rotated by the extent of a blocking face 34 , the chisel 10 can then be worn in a manner optimized in terms of wear, wherein at the same time a high surface quality of the milled road surface is retained. When six blocking faces are used, optimized use of the chisel tip 20 in terms of wear is not achieved, as is possible with 5 blocking faces. When four blocking faces are used, there is an excessively high variance in the surface quality when the chisel tip 20 is intended to be used completely. Furthermore, when 5 blocking faces are used, that is to say, an uneven number of blocking faces 34 , it is also possible to operate in such a manner that the chisel 10 is always rotated to the extent of two blocking faces 34 . In this manner, a continuous uniform wear of the chisel for the purpose of high surface qualities of the milled surface can be achieved.
[0063] FIG. 14 shows another construction variant of a chisel 10 . This chisel is constructed in an identical manner to the chisel 10 according to FIGS. 1 to 3 with the exception of the structure of the chisel shaft 17 . Reference may therefore be made to the corresponding statements above. Furthermore, the nut 30 according to FIGS. 4 to 7 can be screwed to the thread 19 of the chisel 10 , and it can accordingly be fitted in the chisel holder 40 according to FIGS. 8 to 11 .
[0064] The chisel shaft 17 of the chisel 10 according to FIG. 14 has an expansion portion 17 . 1 which is constructed in the form of a cross-section reduction in order to achieve improved expansion behavior.
[0065] FIG. 15 shows a milling roller 60 which has a milling roller pipe 61 . A large number of chisel holders 40 according to FIGS. 8 to 11 are directly secured, for example, welded, to the surface 62 of the milling roller pipe 60 . The chisel holders carry the chisels 10 , for example, according to FIGS. 1 to 3 . As described above, the chisel holder changing systems may accordingly also be fitted in accordance, for example, with FIGS. 12 and 13 with the milling roller pipe 61 . To this end, the lower portions 50 are placed with the support faces 55 thereof on the surface 62 and welded to the milling roller pipe 60 .
[0066] FIGS. 16 to 19 show an alternative construction of the invention to FIG. 1 to 13 or 14 , wherein the chisel 10 and the chisel holder 40 are slightly modified. In order to prevent repetition, reference may therefore be made to the above statements and only the differences will be discussed below. As can be seen in FIGS. 16 and 17 , in the region of the support face 15 a peripheral recess 15 . 1 is formed in a groove-like manner. It extends concentrically about the chisel axis M. FIGS. 18 and 19 show the chisel holder 40 which in the region of the counter-face 44 has a peripheral projection 44 . 1 . It is constructed in a bead-like manner and also extends concentrically about the longitudinal center axis of the chisel holder 40 . The positioning of the projection 44 . 1 is selected in such a manner that, in the assembled state of the chisel 40 , it engages in the recess 15 . 1 . In this manner, a labyrinth-like seal is formed in the region of the support face 15 /counter-face 44 , and impedes the introduction of dirt into the region of the chisel receiving member 45 . Furthermore, the support face 15 is interrupted with the recess 15 . 1 so that reliable surface contact with respect to the counter-face 44 is always ensured, even with production-related deviations from the ideal shape.
[0067] In place of the projection 44 . 1 , it is also possible to use a ring, for example, a sealing ring, in particular a commercially available O-ring or a copper ring or a similar metal ring. This may be laid in a peripheral groove of the chisel holder 40 in the region of the counter-face 44 . With the region thereof which protrudes over the counter-face 44 , this sealing ring then engages in the recess 15 . 1 .
[0068] FIGS. 20 and 21 show another embodiment of a chisel 10 . This chisel is constructed in accordance with the chisel 10 according to FIGS. 1 to 3 , for which reason, in order to prevent repetition, only the differences are intended to be discussed below. The chisel head 11 is provided with a plurality of tool receiving members 14 on an outer periphery. These may be formed as recesses in the outer contour of the chisel head 11 . The recesses are open in a radially outward direction and in an axially upward direction. Consequently, a tool can be readily fitted from the chisel tip 20 . Furthermore, the tool receiving members 14 cannot become clogged with waste material or are easy to clean where applicable.
[0069] FIGS. 22 to 27 show various embodiments of chisel holder changing systems, in which the above-described chisels 10 can be used together with the nut 30 according to FIGS. 4 to 7 . In these drawings, for the identification of identical or equivalent components, the same reference numerals as above are used. Reference may therefore be made in full to the statements above.
[0070] FIG. 22 shows a tool holder changing system having a tool holder 40 , which carries at a base portion 41 an integrally formed plug type attachment 48 . A cylindrical attachment 42 is further formed on the base portion 41 . In the region of the cylindrical attachment 42 , a counter-face 44 corresponding to the counter-face 44 is again constructed in accordance with the chisel holder 40 according to FIGS. 8 to 11 . In the base portion 41 and the cylindrical attachment 42 , there is formed a chisel receiving member 45 which terminates in a sealing portion 46 . The sealing portion 46 is again adjoined by the holder receiving member 47 , in which the nut 30 according to FIGS. 4 to 7 is inserted. In this instance, the nut 30 again has a securing portion 33 with blocking faces 34 . The blocking faces 34 cooperate with retention faces 47 . 1 of the chisel holder 40 in order to secure the nut 30 in a rotationally secure manner. The nut 30 is again sealed with the sealing portion 31 thereof and the seal 32 on the sealing portion 46 of the chisel holder 40 .
[0071] As can further be seen in FIG. 22 , the chisel 10 with the thread 19 is screwed into the thread 36 of the nut 30 until the impact face 37 strikes the chisel holder 40 .
[0072] The chisel holder 40 is inserted with the plug type attachment 48 thereof into a plug type receiving member of a lower portion 50 . The chisel holder 40 is supported with respect to the lower portion 50 and is retained in the lower portion 50 with a pressure screw 56 which acts on the plug type attachment 48 .
[0073] FIG. 23 shows the combination of the chisel holder 40 with the chisel 10 , as described above with reference to FIG. 22 .
[0074] FIG. 24 shows another chisel holder changing system. Accordingly, there is again used a chisel holder 40 which receives the chisel 10 and the nut 30 in the manner described above. The chisel holder 40 is retained in a lower portion 50 with a plug type attachment which cannot be seen in FIG. 24 .
[0075] FIG. 25 shows a construction variant of a chisel holder changing system having a chisel holder 40 and a lower portion 50 .
[0076] FIG. 26 shows another construction variant of a chisel holder changing system having a chisel holder 40 and a lower portion 50 which receives the chisel holder 40 .
[0077] FIG. 27 discloses a tool system having a chisel holder 40 , in which the chisel 10 is inserted. The chisel holder 40 can be placed directly on the surface 62 of a milling roller pipe 60 and secured thereto, for example, welded.
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The invention relates to a chisel ( 10 ) having a chisel head ( 11 ) and a chisel shaft ( 17 ), wherein near its end facing away from the chisel head the chisel shaft has a threaded portion having a thread ( 19 ), wherein the chisel head holds a chisel tip ( 20 ) made of a hard material, and wherein near the side facing the chisel shaft the chisel head is provided with a supporting surface ( 15 ). Especially when superhard hard materials are used for the chisel tip, a load-optimized chisel design is obtained by a domed supporting surface ( 15 ).
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TECHNICAL FIELD
The present invention deals broadly with the field of windows. More specifically, however, the invention applies to a window, such as double-hung window, wherein a sash slides within a frame. The specific focus of the invention is structure employed to effect retention of the window sash within the frame at an intended location along an axis perpendicular to a plane defined by the window frame within which the sash slides.
BACKGROUND OF THE INVENTION
The prior art includes many types of windows which are employed to bring light into a building. One type of window known in the prior art is a double-hung window. Such a window typically employs two vertically movable sash assemblies, each carrying its own pane of glass, which are movable, typically, vertically within the frame.
Opposed, inwardly facing lateral portions of the frame are typically provided with a balance tube which includes appropriate structure to render the window sashes more safe. Balance mechanisms are employed within the balance tube in order to deter undesirable, unintended slamming of a sash such that injury could result.
It is also desirable, however, that the sashes be able to be tilted inward or removed for cleaning of the glass portions of the sash assemblies. Various mechanisms have been employed to release a sash from a position which it is intended to occupy within the frame. Typically, a sash is desired to be located at a position along an axis, generally perpendicular to a plane defined by the frame, for sliding movement along that position. Various types of structures have been utilized to effect maintenance of a sash in the desired position yet allow it to be tilted inward or removed for cleaning. One such structure utilizes a pair of laterally extending latch mechanisms carried by the sash. The latch mechanisms move linearly along an axis through the sash and into the frame. One latch mechanism extends laterally on one side of the sash and a second latch mechanism extends laterally on the other side of the sash. When it is desired to remove a sash, the sash is moved to an intended vertical release location, and the person removing the sash releases one latch with one hand and the other latch with the other hand. The sash is then tilted or slid out of its normal position and removed from the frame for cleaning. Such a structure has a number of drawbacks. One is that the person removing the window sash needs full availability of both hands to effect release of the latches. Attempts have been made to solve this problem by designing a unitary assembly for concurrently releasing both latches (that is, for simultaneously effecting retraction of the latches). While some measure of success has been achieved with these attempts, other problems still exist. For example, linearly moving latches typically do not provide fully adequate definition of structure for sliding of a sash along an intended track and adequate resistance to pressures which might tend to dislodge a sash from the window frame. One reason for the inadequate resistance to dislodgement is the relatively small cross-section of a latch mechanism extending from the sash.
It is to these dictates and shortcomings of the prior art that the present invention is directed. It is a position maintenance mechanism which addresses these dictates and problems and provides solutions which make the invention a significant over prior art apparatuses.
SUMMARY OF THE INVENTION
The present invention is apparatus which functions to maintain a sliding window sash at an intended position along an axis which is generally perpendicular to a plane defined by a frame within which the sash slides. The frame has an inwardly facing surface which, when the sash is in an intended position at which it slides within the frame, is opposite an outwardly facing surface of the sash. The apparatus in order to maintain the sash at such an intended position includes means to define an elongated trough formed in the inwardly facing surface of the frame. The trough extends generally parallel to the plane defined by the frame and generally in the direction of intended sliding of the sash. The apparatus further includes a blade which defines a plane and means to mount the blade within a cavity in the sash. The blade is mounted and oriented with the plane defined thereby generally parallel to the plane defined by the frame. The blade is disposed within the sash for pivotal movement between a first position and a second position. In the first position of the blade, it is retracted within the outwardly facing surface of the sash and does not extend outwardly beyond the surface of the sash. In its second position, the blade is extended beyond the outwardly facing surface of the sash and into the trough. Means are provided to normally bias the blade to the second position thereof, and means are provided to allow selective retraction of the blade to its first position.
It is intended that the blade, when it is in its second position received within the trough, will be extended fully into the trough to engage a bottom thereof. In a preferred embodiment, the bottom of the trough has a slot formed therein. The location of the slot along the bottom of the trough is such that, when the sash is in a closed position, the blade is at a position coextensive with the slot and extends into the slot. The pivotal disposition of the blade wherein it is extended into and through the slot in the bottom of the trough is defined as a third position of the blade.
In the preferred embodiment, the blade includes an edge which is angled such that, as the sash is moved from a closed position to an open position, the angled edge engages an end of the slot and ramps the blade up and out of the slot. Such action facilitates retraction of the blade from its third position to its second position.
The blade is disposed for pivoting about an axis which is generally perpendicular to the plane defined by the window frame. It is envisioned that a coil spring would be employed to bias the blade about such an axis outwardly through, and away from, the outwardly facing surface of the sash to its second and third positions.
The preferred embodiment contemplates employment of a linearly moving actuator to effect retraction of the blade within the outwardly facing surface of the sash. Such an actuator would be operatively connected to the blade to overcome the biasing of the blade to its second and third positions, and would effect rotation of the blade in a direction opposite that in which the coil spring biases the blade.
A preferred embodiment of the invention includes a wire yolk which is attached to the blade and a length of cord which is attached to the yolk. The cord extends away from the yolk and is attached to a driver for drawing the length of cord inwardly with respect to the outwardly facing surface of the sash to effect rotation of the blade against the biasing means.
It is envisioned that an end plate assembly would be provided for cooperation with the sash, the end plate assembly including a face plate mounted generally flush with the outwardly facing surface. The end plate assembly would include a pair of generally parallel tabs extending inwardly from the face plate. The tabs, it is intended, would have oppositely facing surfaces, each of these surfaces mounting a stub axle which is substantially coaxial with a stub axle on the facing surface of the other tab. The two-stub axles would extend toward each other so as to be received within an aperture in the blade, the aperture sized and shaped to receive the stub axles.
Each of opposite sides of the blade defines a ramp surface. When the blade is inserted between distal ends of the stub axles, the ramp surfaces increasingly urge the distal ends of the stub axles apart until the distal ends become registered with the aperture. They then snap into the aperture to effect mounting of the blade.
In practice, a sash configured in accordance with the invention would very likely employ means defining an elongated trough in each of oppositely facing inward surfaces of the frame. Each of said troughs would extend generally parallel to the plane defined by the frame and generally in a direction of intended sliding of the sash. Each of such troughs would be intended to receive one of a pair of blades which define a generally common plane. Each of the pair of blades would be mounted within a corresponding cavity in the sash and oriented with the plane defined by the blades generally parallel to the plane defined by the frame. As in the case of the structure previously described, each blade would be disposed for pivotal movement between a first position, wherein the blade is retracted within a corresponding outwardly facing surface of the sash, and a second position, wherein each of the blades is extended into a corresponding trough in an inwardly facing surface of the frame which is opposite the outwardly facing surface of the sash within which the cavity in which the blade is mounted is formed. The blades would normally be biased to their second positions in engagement with the bottom of the troughs, and means for selectively retracting the blades to their first positions would be provided.
With the dual blade embodiment, means would be provided to effect retraction of the blades from their second positions to their first positions simultaneously. The invention envisions a common member for effecting concurrent retraction of the blades.
The present invention is thus improved apparatus for mounting and maintaining a sash within a window frame. More specific features and advantages obtained in view of those features will become apparent with reference to the accompanying drawing figures, the DETAILED DESCRIPTION OF THE INVENTION, and appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective, exploded view of apparatus in accordance with the present invention, window sashes being shown in phantom, and some portions of the structure being broken away;
FIG. 2 is a side elevational view of a maintaining blade as mounted within an end plate assembly;
FIG. 3 is a top plan view of the end plate assembly without a blade and biasing spring mounted therewithin;
FIG. 4 is a first end view of the face plate assembly of FIG. 3;
FIG. 5 is a second end view of the face plate assembly of FIG. 3; and
FIGS. 6 and 7 are bottom sectional views illustrating the mounting of a blade in an end plate assembly.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings, wherein like reference numerals denote like elements throughout the several views, FIG. 1 is an exploded view illustrating dual sashes 10, 12 of a double hung window and a blade mechanism 14, which is intended to be recessed within a cavity 16 in the inner sash 10. The cavity 16 in the sash 10 is overlain, on a side of the sash, by a face plate 18 mounted generally flush with the outwardly facing side surface 20 of the sash 10. The face plate 18 is part of an end plate assembly 22 which includes, additionally, a pair of generally parallel tabs 24, 24' which extend inwardly from the face plate 18 into the cavity 16. The end plate assembly 22 also includes a base 26 which functions for an intended purpose as will be discussed hereinafter.
The figures illustrate a blade member 14 which is pivotally mounted for rotation about an axis generally transverse to a plane defined by the window sash 10. FIGS. 2-7 illustrate the specific structure of the end plate assembly 22 and its cooperation in mounting the blade 14 for rotation.
FIG. 1 illustrates a coil spring 28 which is shown as being connectable, at one end thereof, to a hook member 30 of the blade 14. The other end of the coil spring 28 is connectable to the base 26 of the end plate assembly 22. The coil spring 28, thereby, biases the blade 14 for rotation, in a direction as seen in FIG. 1, in a clockwise direction.
A yoke member 32 is attached to the blade 14 to effect selective overcoming of the bias of the coil spring 28 in order to retract the blade 14 for a purpose discussed hereinafter. The yoke member is illustrated as being constructed of a wire stock formed into a bail, opposite ends of which are passed through an aperture 34 provided in the blade 14. The bail 32 thereby has an end, proximate the blade 14, which serves to apply force to the blade 14 in a direction, as viewed in FIG. 1, counter clockwise so as to overcome the bias of the coil spring 28. The wire from which the bail 32 is formed is provided with a narrow neck 36 at an end remote from blade 14. The neck 36 defines a channel 38 which extends away from the blade 14, when the bail 32 is connected to the blade 14, to facilitate connection of an actuator mechanism (not shown). A remote end of the actuator is illustrated in FIG. 1. A segment of flexible filament 40 is shown as extending through the narrowed channel 38 formed in the neck 36, an end of the filament 40 having a sleeve 42 crimped onto the filament 40. Typically, the sleeve 42 would have a diameter smaller than an expanded channel 44 formed within the bail 32 so that the filament 40 end, with the sleeve 42 crimped thereon, could be slid through the expanded channel 44 and then withdrawn into the narrowed channel 38 which would have a width smaller than the diameter of the sleeve 42.
The overall actuator structure could be constructed in any manner desirable. The actuator would permit volitional rotation of the blade 14 in the counter clockwise direction, as viewed in FIG. 1. With the embodiment illustrated, it would include means for drawing the filament 40 which in turn would draw the yoke 32 to effect the counter clockwise rotation. It will be understood that any appropriate actuator means, however, could suffice.
FIG. 1 also illustrates a portion of a balance tube 46 which defines an elongated trough or track 48 in an inwardly facing surface 50 of the window frame 52. In double hung window applications, the balance tube 46 employs mechanisms which function to deter undesirable, unintended slamming of a sash where injury could result.
The balance tube 46, in the case of the present invention, includes, defined therein, an elongated trough 48 which faces inwardly. The trough 48 extends generally parallel to a plane defined by the window frame 52. The trough 48 runs generally in a direction of intended sliding of the sash 10.
FIG. 1 illustrates a slot 54 formed in the balance tube 46 at the bottom of the trough 48. This slot 54 is formed at a location such that, when the window sash mechanisms are in their closed positions, a corresponding slot 56 in the end plate assembly face plate 18, through which the blade member 14 can extend, is registered with the slot 54 formed in the balance tube trough 48.
In order to ensure that the slot 56 in the face plate 18 is maintained in the desired position relative to the inner sash 10, it is secured at a location on the side stile overlying the cavity 16. Such affixation is typically effected using wood screws 58 as shown.
FIG. 2 illustrates the blade 14 mounted in place between the tabs 24, 24' extending inwardly into the cavity 16 from the face plate 18. That figure shows a second position of the blade 14 in solid line and first and third positions of the blade 14 in phantom line.
The first position of the blade 14 is such that the blade 14 is retracted within an outwardly facing surface 20 of the sash 10 (that is, recessed within the cavity 16). The third position of the blade 14 is one wherein the blade 14 not only extends into the trough 48 engaging the bottom thereof, as it does in its second position, but wherein the blade 14 extends fully to the bottom of the trough 48 and into and through the slot 54 formed in the bottom of the trough 48.
As will be able to be seen, when the blade member 14 is in its second position, it will ride in the trough 48 and facilitate raising and lowering of the window sash 10. It serves as a track rider which rides on the track defined by trough 48, and the thickness of the blade member 14 can be made so that there is a minimum, if any, wobble of the sash 10 relative to the window frame 52 of which balance tube 46 is a part. Because of the biasing of the blade 14 to the second position by the coil spring 28, the blade 14 will tend to remain received within the trough 48 as long as action is not taken to operate the actuator in order to overcome the bias of the spring 28 and cause rotation of the blade 14 to its first position.
The bias of the spring 28 is sufficiently strong such that, when the sash 10 is moved to its closed position with the slots in the face plate 56 and bottom of the trough 54 registered, the blade 14 will extend into the slot in the trough 54. This will effect an even more positive preclusion of movement of the sash 10 in a direction perpendicular to a plane defined by the window frame 52. The sash 10 will, thereby, be even more securely disposed to deter unwanted removal.
As the sash 10 is moved along the track, a ramped edge 60 of the blade 14 will ride over a correspondingly ramped surface 62 of an end of the slot 54 in the bottom of the trough 48. This will serve to allow the blade 14 to ride up and out of the slot 54 in the trough 48. Nevertheless, because of the coil spring biasing means 28, the tip 64 of the blade 14 will still engage the bottom of the trough 48.
As will be able to be seen then, unless some positive action is taken to move the blade 14 in a rotational manner to its first position, the blade 14 will be maintained in either its second or third positions. When it is desired, however, to remove the sash 10 from the window, operation of the actuator means can be initiated to overcome the bias of the coil spring 28 and rotate the blade 14 to its first position. With the blade 14 in this position, there will be no obstruction to rotation of the sash 10 out of its location between the frame 52 or, if desired, removal of the sash 10.
FIGS. 3-5 illustrate the end plate assembly 22 in different views, and FIGS. 6 and 7 illustrate the assembly 22 in corrbination with the blade 14. FIG. 6 shows the blade in the process of being inserted into position pivotally mounted to tabs 24, 24' of end plate assembly 22. FIG. 7 shows the blade 14 having been fully inserted between tabs 24, 24' with a stub axle 66, 66' carried by each of tabs 24, 24' snapped into an aperture 68 formed in blade 14. Aperture 68 defines the axis of rotation of blade 14.
Referring now to FIGS. 3-5, end plate assembly 22 includes face plate 18 and tabs 24, 24' extending rearwardly therefrom. As previously discussed, tabs 24, 24' are spaced from each other, and each tab 24, 24' has a stub axle 66, 66' extending inwardly from its corresponding tab 24, 24' toward the other stub axle. The stub axles 66, 66', together, define a shaft about which the blade 14 rotates.
Tabs 24, 24' are manufactured from a resilient material so that they can be deflected outwardly, as indicated by arrows 70 in FIG. 6, to allow introduction of blade 14 therebetween. Blade 14 includes a dual-ramped portion knife edge which serves to urge tabs 24, 24' apart as the ramped surfaces of the knife edge engage inwardly-facing surfaces of the stub axles 66, 66'. Tabs 24, 24' will continue to be urged apart as the knife edge is pushed in the direction of arrow 72 as seen in FIG. 6. Eventually, blade 14 achieves a position as seen in FIG. 7, and tabs 24, 24' snap inwardly to position stub axles 66, 66' within pivot aperture 68 in blade 14. Blade 14 is then mounted for rotation.
FIGS. 1 and 2 illustrate a base 26, as previously discussed, of end plate assembly 22. Base 26 includes a rectangular cross-section shaft which is generally parallel to face plate 18. This rectangular cross-section shaft 74 serves as a point of affixation of one end of coil spring 28. The other end of coil spring 28 is extended upwardly, through an expanded portion of yoke/bail 32, and is attached to blade 14 at hook member 30. As can best be seen in FIG. 2, this will effect a clockwise bias on blade 14 in contra-rotation to the force applied to blade 14 by filament 40 extending from the actuator.
FIGS. 1 and 2 illustrate end plate assembly 22 as being mounted to inner sash 10 with face plate 18 overlying cavity 16. Affixation of end plate assembly 22 to sash 10 is shown as being accomplished with a pair of Phillips-head screws 58. Screws 58 are inserted through aperture 78 in face plate 18 and into sash 10.
It will be understood that this disclosure, in many respects, is only illustrative. Changes may be made in details, particularly in matters of shape, size, material, and arrangement of parts without exceeding the scope of the invention. Accordingly, the scope of the invention is as defined in the language of the appended claims.
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Structure for maintaining a sliding window sash at an intended position with respect to a frame within which the sash moves. The structure serves to retain the sash at a position along an axis generally perpendicular to a plane defined by the window frame. An inwardly facing surface of the frame has formed therein an elongated trough which extends generally parallel to a direction of intended sliding movement of the sash. A blade is mounted within a cavity in the sash and disposed for pivotal movement between a first position, wherein the blade is retracted within an outwardly facing surface of the sash, and a second position, wherein the blade is extended through the outwardly facing surface of the sash into the trough defined within the inwardly facing surface of the frame. The blade is normally biased to the second position, but it can volitionally be retracted to the first position to enable tilting inward or removal of the sash from the window frame.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
[0001] This is a continuation application of PCT/AT02/00120, filed on Apr. 23, 2002.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to a method for drilling, in particular impact drilling or rotary percussion drilling, a hole in soil or rock material and fixing an anchorage in said hole, wherein a drill hole is formed by means of a drill bit mounted on a drill rod assembly while simultaneously introducing a jacket tube surrounding the drill rod assembly in a spaced-apart manner, as well as a device for drilling, in particular impact drilling or rotary percussion drilling, holes in soil or rock material and producing an anchorage, wherein a drill bit mounted on a drill rod assembly makes a drill hole and a jacket tube surrounding the drill rod assembly in a spaced-apart manner and following the drill bit is provided.
[0003] In the context of producing a hole or drill hole in soil or rock material and the subsequent fixation of an anchorage or lining in the drill hole it is known, for instance, from WO 98/21439 and WO 98/58132 to introduce a jacket tube into the drill hole during the drilling procedure, for instance impact drilling or rotary percussion drilling, whereupon, after completion of the drilling procedure, part of the drill bit is optionally removed from the drill hole together with the drill rod assembly, while the jacket tube remains within the drill hole such that an anchor will subsequently be formed within the drill hole by filling a curing mass into the same. According to the configuration set out in WO 98/58132, the drill rod assembly may be provided with additional ribs and grooves on its outer periphery so as to ensure an accordingly good anchoring effect in case the drill rod assembly remains within the drill hole and is subsequently filled.
[0004] Alternatively, it is known to remove from the drill hole the drilling tool together with the drill rod assembly after the production of a drill hole, whereupon an anchor or anchoring means is introduced into the drill hole, wherein, for instance, from EP-B 0 241 451, U.S. Pat. No. 4,490,074, DE-AS 21 05 888, U.S. Pat. No. 4,310,266, EP-A 0 875 663 and other documents, configurations are known in which the tubular anchoring means to be introduced subsequently is kept by suitable retention elements at a diameter reduced relative to the final state, whereupon, after the complete introduction of the prestressed tube into the drill hole and removal of the retention means, the tube, which usually comprises a substantially longitudinally extending slot, expands, thus coming into abutment, or being pressed, on the drill hole wall in order to provide the required anchoring effect. That known prior art involves the drawback that, on the one hand, the drill hole has to be made in a first method step, whereupon, after the removal of the drilling tool plus drill rod assembly, the anchoring means is introduced into the optionally very long drill hole in a further method step, after which abutment on the drill hole wall is enabled by the removal of the respective retention means under widening of the outer diameter. It is immediately apparent that the two separate operating steps not only require accordingly more time, but that optionally the subsequent introduction of an anchoring means having a great length involves difficulties. Furthermore, it is to be anticipated that the removal of the drilling device together with the drill rod assembly and the subsequent introduction of an anchoring means is feasible only in comparatively firm soil or rock, where it must be safeguarded that no material will break into the drill hole, for instance, during the drilling procedure or after the removal of the drilling tool and prior to the final introduction of the anchoring means such that the drill hole will not be blocked, thus impeding the introduction of the anchoring means.
SUMMARY OF THE INVENTION
[0005] The present invention, therefore, aims to provide a method and a device of the initially defined kind, by which, with a simplified construction, an at least provisional securing is feasible during the drilling procedure and an anchorage to the inner wall of the drill hole can be obtained immediately upon completion of a drill hole.
[0006] To solve this object, the method according to the invention, departing from a method of the initially defined kind, is essentially characterized in that the jacket tube, which is formed with a longitudinal slot, is at least partially introduced in substantial abutment on the drill hole during drilling. Since the jacket tube, which is formed with a longitudinal slot, abuts at least partially on the wall of the drill hole during the production of the bore, at least provisional securing during the drilling procedure is feasible, whereby it is safeguarded by the provision of the longitudinal slot that the jacket tube is sufficiently elastic and resilient and, therefore, does not offer too much resistance against the introduction of the jacket tube by the aid of, for instance, a tensile or impact stress, even with an at least partial abutment on the wall of the drill hole. Moreover, the longitudinally slotted jacket tube ensures that an appropriate anchorage by the at least partial abutment on the wall of the drill hole will be obtained immediately upon completion of the bore such that time will be saved in the formation of such an anchorage as compared to known configurations in which the drill rod assembly was removed upon completion of a bore and a separate anchor was introduced into the drill hole. In addition, the method according to the invention can be applied irrespectively of the soil or rock material to be drilled, since the jacket tube is introduced directly during the production or formation of the drill hole, so that even with loose rock, where caving in would optionally have to be feared at least after the removal of the drilling tool and prior to the introduction of the anchorage, no difficulties as might occur with an anchorage to be provided subsequently will have to be feared, because the jacket tube introduced during drilling will itself always keep clear the passage cross section of the drill hole in loose rock. After the drill hole is completed, the drilling tool may either be removed at least partially with the drill rod assembly through the interior of the jacket tube remaining within the drill hole or may be left within the drill hole together with the drill rod assembly plus drilling tool to increase the anchoring effect, so that an anchoring effect not only will result from the abutment of the jacket tube on the inner wall of the drill hole, but the anchoring effect will be enhanced by the drilling tool and drill rod assembly remaining within the drill hole. When introducing the jacket tube, which is provided with a longitudinal slot, at least partially in abutment on the wall of the drill hole, it is to be anticipated further that, by the introduction of a scouring fluid into the region of the drill bit as known per se and the thus effected discharging of excavated material also in the region of the outer periphery of the jacket tube, an accordingly liquid or viscous material layer will be present, which will cause a lubricating or sliding effect during the introduction of the jacket tube. After the completion of the bore, and hence interruption of the continued supply of scouring fluid, it is to be anticipated that the friction between the outer periphery of the jacket tube and the inner wall of the drill hole will accordingly increase upon solidification of the material in the region of the outer periphery of the jacket tube such that an accordingly good anchoring effect of the jacket tube abutting on the inner wall of the drill hole will be obtained.
[0007] In order to support the anchoring effect of the jacket tube abutting at least partially on the inner wall of the drill hole already during its introduction, it is proposed according to a preferred embodiment that an expandable element is introduced into the interior of the jacket tube and expanded upon completion of the drill hole and removal of the drill rod assembly. Such an introduction of an expandable element optionally enables the jacket tube to be reliably fixed on the inner wall of the drill hole over partial regions, thus providing an enhanced anchoring effect.
[0008] In a particularly simple manner, an expandable element can be fixed in the interior of the jacket tube in that the expandable element is expanded by an impact stress as in correspondence with a further preferred embodiment of the method according to the invention. Such an expandable element not only ensures the reliable abutment of the jacket tube on the inner wall of the drill hole, but also acts against any reduction of the clear cross section of the jacket tube caused, for instance, by a compressive stress exerted by surrounding material or a tensile stress exerted in the longitudinal direction of the anchor formed by the jacket tube, since, by providing the longitudinal slot, tensile stresses acting in the longitudinal direction of the jacket tube that constitutes the anchorage, in particular, might otherwise result in a reduction of the anchor cross section of the jacket tube, whereby the anchoring effect would be accordingly reduced.
[0009] Depending on the surrounding material and hence on the nature of the jacket tube, it is preferably proposed for the introduction of the jacket tube during the drilling procedure that the jacket tube is introduced into the drill hole by exerting a tensile stress via a connection with the drill bit and/or an impact stress. According to the invention, the jacket tube may thus be coupled, for instance, with the drill bit in a suitable manner and introduced into the drill hole during the drilling procedure merely by means of tensile stress. Particularly in the event of jacket tubes having larger material cross sections and hence elevated strengths, which are employed to provide an accordingly resistant anchorage, the jacket tube, however, may be additionally or alternatively introduced into the drill hole during the drilling procedure by exerting an impact stress so as to avoid excessive forces to be exerted on the drill bit in order to entrain the jacket tube.
[0010] In order to ensure proper introduction of the jacket tube during the drilling procedure, it is proposed in this context, according to another preferred embodiment, that at least one connection provided along the substantially longitudinally slotted jacket tube and defined by a predetermined breaking point is separated upon completion of the bore.
[0011] Particularly simple separation or breaking of the predetermined breaking point is preferably feasible according to the invention in that the separation or breaking of the predetermined breaking point is effected by a slight retraction of at least the impact shoe and jacket tube mounted thereon, as well as an actuation of the impact shoe. Thus, after the completion of the bore, the separation or breaking of the predetermined breaking point can be obtained under the expansion or spreading of the front end of the jacket tube, by a slight retraction of at least the impact shoe and optionally the annular drill bit mounted thereto, and the subsequent, second actuation of the impact shoe with the jacket tube held fast or mounted in the produced drill hole in an at least partially frictionally engaged manner, by an expansion of the internal diameter of the longitudinally slotted jacket tube by the impact shoe, for instance by providing mating bearing surfaces in the region of the front end of the jacket tube, so that, in the main, proper abutment of the outer diameter of the expanded jacket tube on the finished wall of the drill hole can be ensured.
[0012] In order to further increase the anchoring effect, particularly in the event of loose rock or in cooperation with an anchoring plate to be optionally fixed to the end projecting out of the drill hole, it is proposed according to a further preferred embodiment that a curing mass is filled into the interior of the jacket tube in a manner known per se upon completion of the bore. The curing material is able to penetrate into the surrounding material, in particular, in the front region as well as along the longitudinal slot of the expandable jacket tube, thus improving the anchorage of the jacket tube. By the penetration of the curing material and subsequent bracing with an anchor plate to be provided on the external end of the jacket tube, the fixation of optionally loosely layered soil or rock material can be obtained in addition.
[0013] To solve the objects set in the beginning, a device of the initially defined kind, moreover, is essentially characterized in that the jacket tube comprises a longitudinal slot substantially extending in the longitudinal direction of the jacket tube. By providing a jacket tube formed with a longitudinal slot, it is ensured that the jacket tube can be introduced into the drill hole at an accordingly low friction resistance and at least partially in abutment on the inner wall of the drill hole during the drilling procedure, whereupon an appropriate anchoring effect will be obtained upon completion of the drilling procedure by the immediate, at least partial abutment of the jacket tube on the inner wall of the drill hole.
[0014] In order to support the anchoring effect, it is proposed according to a preferred embodiment that an expandable element is introducible into the interior of the jacket tube and expandable in abutment on the inner wall of the jacket tube upon completion of the drill hole and removal of the drill rod assembly. Such an expandable element, which is expandable into abutment on the inner wall of the jacket tube, ensures the safe anchorage of the jacket tube within the drill hole, whereby such an expandable element will counteract, for instance, a cross-sectional reduction of the jacket tube, in particular in the event of a tensile stress exerted on the anchorage formed by the jacket tube, thus reliably maintaining the desired anchoring effect.
[0015] In order to provide a particularly favorable fixation of the expandable element in the interior of the jacket tube, it is proposed according to a particularly preferred embodiment that the expandable element is comprised of a sleeve which is expandable by an impact stress caused by the introduction of an especially conical element, wherein, in particular, if a plurality of expandable elements is provided in the interior of the jacket tube and in order to ensure proper positioning of the same, it is proposed according to another preferred embodiment that the jacket tube on its inner wall is provided with elevations or projections aimed to position the expandable element.
[0016] In order to enable a particularly simple introduction, it is preferably proposed that the jacket tube comprises at least one predetermined breaking point along its longitudinal slot extending substantially in the longitudinal direction of the jacket tube. Due to the at least one predetermined breaking point provided according to the invention along the longitudinal slot of the jacket tube, the jacket tube can be readily introduced into the drill hole during the drilling procedure, while the at least one predetermined breaking point is separated or broken upon completion of the drill hole in order to place the jacket tube in abutment on the inner wall of the drill hole so as to obtain the anchorage.
[0017] After the bore is completed, the at least one predetermined breaking point must be separable by the introduction of an appropriate force. On the other hand, the predetermined breaking point must, however, ensure sufficient strength during the drilling procedure, of the longitudinal slot extending substantially over the total length of the jacket tube. To this end, it is proposed according to another preferred embodiment that the at least one predetermined breaking point provided along the longitudinal slot of the jacket tube is formed by a weld bridging the longitudinal slot. By an appropriate positioning and configuration as well as optionally number of welds forming predetermined breaking points, different demands relating both to the resistance during the drilling procedure and the breaking or separation of the predetermined breaking point upon completion of the bore can be met.
[0018] For the proper introduction of the jacket tube during the drilling procedure, it is moreover proposed that the jacket tube, on its end facing the drill bit, is fixed to an impact shoe of the drill bit as in correspondence with a further preferred embodiment of the device according to the invention. In addition to introducing the jacket tube by exerting an impact stress by fixing the jacket tube to the drill bit or impact shoe, respectively, it may additionally be provided that an impact stress is exerted on the jacket tube end that projects out of the drill hole, which is feasible, in particular, with jacket tubes having elevated strengths.
[0019] In order to obtain a suitable anchoring effect of the jacket tube which is expandable upon completion of the bore, it is proposed according to a further preferred embodiment that the jacket tube is made of a prestressed material, in particular metal.
[0020] In order to complete the anchor, or increase the anchoring effect, in particular with partially loose layers of rock material, it is, moreover, preferably proposed according to the invention that upon completion of the drill hole an anchoring plate is fixable to the jacket tube on its end projecting out of the soil or rock material.
[0021] In order to ensure the proper haulage of the excavated rocks, it is, moreover, proposed according to a further preferred embodiment that the jacket tube, in the region of its end following the drill bit, in a manner known per se comprises at least one passage opening aimed to introduce the excavated soil or rock material into the interior of the jacket tube such that the excavated material can be discharged from the bore also in the free space, in particular annular space, defined between the drill rod assembly and the jacket tube.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] In the following, the invention will be explained in more detail by way of exemplary embodiments schematically illustrated in the accompanying drawing. Therein:
[0023] [0023]FIG. 1 is a partially sectioned, schematic side view of a first embodiment of a device according to the invention for carrying out the method according to the invention;
[0024] [0024]FIG. 2 is a schematic section turned along line II-II of FIG. 1 in an enlarged illustration;
[0025] [0025]FIG. 3 is an illustration similar to that of FIG. 1, of a modified embodiment of a device according to the invention for carrying out the method according to the invention;
[0026] [0026]FIG. 4 is another illustration similar to that of FIG. 1, of a further modified embodiment of a device according to the invention for carrying out the method according to the invention;
[0027] [0027]FIG. 5 shows different steps during the realization of the method according to the invention using a device according to the invention, FIG. 5 a illustrating the procedure of making a drill hole by the method according to the invention in an illustration similar to that of FIG. 1, FIG. 5 a showing the removal of the drill rod assembly upon completion of the drill hole, FIG. 5 c showing the introduction of an expandable element into the interior of the jacket tube upon completion of the drill hole and the removal of the drill rod assembly, and FIG. 5 d showing the procedure of expanding the expandable element; and
[0028] [0028]FIG. 6 is a schematic side view of another modified embodiment of a device according to the invention for carrying out the method of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0029] In FIG. 1 a drilling tool or drill bit generally denoted by 1 is connected through a connecting piece 2 as well as an impact shoe schematically indicated by 3 with a drill rod assembly 5 extending in the interior of a jacket tube 4 . The drill bit 1 is actuated by an impact drilling or rotary percussion drilling device not illustrated in detail and arranged outside the soil or rock material to be worked, whose surface is denoted by 6 , via the drill rod assembly 5 . The inner contour of a drill hole made by the drilling tool or drill bit 1 is schematically indicated by 7 in FIG. 1.
[0030] As is apparent from FIG. 1, the jacket tube 4 comprises a longitudinal slot 8 extending substantially in the longitudinal direction, as is also clearly apparent from the illustration according to FIG. 2. From the illustration according to FIG. 2, it is, furthermore, apparent that the sleeve 4 is made of a prestressed material, in particular metal, wherein said material in its relieved state outside the drill hole, which is shown in full lines, has a larger outer diameter than in its state within the drill hole, which is illustrated by thin, broken lines, the slot being denoted by 8 ′. The jacket tube 4 is, thus, introduced into the drill hole in a prestressed condition so as to ensure that the jacket tube 4 will at least partially abut on the drill hole inner wall 7 in order to thereby enable at least provisional securing already during the drilling procedure.
[0031] From FIG. 2 it is, furthermore, apparent that the drill rod assembly 5 is provided with a central passage channel 9 , via which a scouring fluid is introduced into the region of the drill bit 1 in order to discharge excavated material at least partially in the region of the outer periphery of the jacket tube 4 between the jacket tube 4 and the drill hole inner wall 7 , wherein a lubricating or sliding effect will be obtained by the introduction of the scouring fluid at the interface between the outer periphery of the jacket tube and the drill hole inner wall 7 . This lubricating or sliding effect accordingly reduces the friction resistance between the outer periphery of the jacket tube 4 and the drill hole inner wall 7 during the drilling procedure, while a frictionally engaged connection between the jacket tube 4 and the drill hole inner wall 7 can be obtained by curing upon completion of the drill hole 7 and hence interruption of the scouring agent feed into the region of the drill bit 1 .
[0032] In the embodiment represented in FIG. 1, the introduction of the jacket tube 4 , which has a conically tapering outer shape in the region 4 ′ following the drill bit 1 , is effected by a tensile stress exerted on the jacket tube 4 via the impact shoe 3 .
[0033] In FIG. 1, 10 serves to denote a transition sleeve which enables the fixation of an actuating means for impact drilling or rotary percussion drilling, which is not illustrated in detail.
[0034] In the modified embodiment depicted in FIG. 3, the jacket tube 4 , in addition to the tensile stress applied by the impact shoe 3 , is subjected to an impact stress in the region of the anchor head 6 via the transition sleeve 10 such that the jacket tube 4 is introduced into the interior of the drill hole again denoted by 7 , both under a tensile stress and under an impact stress.
[0035] The jacket tube 4 again comprises a longitudinal slot 8 and is offset, or designed to have a reduced cross section, in partial regions of its outer periphery, such offset partial regions being denoted by 11 in FIG. 3. Thus, only a partial abutment of the jacket tube 4 will be obtained, particularly during the introduction procedure, this being favorable to ensure a proper drilling progress, for instance in the event of a high friction resistance to be expected between the outer periphery of the jacket tube 4 and the drill hole inner wall 7 .
[0036] From the further modified embodiment according to FIG. 4, it is apparent that the jacket tube 4 is introduced into the interior of the drill hole 7 merely by exerting an impact stress on the anchor head 6 by the aid of the transition sleeve 10 , while no tensile entrainment through a connection of the jacket tube 4 with the drill bit 1 is effected in this embodiment. Such an introduction of a jacket tube 4 by means of impact stress is feasible, in particular, in the event of an accordingly sturdier jacket tube or a jacket tube 4 exhibiting an elevated strength.
[0037] From the individual method steps illustrated in FIG. 5, FIG. 5 a shows the formation or production of the drill hole 7 while introducing the jacket tube 4 in a manner, for instance, similar to that of the embodiment of FIG. 4 by exerting an impact stress on the anchor head 6 , without any connection being provided between the jacket tube 4 and the drill head 1 .
[0038] In FIG. 5, an anchor plate 13 is each indicated in the region of the end projecting out of the soil or rock material 12 .
[0039] After the completion of the drill hole 7 as illustrated in FIG. 5 b the drill rod assembly 5 is removed from the drill hole 7 in the sense of arrow 14 , while the drill bit 1 remains within the drill hole 7 .
[0040] After the removal of the drill rod assembly, an expandable element generally denoted by 15 is introduced into the interior of the jacket tube 4 in the sense of arrow 16 . The expandable element 15 is comprised of a conically tapering sleeve 17 at least partially provided with a longitudinal slot 18 , whereby a conical element 19 can be introduced into the interior of the sleeve 17 .
[0041] After the introduction or insertion of the expandable two-part element 15 into the interior of the jacket tube 4 , for instance into the region of stops or projections 20 intended to position the expandable element, the conical element 19 is subjected to an impact stress via the transition sleeve 10 so as to cause the two-part expandable element 15 to be positioned on the desired site in the interior of the jacket tube and fixed to the inner wall of the jacket tube 4 .
[0042] This expandable element 15 upon introduction safeguards that no cross sectional reduction of the jacket tube 4 will occur, for instance, due to a compressive stress exerted by surrounding material or by applying a tensile stress in the sense of an extraction or separation movement of the anchorage, so that the desired anchoring effect will be reliably maintained. If a tensile stress is exerted on the anchor formed by the jacket tube 4 , a cross sectional reduction is feasible through the longitudinal slot 8 of the jacket tube 4 in the event no expandable element 15 is provided, whereby such a cross sectional reduction would deteriorate the anchoring effect.
[0043] Instead of providing positioning projections 20 , the expandable element 15 can also be brought into direct abutment on the drill bit 1 remaining within the drill hole 7 as indicated in FIG. 5 d . Moreover, it may be provided that a plurality of expandable elements 15 is introduced into the interior of the jacket tube 4 in order to obtain an appropriate support of the anchoring effect of the jacket tube 4 at different points. Such multiple expandable elements 15 can be arranged by appropriately designing, and mating with respective positioning projections 20 , in particular the conical sleeve 17 .
[0044] Alternatively or additionally to introducing the expandable elements 15 , it may be provided to fill the interior of the jacket tube 4 with a curable mass upon completion of the drill hole 7 and optionally removal of the drill rod assembly 5 .
[0045] In FIG. 6, which illustrates a further modified embodiment, 1 serves again to denote a drilling tool or drill bit which is connected through a connecting piece 2 as well as an impact shoe schematically indicated by 3 with a drill rod assembly 5 extending in the interior of a jacket tube 4 , wherein the drill bit 1 is actuated by an impact drilling or rotary percussion drilling device not illustrated in detail and arranged outside the soil or rock material to be worked, whose surface is denoted by 6 , via the drill rod assembly 5 . The inner contour of a drill hole made by the drilling tool or drill bit 1 is again schematically indicated by 7 in FIG. 6.
[0046] As is apparent from FIG. 6, the jacket tube 4 again comprises a longitudinal slot 8 extending substantially in the longitudinal direction, wherein at least one predetermined breaking point 29 is provided along the longitudinal extension of the longitudinal slot 8 , said predetermined breaking point being formed, e.g., by a weld 29 . The jacket tube 4 in this case is fixed on the impact shoe 3 via an intermediate element and is entrained by the impact shoe 3 during the drilling procedure such that the jacket tube 4 formed with the longitudinal slot 8 is introduced into the drill hole 7 directly during the drilling procedure.
[0047] To remove the material excavated by the drill bit 1 , a passage opening 31 is provided in the front region of the jacket tube 4 , said passage opening 31 being formed by forming an enlarged clear passage cross section of the longitudinal slot 8 . Through this passage opening 31 , material worked off by the drilling tool 1 reaches the free space or annular space defined between the jacket tube 4 and the drill rod assembly 5 and is discharged on the end facing away from the drill bit 1 . If necessary, a second passage opening may be provided in the jacket tube 4 on the radially opposite partial region of the periphery, for instance, symmetrical with the passage opening 31 .
[0048] Upon completion of the bore, the expansion of the prestressed jacket tube 4 is caused by the breaking or separation of the weld defining the predetermined breaking point 29 , thus providing the desired anchoring effect.
[0049] Upon completion of the bore, the jacket tube 4 and at least the impact shoe 3 as well as drill bit parts mounted thereon, for instance the annular drill bit where a central drill bit and a radially surrounding annular drill bit are provided, are slightly retracted oppositely to the drilling or advancing direction 26 , whereupon, after said retraction, the impact shoe 3 is actuated once more via the drill rod assembly 5 , again in the direction of the drilling procedure 26 , thus separating the predetermined breaking point 29 .
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The invention relates to a method and a device for the drilling, in particular the percussive or percussive rotary drilling of a hole ( 7 ) in earth or rock and for securing an anchorage in said hole. According to the invention, a bore hole ( 7 ) is created by a drill bit ( 1 ) mounted on a drill pipe ( 5 ) and a sliding sleeve ( 4 ) that surrounds the drill pipe ( 5 ) at a distance is simultaneously introduced. The invention is characterised in that a sliding sleeve ( 4 ) configured with a longitudinal slit ( 8 ) is introduced at least partially and rests substantially against the bore hole ( 7 ) during the drilling, whereby a reliable anchorage can be achieved with a simple construction by means of the sliding sleeve ( 4 ) with a longitudinal slit.
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FIELD OF THE INVENTION
The present invention relates generally to safety cabinets for storage of combustibles or volatiles and more specifically to safety cabinets having a self-closing and sequencing door mechanism.
BACKGROUND OF THE INVENTION
The present invention is a safety cabinet having a self-closing and sequencing door mechanism. It is very important for safety cabinets storing flammable, volatile or explosive materials to have doors which automatically close in a tight fit and are flush with the edges of the safety cabinet. A tight and flush fit is necessary to completely seal off the inside of the safety cabinet from the outside thereby protecting the contents from an external hazard or conversely protecting the outside surrounding area from an internal hazard. Safety storage cabinets are desirably constructed such that the doors automatically close after opening in order to assure that the flammable, volatile or explosive material remaining within the cabinet are not exposed. Safety cabinets so constructed reduce the risk of danger in storing hazardous materials.
A majority of door sequencing devices in the art operate on the principle of having a blocking means for holding one door open while allowing a second door to completely close thereby triggering a mechanism to remove the blocking means from the first door. The mechanics of this operating principle usually involves a series of parts to translate vertical motion of the closing door into horizontal motion for removing a blocking means from a different door. Most of the devices in the art use a lever or series of levers and a bellcrank to effectuate the closing of doors in a specified sequence. With exception to the conventional lever door sequencing means are, among others, U.S. Pat. No. 4,265,051 (1981) which uses a pivotable prop located in a contacting arrangement with both doors at the edge opposite the door hinge of each door in order to coordinate the closing movement of the doors. Another device which operates with exception to the lever system is that described in U.S. Pat. No. 4,967,512 (1990), requiring the movement of guide rollers along a cross beam or track on the fixed frame of the cabinet to control the closing sequence of the doors.
Most devices however, including the present invention, operate on the principle of blocking the closure of one door while allowing the other door, usually a door with a sealing flange or lip, to securely close before removing the blocking means. Illustrative of this typical arrangement is U.S. Pat. No. 3,895,461 (1975) which describes a blocking lever biased by a member connected to a second lever which can be moved by the closing of the first door. Upon the closing of the first door, a trigger lever is pivoted which causes the biasing member to move from its extended position to its retracted position thereby allowing the blocking lever to close followed by the door. The disadvantage of this system is that it involves multiple moving parts. Another similar device is described in U.S. Pat. No. 4,949,505 (1990) which involves a blocking lever and trigger lever connected to a actuating link which is connected to a secondary link or rod which holds a biasing member against the blocking lever. This particular sequencing device has even more moving parts as well as uses a larger quantity of material to effectuate door sequencing. Actuating arms and levers or bellcranks and levers are other popular means for blocking one door while simultaneously capturing the vertical motion of the other door to remove the blocking means. The preferred embodiment of U.S. Pat. No. 4,262,448 (1981) utilizes an actuating lever arm pivotally mounted to a timing slide bracket, essentially a blocking lever, which is removed from blocking one door when the other door contacts the actuating arm. An even more complicated system of levers is disclosed in U.S. Pat. No. 5,061,022 (1991). This system involves two protruding levers interconnected by an actuating link. The actuating link is connected to one lever by a bellcrank and the second lever by a pin and notch arrangement. The action of the closing door on the lever connected to the bellcrank translates the motion of the door to the actuating link which disengages the pin from the notch in the second lever allowing the other door to close.
U.S. Pat. No. 3,895,849 (1975) discloses a different arrangement for two levers and a sliding bar or link. In this case the levers or actuating means are connected to the doors with at least one being pivotally secured to one of the doors. The actuating means contacts a sliding bar at the rear of the cabinet. The bar is positioned such that the pivotally secured actuating means is blocked from further movement until the actuating means contacts a bellcrank on the slide bar to remove it from contact from the pivotally secured actuating means. Finally, U.S. Pat. No. 3,822,506 (1974) utilizes a plunger connected to a spring link which biases a lever which holds one door open. The first door contacts the plunger which allows the spring link to move into its retracted position removing the bias from the holding lever allowing the second door to close.
The interconnected lever systems, pivotally secured actuating means and plunger and spring lever means have several disadvantages. These door sequencing mechanisms have a large number of moving parts, use a lot of material in their construction and are intricate and costly to manufacture and install into safety cabinets. Actuating links and pivotal members must be individually manufactured and then connected to each other followed by installation of all the parts in an organized arrangement. These design arrangements are costly and time consuming to build. The unique and simplified design of the present invention overcomes the problems plaguing the sequencing mechanisms in the safety cabinet art.
OBJECTS OF THE INVENTION
It is the principal object of the present invention to provide fire-proof safety cabinets having door self-closing devices which automatically close in the proper sequence.
It is another object of the present invention to provide safety cabinets with self-closing and sequencing mechanisms that are of simple and reliable construction.
It is yet another object of the present invention to provide self-closing and sequencing door mechanisms with very few moving parts.
It is still another object of the present invention to provide self-closing and sequencing door mechanisms in forms simple and economical to manufacture.
Other objects, features and advantages of the present invention will become apparent from the following detailed description taken in conjunction with the accompanying drawings.
SUMMARY OF THE INVENTION
In accordance with one embodiment of the present invention a self-closing and sequencing door mechanism is included in a safety cabinet having two doors, each hingedly mounted to an opposite side wall and connected to an automatic door closing mechanism on the inside face of the door. The self-closing and sequencing door mechanism of the present invention has a simplified design of sturdy construction and only three moving parts.
The sequencing device has three main components which are not connected to each other. The first component is a cam-shaped bracket fixedly mounted on the interior surface of a first door. The cam-shaped bracket is positioned around the midpoint of the length of the first door, preferably between the midpoint and the hingedly mounted edge. The second component is a single piece stop bracket fixedly mounted on the interior surface of the second door positioned near the midpoint of the length of the second door, preferably between the midpoint and the hingedly mounted edge. Both of these components are single pieces having no movement. These two brackets may be small in size as they interact with the third component of the device which is mounted on the front part of the inside surface of the top wall of the safety cabinet.
The third component is a slide bar movably mounted on the inside surface of the top wall adjacent the open front of the safety cabinet. This is the only component with moving parts. The movable slide bar itself is attached to a slide bar mount by a spring. One end of the slide bar is bare while the other end has a rotating roller attached.
When the slide bar is in its rest or relaxed position it blocks the closure of the door having the stop bracket mounted on its inside surface. The stop bracket is long enough so that it contacts the bare end of the slide bar thereby keeping the door it is mounted to in an open position. With one door in the open position, the other door, having a sealing flange, is allowed to pass by and close and the cam-shaped bracket fixedly mounted to this door contacts the roller at the other end of the slide bar. As a result of the motion of the cam bracket on the roller, the slide bar is removed from the path of the stop bracket allowing the door with the stop bracket to subsequently close.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric frontal view of a safety cabinet;
FIG. 2 is a top view of a cabinet self-closing and sequencing mechanism with the right door stopped until the left door closes;
FIG. 3 is a top view of a cabinet self-closing and sequencing mechanism with both cabinet doors closed; and
FIG. 4 is a view of another embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
There is shown in FIG. 1 a fire-proof safety cabinet 2 having an outer top wall 4, an outer bottom wall 6, an outer right wall 8, an outer left wall 10, an outer rear wall 12, a right door 14 and a left door 16. Right door 14 has handle assembly 18 extending through the outside of right door 14 to allow for the opening of right door 14. Throughout the description of the preferred embodiment, the doors are designated right and left to be consistent with the drawings. This designation is arbitrary for purposes of the design of the door sequencing mechanism. Any components attached to the right door may be attached to the left and vica versa.
In keeping with one preferred construction of fire-proof safety cabinets, safety cabinet 2 is a double-walled construction, wherein each said wall has a corresponding inner wall, with said inner and outer walls separated by dead air space or fire-retardant insulation. Thus, in FIG. 2, outer rear wall 12 has a corresponding outer surface 12a and an inner surface 12b. Correspondingly, outer right wall 8 has outer surface 8a and inner surface 8b and outer left wall 10 has outer surface 10a and inner surface 10b. Fire-retardant insulation 11 may be packed between any wall inner surface and outer surface. While not shown in the drawings, outer top wall 4 and outer bottom wall 6 also have an inner and outer surface separated by dead air space or fire-retardant insulation.
As best seen in FIG. 2, the front of cabinet 2 is closed off by right door 14 and left door 16 with both doors having a similar double wall construction. Outer surface 14a of right door 14 is separated from inner surface 14b by side walls 14c, 14d, 14e and 14f (bottom surface 14f is shown in the cut-away portion of FIG. 2) defining an enclosed dead air space. Left door 16 is of similar construction, with side walls 16c, 16d, 16e and 16f (bottom surface 16f is shown in the cut-away portion of FIG. 2) joining outer surface 16a and inner surface 16b.
In the embodiment illustrated in FIG. 2, left door 16 has sealing flange 20 protruding along side wall 16e. Because sealing flange 20 protrudes from surface 16e along the side closest to the interior of safety cabinet 2, left door 16 must close before right door 14 so that the safety cabinet doors 14 and 16 close tightly and are flush with the outside edges of safety cabinet 2. Alternatively, sealing flange 20 could protrude from surface 16e along the side closest to the exterior of safety cabinet 2 and even still, left door 16 must close before right door 14.
Right door 14 is hingedly mounted to outer right wall 8 by hinge 22. Likewise, left door 16 is hingedly mounted to outer left wall 10 by hinge 24. In the preferred embodiment of the present invention hinges 22 and 24 run the length of the respective doors along edges 14d and 16d.
When doors 14 and 16 are closed, safety cabinet 2 defines an inner protected air space surrounded top, bottom, sides, back and front by double-walled elements having insulating spaces created therebetween. It is contemplated that articles placed within safety cabinet 2 will be protected from the effects of fire when said doors 14 and 16 are closed.
An automatic door closing mechanism 26 is mounted to the inner surface 14b of right door 14 by mount 28. Right door closing mechanism 26 extends from inner surface 14b of right door 14 to inner surface 12b of outer rear wall 12 where it is mounted by mount 30. Right door closing mechanism 26 is pivotally mounted on both mounts 28 and 30. Door closing mechanism 26 is positioned close to the inner surface of outer top wall 4 so that it does not interfere with the interior space of safety cabinet 2. Similarly, left door closing mechanism 32 is attached to inner surface 16b of left door 16 by left door mount 34. Door closing mechanism 32 extends from left door 16 to outer rear wall 12. It is mounted to outer rear wall 12 by rear wall mount 36. Again, left door closing mechanism 32 is pivotally mounted on both mounts 34 and 36 so that it may move when left door 16 is opened and closed. Left door mechanism 32 is also positioned close to the inner surface of outer top wall 4 so that it does not consume valuable space in the interior of safety cabinet 2.
Automatic door closing mechanisms 26 and 32 may be of any known type of door closing mechanism such as pneumatic, hydraulic or mechanical self-closing devices. In the preferable embodiment, automatic closing mechanisms 26 and 32 are hydraulic closing mechanisms.
A fusible linking device (not shown) may also be connected to each door 14 and 16. These heat sensitive devices can hold doors 14 and 16 in an open position and in the event of a high temperature hazard, the fusible links will melt allowing doors 14 and 16 to close.
During any automatic closing of doors 14 and 16, it is necessary that the doors close in sequence wherein left door 16 reaches a closed position prior to right door 14. This sequence must be maintained because of the protrusion of sealing flange 20 on surface 16e of left door 16.
A preferred embodiment to sequence the closing of doors 14 and 16 includes a fixedly-mounted, stationary, one-piece right door stop bracket 38. Right door stop bracket 38 is positioned on inner surface 14b of right door 14 adjacent to top surface 14c. The one-piece stop bracket 38 is also positioned near the midpoint of the length of door 14 and preferably closest to surface 14d which is closest to the side hinged by hinge 22 to outer right wall 8. Stop bracket 38 may be of a simple right-triangular shape and is made of metal in its preferable form. Metal provides a durable construction for stop bracket 38. Stop bracket 38 may be of solid or hollow construction.
As part of the sequencing mechanism, mounted on left door 16 is a fixedly-mounted, stationary, one-piece left door cam bracket 40. Cam bracket 40 has a cam shape and is preferably made of a durable material like metal. Cam bracket 40 may be of solid or hollow construction. Single piece cam bracket 40 is mounted on inner surface 16b of left door 16 adjacent to top surface 16c and close to the midpoint of the length of left door 16 and preferably between the midpoint and edge 16d.
Operably associated with single piece right door stop bracket 38 and single piece left door cam bracket 40 is slide bar 42, the third component of the sequencing mechanism of the preferred embodiment of the present invention. Slide bar 42 is slidably mounted on slide bar mount 44 which is mounted by rivets or screws 46a, 46b, 46c and 46d to the inner surface of outer top wall 4. Slide bar 42 is mounted such that it is free to slide left and right in guide openings 43 of slide bar mount 44. The right end of slide bar 42 can be bare or fitted with stoppers 45. Stoppers 45 may be placed, as shown, on slide bar 42 to restrict the motion of slide bar 42. On the left end of slide bar 42 is rotating roller 48 attached to slide bar 42 by roller axle 50. The diameter of roller 48 is typically larger than the width of slide bar 42. Roller 48 may be made of any durable wear-resistant material, preferably nylon.
When doors 14 and 16 are both in the open position, slide bar 42 remains in a relaxed position by the action of a biasing spring 52 which is connected at one end to slide bar mount 44 by biasing spring connection 54 and to slide bar 42 at the other end. The relaxed position of slide bar 42 is shown in FIG. 2. In the relaxed position, slide bar 42 would come in physical contact with both stop bracket 38 and cam bracket 40.
When doors 14 and 16 are held open, and slide bracket 42 is positioned in its rightward most attitude, slide bar 42 will be positioned as shown FIG. 2. The bare end of slide bar 42 will protrude into the path of right door stop bracket 38 so that the closing of right door 14 will be arrested by slide bar 42.
As best illustrated in FIGS. 2 and 3, right door 14 will remain partially open until slide bracket 42 moves leftward a sufficient distance to remove slide bar 42 from the path of stop bracket 38. Such a position is illustrated in FIG. 3.
Movement of slide bar 42 is accomplished as follows: When left door 16 closes, cam bracket 40 comes in contact with roller 48. Sufficient force is exerted on roller 48 by the closing of left door 16 so that roller 48 moves along the cam-shaped surface of cam bracket 40 causing the expansion of spring 52 and the movement of the slide bar 42 to the left. When roller 48 completes its movement along cam bracket 40, slide bar 42 will be completely removed from the path of stop bracket 38, thus allowing right door 14 to close so that outer surface 14a is flush with outer surface 16a of left door 16. In this manner, it is assured that door 16 with sealing flange 20 will close fully before right door 14 thus providing a protective seal for safety cabinet 2.
A second embodiment of the present invention, illustrated in FIG. 4, relates particularly to a closing device which is mounted at the inner surface of outer bottom wall 6. The three components of the door sequencing means, namely single piece stop bracket 38, single piece cam bracket 40 and slide bar 42 may be mounted at the bottom of safety cabinet 2. Stop bracket 38 and cam bracket 40 will be located at the bottoms of doors 14 and 16 respectively. Slide bar 42 will be mounted at the bottom of the inner surface of outer bottom wall 6. All three components will be operably associated with each other, as previously described, such that door 16 with sealing flange 20 closes prior to door 14. A shelf (not shown) may be placed just above the door sequencing mechanism to keep the device clear of obstruction.
While there has been illustrated and described several embodiments of the present invention, it will be apparent that various changes and modifications thereof will occur to those skilled in the art. It is intended in the appended claims to cover all such changes and modifications that fall within the true spirit and scope of the present invention.
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A safety cabinet for the storage of flammable or combustible materials has doors designed to automatically close in a specified sequence. The door sequencing device has three components: a stop bracket mounted to one door, a cam bracket mounted to the other door and a slide bar with a roller on one end mounted to the inside surface of the top of the safety cabinet. The slide bar is operably associated with the two brackets such that it blocks the movement of the stop bracket on one door until the cam bracket of the other door engages the roller and removes the slide bar from the path of the stop bracket thereby allowing the second door to close.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This is a continuation-in-part of application Ser. No. 12/372,862, filed Feb. 18, 2009, now U.S. Pat. No. 8,122,967, issued Feb. 28, 2012.
TECHNICAL FIELD OF THE INVENTION
This invention relates, in general, to equipment utilized and operations performed in conjunction with a subterranean well and, in particular, to an apparatus and method for controlling the connection and disconnection speed of downhole connectors.
BACKGROUND OF THE INVENTION
Without limiting the scope of the present invention, its background is described with reference to using optical fibers for communication and sensing in a subterranean wellbore environment, as an example.
It is well known in the subterranean well completion and production arts that downhole sensors can be used to monitor a variety of parameters in the wellbore environment. For example, during a treatment operation, it may be desirable to monitor a variety of properties of the treatment fluid such as viscosity, temperature, pressure, velocity, specific gravity, conductivity, fluid composition and the like. Transmission of this information to the surface in real-time or near real-time allows the operators to modify or optimize such treatment operations to improve the completion process. One way to transmit this information to the surface is through the use of an energy conductor which may take the form of one or more optical fibers.
In addition or as an alternative to operating as an energy conductor, an optical fiber may serve as a sensor. It has been found that an optical fiber may be used to obtain distributed measurements representing a parameter along the entire length of the fiber. Specifically, optical fibers have been used for distributed downhole temperature sensing, which provides a more complete temperature profile as compared to discrete temperature sensors. In operation, once an optical fiber is installed in the well, a pulse of laser light is sent along the fiber. As the light travels down the fiber, portions of the light are backscattered to the surface due to the optical properties of the fiber. The backscattered light has a slightly shifted frequency such that it provides information that is used to determine the temperature at the point in the fiber where the backscatter originated. In addition, as the speed of light is constant, the distance from the surface to the point where the backscatter originated can also be determined. In this manner, continuous monitoring of the backscattered light will provide temperature profile information for the entire length of the fiber.
Use of an optical fiber for distributed downhole temperature sensing may be highly beneficial during the completion process. For example, in a stimulation operation, a temperature profile may be obtained to determine where the injected fluid entered formations or zones intersected by the wellbore. This information is useful in evaluating the effectiveness of the stimulation operation and in planning future stimulation operations. Likewise, use of an optical fiber for distributed downhole temperature sensing may be highly beneficial during production operations. For example, during a production operation a distributed temperature profile may be used in determining the location of water or gas influx along the sand control screens. In a typical completion operation, a lower portion of the completion string including various tools such as sand control screens, fluid flow control devices, wellbore isolation devices and the like is permanently installed in the wellbore. The lower portion of the completion string may also include various sensors, such as a lower portion of the optical fiber. After the completion process is finished, an upper portion of the completions string which includes the upper portion of the optical fiber is separated from the lower portion of the completion string and retrieved to the surface. This operation cuts off communication between the lower portion of the optical fiber and the surface. Accordingly, if information from the production zones is to be transmitted to the surface during production operations, a connection to the lower portion of the optical fiber must be reestablished when the production tubing string is installed.
It has been found, however, that wet mating optical fibers in a downhole environment is very difficult. This difficulty is due in part to the lack of precision in the axially movement of the production tubing string relative to the previously installed completion string. Specifically, the production tubing string is installed in the wellbore by lowering the block at the surface, which is thousands of feet away from the downhole landing location. In addition, neither the distance the block is moved nor the speed at which the block is moved at the surface directly translates to the movement characteristics at the downhole end of the production tubing string due to static and dynamic frictional forces, gravitational forces, fluid pressure forces and the like. The lack of correlation between block movement and the movement of the lower end of the production tubing string is particularly acute in slanted, deviated and horizontal wells. This lack in precision in both the distance and the speed at which the lower end of the production tubing string moves has limited the ability to wet mate optical fibers downhole as the wet mating process requires relatively high precision to sufficiently align the fibers to achieve the required optical transmissivity at the location of the connection.
Therefore, a need has arisen for an apparatus and method for wet connecting optical fibers in a subterranean wellbore environment. A need has also arisen for such an apparatus and method for wet connecting optical fibers that is operable to overcome the lack of precision in the axial movement of downhole pipe strings relative to one another. Further, a need has arisen for such an apparatus and method for wet connecting optical fibers that is operable to overcome the lack of precision in the speed of movement of downhole pipe strings relative to one another.
SUMMARY OF THE INVENTION
The present invention disclosed herein is directed to an apparatus and method for wet connecting downhole communication media in a subterranean wellbore environment. The apparatus and method of the present invention are operable to overcome the lack of precision in the axial movement of downhole pipe strings relative to one another. In addition, the apparatus and method of the present invention are operable to overcome the lack of precision in the speed of movement of downhole pipe strings relative to one another. In carrying out the principles of the present invention, a wet connection apparatus and method are provided that are operable to control the connection speed of downhole connectors.
In one aspect, the present invention is directed to a method for controlling the connection speed of downhole connectors in a subterranean well. The method includes positioning a first assembly having a first downhole connector and a first communication medium in the well; engaging the first assembly with a second assembly, the second assembly including a second downhole connector and a second communication medium, the second assembly having an outer portion and an inner portion that are initially coupling together with a lock assembly; unlocking the outer portion of the second assembly from the inner portion of the second assembly by radially shifting at least one lug; axially shifting the outer portion of the second assembly relative to the inner portion of the second assembly; and operatively connecting the first and second downhole connectors, thereby enabling communication between the first and second communication media.
The method may also include, radially shifting a plurality of lugs of the lock assembly to unlock the outer portion of the second assembly from the inner portion of the second assembly; longitudinally shifting a plunger of the lock assembly responsive to contact with the first assembly to radially retract the at least one lug; radially retracting the at least one lug responsive to contact between at least one lug extension of the lock assembly and the first assembly; controlling an axial shifting speed of the outer portion of the second assembly relative to the inner portion of the second assembly with a resistance assembly by, for example, metering a fluid through a transfer piston; anchoring the second assembly within the first assembly by propping a key assembly of the second assembly within a profile of the first assembly; overcoming a biasing force of a spring operably associated with the transfer piston to control the axially shifting speed of the outer portion of the second assembly relative to the inner portion of the second assembly; resisting disconnection of the first and second downhole connectors by locking the outer portion of the second assembly with the inner portion of the second assembly by, for example, engaging a collet assembly of the outer portion of the second assembly with a shoulder of the inner portion of the second assembly by continuing the axial shifting of the outer portion of the second assembly relative to the inner portion of the second assembly after connecting the first and second downhole connectors; and/or selecting the communication media from the group consisting of optical fibers, electrical conductors and hydraulic fluid.
In another aspect, the present invention is directed to an apparatus for controlling the connection speed of downhole connectors in a subterranean well. The apparatus includes a first assembly having a first downhole connector and a first communication medium that is positionable in the well. A second assembly includes a second downhole connector and a second communication medium and has an outer portion and an inner portion that are selectively axially shiftable relative to one another. A lock assembly including at least one lug initially couples the outer and inner portions of the second assembly together such that, upon engagement of the first assembly with the second assembly, the at least one lug is radially shifted releasing the lock assembly to allow axial shifting of the outer portion of the second assembly relative to the inner portion of the second assembly, thereby operatively connecting the first and second downhole connectors to enable communication between the communication media.
In one embodiment, the lock assembly includes a plurality of lugs. In another embodiment, the lock assembly includes a plunger assembly that longitudinally shifts relative to the at least one lug responsive to contact with the first assembly to radially retract the at least one lug. In a further embodiment, the lock assembly includes at least one lug extension that radially retracts the at least one lug responsive to contact between the at least one lug extension and the first assembly. In certain embodiments, a resistance assembly is positioned between the outer portion of the second assembly and the inner portion of the second assembly that controls the axial shifting speed of the outer and inner portions of the second assembly relative to one another. In such embodiments, the resistance assembly may include a transfer piston operable to have fluid metered therethrough and a spring operably associated with the transfer piston. In one embodiment, the second assembly includes a key assembly and the first assembly includes a profile such that the key assembly may be propped within the profile to anchor the second assembly within the first assembly. In another embodiment, the inner portion of the second assembly may include a shoulder and the outer portion of the second assembly may include a collet assembly. In this embodiment, continued axial shifting of the outer portion of the second assembly relative to the inner portion of the second assembly after connecting the first and second downhole connectors engages the collet assembly with the shoulder to selectively lock the outer portion of the second assembly with the inner portion of the second assembly to resist disconnection of the first and second downhole connectors. In certain embodiments, the communication media are selected from the group consisting of optical fibers, electrical conductors and hydraulic fluid conductor.
In a further aspect, the present invention is directed to a method for controlling the connection speed of downhole connectors in a subterranean well. The method includes positioning a first assembly having a first downhole connector and a first communication medium in the well; engaging the first assembly with a second assembly having a second downhole connector and a second communication medium; unlocking an outer portion of the second assembly from an inner portion of the second assembly by radially shifting at least one lug; axially shifting the outer portion of the second assembly relative to the inner portion of the second assembly while metering a fluid through a transfer piston to control the axially shifting speed thereof; and operatively connecting the first and second downhole connectors, thereby enabling communication between the first and second communication media.
In yet another aspect, the present invention is directed to an apparatus for controlling the connection speed of downhole connectors in a subterranean well. The apparatus includes a first assembly having a first downhole connector and a first communication medium that is positionable in the well. A second assembly includes a second downhole connector and a second communication medium. The second assembly has an outer portion and an inner portion with a transfer piston positioned therebetween. The outer portion is selectively axially shiftable relative to the inner portion. A lock assembly including at least one lug initially couples the outer and inner portions of the second assembly together such that, upon engagement of the first assembly with the second assembly, the at least one lug is radially shifted to release the lock assembly and allow axial shifting of the outer portion of the second assembly relative to the inner portion of the second assembly while a fluid is metered through the transfer piston to control the speed at which the outer and inner portions of the second assembly axially shift relative to one another such that the first and second downhole connectors are operatively connected at a predetermined connection speed, thereby enabling communication between the communication media.
In an additional aspect, the present invention is directed to a method for controlling the connection speed of downhole connectors in a subterranean well. The method includes positioning a first assembly having a first downhole connector and a first communication medium in the well; engaging the first assembly with a second assembly, the second assembly including a second downhole connector and a second communication medium, the second assembly having an outer portion and an inner portion that are initially coupling together; unlocking the outer portion of the second assembly from the inner portion of the second assembly responsive to contact with the first assembly; axially shifting the outer portion of the second assembly relative to the inner portion of the second assembly; operatively connecting the first and second downhole connectors, thereby enabling communication between the first and second communication media; and resisting disconnection of the first and second downhole connectors by recoupling the outer portion of the second assembly with the inner portion of the second assembly.
In another additional aspect, the present invention is directed to an apparatus for controlling the connection speed of downhole connectors in a subterranean well. The apparatus includes a first assembly having a first downhole connector and a first communication medium that is positionable in the well. A second assembly includes a second downhole connector and a second communication medium. The second assembly has an outer portion and an inner portion that are selectively axially shiftable relative to one another. A first lock assembly initially couples the outer and inner portions of the second assembly together. A second lock assembly is operable to recouple the outer and inner portions of the second assembly together. In operation, upon engagement of the first assembly with the second assembly, the first lock assembly is released to allow axial shifting of the outer portion of the second assembly relative to the inner portion of the second assembly in a first direction which operatively connects the first and second downhole connectors, thereby enabling communication between the communication media. Thereafter, continued axial shifting of the outer portion of the second assembly relative to the inner portion of the second assembly in the first direction engages the second lock assembly thereby recoupling the outer portion of the second assembly with the inner portion of the second assembly to resist disconnection of the first and second downhole connectors.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the features and advantages of the present invention, reference is now made to the detailed description of the invention along with the accompanying figures in which corresponding numerals in the different figures refer to corresponding parts and in which:
FIG. 1 is a schematic illustration of an offshore oil and gas platform operating an apparatus for controlling the connection speed of downhole connectors according to an embodiment of the present invention;
FIGS. 2A-2D are front views of consecutive axial sections of an apparatus for controlling the connection speed of downhole connectors in a running configuration according to an embodiment of the present invention;
FIGS. 3A-3D are cross sectional views of consecutive axial sections of an apparatus for controlling the connection speed of downhole connectors in a running configuration according to an embodiment of the present invention;
FIGS. 4A-4D are front views of consecutive axial sections of an apparatus for controlling the connection speed of downhole connectors in an anchored configuration according to an embodiment of the present invention;
FIGS. 5A-5D are cross sectional views of consecutive axial sections of an apparatus for controlling the connection speed of downhole connectors in an anchored configuration according to an embodiment of the present invention;
FIGS. 6A-6C and 7 A- 7 C are front views turned 90 degrees relative to one another of consecutive axial sections of an apparatus for controlling the connection speed of downhole connectors according to an embodiment of the present invention;
FIGS. 8A-8C and 9 A- 9 C are cross sectional views turned 90 degrees relative to one another of consecutive axial sections of an apparatus for controlling the connection speed of downhole connectors in a running configuration according to an embodiment of the present invention;
FIGS. 10A-10C and 11 A- 11 C are cross sectional views turned 90 degrees relative to one another of consecutive axial sections of an apparatus for controlling the connection speed of downhole connectors in an unlocked configuration according to an embodiment of the present invention;
FIGS. 12A-12C and 13 A- 13 C are cross sectional views turned 90 degrees relative to one another of consecutive axial sections of an apparatus for controlling the connection speed of downhole connectors in a connected configuration according to an embodiment of the present invention;
FIGS. 14A-14C and 15 A- 15 C are cross sectional views turned 90 degrees relative to one another of consecutive axial sections of an apparatus for controlling the connection speed of downhole connectors in a fully compressed configuration according to an embodiment of the present invention;
FIGS. 16A-16C and 17 A- 17 C are cross sectional views turned 90 degrees relative to one another of consecutive axial sections of an apparatus for controlling the connection speed of downhole connectors in a locked configuration according to an embodiment of the present invention; and
FIGS. 18A-18C are cross sectional views of a lock assembly section of an apparatus for controlling the connection speed of downhole connectors in various configurations according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
While the making and using of various embodiments of the present invention are discussed in detail below, it should be appreciated that the present invention provides many applicable inventive concepts, which can be embodied in a wide variety of specific contexts. The specific embodiments discussed herein are merely illustrative of specific ways to make and use the invention, and do not delimit the scope of the invention.
Referring initially to FIG. 1 , an apparatus for controlling the connection speed of downhole connectors deployed from an offshore oil or gas platform is schematically illustrated and generally designated 10 . A semi-submersible platform 12 is centered over submerged oil and gas formation 14 located below sea floor 16 . A subsea conduit 18 extends from deck 20 of platform 12 to wellhead installation 22 , including blowout preventers 24 . Platform 12 has a hoisting apparatus 26 , a derrick 28 , a travel block 30 , a hook 32 and a swivel 34 for raising and lowering pipe strings, such as a substantially tubular, axially extending production tubing 36 .
A wellbore 38 extends through the various earth strata including formation 14 . An upper portion of wellbore 38 includes casing 40 that is cemented within wellbore 38 . Disposed in an open hole portion of wellbore 38 is a completion 42 that includes various tools such as packer 44 , a seal bore assembly 46 and sand control screen assemblies 48 , 50 , 52 , 54 . In the illustrated embodiment, completion 42 also includes an orientation and alignment subassembly 56 that houses a downhole wet mate connector. Extending downhole from orientation and alignment subassembly 56 is a conduit 58 that passes through packer 44 and is operably associated with sand control screen assemblies 48 , 50 , 52 , 54 . Preferably, conduit 58 is a spoolable metal conduit, such as a stainless steel conduit that may be attached to the exterior of pipe strings as they are deployed in the well. In the illustrated embodiment, conduit 58 is wrapped around sand control screen assemblies 48 , 50 , 52 , 54 . One or more communication media such as optical fibers, electrical conducts, hydraulic fluid or the like may be disposed within conduit 58 . In certain embodiments, the communication media may operate as energy conductors that are operable to transmit power and/or data between downhole components such as downhole sensors (not pictured) and the surface. In other embodiments, the communication media may operate as downhole sensors.
For example, when optical fibers are used as the communication media, the optical fibers may be used to obtain distributed measurements representing a parameter along the entire length of the fiber such as distributed temperature sensing. In this embodiment, a pulse of laser light from the surface is sent along the fiber and portions of the light are backscattered to the surface due to the optical properties of the fiber. The slightly shifted frequency of the backscattered light provides information that is used to determine the temperature at the point in the fiber where the backscatter originated. In addition, as the speed of light is constant, the distance from the surface to the point where the backscatter originated can also be determined. In this manner, continuous monitoring of the backscattered light will provide temperature profile information for the entire length of the fiber.
Disposed in wellbore 38 at the lower end of production tubing string 36 are a variety of tools including seal assembly 60 and anchor assembly 62 including downhole wet mate connector 64 . Extending uphole of connector 64 is a conduit 66 that extends to the surface in the annulus between production tubing string 36 and wellbore 38 and is suitable coupled to production tubing string 36 to prevent damage to conduit 66 during installation. Similar to conduit 58 , conduit 66 may have one or more communication media, such as optical fibers, electrical conducts, hydraulic fluid or the like disposed therein. Preferable, conduit 58 and conduit 66 will have the same type of communication media disposed therein such that energy may be transmitted therebetween following the connection process. As discussed in greater detail below, prior to producing fluids, such as hydrocarbon fluids, from formation 14 , production tubing string 36 and completion 42 are connected together. When properly connected to each other, a sealed communication path is created between seal assembly 60 and seal bore assembly 46 which establishes a sealed internal flow passage from completion 42 to production tubing string 36 , thereby providing a fluid conduit to the surface for production fluids. In addition, as discussed in greater detail below, the present invention enables the communication media associated with conduit 66 to be operatively connected to the communication media associated with conduit 58 , thereby enabling communication therebetween and, in the case of optical fiber communication media, enabling distributed temperature information to be obtained along completion 42 during the subsequent production operations.
Even though FIG. 1 depicts a slanted wellbore, it should be understood by those skilled in the art that the apparatus for controlling the connection speed of downhole connectors according to the present invention is equally well suited for use in wellbore having other orientations including vertical wellbores, horizontal wellbores, multilateral wellbores or the like. Accordingly, it should be understood by those skilled in the art that the use of directional terms such as above, below, upper, lower, upward, downward and the like are used in relation to the illustrative embodiments as they are depicted in the figures, the upward direction being toward the top of the corresponding figure and the downward direction being toward the bottom of the corresponding figure. Also, even though FIG. 1 depicts an offshore operation, it should be understood by those skilled in the art that the apparatus for controlling the connection speed of downhole connectors according to the present invention is equally well suited for use in onshore operations. Further, even though FIG. 1 depicts an open hole completion, it should be understood by those skilled in the art that the apparatus for controlling the connection speed of downhole connectors according to the present invention is equally well suited for use in cased hole completions.
Referring now to FIGS. 2 and 3 , including FIGS. 2A-2D and FIGS. 3A-3D , therein is depicted successive axial section of an apparatus for controlling the connection speed of downhole connectors that is generally designated 100 . It is noted that FIGS. 2A-2D and FIGS. 3A-3D as well as FIGS. 4A-4D and 5 A- 5 D below are described with reference to optical fibers as the communication media. As discussed above, those skilled in the art will recognize that the present invention is not limited to this illustrated embodiment but instead encompasses other communication media including, but not limited to, electrical conductors and hydraulic fluid. Also, as described above, apparatus 100 is formed from certain components that are initially installed downhole as part of completion 42 and certain components that are carried on the lower end of production tubing string 36 . As illustrated in FIG. 2 , some the components carried on the lower end of production tubing string 36 have come in contact with certain components of completion 42 prior to connecting the respective wet mate connectors together. The entire apparatus 100 will now be described from its uphole end to its downhole end, first describing the exterior parts of the components carried on the lower end of production tubing string 36 , followed by the interior parts of the components carried on the lower end of production tubing string 36 then describing the components previously installed downhole as part of completion 42 .
Apparatus 100 includes a substantially tubular axially extending upper connector 102 that is operable to be coupled to the lower end of production tubing string 36 by threading or other suitable means. At its lower end, upper connector 102 is threadedly and sealingly connected to the upper end of a substantially tubular axially extending hone bore 104 . Hone bore 104 includes a plurality of lateral opening 106 having plugs 108 disposed therein. At its lower end, hone bore 104 is securably connected to the upper end of a substantially tubular axially extending connector member 110 . At its lower end, connector member 110 is securably connected to the upper end of an axially extending collet assembly 112 . Collet assembly 112 includes a plurality of circumferentially disposed anchor collets 114 , each having an upper surface 116 . In addition, collet assembly 112 includes a plurality of circumferentially disposed unlocking collets 118 . Further, collet assembly 112 includes a plurality of radially inwardly extending protrusions 120 and profiles 122 . At its lower end, collet assembly 112 is threadedly coupled to the upper end of a substantially tubular axially extending key retainer 124 . A portion of collet assembly 112 and key retainer 124 are both slidably disposed about the upper end of a substantially tubular axially extending key mandrel 126 . Key mandrel 126 includes a key window 128 into which a spring key 130 is received.
At its lower end, key mandrel 126 is threadedly coupled to the upper end of a substantially tubular axially extending spring housing 132 . Disposed within spring housing 132 is an axially extending spiral wound compression spring 134 . At its lower end, spring housing 132 is slidably disposed about the upper end of a substantially tubular axially extending connector member 136 . At its lower end, connector member 136 is threadedly coupled to the upper end of a substantially tubular axially extending splitter 138 . Splitter 138 includes an orientation key 140 disposed about a circumferential portion of splitter 138 . At its lower end, splitter 138 is coupled to the upper end of a substantially tubular axially extending fiber optic wet mate head 142 by threading, bolting or other suitable technique. Fiber optic wet mate head 142 includes a plurality of guide members 144 . In the illustrated embodiment, fiber optic wet mate head 142 has three fiber optic wet mate connectors 146 disposed therein. Each of the fiber optic wet mate connectors 146 has an optical fiber disposed therein. As illustrated, the three optical fibers associated with fiber optic wet mate connectors 146 passed through splitter 138 and are housed within a single conduit 148 that wraps around connector member 136 and extends uphole along the exterior of apparatus 100 . Conduit 148 is secured to apparatus 100 by banding or other suitable technique.
In the previous section, the exterior components of the portion of apparatus 100 carried by production tubing string 36 were described. In this section, the interior components of the portion of apparatus 100 carried by production tubing string 36 will be described. At its upper end, apparatus 100 includes a substantially tubular axially extending piston mandrel 200 that is slidably and sealingly received within upper connector 102 . Disposed between piston mandrel 200 and hone bore 104 is an annular oil chamber 202 including upper section 204 and lower section 206 . Securably attached to piston mandrel 200 and sealing positioned within annular oil chamber 202 is a transfer piston 208 . Transfer piston 208 includes one or more passageways 210 therethrough which preferably include orifices that regulate the rate at which a transfer fluid such as a liquid or gas and preferably an oil disposed within annular oil chamber 202 may travel therethrough. Preferably, a check valve may be disposed within each passageway 210 to allow the flow of oil to proceed in only one direction through that passageway 210 . In this embodiment, certain of the check valves will allow fluid flow in the uphole direction while other of the check valves will allow fluid flow in the downhole direction. In this manner, the resistance to flow in the downhole direction can be different from the resistance to flow in the uphole direction which respectively determines the speed of coupling and decoupling of the downhole connectors of apparatus 100 . For example, it may be desirable to couple the downhole connectors at a speed that is slower than the speed at which the downhole connectors are decoupled.
Disposed within annular oil chamber 202 is a compensation piston 212 that has a sealing relationship with both the inner surface of hone bore 104 and the outer surface of piston mandrel 200 . At its lower end, piston mandrel 200 is threadedly and sealingly coupled to the upper end of a substantially tubular axially extending key block 214 . Key block 214 has a radially reduced profile 216 into which spring mounted locking keys 218 are positioned. Locking keys 218 include a profile 220 . At its lower end, key block 214 is threadedly and sealingly coupled to the upper end of a substantially tubular axially extending bottom mandrel 222 . Bottom mandrel 222 includes a groove 224 . A pickup ring 226 is positioned around bottom mandrel 222 . Positioned near the lower end of bottom mandrel 222 is a key carrier 228 that has a no go surface 230 . Disposed within key carrier 228 is a spring mounted locking key 232 . Positioned between key carrier 228 and bottom mandrel 222 is a torque key 234 . At its lower end, bottom mandrel 222 is threadedly and sealingly coupled to the upper end of a substantially tubular axially extending seal adaptor 236 . At its lower end, seal adaptor 236 is threadedly and sealingly coupled to the upper end of one or more substantially tubular axially extending seal assemblies (not pictured) that establish a sealing relationship with an interior surface of completion 42 .
In the previous two sections, the components of apparatus 100 carried by production tubing string 36 were described. Collectively, these components may be referred to as an anchor or anchoring assembly. In this section, the components of apparatus 100 installed with completion 42 will be described. Apparatus 100 includes an orientation and alignment subassembly 300 that includes a locating and orienting guide 302 that is illustrated in FIG. 3 but has been removed from FIG. 2 for clarity of illustration. Locating and orienting guide 302 includes a locking profile 304 , a groove 306 and a plurality of fluid passageways 308 . In addition, locating and orienting guide 302 includes a receiving slot 310 . Disposed within locating and orienting guide 302 , orientation and alignment subassembly 300 includes a top subassembly 312 that supports a fiber optic wet mate holder 314 . In the illustrated embodiment, disposed within wet mate holder 314 are three wet mate connectors 316 . At its upper end, wet mate holder 314 includes a plurality of guides 318 . Positioned between top subassembly 312 and locating and orienting guide 302 is a key 320 . At its lower end, top subassembly 312 is threadedly and sealingly coupled to the upper end of a substantially tubular axially extending splitter 322 . At its lower end, splitter 322 is coupled to the upper end of one or more substantially tubular axially extending packers 324 by threading, bolting, fastening or other suitable technique. Each of the fiber optic wet mate connectors 316 has an optical fiber disposed therein. As illustrated, the three optical fibers associated with fiber optic wet mate holder 314 pass through splitter 322 and are housed within a single conduit 326 that extends through packer 324 and is wrapped around sand control screens 48 , 50 , 52 , 54 as described above to obtain distributed temperature information, for example.
The operation of the apparatus for controlling the connection speed of downhole connectors according to the present invention will now be described. After the installation of completion 42 in the wellbore and the performance of any associated treatment processes wherein the optical fibers associated with completion 42 and companion optical fibers associated with the service tool string may deliver information to the surface, the service tool string is retrieved to the surface. In this process, the optical fibers associated with completion 42 and the optical fibers associated with the service tool string must be decoupled. In order to reuse the optical fibers associated with completion 42 during production, new optical fibers must be carried with production tubing string 36 and optically coupled to the optical fibers associated with completion 42 .
In the present invention, conduit 148 is attached to the exterior of production tubing string 36 and extends from the surface to the anchor assembly. One or more optical fibers are disposed within conduit 148 which may be a conventional hydraulic line formed from stainless steel or similar material. The anchor assembly is lowered into the wellbore until the seal assemblies on its lower end enter completion 42 . As production tubing string 36 is further lowered into the wellbore, orientation key 140 contacts the inclined surfaces of locating and orientating guide 302 . This interaction rotates the anchor assembly until orientation key 140 locates within slot 310 which provides a relatively coarse circumferential alignment of fiber optic wet mate head 142 with fiber optic wet mate holder 314 . The anchor assembly now continues to travel downwardly in completion 42 until no go surface 230 of key carrier 228 contacts an upwardly facing shoulder 328 of top subassembly 312 . Prior to contact between no go surface 230 and upwardly facing shoulder 328 , guides 144 of fiber optic wet mate head 142 and guides 318 of fiber optic wet mate holder 314 interact to provide more precise circumferential and axially alignment of the assemblies.
Once no go surface 230 contacts upwardly facing shoulder 328 , further downward motion of the inner components of the anchor assembly stops. In this configuration, as best seen in FIGS. 2A-2D and 3 A- 3 D, unlocking collets 118 are radially inwardly shifted due to contact with the inner surface of locating and orienting guide 302 . This radially inward shifting causes the inner surfaces of unlocking collets 118 to contact unlocking keys 218 and compress the associated springs causing unlocking keys 218 to radially inwardly retract. In the retraced position, radially inwardly extending protrusions 120 are released from profile 220 , thereby decoupling the outer portions of the anchor assembly from the inner portions of the anchor assembly. Relative axially movement of the outer portions of the anchor assembly and the inner portions of the anchor assembly is now permitted.
As continued downward force is placed on the anchor assembly by applying force to the production tubing string 36 , upper connector 102 is urged downwardly relative to piston mandrel 200 . The movement of upper connector 102 relative to piston mandrel 200 is resisted, however, by a resistance member. In the illustrated embodiment, the resistance member is depicted as transfer piston 208 and the fluid within annular oil chamber 202 . Specifically, the speed at which upper connector 102 can move relative to piston mandrel 200 is determined by the size of the orifice within passageway 210 of transfer piston 208 as well as the type of fluid, including liquids, gases or combinations thereof, within annular oil chamber 202 . As the downward force is applied to upper connector 102 , the fluid from upper section 204 of annular oil chamber 202 transfers to lower section 206 of annular oil chamber 202 passing through passageway 210 . In this manner, excessive connection speed of fiber optic wet mate connectors 146 and fiber optic wet mate connectors 316 is prevented. Even though the resistance member has been described as transfer piston 208 and the fluid within annular oil chamber 202 , it should be understood by those skilled in the art that other types of resistance members could alternatively be used and are considered within the scope of the present invention, including, but not limited to, mechanical springs, fluid springs, fluid dampeners, shock absorbers and the like.
As best seen in FIGS. 4A-4D and 5 A- 5 D, continued downward force on upper connector 102 not only enables connection of fiber optic wet mate connectors 146 and fiber optic wet mate connectors 316 , but also, compresses the outer components of the anchor assembly and locks the anchor assembly within completion 42 . Once the connection between fiber optic wet mate connectors 146 and fiber optic wet mate connectors 316 is established, thereby permitting light transmission between the optical fibers therein, continued downward force on upper connector 102 compresses spring 134 . As spring 134 is compressed, spring housing 132 telescopes relative to connector member 136 . This shortening of the outer components of the anchor assembly allows spring key 130 to engage groove 224 of bottom mandrel 222 . Once spring key 130 has radially inwardly retracted, the outer components of the anchor assembly further collapse as collet assembly 112 and key retainer 124 telescope relative to key mandrel 126 . This shortening allows anchor collets 114 to engage locking profile 304 which couples the anchor assembly within completion 42 . Also, this shortening allows unlocking collets 118 to engage groove 306 which relaxes unlocking collets 118 . In addition, the inner portions of the anchor assembly are independently secured within completion 42 as extension 150 on the lower end of fiber optic wet mate head 142 is positioned under locking key 232 such that locking key 232 engages profile 330 of top subassembly 312 .
In this configuration, not only are fiber optic wet mate connectors 146 and fiber optic wet mate connectors 316 coupled together, there is a biasing force created by compressed spring 134 that assures the connections will not be lost. Specifically, compressed spring 134 downwardly biases connector member 136 which in turn applies a downward force on splitter 138 and fiber optic wet mate head 142 . This force prevents any decoupling of fiber optic wet mate connectors 146 and fiber optic wet mate connectors 316 . In addition, the interaction of surface 116 of anchor collets 114 with locking profile 304 of locating and orienting guide 302 prevents separation of the anchoring assembly and the completion 42 . If it is desired to detach production tubing string 36 from completion 42 , a significant tensile force must be applied to production tubing string 36 at the surface, for example, 20,000 lbs. This force is transmitted via upper connector 102 , hone bore 104 and connector member 110 to collet assembly 112 . When sufficient tensile force is provided, anchor collets 114 will release from locking profile 304 . Thereafter, the outer portions of anchor assembly that were telescopically contracted can be telescopically extended including the release of energy from spring 134 . In order to separate fiber optic wet mate connectors 146 and fiber optic wet mate connectors 316 , the outer portions of the anchor assembly must be shifted relative to the inner portions of the anchor assembly. The rate of the axial shifting is again controlled by the metering rate of fluid through transfer piston 212 . After the outer portions of the anchor assembly have been shifted relative to the inner portions of the anchor assembly, extension 150 no longer supports locking key 232 in profile 330 . As this point the entire anchor assembly may be retrieved to the surface.
Referring now to FIGS. 6-9 , including FIGS. 6A-6C , 7 A- 7 C, 8 A- 8 C and 9 A- 9 C, therein is depicted successive axial section of an apparatus for controlling the connection speed of downhole connectors that is generally designated 400 . It is noted that FIGS. 6A-6C and 7 A- 7 C are multiple views of the same apparatus turned 90 degrees relative to one another with the downhole part of completion 42 being removed in FIGS. 6A-6C . Likewise, FIGS. 8A-8C and 9 A- 9 C are multiple views of the same apparatus turned 90 degrees relative to one another. As described above, apparatus 400 is formed from certain components that are initially installed downhole as part of completion 42 and certain components that are carried on the lower end of production tubing string 36 . As illustrated in FIGS. 7-9 , some the components carried on the lower end of production tubing string 36 have come in contact with certain components of completion 42 prior to connecting the respective wet mate connectors together. The entire apparatus 400 will now be described from its uphole end to its downhole end, first describing the exterior parts of the components carried on the lower end of production tubing string 36 , followed by the interior parts of the components carried on the lower end of production tubing string 36 then describing the components previously installed downhole as part of completion 42 .
Apparatus 400 includes a substantially tubular axially extending upper connector 402 that is operable to be coupled to the lower end of production tubing string 36 by threading or other suitable means. At its lower end, upper connector 402 is threadedly and sealingly connected to the upper end of a substantially tubular axially extending hone bore 404 . Hone bore 404 includes a plurality of lateral opening 406 having plugs 408 disposed therein. At its lower end, hone bore 404 is securably connected to the upper end of a substantially tubular axially extending collet assembly 410 that includes a plurality of circumferentially disposed locking collets 412 each having a radially inwardly extending protrusion 414 with an upper surface 416 . At its lower end, collet assembly 410 is threadedly coupled to the upper end of a substantially tubular axially extending spring housing 418 . Disposed within spring housing 418 is an axially extending spiral wound compression spring 420 . Spring housing 418 includes an annular groove 422 . At its lower end, spring housing 418 is slidably disposed about the upper end of a substantially tubular axially extending spring support member 424 that include a plurality of windows 426 having keys 428 positioned therein. A debris housing 430 is positioned around spring housing 418 and spring support member 424 .
At its lower end, spring support member 424 is threadedly coupled to the upper end of a substantially tubular axially extending fiber optic wet mate head 432 . Fiber optic wet mate head 432 includes an orientation guide 434 that preferably has opposing helical surfaces 436 , 438 . Fiber optic wet mate head 432 includes a plurality of guide members 440 . In the illustrated embodiment, fiber optic wet mate head 432 has three fiber optic wet mate connectors 442 disposed therein. Each of the fiber optic wet mate connectors 442 has an optical fiber disposed therein. As illustrated, the three optical fibers associated with fiber optic wet mate connectors 442 may pass through a splitter such that they are housed within a single conduit 444 that extends uphole from apparatus 400 to the surface. Conduit 444 may be secured to apparatus 400 by any suitable means such as banding or similar technique. At its lower end, fiber optic wet mate head 432 includes a prop member 446 . Slidably received in a pair of slots in fiber optic wet mate head 432 is a pair of plungers 448 , 450 which are individually biased by a pair of springs 452 , 454 .
In the previous section, the exterior components of the portion of apparatus 400 carried by production tubing string 36 were described. In this section, the interior components of the portion of apparatus 400 carried by production tubing string 36 will be described. At its upper end, apparatus 400 includes a substantially tubular axially extending piston mandrel 500 that is slidably and sealingly received within upper connector 402 . Disposed between piston mandrel 500 and hone bore 404 is an annular oil chamber 502 including upper section 504 and lower section 506 . Securably attached to piston mandrel 500 and sealing positioned within annular oil chamber 502 is a transfer piston 508 . Transfer piston 508 includes one or more passageways 510 therethrough which preferably include orifices that regulate the rate at which a transfer fluid, such as a liquid or gas and preferably an oil disposed within annular oil chamber 502 , may travel therethrough. Preferably, a check valve may be disposed within each passageway 510 to allow the flow of oil to proceed in only one direction through that passageway 510 . In this embodiment, certain of the check valves will allow fluid flow in the uphole direction while other of the check valves will allow fluid flow in the downhole direction. In this manner, the resistance to flow in the downhole direction can be different from the resistance to flow in the uphole direction which respectively determines the speed of coupling and decoupling of the downhole connectors of apparatus 400 . For example, it may be desirable to couple the downhole connectors at a speed that is slower than the speed at which the downhole connectors are decoupled.
Disposed within annular oil chamber 502 is a compensation piston 512 that has a sealing relationship with both the inner surface of hone bore 404 and the outer surface of piston mandrel 500 . At its lower end, piston mandrel 500 is threadedly and sealingly coupled to the upper end of a substantially tubular axially extending locking profile assembly 514 that includes a radially outwardly extending annular protrusion 516 having a shoulder 518 . Together, locking profile assembly 514 and locking collets 412 may be referred to herein as a lock assembly. At its lower end, locking profile assembly 514 is threadedly and sealingly coupled to the upper end of a substantially tubular axially extending bottom mandrel 520 . Bottom mandrel 520 includes a radially inwardly extending groove 522 . A pickup ring 524 is positioned around bottom mandrel 520 . A pair of spring operated lugs 526 , 528 is received within a pair of radially reduces sections of bottom mandrel 520 . Together, spring operated lugs 526 , 528 and plungers 448 , 450 may be referred to herein as a lock assembly. Positioned near the lower end of bottom mandrel 520 is a key assembly 530 that has a locator surface 532 and a plurality of locking keys 534 . At its lower end, bottom mandrel 520 is threadedly and sealingly coupled to the upper end of a substantially tubular axially extending seal adaptor 536 . At its lower end, seal adaptor 536 is threadedly and sealingly coupled to the upper end of one or more substantially tubular axially extending seal assemblies (not pictured) that establish a sealing relationship with an interior surface of completion 42 .
In the previous two sections, the components of apparatus 400 carried by production tubing string 36 were described. Collectively, these components may be referred to as an anchor or anchoring assembly. In this section, the components of apparatus 400 installed with completion 42 will be described. Apparatus 400 includes an orienting guide 600 that has a plurality of fluid passageways 602 . In addition, orienting guide 600 preferably has opposing helical surfaces 604 , 606 . Disposed within orienting guide 600 is a top subassembly 608 that supports a fiber optic wet mate holder 612 . In the illustrated embodiment, disposed within wet mate holder 612 are three wet mate connectors 614 . At its upper end, wet mate holder 612 includes a plurality of guides 616 . Top subassembly 608 has a radially reduced section 618 having a frustoconical surface 620 and a frustoconical surface 622 . In addition, at its upper end, top subassembly 608 has a frustoconical surface 628 . Each of the fiber optic wet mate connectors 614 has an optical fiber disposed therein. As illustrated, the three optical fibers associated with fiber optic wet mate holder 614 may pass through a splitter such that they may be housed within a single conduit that extends through a packer disposed below apparatus 400 and is wrapped around sand control screens 48 , 50 , 52 , 54 as described above to obtain distributed temperature information, for example.
The operation of this embodiment of an apparatus for controlling the connection speed of downhole connectors according to the present invention will now be described. After the installation of completion 42 in the wellbore and the performance of any associated treatment processes wherein the optical fibers associated with completion 42 and companion optical fibers associated with the service tool string may deliver information to the surface, the service tool string is retrieved to the surface. In this process, the optical fibers associated with completion 42 and the optical fibers associated with the service tool string must be decoupled. In order to reuse the optical fibers associated with completion 42 during production, new optical fibers must be carried with production tubing string 36 and optically coupled to the optical fibers associated with completion 42 .
In the present invention, conduit 444 is attached to the exterior of production tubing string 36 and extends from the surface to the anchor assembly. One or more optical fibers are disposed within conduit 444 which may be a conventional hydraulic line formed from stainless steel or similar material. The anchor assembly is lowered into the wellbore until the seal assemblies on its lower end enter completion 42 . As production tubing string 36 is further lowered into the wellbore, orientation guide 434 contacts orientating guide 600 . This interaction rotates the anchor assembly to provide a relatively coarse circumferential alignment of fiber optic wet mate head 432 with fiber optic wet mate holder 612 . The anchor assembly now continues to travel downwardly in completion 42 until plungers 448 , 450 contact surface 628 of top subassembly 608 . Further downward motion of the anchor assembly causes plungers 448 , 450 to shift longitudinally relative to fiber optic wet mate head 432 and compress springs 452 , 454 . In addition, this longitudinal movement causes lugs 526 , 528 to shift radially inwardly, as best seen in FIGS. 10A-10C and 11 A- 11 C. This action unlocks the inner components of the anchor assembly from the outer components of the anchor assembly. As further downward movement of the inner components of the anchor assembly is now prevented by contact between surface 532 of key assembly 530 and surface 620 of top subassembly 608 , weight applied to apparatus 400 causes the outer components of the anchor assembly to shift longitudinally relative to the inner components of the anchor assembly in a telescopic manner.
As continued downward force is placed on the anchor assembly by applying force to the production tubing string 36 , upper connector 402 is urged downwardly relative to piston mandrel 500 . The movement of upper connector 402 relative to piston mandrel 500 is resisted, however, by a resistance member. In the illustrated embodiment, the resistance member is depicted as transfer piston 508 and the fluid within annular oil chamber 502 . Specifically, the speed at which upper connector 402 can move relative to piston mandrel 500 is determined by the size of the orifices within passageways 510 of transfer piston 508 as well as the type of fluid, including liquids, gases or combinations thereof, within annular oil chamber 502 . As the downward force is applied to upper connector 402 , the fluid from upper section 504 of annular oil chamber 502 transfers to lower section 506 of annular oil chamber 502 passing through passageways 510 . In this manner, excessive connection speed of fiber optic wet mate connectors 442 and fiber optic wet mate connectors 614 is prevented.
As best seen in FIGS. 12A-12C and 13 A- 13 C, continued downward force on upper connector 402 not only enables connection of fiber optic wet mate connectors 442 and fiber optic wet mate connectors 614 at a predetermined speed, but also, causes prop member 446 of fiber optic wet mate head 432 to prop locking keys 534 of key assembly 530 in radially reduced section 618 of top subassembly 608 which anchors the inner components of the anchor assembly within completion 42 . In addition, this telescopic movement of the outer components of the anchor assembly relative to the inner components of the anchor assembly causes keys 428 to become aligned with annular groove 522 of bottom mandrel 520 . In this configuration, keys 428 are released from annular groove 422 of spring housing 418 . Once the connection between fiber optic wet mate connectors 442 and fiber optic wet mate connectors 614 is established, light transmission is permitted between the optical fibers therein.
As best seen in FIGS. 14A-14C and 15 A- 15 C, continued downward force applied on upper connector 402 further shifts the outer components of the anchor assembly relative to the inner components of the anchor assembly. In this configuration, the telescopic movement causes locking collets 412 to pass downwardly over annular protrusion 516 of locking profile assembly 514 while spring 420 is being compressed between collet assembly 410 and spring support member 424 . Once apparatus 400 is in this configuration, the downward force applied on upper connector 402 may be release such that apparatus 400 will be placed in its production configuration, as best seen in FIGS. 16A-16C and 17 A- 17 C. In this configuration, not only are fiber optic wet mate connectors 442 and fiber optic wet mate connectors 614 coupled together, there is a biasing force created by compressed spring 420 that assures the connections will not be lost. Specifically, compressed spring 420 downwardly biases spring support member 424 which in turn applies a downward force on fiber optic wet mate head 432 . This force prevents any decoupling of fiber optic wet mate connectors 442 and fiber optic wet mate connectors 614 . In addition, the interaction between locking keys 534 of key assembly 530 and top subassembly 408 prevents separation of the anchoring assembly and the completion 42 .
If it is desired to detach production tubing string 36 from completion 42 , a significant tensile force must be applied to production tubing string 36 at the surface, for example, 20,000 lbs. This force is transmitted via upper connector 402 and hone bore 404 to collet assembly 410 . The upward force acts between surfaces 416 of locking collets 412 and shoulder 518 of locking profile assembly 514 . As upward movement of locking profile assembly 514 is prevented by the interaction between locking keys 534 of key assembly 530 and top subassembly 608 , upon application of sufficient force, locking collets 412 will release from locking profile assembly 514 . Thereafter, the outer portions of anchor assembly that were telescopically contracted can be telescopically extended including the release of energy from spring 420 . In order to separate fiber optic wet mate connectors 442 and fiber optic wet mate connectors 614 , the outer portions of the anchor assembly must be further shifted relative to the inner portions of the anchor assembly. The rate of the axial shifting is again controlled by the metering rate of fluid through transfer piston 508 . To aid in full extension of the outer portions of the anchor assembly relative to the inner portions of the anchor assembly, an optional spring 538 may operate between upper connector 402 and transfer piston 508 . As this point the anchor assembly returns to the running configuration as seen in FIGS. 8A-8C and 9 A- 9 C and may be retrieved to the surface or the set down and latch up sequence can be started again.
Referring next to FIGS. 18A-18C , therein is depicted another embodiment of an apparatus for controlling the connection speed of downhole connectors that is generally designated 700 . In the portion of apparatus 700 that is depicted, an alternate embodiment of a lock assembly will be described. In the illustrated section, apparatus 700 includes a portion of an anchor assembly 702 and a portion of a completion 704 . Apparatus 700 is similar to apparatus 400 described above except for the configuration and operation of the lock assembly 706 that releases the outer components of the anchor assembly 702 from the inner components of the anchor assembly 702 . The outer components of anchor assembly 702 include fiber optic wet mate head 708 that has a pair of radially extending openings 710 , 712 having lug extensions 714 , 716 slidably positioned therein and partially extending radially outwardly therefrom. The inner components of anchor assembly 702 include bottom mandrel 718 having a pair of radially reduces sections with a pair of spring operated lugs 720 , 722 received therein. Together, spring operated lugs 720 , 722 and lug extensions 714 , 716 may be referred to herein as lock assembly 706 . The inner components of anchor assembly 702 also include a key assembly 724 that is operable to engage with a profile 726 of top subassembly 728 .
In operation, anchor assembly 702 is lowered into the wellbore until the seal assemblies on its lower end enter completion 704 . As production tubing string 36 is further lowered into the wellbore, anchor assembly 702 may be orientated relative to completion 704 in a manner similar to that described above. Anchor assembly 702 now continues to travel downwardly in completion 704 until lug extensions 714 , 716 reach an upper surface of completion 704 such as an upper surface of the orientation guide, as best seen in FIG. 18A . Further downward motion of the anchor assembly 702 causes lug extensions 714 , 716 to shift radially inwardly relative to fiber optic wet mate head 708 . In addition, this radial movement causes lugs 720 , 722 to shift radially inwardly, as best seen in FIG. 18B . This action unlocks the inner components of the anchor assembly from the outer components of the anchor assembly. As further downward movement of the inner components of anchor assembly 702 is now prevented by contact between key assembly 724 and top subassembly 728 , weight applied to apparatus 700 causes the outer components of anchor assembly 702 to shift longitudinally relative to the inner components of anchor assembly 702 in a telescopic manner, as best seen in FIG. 18C , wherein key assembly 724 is propped within profile 726 of top subassembly 728 . In addition, this downward movement of the outer components of anchor assembly 702 relative to the inner components of anchor assembly 702 also causes coupling of the associated wet mate components (not visible in FIGS. 18A-18C ) in a manner similar to that described above with reference to apparatus 400 .
While this invention has been described with reference to illustrative embodiments, this description is not intended to be construed in a limiting sense. Various modifications and combinations of the illustrative embodiments as well as other embodiments of the invention will be apparent to persons skilled in the art upon reference to the description. It is, therefore, intended that the appended claims encompass any such modifications or embodiments.
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Apparatuses and methods for controlling the connection speed of downhole connectors in a subterranean well are disclosed. An apparatus includes a first assembly having a first downhole connector and a first communication medium that is positionable in the well. A second assembly includes a second downhole connector and a second communication medium and has an outer portion and an inner portion that are selectively axially shiftable relative to one another. A lock assembly including at least one lug initially couples the outer and inner portions of the second assembly together such that, upon engagement of the first assembly with the second assembly downhole, the lug is radially shifted releasing the lock assembly to allow axial shifting of the outer portion of the second assembly relative to the inner portion of the second assembly, thereby operatively connecting the first and second downhole connectors to enable communication between the communication media.
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BACKGROUND OF THE INVENTION
[0001] Silt fences prevent sediment carried by sheet flow from leaving a construction site and entering natural drainage ways or storm drainage systems by slowing storm water runoff and causing the deposition of sediment at the structure. Silt fencing encourages sheet flow and reduces the potential for development of rills and gullies. Silt fencing should be installed where sheet flow runoff can be stored behind the barrier without damaging the barrier or the submerged area behind the barrier. Silt fencing is generally located at the topographically lowest portions of the site where silt migrates during rain events.
[0002] Visual fence is placed just inside the clearing boundaries to define the limits of clearing. This is necessary to prevent the overclearing of trees, brush, etc., and to visually identify the clearing limits. Many local ordinances require that the visual fence have certain minimum visibility requirements.
[0003] Conventional fence systems are installed by first digging a narrow shallow trench the length that the fence is to be run. The stakes are set into the ground in the trench at a specific distance apart. Typically, a wire backing is attached to the stakes using fasteners. The wire backing lends support and strength to the fence and, in particular, to the fabric. The wire backing extends from down in the trench to above the ground level, generally up to at least a portion of the height of the fence material. The fence material, typically a synthetic fabric or mesh, is attached to the stakes using fasteners such that the lower portion of the fabric overlaps the wire backing. The trench is backfilled to secure the fence in the ground. In use, the silt fence blocks silt runoff while permitting water to pass through the fence mesh.
[0004] By the time the construction is completed to the point where the fence is no longer needed, the fence material has often degraded or is otherwise unusable in another application. However, the fence must still be removed by construction crews and either recycled or dumped in the garbage or landfill.
[0005] Currently, at least one line, and often two lines, of silt fence are separately installed and used to prevent silt runoff and a separate line of visual fence is used to provide a visual indication of tree save or other marked area. Each line must ordinarily be manually installed by workers. Often, wire ties are used to attach the fence to the stakes, with each tie taking time to feed through the fabric, around the stake and twisted off. This results in significant time being required to install and later uninstall these fences, increased waste product as the fences are often unreusable after the first use, and increased cost. It would be desirable to have a single fence which could provide a silt barrier yet also serve as a visual fence. It would also be desirable to have fence system that is easier and take less time to install, while reducing the quantity of fence required.
SUMMARY OF THE INVENTION
[0006] Generally described, the present invention provides in a first exemplary embodiment a novel combination of a silt and visual fence to prevent sedimentation from leaving the limits of construction and the visual impact of a clearing tree save fence to define the limits of project clearing. The silt/visual fence combination reduces the need for two separate material and installation processes and will allow for one product and one installation. More particularly, the present invention provides, in one exemplary embodiment, a silt/visual fence comprising a plurality of stakes, each stake comprising, a generally flat surface having a plurality of holes defined therein and spaced along at least a portion of the flat surface, a strip of fabric, comprising, a lower portion having a first visual indicia associated therewith, an upper portion having a second visual indicia associated therewith distinct from the color of the first portion, the upper and lower portions being connected; and, a plurality of fasteners for fastening the strip of fabric to the plurality of stakes. The fence preferably also includes, where use so requires, a wire grid or mesh backing to provide additional strength and support to the lower portion fabric. For certain applications a wire grid or mesh backing is not required.
[0007] Other features and advantages of the present invention will become apparent upon reading the following detailed description of embodiments of the invention, when taken in conjunction with the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The invention is illustrated in the drawings in which like reference characters designate the same or similar parts throughout the figures of which:
[0009] FIG. 1 is a perspective view of one exemplary embodiment of the present invention.
[0010] FIG. 2 is a detailed view of the stake according to one exemplary embodiment of the present invention.
[0011] FIG. 3 is a top schematic view of a stake with a fastener inserted through the wire back and fabric.
[0012] FIG. 4 is a bottom plan view of a fabric fastener according to one exemplary embodiment of the present invention.
[0013] FIG. 5 is a side view of the fabric fastener of FIG. 4 , shown in position in the fence.
[0014] FIG. 6 is a bottom plan view of a wire back fastener according to one exemplary embodiment of the present invention.
[0015] FIG. 7 is a side view of a fastener inserted into a fence system.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0016] The present invention provides a silt fence to prevent sediment from leaving a site with a visual fence to define the limits of project clearing or a protected tree save area. In one exemplary embodiment a silt fence 10 is shown in FIG. 1 and generally comprises a plurality of stakes 12 and a strip of fabric 14 .
[0017] The stake 12 is preferably formed of a durable generally rigid material, such as, but not limited to, metal, wood, plastic, combinations of the foregoing, and the like. In a preferred embodiment the stake is made of wood or steel. The lower end of the stake 12 preferably, though not mandatorily, terminates in a tapered tip for easier insertion into the ground. The stake 12 preferably has a generally flat portion 16 (although a curved portion, or even a cylindrical shaped stake 12 are contemplated as being within the scope of the present invention). Preferably, though not mandatorily, the stake has a reinforcing portion 18 , which can be formed as an L-shaped or T-shaped (as shown in FIG. 1 ) part of the stake. The flat portion 16 has a series of space apart holes 20 along at least a portion of the length of the flat portion 16 . Optionally, there are a series of tabs or protrusions 22 extending generally outward from the flat portion 16 . In one exemplary embodiment, shown in FIG. 1 , the flat portion 16 has a generally vertical line of holes 20 on both left and right sides and a series of tabs 22 between the sets of holes 20 .
[0018] The fabric 14 can be any suitable fluid porous material which can also retain a substantial portion of sedimentous material, such as, but not limited to, silt, topsoil, rocks, branches, leaves, and the like. In one exemplary embodiment the fabric 14 is made of polypropylene, available commercially from a number of manufacturers. The fabric 14 is preferably made of a first horizontal strip 30 and a second horizontal strip 32 . The first and second strips 30 , 32 are joined together, such as by adhesive, fusing or other technique known in the art, with the seam 33 shown in the drawing. Alternatively, the first and second strips 30 , 32 can be part of a single strip of fabric 14 .
[0019] The first strip 30 is preferably located above the top edge of the second strip 32 . The first strip 30 has a first unique visual indicia associated therewith and the second strip 32 preferably has a second unique visual indicia associated therewith. The visual indicia can be any visually distinctive indicator, such as, but not limited to, color, pattern, words, symbols, combinations of the foregoing, or the like. In one preferred embodiment the first strip 30 has an orange color and the second strip 32 has a black color. Preferably, the fabric itself is made of the colored material; alternatively, the color can be applied to the fabric using any suitable technique.
[0020] In one exemplary embodiment, the fence 10 also includes a wire backing 34 as a support and strength adjunct to the fabric 14 . The wire backing 34 preferably has a curved portion 36 at its lower end so as to conform to the shape of a trench into which the wire backing is maintained, as described in greater detail hereinbelow. The wire backing 34 preferably extends upward from the lower portion of the stake 12 to at least a portion of the stake 12 aboveground when installed. The wire backing 34 is preferably made of metal, plastic or other durable strong material. A primary purpose of the wire backing 34 is to provide additional strength to the fabric 14 when silt accumulates behind the fabric 14 and to resist deformation or ripping of the fabric 14 .
[0021] The fabric 14 is preferably attached to the stake 12 using a number of fasteners 38 . The fastener 38 has a shank 40 which is pushed through the fabric 14 and force fit into one of the holes 20 in the stake 12 (see FIG. 3 ). In one exemplary embodiment the fastener 38 can be either a fabric fastener 42 or a wire backing fastener 44 . The fabric fastener 42 may have a circular head. The wire backing fastener 44 may have a rectangular head. The fasteners 42 or 44 preferably have at least one, and more preferably, a plurality of annular barbs to restrict unintentional removal of the fastener. It is to be understood that other fasteners 38 can be used with the present invention, and may include, but are not limited to, wire or plastic ties or wraps, staples, nails, hook and loop fasteners, screws, clips, combinations of the foregoing or the like. A novel fastener is described in detail herein below.
[0022] By spacing the stakes 12 a desired distance apart (usually mandated by state or local regulation) the fabric 14 can be stretched between the stakes 12 and secured in place using the fasteners 38 . A portion of the fabric 14 is placed in a trench in the ground (as discussed above, this is usually mandated by state or local regulation) and soil placed over that portion to maintain the fabric 14 in place and to prevent silt and other nonfluid runoff from passing under the fabric 14 .
[0023] An advantage of the present invention is that the two color fabric 14 eliminates the need for separate silt and visual fences as are conventionally used; i.e., one black fence and one orange fence. The elimination of one fence reduces time and cost of installation and subsequent removal of the fence once construction has ended. The present invention also reduces landfill impacts or the need to recycle one fence.
[0024] In another aspect of the present invention, a novel fastener is provided for use with the fence system 10 . FIGS. 4 and 5 show an exemplary embodiment of a fabric fastener 50 having a head or cap 52 and a shank 54 . The fabric fastener 50 is preferably made of plastic, but can also be made of metal or other material that preferably can be struck without substantial deformation yet be resistant to weathering. The surface of the cap 52 can be rounded or flat. The cap can be circular in circumference or of other shape. The cap 52 has a plurality of ribs 56 or barbs, teeth, fins or the like that protrude from preferably the back side (i.e., the side with the shank extending therefrom) of the cap 52 . The ribs 56 are preferably arranged is a series of concentric circles (with each rib being straight, curved, jagged, or other shape), as shown in FIGS. 4 and 5 . It is to be understood that other regular or irregular arrangements, e.g., grid, spiral, radial, random and the like, are contemplated as being possible. The ribs 56 can be the same height, or can be of different heights above the back of the cap 52 . A purpose of the ribs 56 are to increase the gripping strength of the fabric fastener 50 to the fabric 32 when installed. When the fabric 32 is installed against the support 12 , the shank 54 , which preferably has a pointed tip 58 and a series of protrusions 60 or threads, passes through the fabric 32 and is retained in one of the holes 20 . The ribs 56 are pushed towards and/or into the fabric 32 and preferably engage the fabric fibers. This multiple-point engagement helps to retain the fabric 32 in place and reduce the tendency to rip during extended use. In one exemplary embodiment it is possible for the ribs 56 to be the result of piercing the front of the cap 52 and creating a protrusion of material extending out of the back of the cap 52 .
[0025] FIG. 6 shows an alternative embodiment of a fastener, namely a wire backing fastener 70 , similar in material construction to the fabric fastener 50 , but preferably having a generally rectangular shaped cap 72 . The surface of the cap 72 can be rounded or flat. The ribs 74 are preferably arranged horizontally in rows so as to improve engagement and retention of the wire 34 . The wire backing fastener 70 has a shank 76 similar to the shank 54 . FIG. 7 shows a wire backing fastener 70 installed in a fence system. The shank 76 of the wire backing fastener 70 is inserted through the hole 20 in the support 12 , with at least one row of ribs 74 being below the wire 34 . Preferably, at least one row of ribs 74 is above the wire 34 . In this manner the ribs assist in supporting the wire 34 and maintaining it in position with respect to the support 12 .
[0026] It is to be understood that the caps 52 and 72 of the fasteners 50 and 70 , respectively, may be constructed with different shapes, such as, but not limited to, circular, rectangular, rhomboid, elliptical, oval, hemispherical, square, wedge, asymmetric or other regular or irregular shape.
[0027] Although only a few exemplary embodiments of this invention have been described in detail above, those skilled in the art will readily appreciate that many modifications are possible in the exemplary embodiments without materially departing from the novel teachings and advantages of this invention. Accordingly, all such modifications are intended to be included within the scope of this invention as defined in the following claims. It should further be noted that any patents, applications and publications referred to herein are incorporated by reference in their entirety.
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A fence for retaining silt and providing a visual marker comprising a plurality of stakes, each stake comprising, a generally flat surface having a plurality of holes defined therein and spaced along at least a portion of the flat surface, a strip of fabric, comprising, a lower portion having a first visual indicia associated therewith, an upper portion having a second visual indicia associated therewith distinct from the color of the first portion, the upper and lower portions being connected; and, a plurality of fasteners for fastening the strip of fabric to the plurality of stakes. The fence preferably also includes a wire grid or mesh backing to provide additional strength and support to the lower portion fabric.
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CROSS-REFERENCE TO RELATED APPLICATIONS
Argentine Record No P 2010 0103745
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable.
THE NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT
Not Applicable.
INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC
Not Applicable
BACKGROUND OF THE INVENTION
1—Field of the Invention
This invention is related to elements employed in the petroleum industry in general but it particularly refers to a Free Mandrel System with protected casing. Its main specific purpose is to be applied to petroleum exploitation for the multiple selective injection of fluids, liquids or gases, in different formations of an injection well.
2—Description of Related Art
The present state of technology of mandrel systems for the injection of fluids in several formations only use fixed installations at the bottom hole. Consequently, when it is necessary to repair or replace any of the injection valves placed inside the mandrel, they have to be brought up to the surface. In order to perform this operation, the well has to be depressurized so injection has to be stopped; each of the injection valves have to be raised one at a time from the bottom hole to the surface. After the necessary repair or replacements are made, each of the injection valves have to be lowered again one at a time, and only after they are re-installed, production is resumed. All of the above mentioned operations require not only specialized equipment and personnel but also, down time, during which the well is not operating, and lead time, between order and arrival of the equipment at the well site to start with the operations.
The following documents are related to the present invention:
Document Number
Date
Name
Classification
A
U.S. Pat. No. 4,671,352
June 1987
Magee Jr. et al
166-334
B
U.S. Pat. No. 4,462,465
July 1984
Strickland
166-334
C
U.S. 2004238218(A1)
December 2004
Runia. Douwe Johannes et al.
E21B/60—
D
U.S. 2005011678(A1)
January 2005
Akinlade Monsuru Olatunji et al.
E21B21/00—
E
U.S. Pat. No. 4,050,516(A)
September 1977
Canterbury Robert Houston
E21B34/06—
F
U.S. Pat. No. 4,433,728 (A)
February 1984
Sydansk Robert D et al
C09K8/50—
G
U.S. Pat. No. 4,433,729 (A)
February 1984
Sydansk Robert D
C09K8/50
H
RU2002126207 (A)
February 2004
Stedzhemejer Dzhordzh Leo et al
E21B43/00
BRIEF SUMMARY OF THE INVENTION
The main object of the invention is a Free Mandrel System, Protected Casing which enables selective injection in several well formations, the setting up and simultaneous lifting of all Injection Valves installed in the well from the surface by using the injection fluid as power fluid. This process is performed by one operator without any kind of help, assistance or tool, only operating the valves of a surface component of the invention.
In the present explanation for the embodiment of the invention, the Free Mandrel System is applied to a 139.5 mm (5″½) casing and it has been simplified to only two formations, an upper and a lower one, to facilitate the explanation and comprehension of its constructive layout structure which comprises five Assemblies: A Surface Assembly (SA), A Transport Assembly (TA), the Free Mandrel Assembly (FMA), a Fixed Bottom Hole Assembly (FBHA) and a Complementary Assembly (CA).
(A) The Surface Assembly (SA) made up of an installation Mast ( 4 ), a Lubricator ( 3 ) with a Catcher ( 2 ) to release and catch the Free Mandrel Assembly (FMA), Standard Valves ( 6 1 , 6 2 , 6 3 , 6 4 , 6 5 ), Standard Retention Valve ( 7 ) and the Impeller Circulation Pump ( 5 ).
(B) The Transport Assembly (TA) made up of a Fishing Neck with a Retention Valve, two Rubber Cups, which slide over a central tube, and a Lower Connector.
(C) The Free Mandrel Assembly (FMA), it is the main dynamic element of the System comprising one mandrel for every formation to be selectively injected (only two in this simplified case), where each mandrel lodges its corresponding Injection Valve. The Free Mandrel Assembly has as many mandrels as formations an injection well may have.
(D) The Fixed Bottom Hole Assembly (FBHA), which is the device that is screwed to the bottom of the 73.026 mm (2″⅞) tubing ( 9 ) string and over the On-Off Sealing Connector ( 43 ). When the FMA is inserted into the FBHA, the FMA complements the hydraulic circuits they both contain to accomplish selective injection in every formation. These two Assemblies are composed of designed-to-measure parts and are the core of the Invention.
(E) A Complementary Assembly (CA), which is screwed to the lower part of the FBHA (D), and comprises several parts, some of them are standard and others are specifically designed to build the fluid circuit required for the operation of the Free Mandrel System, Protected Casing. The CA (E) is screwed in its interior part to the central and lower end of the Fixed Bottom Hole Assembly FBHA (D); the Telescopic Union Inner Body ( 37 ); the Telescopic Union Outer Body ( 39 ) and the Injector Tube ( 40 ). All of these parts have been specifically designed for the Free Mandrel System, Protective Casing.
In its exterior part, the Complementary Assembly CA (E) is made up of the upper end of the On-Off Sealing Connector ( 43 ) screwed to the outer and lower end of the Fixed Bottom Hole Assembly FBHA (D). The lower end of the On-Off Sealing Connector ( 43 ) is screwed to the upper end of the Upper Packer F. H. ( 44 ) (standard parts) while the Injector Plug ( 41 ) (designed-to-measure part) is screwed at its lower end.
To complete the installation, the 60.325 mm (2″⅜) tubing ( 47 ) string is screwed to the lower end of the Injector Plug ( 41 ) to fix the Lower Packer F.H. ( 46 ) in the adequate position to separate both formations. The 60.325 mm (2″⅜) tubing ( 47 ) string is screwed to the upper end of the Lower Packer F.H. ( 46 )
One or two 60.325 mm (2″⅜) tubing are placed below the Lower Packer F.H. ( 46 ), and the Shear Out ( 48 ) is placed on its end (standard parts)
With this invention, the problems which derive from a fixed mandrel system are advantageously solved because the complete Free Mandrel Assembly FMA (C) is raised containing all the Injections valves that the injection well requires.
The Free Mandrel Assembly FMA (C) is not fixed to the bottom of the well, it is free and travels through the tubing from the FBHA (D) (upstroke) to the surface and vice versa, driven by the Injection fluid which is used as power fluid.
An additional advantage is that fluid injection is continuously pressurized in all formations so injection is not interrupted in any of the operational stages. That is to say, the fundamental purpose of fluid injection (secondary recovery) is to pressurize the formations to achieve a larger formation volume in the surrounding or adjacent producing wells. An important time and extra hand work advantage is achieved because no additional equipment such as Wireline, slikeline, or external personnel is not required for valve setting up or removal. This operation can be performed by control personnel of injector wells (either the operator or field supervisor) from the surface by handling the well head manifold valves at the moment it is required.
Consequently, for example, for 2500 m deep installations, the FMA (C) described herein reaches the surface with all valves installed in about 30 minutes and requires a slightly shorter time in the down stroke. Both strokes are attained with the same injection fluid, used as power fluid. This advantage is utilized several times while the well is producing, thus, accumulatively, adding a significant value.
Free Mandrel System, Protected Casing allows obtaining samples of the material deposited in the tubing string. With that purpose, strokes can be performed to bring the material to the surface to be analyzed.
Strokes can be performed to verify the accumulated depositions and in increasing periods, that is to say, beginning with short periods and increasing them in order to define the most suitable one for each well without depressurizing the formations, and with no additional equipment or external personnel costs.
To maximize the Casing ( 10 ) protection in case of long injection periods without replacing injection valves, Casing Protection fluid can be replaced from the surface by the well operator without employing pulling equipment to disconnect the On-Off Sealing Connector ( 43 ).
Besides, it can block any formation to examine or stimulate others. This is achieved by removing the FMA (C), leaving the formation circuits in service and blocking one of them, or leaving one formation in service and blocking the remaining ones.
For the two Formations used in this example, in the Upper Mandrel we can install a Blind Upper Injection Valve ( 51 ) and inject in the Lower Formation using the Lower Formation Injection Valve ( 21 ) ( FIG. 11 ). We can also use a Blind Lower Injection Valve ( 52 ) and inject only in the Upper Formation installing the Upper Formation Injection Valve ( 18 )( FIG. 9 )
This also allows determining if there is any interference between the formations by injecting fluid (at different pressures and volumes) in one and placing Amerada® Gauge, an instrument to measure pressure in the bottom hole, inside another mandrel to verify pressure variation in different injection flows.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
Here follows a list of the five assemblies which comprise the system, their Components, Vertical Passages and Annular Spaces with their respective reference characters as they will be identified in the detailed description of the system, drawings and claims:
A—Surface Assembly (SA)
B—Transport Assembly (TA)
C—Free Mandrel Assembly (FMA)
D—Fixed Bottom Hole Assembly (FBHA)
E—Complementary Assembly (CA)
Components of the five assemblies:
1 —Pipeline from Water Power Plant. 2 —Catcher. 3 —Lubricator. 4 —Mast. 5 —Impeller Circulation Pump. 6 1 —V1 Standard Valve. 6 2 —V2 Standard Valve. 6 3 —V3 Standard Valve. 6 4 —V4 Standard Valve. 6 5 —73.026 mm (2″⅞) Standard Full Passage Injection Valve 7 —Standard Retention Valve. 8 —Well Head. 9 —73.026 mm (2″⅞) Tubing i—Tubing ( 9 ) Interior (Direct) 10 —Casing. 11 —Fishing Neck. 12 —Retention Valve. 13 —Rubber Cups. 14 —Lower Connector. 15 —Outer Jacket. 16 —Outer Jacket Seal Ring. 17 —Middle Plug. 18 —Upper Formation Injection Valve. 19 —Middle Plug Radial Passage. 20 —Middle Plug Seal Ring. 21 —Lower Formation Injection Valve. 22 —Lower Plug. 23 —Lower Plug Seal Ring. 24 —Upper Body. 25 —Upper Packer Collar. 26 —Upper Packer Collar Seal Ring. 27 —Lock Nut. 28 —Lower Body. 29 —Lower Body Seal Ring. 30 —Spacer. 31 —Spacer Injection Outlet Perforation. 32 —Lower Packer Collar. 33 —Lower Packer Collar Seal Ring. 34 —Seat. 35 —Seat Seal Ring. 36 —Casing Protective Valve. 37 —Telescopic Union Inner Body. 38 —Telescopic Union Seal Ring. 39 —Telescopic Union Outer Body. 40 —Injection Tube. 41 —Injector Plug. 42 —Rupture Disc Passage. 43 —On-Off Sealing Connector. 44 —Upper Packer F.H. 46 —Lower Packer F. H. 47 —60.325 mm (2″⅜) Tubing 48 —Shear Out. 49 —Casing Upper Formation Perforations 50 —Casing Lower Formation Perforations 51 —Blind Upper Injection Valve. 52 —Blind Lower Injection Valve-
Vertical Passages
C 1 —It is placed in the Middle Plug ( 17 ). They are passages in the Free Mandrel Assembly central body C 2 —It is placed in the Lower Body (FBHA). The Annular Space (e 6 ) where the regulated pressure is discharged through the Upper Valve ( 18 ) and conducted to the Annular Space (e 9 ) placed between Telescopic Union Inner Body ( 37 ) and the interior of the Fixed Bottom Hole Assembly (D) FBHA eccentric vertical passage C 3 —Casing Protective Valve ( 36 ) Passage C 4 —Shear Out ( 48 ) passage
Annular Spaces
e 1 —Between the Casing ( 10 ) and the 73.026 mm (2″⅞) Tubing ( 9 ) e 2 —Between the Casing ( 10 ) and the FWBA (D) e 3 —Between the Casing ( 10 ) and the Injector Plug ( 41 ) e 4 —Between the Casing ( 10 ) and the 60.325 mm (2″⅜) tubing ( 47 ) e 5 —Between the Casing ( 10 ) and the Shear Out ( 48 ) e 6 —Between the FBHA (D) and the Middle Plug ( 17 ) e 7 —Between the Upper Mandrel Jacket ( 15 ) and the Upper Formation Injection Valve ( 18 ) e 8 —Between the FBHA (D) interior and the Lower Formation Injection Valve ( 21 ) e 9 —Between the lower inner part of the FBHA (D) and the Telescopic Union Inner Body ( 37 ) e 10 —Between the On-Off Sealing Connector ( 43 ) and the Telescopic Union Outer Body ( 39 ) e 11 —Between the Injector Plug ( 41 ) and the Injection Tube ( 40 )
The invention components are schematically represented in 21 different views of FIG. 1 . As the component parts of the Free Mandrel System have a great length but a relatively small diameter, the 27 Figures have been deliberately deformed so that the component parts can be distinguished to be explained. With the same purpose, an enlargement of FIG. 1 has been added divided into four partial views of FIG. 1 .
In all Figures, except 6 and 22 , the following hydraulic flow circulations are identified and described to facilitate the comprehension of the Free Mandrel System, Protected Casing operations:
1—Injection fluid, provided by the Power Plant with the highest pressure flowing into all injection valves to be regulated according to the conditions of every formation. 2—Controlled fluid to be injected in the upper formation. It comes out through the lower end of the Upper Formation Injection Valve ( 18 ) 3—Controlled fluid to be injected in the lower formation. It comes out through the lower end of the Lower Formation Injection Valve ( 21 ) 4 —Fluid injected at low pressure through the Annular Space (e 1 )) to achieve the upstroke of the Free Mandrel Assembly, containing all the Injection Valves required by the well. The pressure is approximately 2 or 3 kg/cm 2 . (Obviously the higher the pressure, the faster the return speed, but the mentioned pressure is the recommended one). Again, 30′ return time is achieved in a 2500 m deep installation. 5—Fluid removed from the tubing as the Free Mandrel Assembly moves up to the surface. Its pressure is slightly lower than the one that pushes up the Free Mandrel Assembly. 6—White (empty space)=Settled fluid or only with hydrostatic pressure (for example in the Annular Space between the Casing ( 10 ) and the 70.026 mm (2″⅞) tubing ( 9 ) during the injection process).
The 22 Figures are as follows:
FIG. 1 is an elevational longitudinal view of the general layout of the invention. The view of the Free Mandrel System, Protected Casing in its entirety ( FIG. 1 ) has also been broken into four partial views to facilitate the understanding of the view ( FIG. 1 a : top left side, FIG. 1 b : top right side, FIG. 1 c : bottom left side, and FIG. 1 d : bottom right side). These partial views have been extended over four sheets which can be linked edge to edge so that no partial view contains parts of another partial view.
The position of a series of transverse cross sectional lines, indicated with numbers I to VIII, correspond to cross-sectional views which show fluid flows
The capital letters A, B, C, D and E show the position of the five structures that compose the equipment are: Surface Assembly (A); Transport Assembly (B); Free Mandrel Assembly (C); Fixed Bottom Hole Assembly (D); and Complementary Assembly (E). Four exploded views show the four main components that are inside the well:
1 The two free components, the Transport Assembly (TA) (B) and the Free Mandrel Assembly (FMA) (C) are shown on the left. 2 The two fixed components, the Fix Bottom Hole Assembly (FBHA) (D) and the Complementary Assembly (CA) (E) are shown on the right.
FIG. 2 is an enlarged partial view of the surface section of the Free Mandrel System, Protected Casing where the Surface Assembly (SA (A), the only component of the invention located on the surface of the well site, is shown in detail.
FIG. 3 is an elevational longitudinal view of the Transport Assembly (TA) (B). When the Free Mandrel System, Protective Casing is operating, the only fluid that circulates is the supplied by the Power Plant coming through 73.025 mm (2″⅞) tubing ( 9 ) (i), the Fishing Neck ( 11 ), Retention Valve ( 12 ), and Lower Connector ( 14 ), finally connecting with the Free Mandrel Assembly (FMA)(C).
FIGS. 4 A and B are two elevational longitudinal views of the Free Mandrel Assembly (C) Incoming Injection fluid is divided into two streams:
1— FIG. 4 A shows how the fluid flows on the plane of Middle Plug Radial Passage ( 19 ). It enters through the upper part of the Outer Jacket ( 15 ), goes into the Upper Formation Injection Valve ( 18 ) which delivers the controlled fluid to be injected in the Upper Formation through the Middle Plug ( 17 ) Radial Passage ( 19 ).
2— FIG. 4B . It circulates through the Annular Space (e 7 ) to guide the fluid through the Middle Plug ( 17 ) Vertical Passages (C 1 ) and feed with injection fluid to the Lower Injection Formation Valve ( 21 ) which delivers the controlled fluid to inject in the Lower Formation through the Lower Plug ( 22 ).
FIGS. 5 A and B are elevational longitudinal views of the Transport Assembly (TA) (B) and the Free Mandrel Assembly (FMA) (C) as they run together through the well from the Catcher ( 2 ) to the Fixed Bottom Hole Assembly (FBHA) (D) in their down stroke, and from the Fixed Bottom Hole Assembly (FBHA) (D) to the Catcher ( 2 ), in their upstroke. Different fluids are shown inside both assemblies, the incoming injection fluid, the one to be injected in the upper formation and the one to be injected in the lower formation.
FIG. 5 B shows the fluid going through the Middle Plug Radial Passage ( 19 ) in a perpendicular plane. Vertical Passages C 1 , allow the injection fluid go into the Lower Injection Formation Valve ( 21 ) to release fluid at the pressure and volume to be injected in the Lower Formation.
FIG. 6 is an elevational longitudinal view of the Fixed Bottom Hole Assembly (FBHA) (D) with its essential components which are designed-to-measure for the Free Mandrel System, Protected Casing.
FIG. 7 A is an elevational longitudinal view of the Free Mandrel Assembly (FMA) (C) and Transport Assemblies (TA) (B) inserted in the Fixed Bottom Hole Assembly (FBHA) (D). The injection fluid entering through the 73.025 mm (2″⅞) Tubing ( 9 ) i, at the Upper Free Mandrel, the out coming fluid through the Middle Plug ( 17 ) Radial Passage ( 19 ), to be injected in the Upper Formation, on the plane of Middle Plug Radial Passage ( 19 ). FIGS. 7A and 7B are the same Figures but, in 7 B, the sectional plane is perpendicular to Radial Passage ( 19 ). The incoming Injection fluid flows to the Lower Formation Injection Valve ( 21 ) through the Middle Plug ( 17 ) Vertical Passages (C 1 ) to be injected in the Lower Formation.
FIG. 8 is an elevational longitudinal view of the Fixed Bottom Hole Assembly (FBHA) (D) screwed to the Complementary Assembly (CA) (E) only down to the Injection Plug ( 41 ). The Transport Assembly (TA) (B) together with the Free Mandrel Assembly (FMA) (C) is inserted inside the FBHA (D) during simultaneous injection in both formations. Fluids are also shown as they flow through different passages.
In FIG. 8 , the injection circuits of both formations are represented. The injection fluid enters through 73.026 mm (2″⅞) Tubing ( 9 ) (i), goes through the Transport Assembly (TA) (B), gets into the Free Mandrel Assembly (FMA) (C), reaches the Upper Formation Injection Valve ( 18 ) and comes out as controlled fluid towards the Upper Formation through the Middle Plug ( 17 ). The fluid goes on through the Annular Space (e 6 ) and the Spacer Injection Outlet Perforation ( 31 ). Then it channels through the FBHA (D) Vertical Passages (C 2 ), the Annular Spaces (e 9 ), (e 10 ) and (e 11 ), and the Rupture Disc Passage ( 42 ). Simultaneously, the other injection fluid stream that goes into the Upper Mandrel, flows through the Annular Space (e 7 ), the Middle Plug ( 17 ) Vertical Passages (C 1 ) until it reaches the upper end of the Lower Formation Injection Valve ( 21 ) which controls the fluid to be injected in the Lower Formation. The fluid goes through the Lower Plug ( 22 ) and continues through the inside of the Telescopic Union ( 37 and 39 ), the Injection Tube ( 40 ) and the Injector Plug ( 41 ) inner passage. Meanwhile the Annular Spaces (e 1 ), (e 2 ) and the vertical passages (C 3 ) are kept without pressure (white space).
FIG. 9 is an elevational longitudinal view. It only shows the injection in the upper formation of the invention layout. The Transport Assembly (TA) (B), Free Mandrel Assembly (FMA) (C), Fixed Bottom Hole Assembly (FBH) (D) and Complementary Assembly (CA) (E) are represented while showing operative hydraulic flows. The Upper Formation Injection Valve ( 18 ) is regulating the flow and the Lower Formation Injection Valve ( 21 ) is replaced by a Blind Lower Injection Valve ( 52 ).
The central passage (corresponding to the Lower Formation circuit) is shown without pressure or fluid (white space). Consequently, the Injection Plant pressure acts through 73.026 mm (2″⅞) Tubing ( 9 ) (i), as the regulated fluid is injected to the Upper Formation through the Casing Upper Formation Perforations ( 49 ). Through the Annular Spaces (e 1 ), (e 2 ) and the passage (C 3 ) there is no fluid circulation. There is only hydrostatic pressure (white space).
FIG. 10 , a transverse cross sectional view on line III-III ( FIG. 1 ), shows the Upper Formation injection fluid in the Middle Plug ( 17 ) Radial Passage plane ( 19 ), the Fixed Bottom Hole Assembly (FBHA) (D), Vertical Passages (C 1 ) and Casing ( 10 ). The Annular Spaces (e 2 ) (white space) and (e 6 ) with the Upper Formation Injection Fluid are also shown.
The Plant injection fluid circulation goes through the Middle Plug ( 17 ) Vertical Passages (C 1 ) and comes out regulated through the Middle Plug ( 17 ) Radial Passage ( 19 ) to the Annular Space (e 6 )
FIG. 11 is an elevational longitudinal view. It shows the injection in the Lower Formation of the invention layout. In this Figure, The Transport Assembly (TA) (B), Free Mandrel Assembly (FMA) (C), Fixed Bottom Hole (FBHA) (D) and Complementary (E) Assemblies are represented while showing operative hydraulic flows in the Annular Spaces (e 1 ), (e 2 ) and the passage (C 3 ) there is no pressure (white space) as only the Lower Injection Formation flow is represented. The injection fluid that enters through 73.026 mm (2″718) ( 9 ) (i) goes through the Transport Assembly (TA) (B) and comes into the Free Mandrel Assembly (FMA) (C) and reaches the Blind Upper Valve ( 51 ). The Annular Space (e 6 ), the FBHA (D) vertical passages (C 2 ), the Annular Spaces (e 9 ), (e 10 ) and (e 11 ) and the Rupture Disc passage ( 42 ) have no pressure.
At the same time, the other injection fluid stream flows through the Annular Space (e 7 ) and Vertical Passages (C 1 ) until it reaches the upper end of the Lower Formation Injection Valve ( 21 ), which controls the fluid to be injected in the Lower Formation. Lower injection fluid stream goes through the Lower Plug ( 22 ) and continues through the interior of the Telescopic Union ( 37 and 39 ), Injection Tube ( 40 ), Injector Plug ( 41 ) inner passage, 60.325 (2″⅜) ( 47 ) Tubing, Lower Packer F.H. ( 46 ), the 60.325 mm (2″⅜) tubing ( 47 ) and Shear Out ( 48 ). Meanwhile, the Annular Spaces (e 1 )) and (e 2 ), and the vertical passage (C 3 ) are kept without pressure (white space).
FIG. 12 , a transverse cross-sectional view on line IV-IV ( FIG. 1 ), shows lower formation fluid flowing out of the Lower Formation Injection Valve ( 21 ). As in the previous FIG. 11 ) the Casing ( 10 ), the Fixed Bottom Hole Assembly (FBHA) (D) and the Lower Plug ( 22 ) are also shown together with (C 2 ) and (C 3 ) (white space) Vertical Passages, and the Annular Space (e 2 ) (white space).
FIG. 13 an elevational longitudinal view. It shows simultaneous injection in both formations. The incoming plant fluid is controlled by the corresponding Upper Injection Formation Valve ( 18 ) and Lower Injection Formation Valve ( 21 ). The Transport Assembly (TA) (B), Free Mandrel Assembly (FMA) (C), inserted in the Fixed Bottom Hole (FBHA) (D) and Complementary Assemblies (CA) (E) are represented while showing operative hydraulic flows.
In the Annular Spaces (e 1 )) and (e 2 ), and Vertical Passage (C 3 ) there is no pressure as simultaneous Injection in the Upper and Lower Formations with regulated fluids are represented here. Upper Formation Injection Valve ( 18 ) and Lower Formation Injection Valve ( 21 ) are regulating injection fluids in both formations. Consequently, the injection fluid enters the 73.026 mm (2″⅞) Tubing ( 9 ) (i), goes through the Transport Assembly (TA) (B) and flows into the Free Mandrel Assembly (FMA) (C) through the Outer Jacket ( 15 ) and reaches the Upper Formation Injection Valve ( 18 ) from this lower end flows the upper formation regulated fluid. The injection fluid flows through the Middle Plug ( 17 ) Vertical Passages (C 1 ) reaches the Lower Formation Injection Valve ( 21 ) that releases the regulated fluid to inject in the Lower Formation.
To complete the regulated fluid circuit to be injected in the Upper Formation, as shown in FIGS. 9 and 13 ), this fluid course comes out of the Rupture Disc Passage ( 42 ) until the fluid gets into the chamber delimited as follows:
1—At the upper end by the lower side of the Upper Packer F. H. ( 44 )
2—On the outer side by the Casing ( 10 )
3—On the inner side by the Injection Tube ( 40 ) and Injector Plug ( 41 )
4—At the lower end by the upper side of the Lower Packer F. H. ( 46 )
That is to say, the regulated fluid is forced to go through the Casing Upper Formation Perforations ( 49 ) to the Upper Formation.
To complete the regulated fluid circuit to be injected in the Lower Formation as shown in FIGS. 11 and 13 ) this fluid comes out of the Injector Plug central passage ( 41 ), 60.325 mm (2″⅜) Tubing ( 47 ), Lower Packer ( 46 ) F. H. inner passages, 60.325 mm (2″⅜) Tubing ( 47 ), and Shear Out ( 48 ), until it gets into the chamber delimited as follows:
1—At the upper end by the lower side of the Lower Packer ( 46 )
2—On the outer side by the Casing ( 10 )
3—On the inner side by the 60.325 mm (2″⅜) Tubing and the Shear Out ( 48 )
4—At the lower end by the bottom hole
That is to say, the regulated fluid is forced to go through the Casing Lower Formation Perforations ( 50 ) and enter the Lower Formation,
FIG. 14 , a transverse cross-sectional view on line V-V ( FIG. 1 ), corresponds to Upper and Lower Formation simultaneous injection at the height of the Casing Protective Valve ( 36 ) of the Fixed Bottom Hole Assembly (D) lower end. Upper Formation injection fluid goes through the Annular Space (e 9 ) defined by the FBHA (D), inner diameter and the outer diameter of the inner body of the Telescopic Union ( 37 ) and the Lower Formation injection fluid goes through the inside of the Telescopic Union ( 37 ). Vertical Passages (C 3 ) and Annular Space (e 2 ) are without pressure (white space)
FIG. 15 , a transverse cross-sectional view on line VI-VI ( FIG. 1 ), corresponds to the lower part of the Fixed Bottom Hole Assembly (D) below the Casing Protective Valve ( 36 ) with the simultaneous injection fluids of Annular Space (e 9 ) acting in the Upper injection fluid and Lower Formation fluid through the inside of the Injection Tube ( 40 ). Also, Annular Space (e 2 ) is without pressure (white space)
FIG. 16 , a transverse cross-sectional view on line VII-VII ( FIG. 1 ), shows Upper and Lower Formation injection fluid and flow in the Injector Plug ( 41 ) plane through the Rupture Disc passage ( 42 ). Casing Upper Formation Perforations ( 49 ), Injection Tube ( 40 ) and the Injector Plug ( 41 ) together with Annular Spaces (e 3 ) and (e 11 ) can also be seen. Lower Formation fluid circulates through the inside of the Injection Tube ( 40 )
FIG. 17 , a transverse cross-sectional view on line VIII-VIII ( FIG. 1 ), only shows Lower Formation injection and fluid circulation in the Shear Out ( 48 ) passage plane and Casing Lower Formation Perforations ( 50 ) in that area. Annular Space (e 5 ) and the Shear Out inner passage (C 4 ) are also shown.
FIG. 18 is an elevational longitudinal view. It represents fluid distribution during the Free Mandrel Assembly (FMA) (C) upstroke while the low pressure fluid is injecting in both formations without flow control. It is only when the Free Mandrel Assembly (FMA) (C), together with the Transport Assembly (TA) (B) is inserted in its position inside the Fixed Bottom Hole Assembly (FBHA) (D), that the injection in both formations is controlled. FIG. 18 represents the recovery chamber where it can be seen how low pressure fluid is injected through the Annular Space (e 1 )) to recover the TA (B) and the FMA (C). The initial upstroke is shown.
Fluid with the necessary pressure to perform the TA and FMA upstroke has to be injected through the Annular Space (e 1 ). This fluid enters through the Casing Protective Valve ( 36 ). This makes the TA (B) and the FMA (C) move up to the surface where they will finally insert into the Catcher ( 2 ). Fluid with a pressure slightly lower than injection pressure flows over these assemblies. Low pressure fluid pressurizes both formations This particularity has already been mentioned as a technical operational advantage of the invention because the formations are never depressurized.
FIG. 19 shows a transverse cross-sectional view on line I-I ( FIG. 1 ) with fluid circulation in simultaneous injection process in both formations. This takes place at the Well Head ( 8 ). The Casing ( 10 ) and the 73.026 mm (2″⅞) Tubing ( 9 ) (i) are shown. There is only hydrostatic pressure (white space) in the Annular Space between them (e 1 ). There is injection fluid in the inside of the Tubing ( 9 ) (i).
FIG. 20 , a transverse cross-sectional view on line II-II ( FIG. 1 ), shows fluid circulation in the with Free Mandrel Assembly upstroke. Fluid displaced by the Transport Assembly (TA) (B) together with Free Mandrel Assembly (FMA) (C) flows inside the 73.026 mm (2″⅞) Tubing ( 9 ) (i), and the low pressure fluid released by the Impeller Circulation Pump ( 5 ), flows through Annular Space (e 1 ). It also shows Retention Valve ( 12 )
FIG. 21 is an elevational longitudinal view of the Surface Assembly when the Transport Assembly (TA) (B) together with the Free Mandrel Assembly (FMA) (C) are finishing their upstroke and arriving at the Lubricator ( 3 ). Fluid circulations are also shown
FIG. 22 is an elevational longitudinal view of the general layout of the Complementary Assembly (CE) (E), It shows their components, as follows:
1 Internal components screwed at the central lower end of Fixed Bottom Hole Assembly (FBHA) (D): Telescopic Union Inner Body ( 37 ), Telescopic Union Seal Ring ( 38 ), Telescopic Union Outer Body ( 39 ), Injection Tube ( 40 ), screwed in its lower end to the Injector Plug ( 41 ). All of them are designed-to-measure parts for the Free Mandrel System, Protected Casing. 2 External components screwed on the lower end of the Fix Bottom Hole Assembly (FBHA) D screwed to the upper end of On-Off Sealing Connector ( 43 ) which, in its lower end is screwed to the upper end of Upper Packer F. H. ( 44 ) (both parts are of common use in the petroleum industry). The Injector Plug ( 41 ) screws in the Upper Packer F.H. ( 44 ) lower end. The Injector Plug ( 41 ) is a designed-to-measure part of the Free Mandrel System, Protected Casing. The Injector Plug ( 41 ) contains the Rupture Disc Passage ( 42 ). The Injector Plug ( 41 ) is also screwed, in its lower end, to the upper end of the last 60.235 mm (2″⅜) Tubing ( 47 ) required quantity to separate both packers in the injector well. At the lower end of 60.235 mm (2″⅜) Tubing ( 47 ) string, the Lower Packer F.H. ( 46 ) is screwed in its upper end. Another section of the 60.235 mm (2″⅜) Tubing ( 47 ) is connected to the Lower Packer F. H. ( 46 ) with the Shear Out ( 48 )
DETAILED DESCRIPTION OF THE INVENTION
According to the scheme represented in FIG. 1 of the Free Mandrel System, Protected Casing, the invention layout is composed of:
A—Surface Assembly (SA) B— Transport Assembly (TA) C— Free Mandrel Assembly (FMA) D—Fixed Bottom Hole Assembly (FBHA) E—Complementary Assembly (CA)
1-(A)—Surface Assembly (SA):
It is schematically represented in FIG. 2 . It is the assembly which comprises standard parts such as valves ( 6 1 ), ( 6 2 ), ( 6 3 ), ( 6 4 ), ( 6 5 ,), ( 7 ) and ( 8 ), properly laid out to perform the required operations of the Free Mandrel System, Protected Casing, with the following additional parts designed-to-measure: the Lubricator ( 3 ) with the Catcher ( 2 ), the Mast ( 4 ) and the Impeller Circulation Pump ( 5 ), a low pressure pump, with no movable parts which makes the system work.
The SA is screwed over the Well Head ( 8 ) in the 73.026 mm (2″⅞) Full Passage Standard Injection Valve ( 6 5 ). The Lubricator ( 3 ) with the Mast ( 4 ) and the Catcher ( 2 ) in its lower end is screwed on Standard Valve ( 6 5 ).
Injection Fluid comes from the Water Injection Plant through Pipeline ( 1 ) which separates into two branches: the first branch goes into the SA (A) central passage into the well through Standard Valve ( 6 1 . When Standard Valve ( 6 1 ) is open, the well can inject simultaneously in all Formations. When it is shut, it does not allow the injection fluid flow and so the well does not operate. (Stand-By stage); the second branch connects with the Impeller Circulation Pump ( 5 ) through a second valve ( 6 2 ) which is shut during that operation. When it is open, it allows the injection fluid to flow to the Impeller Circulation Pump ( 5 ) which injects at low pressure in the Annular (e 1 )) to perform the FMA (C) upstroke, required to recover all installed Injection Valves. This procedure is used to drive the Impeller Circulation Pump ( 5 ) which uses this fluid as power fluid and injects a low pressure fluid in the Annular Space (e 1 ) with the fluid it sucks from 73.026 (2″⅞) Tubing ( 9 ) (i). The Impeller Circulation Pump ( 5 ) connects to the Annular Space (e 1 )) through the Well Head ( 8 ).
Standard Valve ( 6 3 ), placed at the upper end of the Lubricator ( 3 ) is kept closed during the injection in several formations. It is only opened to retrieve the FMA (C) (upstroke). The Impeller Circulation Pump ( 5 ) allows low pressure injection fluid to circulate from the Casing ( 10 ) to the 73.026 (2″⅞) Tubing ( 9 ) (i) through the Casing Protective Valve ( 36 ) for the FMA (C) upstroke to the surface. Standard Retention Valve ( 7 ) is used to orient the low pressure injection fluid into the Annular Space (e 1 )) and to avoid pressurizing the Lubricator ( 3 ).
When the FMA (C) upstroke starts up, the Standard Retention Valve ( 7 ) allows the fluid to be removed from the tubing as the FMA (C) moves up to the surface. The fluid pressure is slightly lower than the one that pushes the FMA (C) up to the surface and is sucked by the Impeller Circulation Pump ( 5 ) intake. This operation enables low pressure circulation to drive the Transport Assembly (B) together with the Free Mandrel Assembly (C) in their upstroke from the FBHA (D) until it is trapped in the Catcher ( 2 ).
Valve ( 6 1 ) is kept open for the down stroke whereas Valves ( 6 2 ), ( 6 3 ) and ( 6 4 ) are kept shut. The injection fluid pushes and the FMA (C) inserts into the FBHA (D) while automatically beginning the selective injection in both Upper and Lower Formations
For the down stroke operation, a flow, not larger than 400 m 3 /a day, is recommended to go through Valve ( 6 1 ) to prevent the FMA (C) from inserting into the FBHA (D) with excessive impact.
In down strokes, the Operator opens Valve ( 6 1 ). Then, he can leave the location as the operation is completely automatic. Only in injected flows over 400 m 3 /a day, it is necessary for the Operator to liberate the flow completely after the FMA (C) is inserted in the FBHA (D) to leave the well in ideal operating conditions.
The third Valve ( 6 3 ) is placed at the Lubricator ( 3 ) outlet and is closed while operating. When it is open, it allows the 73.026 (2″⅞) Tubing ( 9 ) (i) fluid to re-circulate to the Annular (e 1 )) for the FMA (C) upstroke.
The 73.026 mm (2″⅞) Full Passage Standard Injection Valve ( 6 5 ) connected to the Well Head ( 8 ), allows the FMA (C) to run in both strokes, and the injection and return fluids flow to retrieve the FMA (C).
2-(B)—Transport Assembly—(TA):
It is schematically represented in FIG. 3 . It is one of the dynamic components that moves together with the Free Mandrel Assembly (C) from the Surface Assembly (A) to its insertion in the Fixed Bottom Hole Assembly (D) during the FMA (C) down stroke or vice versa, upstroke. The TA (B) consists of the Fishing Neck ( 11 ), a Retention Valve ( 12 ), Rubber Cups ( 13 ) and the Lower Connector ( 14 ) screwed together. The Transport Assembly (B) is used to transport the Free Mandrel Assembly (C).
The Transport Assembly (B) is designed-to-measure according to the operating requirements of the invention device and It is essential in the FMA (C) upstroke as the Rubber Cups ( 13 ) expand against the 73.026 mm (2″⅞) Tubing ( 9 ) (i) taking the utmost advantage of the fluid volume when they receive the upward injection fluid push. This push also closes the Retention Valve ( 12 ) for the greatest fluid flow efficiency.
FIG. 5 shows the Transport Assembly (B) screwed to the Free Mandrel Assembly (C) upper end. The TA (B) ends in its upper extreme in an API normalized Fishing Neck ( 11 ). which allows it to be trapped by the Catcher ( 2 ) ( FIG. 2 ) at the end of the upstroke and detached from it at the down stroke start. In case of any inconvenience, as for example tubing leakage, the TA (B) and FMA (C) can be trapped by means of a Slickeline equipment.
The TA (B) ends, in its lower extreme, in the Lower Connector ( 14 ) where it is screwed to the Free Mandrel Assembly (C). The assembly of (B) and (C) is schematically represented in FIGS. 5 A and 7 B.
3-(C)—Free Mandrel Assembly—FMA:
It is schematically represented in FIG. 4 A/B. It is the main dynamic component of the Free Mandrel System that travels from SA (A), in its down stroke, to be inserted into the FBHA (D) (in FIG. 6 ) and automatically begins selective injection in different Formations. The Free Mandrel Assembly upstroke carries injection valves to be examined or removed. The FMA (C) is one of the five Assemblies composed of totally new parts. It has been graphically represented in FIGS. 4 A/B, 5 A/B, 7 A, 7 B, 8 , 9 , 11 , 13 and 18 .
The FMA (C) has been designed-to-measure for the operations of the Free Mandrel System, Protected Casing applied to selective injection in several Formations. As mentioned above, can be applied to several formations but, in this specific explanation, has been reduced to only two formations, an upper and a lower one, for a better comprehension. Every Mandrel contains an Injection Valve in its interior, except the Lower one which is the only one integrated by an Injection Valve designed-to-measure for this purpose. A Free Mandrel Assembly designed to inject in two formations is schematically represented in FIG. 4 A/B.
The difference between the Upper Mandrel which contains an Upper Formation Injection Valve ( 18 ) in its interior and the Lower Mandrel composed by a designed-to-measure Lower Formation Injection Valve ( 21 ) and the Lower Plug ( 22 ) can be observed in FIG. 4 A/B.
The upper end of the Upper Free Mandrel is screwed at the lower end of the Transport Assembly (B) by the Outer Jacket ( 15 ) to the Lower Connector ( 14 ). The Outer Jacket ( 15 ) closes with the FBHA (D) Upper Packer Collar ( 25 ) through the Outer Jacket Seal Ring ( 16 ), which contains the Upper Formation Injector Valve ( 18 ) in its interior and is screwed to the Middle Plug ( 17 ) at its lower end. The Middle Plug ( 17 ) closes the FBHA (D) Lower Packer Collar ( 32 ) with Middle Plug Collar Seal Ring ( 20 ).
The Lower Formation Injection Valve ( 21 ) is screwed in its upper end to the Middle Plug ( 17 ) lower end. The Lower Formation Injection Valve ( 21 ) in its lower end is screwed to the Lower Plug ( 22 ) which closes with Lower Plug Seal Rings ( 23 ) in the Seat ( 34 ) of the Fixed Bottom Hole Assembly (D) ( FIG. 6 )
FIG. 4 A/B shows the incoming injection fluid which comes out regulated from the Upper Formation Injection Valve ( 18 ) lower end to fulfill the upper formation required conditions, Whereas, the incoming injection fluid flows through the Annular Space (e 7 ) limited on the outside by the Upper Mandrel Jacket ( 15 ), goes through the Middle Plug ( 17 ), Vertical Passages (C 1 ) (only shown in FIG. 4 B), reaches the Lower Mandrel and is admitted by the Lower Formation Injection Valve ( 21 ) which transforms the fluid to fulfill the lower formation required conditions.
As it has been previously described, the Upper Mandrel, which contains the Upper Formation Injection Valve ( 18 ), receives the Plant fluid and the regulated fluid for upper formation required conditions, finally comes out from the Upper Injection Valve ( 18 ) lower end.
The incoming injection fluid moves through the annular (e 7 ) limited on the outside by the Upper Mandrel Jacket ( 15 ) and on the inside by the Upper Formation Injection Valve ( 18 ) This fluid reaches the Lower Mandrel through the Middle Plug ( 17 ) Vertical Passages (C 1 ) (only shown in FIG. 4B ) and is admitted by the Lower Formation Injection Valve ( 21 ). That is to say, the Lower Formation Injection Valve ( 21 ) receives the incoming injection fluid and transforms it into the fluid with the necessary conditions to be injected in the Lower Formation.
4-(D)—Fixed Bottom Hole Assembly—FBHA:
It is schematically represented in FIG. 6 . This Assembly is static. All of its parts are designed-to-measure for the Free Mandrel System, Protective Casing. The Workover Equipment installs it with its lower end screwed to the On-Off Sealing Connector ( 43 ) upper end, and its upper end to the first 73.026 (2″⅞) Tubing ( 9 ) at its lower end screwed in the string that communicates the FBHA (D) with the Well Head ( 8 )
The FBHA (D) lodges the FMA (C) so that hydraulic circuits are complemented. They allow the Upper Packer F.H. ( 44 ) and the Lower Packer F.H. ( 46 ) to be fixed from the surface during the Free Mandrel System, Protected Casing installation, without having to resort to Slickline or Wireline equipment. When the installation is over, Selective Injection is performed in every Formation.
The FMA (C) seals the Upper Packer Collar ( 25 ) with Outer Jacket Seal Ring ( 16 ) ( FIGS. 4 A/B and 6 ) and separates the injection fluid contained in the 73.026 mm (2″⅞) Tubing ( 9 ) (i) that enters the Upper Mandrel through the Transport Assembly (B).
The Upper Free Mandrel is provided with a Middle Plug ( 17 ) in its lower end ( FIG. 4 A/B). This Middle Plug seals the Lower Packer Collar ( 32 ) with Middle Plug Seal Ring ( 20 ) ( FIGS. 4 A/B and 6 ) and prevents the fluid regulated by the Upper Formation Injection Valve from passing to the FBHA (D) lower chamber.
The Lower Formation Injection Valve ( 21 ) receives Injection fluid through the Middle Plug ( 17 ), Vertical Passages (C 1 ), ( FIGS. 4B , 5 B and 7 B) regulates the flow that is required for the Lower Formation Injection, and channels it through the Lower Plug ( 22 ) ( FIGS. 4 A/B, 5 A/B, 7 A and 7 B)
The Casing Protective Valve ( 36 ) is located in the lower chamber of the FBHA (D) ( FIG. 6 ). The Casing Protective Valve ( 36 ) allows low pressure fluid passage to go through the Annular Space (e 1 )) to 73.026 (2″⅞) Tubing ( 9 ) (i) Interior (Direct) but prevents the high pressure of injection fluid from passing from the 73.026 mm (2″⅞) Tubing (i) Interior (Direct) to the Annular Space (e 1 )) thus keeping the Casing ( 10 ) totally isolated from injection fluid high pressure and contact. In the upstroke, the low pressure fluid impulses the Free Mandrel Assembly (C) up to remove injection valves.
FIGS. 7 A and B represent two views of the TA (C) assembled together with the FMA (C) inserted in the FBHA (D) in operating position, that is to say, ready to inject selectively in both Formations.
5-(E)—Complementary Assembly—CA:
The CA (E) has been schematically represented in FIG. 22 . It is screwed in the lower part of the FBHA (D). It is composed of specific parts that correspond to the invention equipment design. They are complemented by other standard parts of common use in the Petroleum Industry.
On the outside, the lower part of the FBHA (D) screws in the upper part of On-Off Sealing Connector ( 43 ) which, in its lower part screws in the Upper Packer F.H. ( 44 ) upper end ( 44 ). Both are standard parts of common use in the petroleum industry. The Injector Plug ( 41 ) screws in the Upper Packer F.H. ( 44 ) lower part. This Plug lodges the passage where the Rupture Disc is located ( 42 ). The Injector Plug is another designed-to-measure part of the Free Mandrel System, Protected Casing.
This Rupture Disc ( 42 ) is used to fix the Upper Packer F.H. ( 44 ) and, once it has been fixed, pressure is raised until the Rupture Disc bursts and enables the circuit to perform Upper Formation Injection.
The Telescopic Union Inner Body ( 37 ) is screwed to the FBHA (D) internally and in a concentric pattern. It slides and seals by means of Telescopic Union Seal Rings ( 38 ), the inside of the Telescopic Union Outer Body ( 39 ). The Telescopic Union has two functions:
I) When the Upper Packer F.H. ( 44 ) is fixed, there is a longitudinal displacement that is absorbed by the Telescopic Union.
II) The Telescopic Union allows On-Off Sealing Connector ( 43 ) rotation and longitudinal displacement to remove the FBHA (D) with the tubing string.
The Injection Tube ( 40 ) is screwed in the lower part of the Telescopic Union Outer Body ( 39 ) and in the lower end of the Injector Plug ( 41 ). These three parts, Telescopic Union Outer Body ( 39 ), Injection Tube ( 40 ) and Injector Plug ( 41 ) are designed-to-measure for the Free Mandrel System, Protected Casing.
The 60.325 mm (2″⅜) ( 47 ) Tubing that connect the Injector Plug ( 41 ) with the Lower Packer F.H. ( 46 ) are schematically represented in FIGS. 1 and 22 ). The required quantity of 60.325 mm (2″⅜) ( 47 ) to separate both packers are screwed in the lower part of the Injector Plug ( 41 ) and the Lower Packer F.H. ( 46 ), in its upper part.
Other sections of the 60.325 mm (2″⅜) ( 47 ) Tubing connect the Lower Packer F.H. ( 46 ) with the Shear Out ( 48 ).
The 60.325 mm (2″⅜) ( 47 ) Tubing is screwed in the lower part of the Lower Packer F.H. ( 46 ) and, at the other end, in the upper part of the Shear Out ( 48 ) which is also used to fix the Lower Packer F.H. (46). This circuit is closed by the Shear Out ( 48 ) interior ball that increases pressure in the 60.325 mm (2″⅜) Tubing ( 47 ). Once the Lower Packer F.H ( 46 ) is fixed, pressure continues increasing until the Shear Out ( 48 ) ball is displaced thus enabling the circuit to perform the Lower Formation Injection.
Assembly Sequence for the Invention Equipment Installation:
A) The assembly sequence of the fixed designed-to-measure components of the Free Mandrel System, Protective Casing and standard parts to be installed at the Well Head ( 8 ) is the following:
I) The Shear Out ( 48 ) ( FIGS. 1 and 22 ) is assembled, ball included, in the 60.325 mm (2″⅜) ( 47 ) Tubing. II) The 60.325 mm (2″⅜) ( 47 ) Tubing is screwed with the Lower Packer ( 46 ). ( FIGS. 1 and 22 ) III) The 60.325 mm (2″⅜) Tubing ( 47 ) required for the separation between the Formations to be injected are screwed to the upper end of the Lower Packer. IV) The Injector Plug ( 41 ) ( FIGS. 1 and 22 ) is screwed to the last 60.325 mm (2″⅜) Tubing ( 47 ).
The FBHA (D), factory assembled, is screwed to the CA (E) down to Injector Plug ( 41 ) ( FIGS. 1 and 22 ) including the Rupture Disc with the proper torque so that the Workover Equipment screws then Injector Plug ( 41 ) on the 60.325 mm (2″⅜) Tubing upper end ( 47 ), required by the well to comprise the distance of the Casing Upper Formation Perforations ( 49 )
V) The required quantity of 73.026 mm (2″⅞) Tubing ( 9 ) to reach the surface and to be screwed in the Full Passage Standard Injection Valve is assembled to the FBHA (D) upper end. VI) The Lubricator ( 3 ) will be installed on the 73.026 mm (2″⅞) Tubing Full Passage Standard Injection Valve ( 6 5 ) VII) The Mast ( 4 ) can be left assembled in the Lubricator or will be placed whenever a change of the Free Mandrel Assembly (C) is necessary. The other components of the SA (A) are assembled as indicated in FIG. 2 .
B) Once the fixed components of the Free Mandrel System, Protective Casing are assembled in the well, additional operations are required to get the Free Mandrel System, Protected Casing installation ready to inject in several formations. The descriptions of these operations are the following:
1::1 Verification of the Tubing String Water Tightness
As the complete Tubing String is assembled, water tightness tests are performed using the Full Blind Mandrel Assembly (c). (Not illustrated). The Full Blind Mandrel Assembly (C) is the one with a Blind Upper Injection Valve ( 51 ) in its Upper Mandrel and a Blind Lower Injection Valve ( 52 ) in its Lower Mandrel. Once the 73.026 mm (2″⅞) Tubing ( 9 ) (i) has been assembled up to surface, its water tightness is tested. The Well Head pressure is increased up to 3000 psi; the valve is closed and, for 20 minutes, it is necessary to verify that it keeps constant. Once tubing water tightness testing has been satisfactory, the Full Blind Mandrel Assembly is removed.
1::2 Lower Packer ( 46 ) Fixing
The FMA (C) is lowered with the Blind Upper Injection Valve ( 51 ) screwed in the Middle Plug ( 17 ) upper end, and the fluid pumped by the Workover Equipment is only injected through the Lower Mandrel (Lower Formation Injection Valve ( 21 ) full passage). It pressurizes the Telescopic Union ( 37 and 39 ), the Injection Tube ( 40 ), the 60.325 mm (2″ ⅜) Tubing ( 47 ) and the Shear Out ( 48 ) with ball. (This circuit is closed). As the pressure is slowly increased, the Lower Packer F.H. ( 46 ) is fixed by cutting the pins. This is perceived by the impact of Jaws against the Casing ( 10 ). The proper fixing is verified according to the Packer supplier specifications.
After that, the pressure is increased until the Shear Out ( 48 ) ball enables the Lower Formation Injection. Meanwhile, Formation admission tests are made according to the established program. The Lower Injection Circuit has no restrictions so the above mentioned tests can be performed. Pressures and volumes are also checked. During this operation, the pressure in the circuit to fix the Upper Packer ( 44 ) is null (white space).
1::3 Upper Packer F.H. ( 44 ) Fixing
The FMA (C) is removed with the Blind Upper Injection Valve ( 51 ) which is replaced by Upper Formation Injection Valve ( 18 ) without restriction and the Blind Lower Injection Valve ( 52 ) is screwed in the Middle Plug ( 17 ) lower end. In this case, when the fluid is pumped through the 73.026 mm (2″⅞) Tubing ( 9 ), (i) it is all directed to the Upper Formation Injection Circuit. This is blocked in the Injector Plug ( 41 ) by the Rupture Disc ( 42 ).
The Workover positions the Upper Packer F.H. ( 44 ) over the Casing Upper Formation Perforations ( 49 ) as the packer supplier recommends. When pressure is increased by the Workover Equipment Pump, the required pressure is reached by the rupture of the Upper Packer ( 44 ) pins and the Upper Packer F.H. ( 44 ) is fixed. Its proper position is checked according to what has been recommended by the manufacturer.
Thereon, the pressure continues to be increased until the Rupture Disc bursts and this enables the circuit to inject in the Upper Formation. Admission tests are performed at different pressures according to the defined program. The Upper Injection Circuit has no restrictions so the above mentioned tests can be performed.
1::4 Down Stroke or FMA (C) Insertion
Open Valves ( 6 1 ) and ( 6 5 ). Keep all the other valves closed. The FMA (C) is normally assembled for simultaneous injection with the Middle Plug ( 17 ), the Lower Plug ( 22 ) and corresponding regulated Injection Formation Valves according to the injection program. The Formation Selective Injection begins automatically when the FMA (C) arrives and inserts into the FBHA (D). After assembling the Well Head ( 8 ), the FMA (C) can be installed with the Workover Equipment Pump or with the Plant Injection Fluid. During the down stroke, fluid is injected in both formations without any type of control. In both cases, the fluid pushes the FMA (C) with the Upper and Lower Formation Injection Valves regulated according to the well Injection program until the FMA (C) inserts into the FBHA (D). At this moment, Selective Injection is automatically started in both formations according to what has been programmed. This is usually the last operation performed by the Workover Equipment.
After the first installation has been performed and once the down stroke has begun, the Operator does not need to wait for the FMA (C) to reach and insert into the FBHA (D) as it will be accomplished in 20 or 25 minutes and Selective Injection will begin automatically.
1::5 Upstroke to Recover the FMA (C) on the Surface
If for some reason, one or both injection valves need to be replaced, the upstroke is performed as follows:
Close ( 6 1 ) Valve ( FIG. 2 ) and partially open Valve ( 6 2 ) and completely open Valve ( 6 3 ). This allows Injection Fluid to flow into the Impeller Circulation Pump ( 5 ). This component drives the low pressure fluid through the Annular Space (e 1 ), opens the Casing Protective Valve ( 36 ), goes into the FBHA (D) lower chamber and pushes the FMA (C) to the surface until it is hooked in the Catcher ( 2 ) of the SA (A). After the well is depressurized, the FMA (C) together with the TA (B) is removed by turning round the Catcher ( 2 ) and then, they are hoisted by the Mast ( 4 ).
If the well is not depressurized, the Catcher ( 2 ) cannot be turned round. For safety reasons, it is designed to block itself, even if there is low pressure. In this case, the Operator can leave and perform other activities. When the operator comes back, he will find the FMA (C) in the Catcher ( 2 ) and the Formations already pressurized.
If the operator needs to depressurize the well, he can proceed as follows:
1) Verify that the TA (B) together with the FMA (C) is hooked in the Catcher ( 2 ) 2) Verify all valves are closed 3) Open a purge valve included in the Lubricator. 4) The Lubricator will be at atmosphere pressure so the operator opens the Catcher ( 2 ) and releases the TA (B) together with the FMA (C) with the Mast ( 4 )
At the Well Head, the following components can be replaced:
a) The Injector Valves by removing the used ones and placing new controlled units. b) The FMA (C) with the valves already installed.
In both cases the task will be performed by the operator in a few minutes and the well will start up the selective injection in both formations. Obviously, FMA (C) replacement is faster with the valves already controlled.
1::6 Selective Injection Operation in Both Formations
The Injection Fluid reaches the Surface Assembly (A) along a Pipeline ( 1 ) fed from the Water Plant and enters the System through V1 Standard Valve ( 6 1 ) completely open. Standard Valves ( 6 2 ), ( 6 3 ) and ( 6 4 ), shown in FIG. 2 , must be closed.
The 73.026 mm (2″⅞) Standard Full Passage Injection Valve ( 6 5 ) has to be open to allow the FMA (C) to get through. The injection fluid, which enters the well through Standard Valve ( 6 1 ), fills the Lubricator ( 3 ) ( FIG. 2 ) and the fluid flows through 73.026 (2″⅞) Tubing ( 9 ) (i), goes through the Transport Assembly (TA) (B) and enters in the Free Mandrel Assembly (FMA) C, Upper Mandrel
In the Upper Mandrel, the Upper Formation Injection Valve ( 18 ) ( FIGS. 4 A/B, 5 A/B, 7 A, 7 B, 8 , 9 and 13 ) intakes the injection fluid and regulates the flow that must be injected in the Upper Formation by guiding it through the Middle Plug ( 17 ) Radial Passage ( 19 ). This Upper Formation regulated fluid fills the chamber limited in the upper end by the Outer Jacket Seal Ring ( 16 ) that blocks the Upper Packer Collar ( 25 ). In the lower part, it is limited by Middle Plug Seal Ring ( 20 ) with the Lower Packer Collar ( 32 ). The Upper Formation regulated fluid is compelled to go through the Annular Space (e 6 ) to the FBHA (D) inner side passage (C 2 ) ( FIGS. 7A , 7 B, 8 and 13 ) through which it successively discharges in the Annular Spaces (e 9 ), (e 10 ) and (e 11 ). On the outside, they remain limited with the On-Off Sealing Connector ( 43 ) (interior) and the Upper Packer ( 44 ). On the inside, it is limited by the Telescopic Union (exterior) ( 37 and 39 ) and the Injection Tube ( 40 ). At the lower end, the limit is the Injector Plug. ( 41 ). The Upper Formation regulated fluid goes out through the Rupture Disc passages ( 42 ) ( FIGS. 1 , 8 , 9 and 13 ).
The Upper Formation fluid, which is regulated by the Upper Formation Injection Valve ( 18 ) ( FIG. 4 A/B), is oriented through the Injector Plug ( 41 ) Rupture Disc passage ( 42 ) ( FIGS. 1 , 8 , 9 and 13 ) to the chamber limited by:
I) The Upper Packer F.H. ( 44 ) lower side in the upper end ( FIGS. 1 , 8 , 9 and 13 ) II) The Well Casing ( 10 ) on the outside ( FIGS. 1 , 8 , 9 and 13 ) III) The Telescopic Union ( 37 and 39 ) and the Injector Tube ( 40 ) in the inside ( FIGS. 1 , 8 , 9 and 13 ) IV) The Lower Packer ( 46 ) upper side in the lower end ( FIGS. 1 , 9 and 13 )
The Upper Formation fluid regulated by the Upper Formation Injection Valve ( 18 ) ( FIGS. 1 , 9 and 13 ) is then pushed to inject in the Upper Formation through the Casing Upper Formation Perforations ( 49 ) ( FIGS. 9 and 13 ).
This is the course taken by the regulated fluid to go into the Upper Formation ( FIG. 16 ).
Injection fluid takes up the Upper Formation Injection Valve Annular Space (e 7 ) in the Upper Mandrel. The fluid flows through the Middle Plug ( 17 ) Vertical Passages (C 1 ) ( FIGS. 4B , 5 B, 7 B, 8 , 11 and 13 ). These passages run into a chamber and the injection fluid is taken by the upper part of the Lower Formation Injection Valve ( 21 ) ( FIGS. 4 b , 7 B, 11 and 13 ), which regulates the flow to be injected in the Lower Formation. This Lower Formation regulated fluid to be injected in the Lower Formation is conducted through the Lower Plug ( 22 ) inner part, Seat ( 32 ) inner part, Telescopic Union ( 37 and 39 ) inner part, Injection Tube ( 40 ), Injector Plug inner part ( 41 ), 60.325 mm (2″⅜) Tubing ( 47 ) and Lower Packer ( 46 ) inner part, and finally unloaded through the Shear Out ( 48 ) ( FIGS. 1 , 11 and 13 ) into the chamber limited by:
I) Lower Packer F.H. ( 46 ) lower side in the Upper end ( FIGS. 1 , 11 and 13 )
II) The Well Casing ( 10 ) on the outside (FIGS. 1 , 11 , 13 and 17 )
III) The bottom hole in the lower end
The Lower Formation regulated fluid is introduced through the Casing Lower Formation Perforations ( 50 ) in the above-mentioned Formation ( FIGS. 1 , 11 , 13 and 17 ).
This is the course taken by the Lower Formation regulated fluid to go into the Lower Formation
FIGS. 7A and 7B show two views of the Transport Assembly (TA) (B) screwed in the upper end of the Free Mandrel Assembly (FMA) (C) inserted into the FBHA (D) and injecting selectively in both formations. Both sections show the circuits that drive fluids to every formation. The Plant Fluid is taken to be regulated by the Upper Formation Injection Valve ( 18 ) for the Upper Formation and the Lower Formation Fluid is taken to be regulated by the Lower Formation Injection Valve ( 21 ).
In FIG. 7A , the view of the TA (B) is parallel to the Middle Plug ( 17 ) Injection Passage ( 19 ).
In FIG. 7B , view of the TA (B) is perpendicular to the Middle Plug ( 17 ) Injection Passage ( 19 ). FIG. 4 shows the fluid that has been regulated for the Upper Formation required conditions.
According to the previous detailed explanations and in order to reinforce the invention operational comprehension here follows a summary of the injection fluid operative paths: Injection fluid flows through the component parts of the invention structure in two formations: Upper and Lower Formations in the simplified model adopted as an example to perform one of the possible applications of the invention.
The fluid that comes from the Plant, injection fluid, goes into the Tubing ( 9 ) (i) through the 2″⅞ Standard Full Passage Injection Valve ( 6 5 ). To make this operation possible, the Standard Valve ( 6 1 ) must be open and the ( 6 2 ), ( 6 3 ), and ( 6 4 ) Standard valves shut. The fluid reaches the Free Mandrel Assembly (FMA) (C) ( FIG. 4 A/B) through the Transport Assembly (ta) (B) ( FIG. 3 ). Selective Injection is then performed in the two formations, Upper Formation and Lower Formation In a downward description, it can be observed that two watertight chambers have been formed. They make it possible to direct the fluid to be injected:
1—An upper chamber ( FIGS. 1 , 7 A, 7 B, 8 , 9 , 11 and 13 ) limited by the closure produced between the upper Outer Jacket Seal Ring ( 16 ) that packs in the Upper Packer Collar ( 25 ), and the Plant pressure (injection fluid) contained in the Tubing string up to this location.
2—At the same time, an Upper Mandrel chamber will also be determined. This is contained between said closure produced by the upper Outer Jacket Seal Ring ( 16 ) with the Upper Packer Collar ( 25 ) and the closure produced between the Middle Plug Seal Ring ( 20 ) with the Lower Packer Collar ( 32 ). This chamber contains the fluid to be injected in the Upper Formation with pressure regulated by Upper Formation Injection Valve ( 18 ) and channeled through the Middle Plug ( 17 ) Radial Passage ( 19 ). Both the Plant pressure, injection fluid, in the Annular Space (e 7 ) and in the (C 1 ) Vertical Passage and the Injection Pressure in the Upper formation coexist in this chamber. ( FIGS. 1 , 4 A/B, 5 A/B, 7 A, 7 B, 8 , 9 , and 13 ).
The Free Mandrel Assembly (FMA) (C) ( FIG. 4 A/B) lodges the Upper Formation Injection Valve ( 18 ) that regulates the Upper Formation Injection flow pressure and is screwed in the Middle Plug ( 17 ) in its lower end The circuit that drives this already regulated fluid is driven ( FIGS. 1 , 9 and 13 ) through the Middle Plug ( 17 ) Radial Passage ( 19 ), Annular Space (e 6 ), FBHA (D) Vertical Passages (C 2 ) to Annular Spaces (e 9 ), (e 10 ) and (e 11 ), Injector Plug ( 41 ) through Rupture Disc ( 42 ) passage to Annular Space limited by:
I The Upper Packer F.H. ( 44 ) lower end ( FIGS. 9 and 13 )
II The Lower Packer F.H. ( 46 ) upper end ( FIGS. 9 and 13 )
III On the outside by the Casing ( 10 ) ( FIGS. 9 and 13 )
The fluid to be injected goes through the Casing Upper Formation Perforations ( 49 ) and enters the Upper Formation. ( FIGS. 1 , 9 , 13 , 16 ).
3—The Lower chamber ( FIGS. 11 and 13 ) is determined by the closure of the Lower Packer Collar ( 32 ) and Middle Plug Seal Ring ( 20 ), Lower Plug ( 22 ) Lower Plug Seal Ring ( 23 ) with Seat ( 34 ). The Lower Formation Injection Valve ( 21 ) admits the Plant Fluid (injection fluid) by its upper end and regulates the pressure to be injected in the Lower Formation.
Between the Upper Mandrel Jacket ( 15 ) and the outside of the Upper Formation Injection Valve ( 18 ), in the Annular Space (e 7 ), the Plant, injection fluid feeds the Lower Formation Injection Valve ( 21 ) through the Middle Plug ( 17 ) Vertical Passages (C 1 ). Lower Formation Injection Valve ( 21 ) transforms the pressure and the volume as requested for Lower Formation Injection.
FIGS. 11 and 13 show in the FBHA (D) the circuit that drives Lower Formation Injection regulated flow to be injected in the Lower Formation. It must go through the Lower Plug ( 22 ), Seat ( 34 ), Telescopic Union ( 37 and 39 ), Injector Tube ( 40 ) through Injector Plug ( 41 ) central passage ( FIGS. 11 and 13 ). In the Injector Plug ( 41 ) lower end, the 60.325 mm (2″ ⅜) Tubing ( 47 ) strings are screwed. These tubing connect the Injector Plug ( 41 ) with the Lower Packer F.H. ( 46 ). The 60.325 mm (2″⅜) Tubing ( 47 ) and the Shear Out ( 48 ) are screwed to the Lower Packer F.H. ( 46 ) lower end. The Lower Formation Injection fluid flows through the Casing Lower Formation Perforations ( 50 ) ( FIGS. 1 , 11 13 and 17 ).
4—The Free Mandrel Assembly Recovery Chamber ( FIG. 18 ) is the chamber limited by the FBHA (D) inner diameter and the outside of the Lower Formation Injection Valve ( 21 ) Jacket, Annular Space (e 8 ) ( FIG. 18 ). The chamber is closed by the Casing Protective Valve ( 36 ). The fluid that fills the said chamber is at the pressure of the column that contains the Annular Space (e 1 )
To enable the Free Mandrel Assembly (C) upstroke, low pressure fluid is injected through the Annular Space (e 1 )) and 73.026 mm (2″⅞) Tubing 9 (i) (Direct) is depressurized by opening Standard Valve ( 6 3 ). The Casing Protective Valve ( 36 ) opens and lets the fluid in. This fluid pushes up the Free Mandrel Assembly (C) until it is caught in the Catcher ( 2 ).
To remove the Free Mandrel Assembly (FMA) (C) together with the Transport Assembly (TA) (B), it is only necessary to operate the Surface Valves in the following way:
1—Close Standard Valve ( 6 1 ) 2—Open Standard Valve ( 6 2 ) 3—Open Standard Valve ( 6 3 ) 4—Keep Standard Valve ( 6 4 ) closed.
With this configuration, the Plant Water enters through the Impeller Circulation Pump ( 5 ) to the Annular Space (e 1 ). This opens the Casing Protective Valves ( 36 ) allowing the fluid to enter and disconnect the Free Mandrel Assembly (FMA) (C) and the Transport Assembly (TA) (B) from the Fix Bottom Hole Assembly (FBHA) (D). From this moment on, the fluid produces the upward push that makes the Rubber Cups ( 13 ) expand and closes the Transport Assembly Valve ( 12 ) located in the Fishing Neck ( 11 ). The upward speed is proportional to the volume of the fluid injected in the Annular Space (e 1 ). The upstroke ends with the Free Mandrel Assembly (FMA) (C) and the Transport Assembly (TA) (B) hooked together in the Catcher ( 2 ) located in the Lubricator ( 3 ).
To remove the Free Mandrel Assembly (FMA) (C) together with the Transport Assembly (TA) (B) from the well:
1) Turn Catcher ( 2 ) eye-bolt until it adopts the “Catching” position. In this position, the Catcher cage retains the assemblies when they make an impact in their upstroke. 2) Close all Surface Assembly Valves ( 6 1 , 6 2 , 6 3 , 6 4 ). 3) Wait until 73.026 mm (2″⅞) Tubing ( 9 ) (i) (Direct) pressure reaches zero. 4) Turn Catcher ( 2 ) 90° to remove Catcher from the Lubricator ( 3 ). 5) Raise the Free Mandrel Assembly (FMA) (C) and the Transport Assembly (TA) (B) with the Mast ( 4 ). 6) Lower the assemblies and unhook them for inspection or replacement.
To install the Free Mandrel Assembly (FMA) (C) and the Transport Assembly (B), the reverse process has to be performed:
1) All surface Valves must be shut. ( 6 1 to 6 5 ). 2) The two assemblies are hooked together, installed in the hoisting system and then introduced in the Lubricator ( 3 ). 3) The Catcher ( 2 ) is turned 90° to close the Lubricator ( 3 ). 4) Open 73.026 (2″⅞) Standard Full Passage Injection Valve ( 6 1 ). 5) The Catcher eye-bolt is turned to the releasing position so that the Free Mandrel Assembly (FMA) (C) and the Transport Assembly (TA) (B) unhook from the Catcher ( 2 ) and start the downward movement. 6) Valve ( 6 1 ) is opened so that the fluid push makes the assemblies descend at a proper speed, according to the injected flow. A speed of about 70 to 85 meters/minute is considered reasonable for the down stroke. Once the two assemblies, Free Mandrel Assembly (FMA) (C) and Transport Assembly (TA) (B) are engaged in the Fixed Bottom Hole Assembly (FBHA) (D), the pressure begins to rise until it reaches the Pipeline pressure. In this moment, the system begins automatically to inject selectively in the two formations.
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The Free Mandrel System, Protected Casing is to be applied in the petroleum industry for selective injection of fluids, liquids or gases, in different formations while keeping the casing isolated from fluid pressure. As it is hydraulically driven by the injection fluid, an operator can handle the provided surface valves. The system includes five assemblies: Surface, Transport, Free Mandrel, Fixed Bottom Hole and Complementary. The Free Mandrel Assembly is the dynamic main device that carries all the Injection valves together, one for each formation, from the Fixed Bottom Hole to the surface in 30′ and vice versa. As this operation is performed many times in the well lifetime, it allows a cumulative time and money saving. Workover equipment is only used for installing the system and for fixing the required packers. Formation Pressure is kept at any time when the system is either operated, set up, or pulled up.
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BRIEF DESCRIPTION OF THE INVENTION
Field of the Invention
This invention relates to methods for measuring, at ground surface, the direction of fracture propagation induced in a formation around a well bore.
Setting of the Invention
Massive stimulation of natural gas wells by hydraulic and other fracturing methods holds considerable promise for recovery of additional gas from such wells located in thick, low permeability sandstone reservoirs, and the like. To achieve economic and efficient recovery from such well fracturing, several important questions need to be answered, such as: (1) What is the azimuthal direction of growth of hydraulic fractures in the field? 2) Is the direction of fracture propagation consistent over large areas in relationship to the geologic setting of the region? (3) What is the length and height of each such fracture?
This invention proposes to answer the first question directly by providing a method for measuring, at ground surface, the redistribution of compressional forces or stresses in rock formations around a well bore as the rock at or above the pay zone thereof is being hydraulically fractured. Practicing the method of the invention provides for a direct and unambiguous measurement of the fracture propagation by sensing stress changes at or near the ground surface above the gas reservoir, which stress changes can be used as data for mathematically calculating fracture direction. Obviously, by locating the azimuthal direction of hydraulic fractures from numerous well bores within a region, it should be possible to answer question (2) as to whether the fracture propagation is consistent over large areas so as to aid in avoiding future overlapping fractures or like unnecessary fracturing.
Prior Art
Numerous methods have heretofore been developed to affect fracturing of geothermal and gas wells for recovering additional water and hydrocarbons from thick low permeability reservoirs. A sampling of such prior art includes: U.S. Pat. No. 2,813,583 and 2,914,304, which patents involve use of air, under pressure, to fracture such a well bore; and U.S. Pat. No. 3,050,119, 3,587,743, 3,020,954, 3,630,279 and 3,659,652, which patents involve packing off such a well bore and introducing a pressure medium, either liquid, air or explosive, to produce, from an expansion of the medium, fractures that extend outwardly and downwardly from within the well bore. While all these patents involve methods for producing such fracturing, no patent, or disclosure to our knowledge, involves a method like that of the present invention for plotting the direction of such fractures. Stress meters like those useful for practicing the method of the present invention and their use for measuring earth stress changes are not new, but such measuring equipment and techniques have recently become better known for their use in predicting earthquakes. One such prior disclosure, relating to earthquake prediction, was contained in a report authored by H. S. Swolfs, C. E. Brechtel, H. R. Pratt, and W. F. Brace in an article entitled, "Stress Monitoring Systems for Earthquake Predictions", Terra Tek Report TR75-10, 1975, pp. 16. However, use of such stress measuring techniques around a well bore, at a time of fracture thereof, for determining the direction of fractures propagated in that well bore has not, to our knowledge, heretofore been attempted. Therefore, within the knowledge of the inventors there has not heretofore been known a method like that of the present invention involving monitoring surface stress changes, at a time when the area surrounding a well bore in hydraulically fractured for determining the direction of such fracturing.
SUMMARY OF THE INVENTION
It is the principal object of the present invention to provide a method for determining fracture direction, in a rock formation containing a well bore, when the well bore is fractured, involving sensing ground stress changes at the surface at the time of the fracture providing stress change measurements useful for determining mathematically the direction of such fracture.
Another object is to provide, by locating stress meters used to record surface stress changes at appropriate distances from the well bore, accurate stress change data, sufficient to enable the mathematical calculation, from those stress changes, an accurate plottage of the direction of a fracture in the material surrounding a well bore.
Still another object, is to provide for the optimum placement of stress meters preferably utilized in practicing the method of the present invention, around a well bore so as to gather sufficient stress change data for locating mathematically the direction of fractures induced in the formation surrounding that well bore.
The steps involved in practicing the method for the present invention include the selection of a well bore in a natural gas producing area, or the like, located in a rock formation appropriate for hydraulic fracturing, or fracturing by like methods. Prior to effecting such fracturing, groupings of stress meters consisting of 120° rosettes of three sensing devices are spaced around the wall bore. Such stress meters should be capable of accurately sensing small or slight stress changes that are transmitted through the ground.
Each such grouping of sensing devices makes up a single stress meter that is preferably installed beneath ground surface an appropriate distance from a well bore so as to provide for a faithful transmission of stress changes from fracturing the material around the well bore through the ground to the individual sensing devices. Such stress meters appropriately spaced around the well bore, should accurately sense stress changes no matter the fracture direction, with results measured by one stress meter useful for comparison with data from another. Each sensing device of a preferred stress meter individually measures stress changes in a plane normal thereto, with three sensing devices per stress meter, to provide data that can be reduced mathematically to horizontal stress component measurements for location of the direction of the well bore fracture.
Stress meters useful for practicing the method of the present invention, should be, in addition to being sufficiently sensitive as mentioned hereinabove, insensitive to temperature changes and other enviromental conditions that make difficult the precise measurements of earth strain, tilt, and other stress related variables. Practicing the method of the present invention, using such stress meters, makes unnecessary the calculation or consideration of the particular types of materials and physical properties of the material wherein the well bore to be fractured is located.
Other objects and steps of the present invention will be further elaborated on herein and will become more apparent from the following detailed description, taken together with the accompanied drawings.
THE DRAWINGS
FIG. 1, is a finite-element model of a well bore formed in a strata having both fixed and free boundaries;
FIG. 2, a finite-element calculation of horizontal surface stress changes as a function of horizontal distance from the well bore of FIG. 1, showing different fracture pressures as parameters that could occur during fracturing thereof;
FIG. 3, a top plan view looking down at a well bore having three groupings of stress meters preferrably utilized in practicing the method of the invention located therearound;
FIG. 4, a pottage of axial stresses sensed by one of the stress meters of FIG. 3;
FIG. 5, a graph of a plane strain stress distribution for both model and theoretical fractures, the graph relating stress distribution to horizontal distance from the well bore, and;
FIG. 6, a profile perspective view of a preferred sensing device for inclusion as part of a preferred stress meter, the sensing device shown installed below ground surface and is included to illustrate the working principles thereof when used in practicing the method of the present invention.
DETAILED DESCRIPTION
Referring now to the drawings:
In FIG. 1, is shown as a sectional underground view, a well bore 10 that should be taken as having been formed in a low permeability, sandstone reservoir or the like, wherein a hydrocarbon or hot water source is found. Assuming that the well bore 10 depicts a single well within a field of wells sunk into such rock formation, it is desired to fracture, preferably by hydraulic methods, that well bore at approximately a depth of 2400 meters so as to increase the flow into said well bore. The object of the practice of the method of the present invention, therefore, is to locate the direction of a fracture induced in the formation around such well bore by taking surface stress change measurements during the time well bore 10 is fractured. Such measurement thereafter being useful to mathematically plot such fracture direction within a field so as to avoid overlapping fracturing, and like problems.
Practicing the method of the present invention will be described herein in relation to one well bore 10 only but should be taken as being the same method as would be practiced on all well bores within a field where fracturing is to be undertaken.
Practicing the method of the invention assumes a plurality of producing natural gas wells, or like wells, all located in a low permeability sandstone formation, or the like, wherein it is determined additional production can be obtained by fracturing the formation materials around individual well bore. Well bore 10 of FIG. 1 represents one such well bore selected to be subjected to fracturing of the formation there surrounding. In preparation for such fracturing the well bore 10 is packed off at 10a and 11, as shown in FIG. 1, above and below the preferred depth. The packing should, of course, be understood to be strong enough to hold fast at pressures below the fracture opening pressure for the formation. A number of commonly known packing materials and techniques could be employed to provide such packing to include RTTS Packer, commercially available from Halliburton Company, Duncan, Oklahoma, or a like packing manufacturing company. Of course, if the desired fracture point of the formation is determined to be proximate to the well bore 10 bottom, then packing 11 could be dispensed with.
Prior to installation of packing 10a , a high pressure hose 22, FIG. 1, is installed through packing 10a, which hose 22 is connected above the gound surface to pump 23, that is shown in schematic in FIG. 1. To effect a desired well bore 10 fracturing, a liquid under pressure is preferably pumped from pump 23, through hose 22, and into cavity 24, fracturing the well bore at 25, as shown in FIG. 1, to a height of 150 meters.
Recognizing that the pumping of a liquid under pressure into cavity 24 will cause a fracture 25, it is desirable to know the direction of that fracture which fracture direction is the object of the practice of the method of the present invention. Therefore, prior to introduction of the fluid under pressure into cavity 24, preferred stress meters 16, that consist individually of three sensing devices 17 arranged in a 120° rosette pattern, as shown in FIG. 3, are arranged around the well bore 10. While there may exist other stress meters sufficiently sensitive to record such surface stress changes from fracturing of material surrounding well bore 10, the present disclosure will be confined to a description of stress meter 16 only which will be described in detail later herein, though it should be understood that, other sensing devices which would be sufficiently sensitive to record such surface stress changes could be substituted for stress meters 16 without departing from the scope of the present disclosure.
The individual sensing device 17, shown in FIG. 6, will be described later herein relating to its construction and functioning. Assuming stress meters 16 are arranged around well bore 10, as is shown in FIG. 3 when the formation around the well bore is fractured the meters will record present surface stress changes, with the individual stress meters 16 each being capable of sensing and recording such changes to a resolution to 0.1 millibar of pressure. The stress change measurements recorded by the individual stress meters can then be resolved, as to magnitude and direction, into principal horizontal components of stress change at each stress meter location. While two such stress meters may be sufficient to provide adequate stress change measurements useful to calculate the direction of a fracture, the use of three such meters provides a redundancy of measurement data to provide a more accurate fracture direction calculation. Discussion of the actual plottage of such fracture direction, from data produced by individual stress meters 16, will be outlined later herein with respect to a model calculation, in reference to FIG. 4.
Measurement of such surface stress changes, in addition to providing data useful for plotting well bore fractures can, by comparison with measurements taken during other well bore fractures, be used to calculate the overall tectonic or structural setting of the region. By such analysis, optimum future well spacing can be calculated so as to maximize yield efficiency in the development of the field.
To further describe the method of the present invention, in relation to a theoretical model, it should be assumed that: the fracture 25 in well bore 10, is some 152 meters in height; occurs at a depth of 2400 meters; is preferably induced by hydraulic methods; and occurs in a formation consisting of three layers of material. A top layer 12 thereof, that has a modulus of 34 k-bars; a next lower layer 13, that has a modulus of 69 k-bars; and a bottom layer 14, that has a modulus of 345 k-bars. The three layers 12, 13, and 14, are intended to simulate the effect of a soft overlying layer, an intermediate layer, and a high modulus layer, wherein a pay zone is located, which formation is typically of one found in a gas bearing formation. The material is further assumed to have a fixed boundary, shown in FIG. 1, at 15, and a free boundary 15a that exists on a vertical plane parallel to and at a distance of 2,800 meters from the plane of the well bore 10. FIG. 1 therefore, shows a finite element idealization of a well bore wherein a hydraulic fracture has been induced, with the graph of FIG. 2 showing the result of calculations for both free and fixed boundary conditions for various pressure conditions experienced on the fracture face. The horizontal stress component, thereof is plotted along the ground surface as a function of the horizontal distance normal to the plane of the fracture. The solid and broken line plots, shown in the graph of FIG. 2, relate to the fixed and free boundary material conditions, the lines showing that an ideal positioning of the sensing meters 16, would be at 1500 meters from the well bore 10, but that positioning should not be less than 400 or greater than 2800 meters from the well bore. As per the vertical component of the graph of FIG. 2, the best distance for efficient transmital of stress changes through the ground is at 1500 meters and that between 400 to 2800 meters from the well bore is acceptable for stress meter positioning.
Shown in the graph of FIG. 2, the fixed boundary material passes approximately 250 millibars (0.35 psi) and the free boundary passing approximately 350 millibars (0.50 psi) at a distance of 1500 meters from well bore 10, which pressure transmission occurs at a face pressure of 1000 psi. A face pressure of 1000 psi has been found in practice to be approximately that pressure produced during hydrofracturing of a material similar to the material assumed herein to contain well bore 10.
The individual preferred sensing device 17, as will be described in detail later herein, is capable of sensing pressure changes of an order of magnitude of as low as 1 millibar, and, therefore, surface stress changes of 300 millibars are some 300 times greater than the maximum pressures that are capable of being sensed by the individual sensing device 17. Likewise, for the free boundary condition, whereat pressures of approximately 500 millibars are calculated to be present the sensing device 17 is, of course, also effective in sensing stress changes.
In FIG. 4 is shown a mathematical model for checking the above recited calculated results for the interior of the model. In that model: 2 C equals fracture height; θ equals the angle between r and x; x equals the horizontal axis that is normal to the fracture; y equals the vertical axis; r equals the radius vector indicating direction and distance from the point of the fracture; and σ x and σ y equal, respectively, horizontal and vertical stresses at the distance r from the fracture. FIG. 4 represents a theoretical result for a fracture produced in an infinite medium that is subjected to internal pressure wherein a fracture, shown as an elipse, is normal to the x,y, and r planes. Using the model a solution for a stress distribution at some point away from the crack center is given by the formula: ##EQU1## where: r= √x 2 + y 2
θ= tan -1 (y/x)
r 1 =√x 2 + (y-c) 2
r 2 =√x 2 + (y+c) 2
θ 1 = tan -1 [(y-c)/x]
θ 2 = tan -1 [(y+c)/x]
FIG. 5. shows a plattage using the above formula of curve A, for an exact solution in infinite media, with curves B and C, being plottages of finite elements (fixed and free boundaries respectively). The graph illustrates a good agreement between the theoretical and calculated solutions, with differences therebetween being due to the multilayered model and the finite boundary condition assumed in the finite element calculation. From FIG. 5 an important observation can be made that the fixed boundary solution is very close to the exact solution at distances from 1600 meters to 2800 meters from the well bore. This result suggests that the plot of the fixed boundary solution for surface stress changes, shown in FIG. 2, is probably the more correct.
As per the above, stress changes on the order of from 0.3 to 0.6 psi can be expected to occur at the surface of the ground as a result of a hydraulic fracturing of the material around well bore 10 at a depth of approximately 2400 meters, as has been earlier herein described with respect to FIGS. 1 and 2. To assure a faithful transfer of stress changes reaching the ground surface from the underlining rock structure, the individual sensing devices 17 of each stress meter 16 should be placed in the soil at a depth of not more than 4 meters below the surface. Some compaction should be made but not so much as to damage the device.
FIG. 6, shows a pictorial representation of an individual sensing device 17, shown to resemble a bladder that should be taken as being of one of three such sensing devices making up stress meter 16. As outlined earlier herein, three such stress meters are preferrably arranged, as per FIG. 3 around the well bore 10, though, as was mentioned earlier herein, two such stress meters 16, spaced appropriately around the well bore would be sufficient to provide sufficient data to calculate fracture direction.
The individual sensing device 17, as shown in FIG. 6, preferably consists of an outer shell 18 and contains a pressurized working fluid. A pressure gauge 19 is connected through a tube 20 to sense changes in fluid pressure within the interior of the sensing device. After installation of the sensing device 17 in the ground, which installation is shown as broken lines in FIG. 6, any stress changes transmitted through the ground to the sensing device will cause a movement of the working fluid therein, effecting, thereby, a change in pressure that will be detected on pressure gauge 19. Such changes in pressure, of course, occurs at the time the material around well bore 10 is fractured, with such stress changes being sensed in a direction perpendicular to the plane of the sensing device as, indicated by arrow D, which arrow extends normal to front and rear walls 18a the outer shell 18 of sensing device 17. Ideally, the slenderness ratio of the cavity of the sensing device 17 should be so small, in comparison to its length, that any pressure changes sensed in a plane parallel to the planes of the outer shell front and rear walls 18a of the sensing device outer shell 18 can be ignored. Assuming that good transmission of stress changes is present perpendicular to the planes of the outer shell front and rear walls 18a, and that the earth around the sensing device is elastic and isotropic, a faithful transmission of stress changes into the described device should occur.
As stated hereinbefore, the preferred slenderness ratio of the outer shell 18, i.e. the shell width or length divided by the thickness, should be much greater than unity. Therefore, because the volume of fluid within the outer shell 18 is a function of pressure and temperature, and as the temperature of the fluid in the sensing device 17 can be assumed to be constant and therefore, the fluid volume is a function of the fluid pressure. Changes in the fluid volume in the shell equate, therefore, to pressure changes in the horizontal and vertical axes of the sensing device, which axes are in the plane of the outer shell, and pressure changes in the other horizontal axis, which axis is normal to the outer shell front and rear walls 18a. However, as the fluid modulus is relatively small, due to the large slenderness ratio, the pressure changes in the plane of the outer shell can be ignored as they are, in comparison, very small, and, therefore, only those pressure changes in the horizontal axis normal to the outer shell as indicated by arrow D in FIG. 6, which horizontal axis is the same as axis x shown in FIG. 4, will closely equal stress changes transmitted to the sensing device 17 through the ground.
Referring to FIG. 3, and to the graph of FIG. 2, the preferred individual stress meter 16 for practicing the method of the present invention, as has been mentioned earlier herein, consists of the three sensing devices 17 that are positioned in a 120° rosette pattern. While the described stress meter 16 is preferred for practicing the method of the invention, another stress meter capable of sensing pressure changes of a magnitude similar to those produced during fracturing of material surrounding a well bore, could, of course, be used. Such stress meter as per the curves of FIG. 2, for both free and fixed boundary conditions optimally should be located at approximately a distance of some 1500 meters from the well bore 10 for best sensing of stress changes transmitted through the ground. However, depending upon the sensitivity of such sensing meter used in practicing the method of the invention, such sensing meter could be located any convenient distance between 400 and 2800 meters from the well bore to still produce sufficient stress change data for locating fracture direction.
While the above described method is that preferred in practicing the invention, it is to be understood that modifications of the described steps or substitution of other apparatus could be made for those described without departing from the scope or spirit of the invention.
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This is an invention in a method for locating the azimuthal direction of fractures induced into an underground formation adjacent to a well bore. Practicing the method of the invention involves measurement of stresses created at or near ground surface by such fracture propagation, utilizing pressure sensitive devices making up stress meters which reflect those stress changes on standard pressure gauges. Such stress meters are preferably each placed at an optimum distance from a well bore and spaced therearound, and, when a fracture is induced in the formation around the well bore, preferably by hydraulic means, said stress meters measure surface stress changes as horizontal pressure changes, which pressure change measurements can then be used to mathematically determine the direction of the fracture.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF INVENTION
This invention relates to a portable multi-station sink unit that includes a rigid outer water tank for storing fresh water and a flexible inner water tank mounted within the rigid outer tank for storing used water.
Conventional portable stand-alone sink units are typically placed at outdoor sights, such as outdoor concerts, constructions sights and public events for hygiene purposes. Such units typically have two or more water faucets and sinks, thereby permitting people to wash their hands at locations where such wash facilities are usually unavailable.
Typically, these sink units include self contained water tanks, as an external water supply is usually not readily available. Such water tanks must include the equivalent of two water tanks; one for storing clean, unused water, and one for storing water dispensed from the faucet and into the sink, otherwise known as "grey" water. Once a typical portable sink unit is placed in its desired location, water may be supplied to the first water tank through water delivery means such as a water tanker truck. Grey water may be removed from the second tank by means such as a vacuum tanker truck.
Several different types of designs exist in conventional portable sink units. One typical design includes a fiberglass outer housing defining both a rigid inner tank and a rigid outer tank and having two wash basins forming the lid of the structure. However, the fiberglass material makes such units relatively heavy. Also, due to the sometimes extreme loads placed on the structure and given the relatively fragile nature of fiberglass, such fiberglass structures are susceptible to damage. Further, typical tank designs offer limited access to the inner tank that houses the clean water, thus making cleaning of the inner tank difficult and sometimes impossible. Clean water dispensed into such an uncleaned tank often becomes contaminated. In addition, because both the inner and outer tanks are rigid, the maximum usable volume for each of the tanks is 50% of the total tank volume, as an equal amount of volume must be reserved for both the clean and the grey water.
In a second known configuration, a free standing sink unit includes a rotationally molded tank separated in half by a rigid partition, thereby keeping the clean water separate from the grey water. However, such a tank typically includes a water capacity for both the clean and the grey water of only approximately 35 U.S. gallons, as the rigid partition limits maximum clean water and grey water tank volume.
In a third type of stand-alone sink unit, a rotationally molded external tank is provided to store clean water. A bin liner bag is located within the external tank and fills with dispensed grey water as grey water is dispensed from the sink unit into the bag. However, such liner bags are susceptible to failure due to the hydraulic pressure placed on the bags as the bags are filled with grey water. Additionally, vacuum tanker suction hoses, when inserted into the bin liner bag to remove the grey water from the bag, have a tendency to either tear the liner bags or suck the liner bags into the tanker along with the grey water, thereby adding expense both to the unit and to the process of removing the grey water, as bags must be frequently replaced.
Alternatively, in the previously-described sink unit water tank designs, a diaphragm is sometimes placed across the rotationally molded tank from the front of the tank to the back of the tank, thereby partitioning the tank into a clean water side and a grey water side. Such a design allows a maximum amount of clean water to be dispensed into the tank, as the diaphragm is flexible and does not limit the clean water capacity to just one half of the tank, as do aforementioned prior rigid tank partitions. However, diaphragms, as with liner bags, are susceptible to failure caused by hydraulic pressure, as the diaphragm has a tendency to break loose from its retainers as water volume is increased. Also, vacuum tanker hoses also have a tendency to puncture the diaphragm, thereby causing mixing of the grey water with the fresh water.
Thus, it would be desirable to provide a portable stand-alone sink unit including both a clean water storage tank and a grey water storage tank, with the grey water storage tank being designed so as to exhibit a low failure rate and to effectively maintain separation of grey water from fresh water. It would also be desirable to provide a portable stand-alone sink unit that exhibits minimal interference with vacuum suction hoses used for removing grey water from the tank, thereby minimizing grey water disposal problems.
SUMMARY OF INVENTION
This invention contemplates a portable stand alone sink unit constructed of lightweight molded plastic and including a rigid outer water tank and a flexible inner water tank mounted within the rigid outer tank. The flexible inner tank expands and contracts in volume in response to the amount of grey water dispensed therein. Therefore, the water tanks of the present invention allow a maximum amount of fresh water to be held by the rigid outer tank. Further, the water tanks of the present invention provide an inner water tank that effectively stores grey water separately from fresh water and minimizes the chance of inner tank failure and thus mixing of grey water with fresh water. Minimal hydraulic pressure is exerted on the flexible inner tank, as the bottom of the flexible inner tank is immersed in the fresh water stored in the rigid outer tank. Further, the flexible inner tank is rigid enough so as to minimize interference with grey water removal upon removal of grey water from the inner tank through a tanker suction hose or other similar grey water disposal means.
In particular, the present invention provides a portable wash station, comprising an outer water tank, a flexible inner water tank secured within the outer tank, and a sink basin affixed atop the outer tank and including at least one sink, one water faucet for dispensing water from the outer tank, and one drain for draining water from the sink into the flexible inner tank. The flexible inner tank has an associated volume that expands as the water is dispensed from the outer tank and into the flexible inner tank, and that contracts as the water is removed therefrom. The flexible inner tank is immersed in the water held by the outer tank as it becomes filled to reduce hydraulic pressure thereon.
An object of this invention is to provide a portable stand alone sink unit having its own fresh water and grey water storage system.
A further object of this invention is to provide a portable stand alone sink unit composed primarily of a lightweight high or low density plastic, thereby making the sink unit lightweight, durable and easily transportable.
A further object of this invention is to provide a portable stand alone sink unit having a rigid outer tank and a flexible inner tank that effectively maintains separation of grey water from fresh water and that is less susceptible to failure when compared to conventional grey water holding tanks.
Still another object of this invention is to provide a portable stand alone sink unit that maximizes fresh water storage volume through use of a flexible inner grey water storage tank that expands and contracts in direct relation to the volume of grey water dispensed therein.
An additional object of this invention is to provide a portable free standing sink unit having a fresh water tank and a grey water tank, each of which is easily accessible for filling, draining, maintenance and cleaning purposes.
These and other objects and advantages of this invention will become apparent upon reading the following description, of which the attached drawings form a part.
DESCRIPTION OF DRAWINGS
FIG. 1 is a perspective view of a portable stand-alone sink unit according to a preferred embodiment of the present invention;
FIG. 2 is an exploded view of the sink unit shown in FIG. 1;
FIG. 3 is a front elevational view of a portable stand-alone sink unit according to a second embodiment of the present invention;
FIG. 4 is a side cross-sectional view of the outer and inner tanks of the sink unit of the present invention, showing the outer tank being completely filled and the inner tank being completely empty;
FIG. 5 is a cross-sectional view of the tanks as shown in FIG. 3, with both the outer and inner tanks each partially being filled;
FIG. 6 is the cross-sectional view of FIG. 3, showing a near-empty outer tank and an inner tank being almost completely filled; and
FIG. 7 is a perspective view of a portable stand-alone sink unit according to a third embodiment of the present invention.
DETAILED DESCRIPTION
Referring to the drawings, in which like numerals reference like parts, a portable stand-alone sink unit according to a preferred embodiment of the present invention is shown generally at 10. The sink unit of the present invention is a single integral unit that is movable and easily transportable from one location to another. The outer components of the sink unit are composed of high or low density rotationally molded plastic, thus making the sink unit extremely durable and capable of withstanding extreme environmental conditions and substantial amounts of abuse. As will be described in more detail below, the sink unit 10 includes a dual tank water storage system that maximizes the amount of fresh water that can be stored within the unit and minimizes the probably of contaminating the fresh water with grey water, and also facilitates ease of filling, drainage and cleaning of the dual tank system.
Referring to both FIGS. 1 and 2, the sink unit 10 includes a rigid outer tank 12, a flexible inner tank 14 located within the outer tank 12, and a sink basin 16 form fitted over both the outer and inner tanks 12, 14. The structure and function of each of these components will now be described in more detail.
Referring to FIG. 2, the rigid outer tank 12 is formed from linear low, or high, density thermoplastic material such as polyethylene and is rotationally molded into a shape which conforms to the shape of the sink basin 16. The body of the tank may be formed within indents, protrusions or other functional or ornamental shapes as desired. The outer tank 12 defines an interior liquid retaining cavity 18 having an associated volume, which is preferably about 70 U.S. gallons. Additionally, two recesses 20a, 20b are formed in the front of the tank to allow foot access to whale foot pumps 22a, 22b such as Whale foot pumps manufactured by Munster Simms Engineering Limited of Bangor, Northern Ireland, which are operatively mounted on a skid panel 24 formed from recycled plastic and secured to the underside of the tank 12 by rivets or any other like fasteners.
A fill port 26 is located near the upper portion of the outer tank 12 and is capped by a fill plug 28. Upon removal of the fill plug 28, a water hose may be inserted into the fill port to fill the inner cavity 18 of the tank with fresh water. Also, a drain port 30 is located near the bottom of the outer tank 12 and is capped by a threaded drain plug 32. Upon removal of the threaded drain plug 32, fresh water may be drained from the tank to reduce the overall weight of the sink unit for transportation purposes. Upon removal of the fill plug 28, the fill port may also be used to determine the volume of fresh water remaining in the outer tank 12.
The outer tank 12 additionally includes a shoulder 40 recessed from the outer periphery of the tank around the upper edge of the tank. The shoulder 40 includes several studs 42 that are used to secure the flexible inner tank 14 to the outer tank 12 in a manner described in detail below.
Still referring to FIG. 2, the flexible inner tank 14 is formed from material that may both expand and contract, while at the same time being durable enough to withstand substantial hydraulic pressure created as it is filled with water from the outer tank 12. Preferably, the inner tank 14 is formed from reinforced non-stretch plastic sheeting, which is a material typically used in the manufacture of pool liners. Such a material exhibits a high degree of durability, but yet is resilient enough so as not to be susceptible to being sucked up into a grey water removal hose (FIG. 6) when such a hose is inserted into the inner tank to remove grey water, unlike presently used diaphragms and soft plastic liners. The inner tank includes a liquid retaining inner cavity 44 that is capable of expanding and contracting in response to the volume of water dispensed therein. The inner tank also has an integral outer band 46 that defines the outer circumference of the flexible inner tank. The outer band is substantially thicker than the portion of the tank defining the cavity 44. The band 46 includes a plurality of snap buttons 48 that cooperate with the studs 42 on the outer tank shoulder 40 to maintain the inner tank 14 in fixed relation within the outer tank cavity 18. The inner tank bottom also includes a double-lined layer 47 to prevent the bag from being sucked up by a grey water disposal vacuum base during removal of the grey water.
While it is contemplated that the tab/aperture fastening system shown is preferably utilized to fasten the inner tank within the outer tank, it should be appreciated that other fastening devices may be utilized to maintain the flexible inner tank within the outer tank. Such fasteners may include screws, velcro, a cooperating tab/aperture arrangement or any other like retaining devices or configurations.
Still referring to FIG. 2, the sink basin 16 is placed over the opening 44 of the inner tank 14 and secured onto the shoulder 40 of the outer cavity 12 by rivets or other similar like fasteners (not shown). The sink basin includes faucets 54a, 54b and corresponding sinks 56a, 56b and drains 57a, 57b. A grey water disposal access port 60 is also located between the sinks 56a, 56b and provides limited access to the inner tank 14 to allow removal of the grey water by means such as a suction hose (FIG. 6) operatively connected to a suction tanker (not shown). A hinged disposal port lid 62 and corresponding lock 64 may be affixed over the disposal access port 60 to allow access to the inner tank only by personnel having an appropriate key.
Also, as shown in FIG. 2, a dispenser unit 68 is secured to a dispenser unit plate 70 by rivets or other like fasteners. Soap dispenser units 72a, 72b of the type well known in the art are affixed to the dispenser unit 68 on soap dispenser mountings 74a, 74b. Additionally, a paper towel dispenser 76 is also secured to the dispenser unit 68.
Additionally, as shown in FIG. 1, trash receptacles 80a, 80b may also be affixed to the outer tank 12 or alternatively to the sink basin 16 by any known fastening means. Alternatively, the trash receptacles 80a, 80b may be integrally formed along with either the outer tank or with the sink unit. The trash units each include a removable peripheral lid 82a, 82b each having associated apertures 84a, 84b insertable in a friction fit over each trash receptacle 80a, 80b to thereby engage the upper edges of a trash bag placed within the trash receptacle 80 in a friction fit between the lid 82 and the trash receptacle.
The trash receptacles may also be formed as shown at 80a', 80b' in a second embodiment 10' in FIG. 3. The trash receptacles 80a', 80b' include removable peripheral lids 82a', 82b' that include chutes 83a', 83b' that prevent rainwater and large pieces of trash from entering the receptacles. The receptacles 80a', 80b' include open ended lower portions 84a', 84b' that allow inserted trash bags (not shown) to bulge out therefrom as the bags are filled and to facilitate removal of the bags from the receptacles once the bags become filled.
Referring now to FIGS. 4-6, operation of the sink unit of the present invention, and specifically the water tank system of the present invention, will now be described.
As shown in FIGS. 4 and 5, the outer tank 12 is filled with fresh water to a level coinciding with the fill port 26. Upon the tank becoming filled, the fill plug 28 is inserted into the fill port 26 to effectively seal the outer tank 12 and contain the water within the cavity 18. As shown in FIG. 4, the water level causes the inner tank 14 to contract, thereby allowing maximum filling of the outer tank 12 with the fresh water. Such maximum filling of the outer tank 12 is not possible in conventional water tank systems employing a rigid partition dividing the outer tank effectively in half or by diaphragm type mechanisms.
As shown in FIGS. 1 and 5, a person desiring to dispense water from one of the faucets 54a, 54b pumps one of the pumps 22a, 22b with his or her foot, causing water to flow out of the outer tank 12 through one of the faucets and into one of the corresponding sinks 56a, 56b in a manner well known in the art. As the water is used and dispensed into the sink, the water flows through one of the sink drains 57a, 57b into the inner tank 14. As shown in FIG. 5, the grey water is contained within the inner tank separately from the fresh water in the outer tank 12. As the inner tank becomes immersed in the water contained in the outer tank, the remaining fresh water in the outer tank reduces hydraulic pressure on the flexible inner tank as the inner tank fills with grey water and its associated volume expands. Therefore, failure of the flexible inner tank due to hydraulic pressure is greatly reduced.
As shown in FIG. 6, the inner tank remains at least partially immersed in the fresh water even as the fresh water is almost depleted, and the inner tank becomes almost completely filled with grey water. At the end of a day of usage, after the sink unit has ceased being used, or upon depletion of the fresh water supply held by the outer tank 12, a grey water removal mechanism, such as the suction hose 90 operatively connected to a tanker truck (not shown), may be inserted through the inner tank disposal access port 60 subsequent to the access port lid 62 being unlocked and lifted. The grey water is then removed from the flexible inner tank through the hose. The flexible inner tank volume subsequently contracts, thereby allowing a new supply of fresh water to be dispensed into the outer tank 12 in a manner that maximizes the fresh water volume of the outer tank as described above.
Periodically, the sink basin 52 may be removed, and the flexible inner tank may be separated from the rigid inner tank for cleaning purposes. Such cleaning capability, which is not available in many conventional portable sink designs, permits high sanitary standards to be maintained and minimizes the chance of germs and bacteria being spread through contaminated water.
Referring to FIG. 7, a third alternate embodiment of the present invention is shown generally at 100. The embodiment shown generally at 100 comprises a four sink unit having dual two sink units 102a, 102b, each being a mirror image of the other and each having a structure identical to the sink unit shown generally at 10. In addition, an umbrella 106 is maintained within an aperture (not shown) defined by the dispenser units 110a, 110b for providing shade to persons using the sink units and to provide a display area for advertising.
Thus, at this point, it should be appreciated that the portable stand-alone sink unit of the present invention provides for a maximum sink unit usage period through maximum use of the water storage tank. The sink unit of the present invention utilizes a flexible grey water storage tank that is constructed of a material that is durable enough to withstand hydraulic pressures and minimize the chance of being torn or otherwise damaged upon insertion of a grey water removal mechanism, while at the same time is flexible enough to allow the inner tank volume to be expanded or contracted according to the level of fresh water in the outer tank and the level of grey water in the inner tank. Therefore, sink unit repair and down time is minimized, as the inner tank does not need to be replaced as often as less durable inner tank liners and diaphragms as used in conventional sink unit water tank systems. Overall long term sink unit maintenance costs are thus reduced.
This invention may be further developed within the scope of the following claims. Thus, the foregoing description is intended to be illustrative of an operative embodiment and not in a strictly limiting sense.
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A portable wash station, comprising an outer water tank, a flexible inner water tank secured within the outer tank, and a sink basin affixed atop the outer tank including at least one sink, one water faucet for dispensing water from the outer tank and one drain for draining water from the sink into the inner tank. The flexible inner tank has an associated volume that expands as the water is dispensed from the outer tank and into the flexible inner tank, that contracts as the water is removed therefrom, and that is subjected to minimal hydraulic pressure from the water dispensed therein.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a device for orienting construction materials such as, for example, adjacent sheet of plywood. More particularly, the present invention relates to a device for spacing multiple construction materials a fixed distance apart, while simultaneously positioning those construction materials parallel to one another in a preferred orientation thereof, and placing the materials in a straight line, with respect to one another.
[0003] 2. Description of the Background Art
[0004] The building construction trade is a relatively fast paced industry; a great deal of pressure is exerted on those engaged in such labor to work as quickly as possible, particularly as favorable weather permits. However, the major portion of such work is hand labor; very little has been accomplished in the way of mass production methods, or the development of tools and equipment, other than electrical power tools, to permit those engaged in the building construction trade to work more rapidly and efficiently.
[0005] One of the more time consuming tasks in the trade is the precise alignment, spacing, and cutting of construction members such as plywood sheets. The methods used to date have been relatively crude, involving the use of nails as makeshift spacing guides, and the experience and judgment of the worker. The need arises for a device which allows the worker to quickly, efficiently, and accurately mark, cut, align, and secure plywood sheets, and the like.
[0006] Many of these materials are installed vertically or in a pitched manner, such as plywood sheets. Workers assembling such structures could benefit from, and could save time on the job with a reliable spacer template, which would allow them to assemble components for such structures at the correct spacing and orientation thereof. Some materials for use as spacers in the construction industry are known. Examples of these known spacers may be found in U.S. Pat. No. 3,959,945 to Allen, U.S. Pat. No. 4,322,064 to Jarvis; U.S. Pat. No. 4,420,921 Hardin, U.S. Pat. No. 4,958,814 to Johnson, U.S. Pat. No. 5,190,266 to Barrera, and U.S. Pat. No. 5,491,905 to Jablonski et al.
[0007] While the known spacers are useful for their intended purposes, a need still exists in the art for a versatile spacer device, which will allow for fast, inexpensive installation on a variety of surfaces, including vertical and pitched.
[0008] The invention is directed to a device for maintaining two construction members, such as boards, in spaced relative relationship to each other, as for example, plywood boards or similar wooden boards incident to nailing during construction activities. Typical of spacers for spacing two boards are disclosed in U.S. Pat. No. 3,735,497 (Boettcher), U.S. Pat. No. 5,560,117 (Tallman), U.S. Pat. No. 4,930,225 (Phillips), U.S. Pat. No. 4,955,142 (Rieck). These patents each disclose structures for accomplishing the broad concept of board spacing, but each includes the disadvantage of preventing the worker or other person using the spacer from placing the spacer on the construction member, regardless of the pitch or angle of that construction member. The prior art lacks self-adhering spacers that allow for quick, stable, and accurate spacing during construction activities. The self-adhering spacer solves these problems.
SUMMARY OF THE INVENTION
[0009] The present invention provides an improved spacing and positioning device for facilitating quick and easy spacing, positioning and alignment of construction materials, and to place those materials in a desired configuration. The spacer device according to a preferred embodiment of the present invention allows for similarly aligning and spacing a plurality of similar workpiece materials, in relation to each other.
[0010] One embodiment of the spacing and positioning device hereof includes one or more self-adhesive strips so that the user can quickly and easily position the spacer at the desired location without the need to take additional time to secure the spacer. In one embodiment, the spacer has a tab affixed for easy removal of the spacer after use.
[0011] Another embodiment of the spacing and positioning device hereof and attached thereto includes one or more tacks that can be pressed into the construction member at the desired location without any additional time needed to secure the spacer. This embodiment would allow the spacer to be affixed and removed easily and also be used multiple times.
[0012] Accordingly, one of the objects of the present invention is to provide an improved device for the proper and precise alignment of construction members.
[0013] Another object of the present invention is to provide a device capable of serving as a guide for the precise measuring, marking, and/or cutting of such materials at a variety of angles.
[0014] A further object of the present invention is to provide a device serving as a guide for the proper and precise spacing and location of nails or other fasteners.
[0015] Yet another object of the present invention is to provide a device which will protect the material upon which it is being used from hammer marks or other defacement.
[0016] An additional object of the present invention is to provide a device, which could be color coded to denote particular sizes, making identification simple and reducing mistakes.
[0017] Another object of the present invention is to provide a device serving all of the above functions and is compact, portable, and disposable and may perform the above functions with a variety of standard shapes and sizes.
[0018] With these and other objects in view which will more readily appear as the nature of the invention is better understood, the invention consists in the novel combination and arrangement of parts hereinafter more fully described, illustrated and claimed with reference being made to the attached drawings.
[0019] Preferably, the spacer device hereof will be used in a set of two or more at opposed ends or sides of the materials being spaced, to ensure correct spacing along the lengths thereof.
[0020] A self-adhering spacer is provided for maintaining accurate spacing between adjacent construction members during construction activities. The spacer can be formed from a variety of materials, including wood, metal, or plastic. The self-adhering spacer can also be shaped in a variety of configurations, including T or L shapes.
[0021] In one embodiment, an adhering material, such as one or two-sided tape, is affixed to at least one surface of the spacer surface that will allow the spacer to be temporarily affixed to the construction member. In another embodiment, one or more small tacks protrude from one or more surfaces of the spacer, which will allow the spacer to be affixed to the construction member. The self adhering qualities of the spacer will allow the easy placement of spacers on many different construction member surfaces and at all angles of orientation. This will reduce construction time and costs.
[0022] With the above and other objects in view that will hereinafter appear, the nature of the invention will be more clearly understood by reference to the following detailed description, the appended claims and the several views illustrated in the accompanying drawings.
DETAILED DESCRIPTION
[0023] A spacer device in accordance with the present invention, generally, includes: a generally T shaped spacer body having a top edge, a left bottom edge, a right bottom edge, a left edge, and a right edge, wherein each spacer may be manufactured in various sizes and lengths of the various edges, as well as the relative lengths and sizes of the edges; or a a generally L shaped spacer body having a bottom edge, a right edge, and a left edge, wherein each spacer may be manufactured in various sizes and lengths of the various edges, as well as the relative lengths and sizes of the edges
[0024] A generally L shaped spacer body with a triangular piece connecting the two edges, positioned on top of the leading edges, as shown in FIGS. 7, 8 , 9 , and 10 for use as a corner spacer.
[0025] A spacer as described with an affixed tab for extraction following use.
[0026] A spacer as described, with self adhesive material on one or more edges, thus allowing simple and secure placement of the spacer on a variety of surfaces and at a variety of angles and slopes.
[0027] A self adhering spacer as described, with one or more small tacks protruding from it, thus allowing simple and secure placement of the spacer on a variety of surfaces and at a variety of angles and slopes.
[0028] The spacer as described, can be manufactured using a variety of materials, including, but not limited to plastic, metal or wood. In one embodiment, the spacer would be made of plastic to facilitate uniformity, low weight, and amenability to mass production. It is anticipated that the described spacers can be manufactured in strips containing multiple units, allowing for easier mass production and also allows the user to remove one or more of the spacers from the strip as desired. See FIGS. 11 and 12 .
[0029] For a more complete understanding of the present invention, the reader is referred to the following detailed description section, which should be read in conjunction with the accompanying drawings. Throughout the following detailed description and in the drawings, like numbers refer to like parts.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] FIG. 1 is a perspective view of a spacer tool in accordance with the present invention;
[0031] FIG. 2 is depicts another perspective view of the spacer tool in FIG. 1 in accordance with the present invention. This drawing illustrates a typical positioning of the spacer against a construction member.
[0032] FIG. 3 is a side view of the spacer between two construction members of a butt joint, being used to stabilize, and space apart the members;
[0033] FIG. 4 is a side view of a spacer wherein left bottom edge is shorter than the right bottom edge, between two construction members of a tongue and groove joint, being used to stabilize, and space apart the members;
[0034] FIG. 5 is a front view of four of the spacer devices of FIG. 1 in a use thereof to align a structural workpiece member in a configuration thereof.
[0035] FIG. 6 is a front view of 10 of the spacer devices of FIG. 1 in a typical use thereof to align a structural workpiece member in a configuration thereof.
[0036] FIG. 7 depicts a spacer with a triangular piece connecting the two edges, positioned on top of the leading edges, for use as a corner spacer. This figure also shows a tab positioned on top of the triangular piece, typically used for extraction of the spacer following use.
[0037] FIG. 8 depicts a different perspective view of the spacer tool in FIG. 7 in accordance with the present invention.
[0038] FIG. 9 depicts a different perspective view of the spacer tool in FIG. 7 in accordance with the present invention.
[0039] FIG. 10 depicts a different perspective view of the spacer tool in FIG. 7 in accordance with the present invention.
[0040] FIG. 11 is a front view of 10 of the spacer devices of FIG. 7 in a typical use thereof to align a structural workpiece member in a configuration thereof.
[0041] FIG. 12 depicts a strip containing multiple spacer tools in accordance with the present invention.
[0042] FIG. 13 depicts a different perspective view of the spacer tool in FIG. 11 in accordance with the present invention.
[0043] FIG. 14 is a perspective view of a spacer tool in accordance with the presentinvention using tacks on one surface to fasten or affix to construction member
[0044] FIG. 15 is a side view of a spacer tool in accordance with the present invention using a tack on one surface of the spacer.
DETAILED DESCRIPTION OF THE DRAWINGS
[0045] FIG. 1 is a perspective view of a spacer tool in a generally T shaped configuration. The spacer has a top portion 21 , a left bottom portion 23 , a right bottom portion 25 , a left edge portion 27 , a right edged portion 29 , and an adhesive material 31 located on the left edge 27 portion. In this particular configuration, it is anticipated that the spacer will be affixed to a first construction member 37 such that the spacer makes initial contact along the adhesive material 31 located along the left edge, and the left bottom portion. It is also anticipated in this configuration that a second construction member 39 will be placed along side or against the top portion and/or against the right bottom 25 and right edge 29 portion.
[0046] FIG. 2 is a side view of a spacer tool in a generally T shaped configuration. This drawing illustrates the spacer after it has been affixed to a construction member 37 . The adhesive material 31 is attached to the left edge of the spacer. The construction member 37 is in contact with the adhesive material 31 and the left bottom portion of the spacer. With the spacer so affixed, the user becomes free to place additional construction members against the spacer while the spacer remains affixed to the original construction member. The user would then be free to secure the construction members while the spacer maintains the desired separation between the members. After the construction members have been secured, the user may elect to remove the spacer(s) to use again, or dispose of them. The user may also chose to leave the spacer(s) in place as desired.
[0047] FIG. 3 is a side view of the spacer between two construction members of a butt joint, being used to stabilize, and space apart the members. This configuration shows the adhesive material located on the left edge 27 of the spacer. The spacer contacts the first construction member 37 at the left bottom portion 23 and along the left edge 27 . The adhesive material 31 is between the left edge 27 and the first construction member 37 . A second construction member 39 may now be placed against the top portion 21 of the spacer, or along the right edge 29 portion. The second construction member 39 in this illustration is adjacent to the top portion of the spacer. After the construction members have been secured, the user may elect to remove the spacer(s) to use again, or dispose of them. The user may also-chose to leave the spacer(s) in place as desired.
[0048] FIG. 4 is a side view of a spacer wherein the left bottom edge is shorter than the right bottom edge, between two construction members of a tongue and groove joint, being used to stabilize, and space apart the members. This configuration shows the adhesive material 31 located on the left edge 27 of the spacer. The spacer contacts the groove containing construction member at the left bottom portion 23 and along the left edge 27 of the spacer. The adhesive material 31 is between the left edge 27 and the top of the groove containing construction member. The shorter length of the left bottom 23 portion allows for proper spacing of the construction members without interfering in the tongue and groove connection. The tongue containing construction member will contact the spacer on the top portion of the spacer. After the construction members have been secured, the user may elect to remove the spacer(s) to use again, or dispose of them. The user may also chose to leave the spacer(s) in place as desired.
[0049] FIG. 5 is a front view of four of the self adhering spacer devices 43 in a use thereof to align structural workpiece members 45 in a configuration thereof. The drawing shows spacers being used to space and separate three construction members in a side by side configuration. As the drawing illustrates, one of the advantages of this invention is its ability to affix itself to construction members at any angle. Both the spacer(s) with the adhesive material and the spacer(s) with the tack(s) would allow for this configuration. After the construction members have been secured, the user may elect to remove the spacer(s) to use again, or dispose of them. The user may also chose to leave the spacer(s) in place as desired.
[0050] FIG. 6 shows a front view of 10 of the self adhering spacer devices 43 in a use thereof to align structural workpiece members 45 in a configuration thereof. The drawing shows spacers being used to space and separate four construction members in side by side and vertical configurations. As the drawing illustrates, one of the advantages of this invention is its ability to affix itself to construction members at any angle. Both the spacer(s) with the adhesive material and the spacer(s) with the tack(s) would allow for this configuration. After the construction members have been secured, the user may elect to remove the spacer(s) to use again, or dispose of them. The user may also chose to leave the spacer(s) in place as desired.
[0051] FIG. 7 depicts a spacer with a triangular top piece 47 connecting the two edges portions 49 , positioned on top of the leading edges, for use as a corner spacer. This figure also shows a tab 35 positioned on top of the triangular piece 47 , typically used for extraction of the spacer following use. Although not shown in this drawing, it is anticipated that this corner spacer will have adhesive material located on one or both of the inside surfaces of the edge pieces 49 , or as depicted in FIG. 8 , on the bottom portion of the triangular top piece 47 connecting the two edges. Alternatively, or in conjunction with other means, the corner spacer could utilize tacks on or in the spacer's edge pieces 49 or triangular top piece to allow it to be affixed to the desired construction member.
[0052] FIG. 8 depicts a different perspective view of the spacer tool in FIG. 7 in accordance with the present invention. In particular, the illustration depicts the underside of the triangle shaped corner spacer of FIG. 7 , including two strips of adhesive material 31 on the underside of the triangular top piece 47 . It is anticipated that this corner spacer will have adhesive material located on one or both of the inside surfaces of the edge pieces 49 , or as depicted here, on the bottom portion of the triangular top piece 47 connecting the two edges. Alternatively, or in conjunction with other means, the corner spacer could utilize tacks on or in the spacer's edge pieces 49 or triangular top piece 47 to allow it to be affixed to the desired construction member.
[0053] FIG. 9 depicts a different perspective view of the spacer tool in FIG. 7 in accordance with the present invention. Specifically, this drawing illustrates a side view of the corner spacer shown in FIGS. 7 and 8 . The drawing shows the tab 35 on top of the triangular top piece 47 , as well as two strips of adhesive material 31 . Also, the interior surfaces of the edge portions 49 are shown.
[0054] FIG. 10 depicts a perspective view of a spacer with a triangular top piece 47 connecting two edges portions. However, in contrast to FIGS. 7-9 , the middle section of the edge portions are absent such that the edge portions consist of surfaces perpendicular to the triangular top piece at only the corners of the top piece. This figure also shows a tab 35 positioned on top of the triangular piece 47 , typically used for extraction of the spacer following use.
[0055] FIG. 11 shows a front view of ten of the self adhering spacer devices 43 in a use thereof to align structural workpiece members 45 in a configuration thereof. Specifically, the drawing shows the corner spacer embodiment illustrated in FIGS. 7-10 being used to space and separate three construction members in a typical configuration. The illustration depicts the use of the corner spacers at varying angles. Both the spacer(s) with the adhesive material and the spacer(s) with the tack(s) would allow for this configuration. After the construction members have been secured, the user may elect to remove the spacer(s) to use again, or dispose of them. The user may also chose to leave the spacer(s) in place as desired.
[0056] FIG. 12 depicts a strip containing multiple spacer tools in accordance with the present invention. The drawing illustrates the invention's ability to be produced in strips containing multiple and independent spacer devices. It is anticipated that these spacers can be manufactured in such a way as to allow them to be mass produced. This figure shows the spacers attached to each other so that they could be easily detached from the strip and used as desired. This embodiment would also make carrying the spacers more convenient.
[0057] FIG. 13 depicts a different perspective view of the strip of spacer tools in FIG. 12 in accordance with the present invention. In particular, the illustration depicts the underside of the strip of temporarily attached spacer tools shown in FIG. 12 .
[0058] FIG. 14 is a perspective view of a spacer tool in a generally T shaped configuration. The spacer has a top portion 21 , a left bottom portion 23 , a right bottom portion 25 , a left edge portion 27 , a right edged portion 29 , and tacks 33 located on the left edge 27 portion. In this particular configuration, it is anticipated that the spacer will be affixed to a first construction member 37 such that the spacer makes initial contact along the adhesive material 31 located along the left edge, and the left bottom portion. It is also anticipated in this configuration that a second construction member 39 will be placed along side or against the top portion and/or against the right bottom 25 and right edge 29 portion.
[0059] FIG. 15 is a side view of a spacer tool in a generally T shaped configuration. T tack(s) are attached to the left edge of the spacer. The tack(s) are used to affix the spacer to a construction member while in use, and may be utilized as an alternate means to secure the spacer. The user would then be free to secure the construction members while the spacer maintains the desired separation between the members. After the construction members have been secured, the user may elect to remove the spacer(s) to use again, or dispose of them. The user may also chose to leave the spacer(s) in place as desired.
[0060] Although particular embodiments of the present invention have been disclosed herein for purposes of explanation, it should be understood that further modifications or variations thereof would be apparent to those skilled in the art to which this invention pertains.
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An improved spacing and positioning device is provided for facilitating spacing and positioning of construction materials. The device allows for the installation of construction materials in various orientations. Preferably, the device is used in a set of two or more, which are placed at proximate opposed ends of the materials being spaced, to ensure correct spacing and positioning of the workpiece materials along the length thereof. The device includes a self-adhesive material on one or more surfaces to allow the spacer to be positioned on vertical or pitched construction members. A self-adhering spacer is provided for maintaining accurate spacing between adjacent wooden boards or other construction members during construction activities. The spacer can be formed from a variety of materials, including wood, metal, or plastic. The self-adhering spacer can also be shaped in a variety of configurations, including a T or L shape. The self-adhering spacer has at least one surface a material, such as one or two-sided tape, that will allow the spacer to be temporarily affixed to the construction member. The self adhering qualities of the spacer will allow the easy placement of spacers on many different construction member surfaces and at all angles of orientation.
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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 an installation tool for landing a casing hanger in a wellhead and setting a seal assembly in the annulus between the casing hanger and wellhead in a single trip. The installation tool can perform these functions without requiring any rotation of the drill pipe string used for lowering the installation tool, casing hanger and seal assembly into the bore of a subsea wellhead.
[0003] The non-rotational casing hanger and seal assembly running tool of the present invention is used in oil and gas drilling operations of the type typically referred to as subsea. These type of oil and gas operations have a wellhead sitting on the ocean floor. As drilling operations proceed, various sizes of casing hangers will be lowered into the wellhead, each casing hanger having a length of casing threaded into to the lower end of the casing hanger. The lengths of casing typically will be from a few hundred feet in length for the larger size casings to several thousand feet of casing for the smaller sizes of casing. The casing hanger itself is a generally tubular member with a beveled outer shoulder sized to land on a mating inner shoulder in the wellhead or a previously installed casing hanger.
[0004] After each casing hanger and attached string of casing is landed in the wellhead a cement slurry is pumped through the casing hanger and casing. This cement slurry is forced to the bottom of the casing string where it then flows around the bottom end of the casing string and back up the annulus between the casing string and the drilled hole. After the cement has been placed, a seal assembly or packoff is lowered into the wellhead where it is urged into the annulus between the casing hanger and the inner wall or bore of the wellhead. The seal assembly often requires some mechanism to urge it into its sealed or energized position to ensure a positive seal in the annulus between the casing hanger and the inner wall or bore of the wellhead.
[0005] The seal assemblies used in this type of oil and gas drilling operations are typically either an elastomeric seal using the natural elasticity of a rubber compound to seal the annulus or a metal seal using a soft metal compound formed into a plurality of lips that are deformed or energized into contact with the bore of the wellhead and outside diameter of the casing hanger to form the aforementioned annular seal. The metal seals require substantially more force to deform and energize them into their sealing configuration. Previous designs in the industry have either used torque or annulus pressure to energize these metal seals. Those designs utilizing torque have used rotation of the drill string to operate a threaded ring to apply the needed force. These designs have a couple of major limitations: it is difficult to determine how much of the applied torque is being applied to the threaded ring and how much of the torque is being expended in rotation of the long drill pipe string and the drag of the drill pipe string on the wellbore and as wellheads are deployed in ever greater water depths more of the applied torque is lost in the drag of the drill pipe string on the wellbore than is applied to the threaded ring. The previous designs using annulus pressure have been limited by the pressure that can be applied in the annulus between the inner and outer casing strings being sealed. This pressure limitation prevents enough pressure from being generated to generate the substantial force required to energize a metal seal.
[0006] Additionally, it is preferable if the tool used to lower the casing hanger and set the seal assembly in the casing hanger—wellhead annulus can accomplish these tasks in one trip. As wells are drilled in ever deeper water depths, the time for lowering a tool to the sea floor and retrieving it increases dramatically and this translates into higher drilling costs as the cost of the rig time required to perform these operations is high. It is therefore desirable to have an installation tool that can lower a casing hanger and associated seal assembly into a well bore, land the casing hanger, allow cementing and energize the seal assembly in a single trip without requiring rotation of the drill string. The non-rotational casing hanger and seal assembly running tool of the present invention offers a substantial improvement by offering a tool that can perform these functions in a single trip and allow testing of the installed seal assembly without requiring rotation of the drill striing.
[0007] 2. Description of Related Art
[0008] U.S. Pat. No. 4,903,776 to P. C. Nobileau et al. shows a casing hanger running tool using drill string tension to set the packoff. The axial movement of the drill string is used in conjunction with differential area pistons to apply force on a sleeve to set the packoff.
[0009] A casing hanger running tool using string weight is disclosed in U. S. Pat. No. 4,928,769 to L. J. Milberger et al. This device also uses the weight of the drill string acting on differential area pistons to drive a setting sleeve downward to set the packoff.
SUMMARY OF THE INVENTION
[0010] The non-rotational casing hanger and seal assembly running tool of the present invention is designed for use in those subsea applications where non-rotation of the drill string is preferred or a requirement, i.e., primarily deep water applications or those involving reeled pipe installations. The non-rotational casing hanger and seal assembly running tool includes a mandrel having an upper end adapted for connection to a string of drill pipe and a bore therethrough. A tool body is carried by the mandrel and the mandrel and the tool body are axially moveable relative to one another.
[0011] The tool body includes a main body, an upper body and a lower body having a lower end adapted for connection to a string of drill pipe. The main body of the tool body supports a plurality of latching segments circumferentially spaced for releasably connecting the tool body to a seal assembly. A plurality of latching dogs are positioned circumferentially on the lower body of the tool body for releasably connecting the tool body to a casing hanger. The axial movement between the tool body and mandrel operates a pressure responsive shuttle piston positioned on the upper body to urge the seal assembly into the annulus between the casing hanger and a wellhead in which the casing hanger is landed.
[0012] The mandrel also includes a ball valve positioned in the mandrel bore that is operable between open and closed positions by axial movement of the mandrel relative to the tool body. The opening and closing of the ball valve allows independent operations to be carried out such as cementing the casing hanger in position through the mandrel bore and operating the shuttle piston to unlatch the tool from the casing hanger for retrieval.
[0013] A principal object of the present invention is to provide a seal assembly and casing hanger installation tool that can install a seal assembly and a casing hanger without requiring rotation of the drill pipe string used to lower the seal assembly and casing hanger to the subsea wellhead.
[0014] Another object of the present invention is to provide a seal assembly and casing hanger installation tool that can install a seal assembly and casing hanger in a single trip.
[0015] A final object of the present invention is to provide a seal assembly and casing hanger installation tool that can perform the additional functions of cementing the casing hanger and perform pressure testing of the seal assembly after installation in a single trip.
[0016] These with other objects and advantages of the present invention are pointed out with specificness in the claims annexed hereto and form a part of this disclosure. A full and complete understanding of the invention may be had by reference to the accompanying drawings and description of the preferred embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] These and other objects and advantages of the present invention are set forth below and further made clear by reference to the drawings, wherein:
[0018] FIGS. 1A, 1B and 1 C comprise a full sectional view of the installation tool for landing a casing hanger in a wellhead and setting a seal assembly in the annulus between the casing hanger and wellhead without requiring rotation of the drill pipe string of the present invention with a seal assembly secured on the installation tool and the installation tool lowered into a casing hanger.
[0019] FIGS. 2A, 2B and 2 C comprise a half sectional view of the installation tool secured to the casing hanger by the latching dogs.
[0020] FIGS. 3A, 3B and 3 C comprise a half sectional view of the installation tool during well bore cementing operations.
[0021] FIGS. 4A, 4B and 4 C comprise a half sectional view of the installation tool as the seal assembly is urged into the annulus between the casing hanger and a wellhead housing.
[0022] FIGS. 5A, 5B and 5 C comprise a half sectional view of the installation tool as the seal assembly is tested.
[0023] FIGS. 6A, 6B and 6 C comprise a half sectional view of the installation tool as disengaged from the casing hanger, prior to retrieval to the surface.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0024] With reference to the drawings, and particularly to FIGS. 1A, 1B and 1 C a full sectional view of installation tool 10 for landing a casing hanger in a wellhead and setting a seal assembly in the annulus between the casing hanger and wellhead without requiring rotation of the drill pipe string of the present invention is shown. Installation tool 10 includes mandrel 12 with central bore 14 extending therethrough and tool body 16 carried on mandrel 12 and axially moveable relative to mandrel 12 . Mandrel connector 18 is secured to the upper end of mandrel 12 by suitable connection means as threads 20 . Mandrel connector 18 has internal drill pipe thread 22 formed at the opposite end for connection to a drill pipe string (not shown) that is used for lowering installation tool 10 to a wellhead positioned on the seafloor. Mandrel connector 18 is sealed to mandrel 12 by lip seals 24 adjacent threads 20 .
[0025] The lower end of mandrel 12 has selectively operable closure means or ball valve 26 secured thereon by threads 28 and sealed by lip seals 30 . Ball valve 26 has flow control member or ball 32 positioned in its central bore that is selectively operable by movement of ball pin 34 . Movement of ball pin 34 rotates ball 32 between open and closed positions thereby opening and closing bore 14 of mandrel 12 . Movement of ball pin 34 is controlled by the relative movement between mandrel 12 and tool body 16 in a manner to be described hereinafter.
[0026] Tool body 16 is composed of upper body 36 , main body 38 and lower body 40 . Upper body 36 is secured to the upper end of main body 38 by threads 42 and lower body 40 is secured to the upper end of main body 38 by threads 44 . Upper body 36 forms piston 46 at its upper end with exterior seals 48 sealing on the interior of shuttle piston 50 . Three sets of interior seals 52 are spaced axially along the interior of piston 46 . The position of interior seals 52 relative to lateral port 54 in mandrel 12 controls the flow of pressurized drilling fluid from lateral port 54 to piston port 56 and thereby the movement of shuttle piston 50 . The movement of mandrel 12 relative to upper body 36 opens and closes this passage. Lip seals 58 on the interior of annular shoulder 60 of shuttle piston 50 allow cycling of shuttle piston 50 . In the initial running position shown in FIG. 1 , shuttle piston 50 is prevented from movement relative to upper body 36 by frangible connection means as tensile bolts 62 , circumferentially spaced around upper body 36 in counterbore holes 64 . Counterbore holes 64 are plugged with pipe plugs 66 to ensure the pressure integrity of piston 46 .
[0027] Shuttle piston 50 is a generally cylindrical member with stepped outer shoulder 68 adjacent to interior annular shoulder 60 . Lower skirt 70 extends axially downward from stepped outer shoulder 68 . A plurality of flow ports 72 are circumferentially spaced around lower skirt 70 and allow drilling fluid to flow between the interior and exterior of shuttle piston 50 . A plurality of laterally disposed and circumferentially spaced counterbore holes 74 are formed adjacent the lower end of lower skirt 70 . Frangible connection means as shear bolts 76 are positioned in holes 74 and threaded into mating holes in actuator rod head 78 . Actuator rod head 78 is an annularly shaped flange with a plurality of actuator rods 80 secured at its inner edge and circumferentially spaced. Actuator rods 80 extend axially from lower skirt 70 .
[0028] Main body 38 of tool body 16 is secured to upper body 36 by threads 42 as noted above. Main body 38 is a generally cylindrically shaped member surrounding mandrel 12 . Actuator rod holes 82 are formed at the upper end of main body 38 and aligned with actuator rods 80 when installation tool 10 is assembled. Positioned on the exterior of main body 38 are a plurality of connection means as latching segments 84 that are axially moveable in tracks 86 formed on the exterior of main body 38 . Latching segments 84 are initially held in the up position of FIG. 1 by frangible tensile bolts 88 extending through retainer flange 90 . Retainer flange 90 is fastened to main body 38 by bolts 92 , shown in FIG. 2B , that are circumferentially spaced from tensile bolts 88 . In the up, i.e., initial running position of FIG. 1 , latching segments 84 extend radially outward sufficiently to allow retainer lip 94 to engage the interior of seal assembly 96 and hold seal assembly 96 in place.
[0029] Seal assembly 96 is designed to effect a metal to metal seal in the annulus between the casing hanger and wellhead. Seal assembly 96 includes outer seal lips 98 and inner seal surfaces 100 that are urged into sealing engagement with the wellhead and casing hanger. Actuator ring 102 urges seal assembly 96 into its sealing position when acted upon by lower skirt 70 of shuttle piston 50 . Lock ring 104 engages a complementary groove in the wellhead to lock seal assembly 96 in place.
[0030] Lower body 40 of tool body 16 is secured to main body 38 by threads 44 as noted above. Lower body 40 is a generally cylindrically shaped member surrounding mandrel 12 . Apertures or windows 106 are formed at the upper end of lower body 40 and evenly spaced around the circumference of lower body 40 . Dogs 108 are disposed in windows 106 and include multiple shoulders 110 formed on their outer periphery. Dogs 108 are radially moveable and multiple shoulders 110 engage mating shoulders 112 in casing hanger 114 when installation tool 10 is landed in casing hanger 114 . Casing hanger 114 is of the mandrel or shouldered type, with frustoconical outer shoulder 116 designed to land on mating shoulder 118 of previous casing hanger 120 which is landed in wellhead 122 (See FIG. 3B ). Frustoconical outer shoulder 116 has mud slots 124 formed in its outer periphery and evenly spaced circumferentially to allow drilling fluid to be circulated past casing hanger 114 . The lower end of lower body 40 has drill pipe thread 126 formed thereon for connection to cementing equipment, well known to those of ordinary skill in the art.
[0031] Radial movement of dogs 108 is controlled by cam ring 128 positioned on mandrel 12 . Cam ring 128 is initially retained by spring plunger 130 , radially disposed in lower body 40 . Cam ring 128 is aligned with actuator rods 80 through lower body 40 by alignment pin 132 . Retrieval ring 134 is positioned near the upper end of cam ring 128 to ensure cam ring 128 is held in position during retrieval of installation tool 10 .
[0032] The initial assembly of installation tool 10 , seal assembly 96 and casing hanger 114 is shown in FIGS. 1 and 2 . Seal assembly 96 is secured to the exterior of main body 38 as noted above and installation tool 10 is set in casing hanger 114 with dogs 108 retracted ( FIG. 1 ). Weight is set on mandrel 12 that overrides the detenting of spring plunger 130 and moves axially allowing cam ring 128 to urge dogs 108 radially outwardly and engage mating shoulders 112 in casing hanger 114 ( FIG. 2 ). Shuttle piston 50 is in its upward position and ball valve 32 is open. At this point, installation tool 10 , seal assembly 96 and casing hanger 114 are lowered into wellhead 122 .
[0033] As best seen in FIG. 3 , installation tool 10 , seal assembly 96 and casing hanger 114 are landed in wellhead 122 with frustoconical outer shoulder 116 of casing hanger 114 setting on mating shoulder 118 of previous casing hanger 120 . Although shown with casing hanger 114 sitting on previous casing hanger 120 , it will be understood by those of ordinary skill in the art that casing hanger 114 could be landed on a mating shoulder (not shown) in wellhead 122 , if appropriately sized, without departing from the scope of the present invention. Ball 32 is open and normal cementing operations are carried out to cement casing (not shown) suspended from casing hanger 114 through central bore 14 of mandrel 12 .
[0034] Referring to FIG. 4 , with cementing operations completed, weight is set on mandrel 12 to allow mandrel 12 to move axially relative to tool body 16 . This causes ball pin 34 to close ball 32 . Pressure is then applied through the drill string to bore 14 of mandrel 12 . The axial movement of mandrel 12 causes lateral port 54 to align with piston port 56 . Pressure applied in bore 14 acts through ports 54 and 56 and on top of annular shoulder 60 between exterior seals 48 and lip seals 58 . This force breaks tensile bolts 62 and shuttle piston 50 can move axially. This axial movement of shuttle piston 50 allows lower skirt 70 to act on seal assembly 96 and actuator ring 102 and urge seal assembly 96 into its sealing position. Actuator ring 102 also moves lock ring 104 into a mating groove in wellhead 122 and locks seal assembly 96 in position. As seal assembly 96 is moved into position, latching segments 84 release seal assembly 96 , and latching segments 84 move radially inwardly. Also, as shuttle piston 50 moves axially, shear bolts 76 are sheared and actuator rods 80 contacts cam ring 128 and retrieval ring 134 to lock them to mandrel 12 .
[0035] Referring to FIG. 5 , pressure testing of seal assembly 96 is accomplished by applying pressure in the kill and choke lines (not shown) to apply pressure in the annulus between casing hanger 114 and wellhead 122 and on top of seal assembly 96 . This pressure also serves to cycle shuttle piston 50 back to its initial (up) position. This is due to the force acting on the lower side of annular shoulder 60 between seals 48 and 58 . Since shear bolts 76 are broken, actuator rod head 78 and actuator rods 80 are left in the lower position locking cam ring 128 and retrieval ring 134 to mandrel 12 .
[0036] As best seen in FIG. 6 , once pressure testing is completed and it is desired to retrieve installation tool 10 , tension is applied to mandrel 12 . This tension on mandrel 12 and axial movement of mandrel 12 causes cam ring 128 and retrieval ring 134 to move with mandrel 12 , thereby releasing cam ring 128 from behind dogs 108 . Continued tension on mandrel 12 , causes shoulders 110 on dogs 108 to cam against shoulders 112 on casing hanger 114 and urge dogs 108 radially inwardly in windows 106 . Installation tool 10 can then be retrieved to the surface.
[0037] The construction of our seal assembly and casing hanger installation tool will be readily understood from the foregoing description and it will be seen that we have provided a seal assembly and casing hanger installation tool that can install a seal assembly and a casing hanger without requiring rotation of the drill pipe string used to lower the seal assembly and casing hanger to the subsea wellhead. Furthermore, while the invention has been shown and described with respect to certain preferred embodiments, it is obvious that equivalent alterations and modifications will occur to others skilled in the art upon the reading and understanding of the specification. The present invention includes all such equivalent alterations and modifications, and is limited only by the scope of the appended claims.
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A non-rotational casing hanger and seal assembly running tool for use in oil and gas drilling operations is disclosed having a mandrel and a tool body is carried by the mandrel. The tool body supports a plurality of latching segments for releasably connecting the tool body to a seal assembly. A plurality of latching dogs on the tool body releasably connect the tool body to a casing hanger. Axial movement between the tool body and mandrel operates a pressure responsive shuttle piston positioned on the mandrel to urge the seal assembly into sealing position. A ball valve positioned in the mandrel bore is operable between open and closed positions to allow independent operations to be carried out such as cementing the casing hanger in position through the mandrel bore and operating the shuttle piston to then allow overpull to unlatch the tool from the casing hanger for retrieval.
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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 concerns apparatus, adapted to be carried by a transport vehicle such as a truck, for compacting snow and for ejecting the compacted snow after removal to a different location.
[0002] In cold climates the removal of snow from city streets and parking lots is a difficult problem for governments and private concerns alike. Traditionally, snow removal in cities has involved plowing snow to the side of the roadway or parking lot and removing it using a snow blower, front-end loader or the like to fill dump trucks that, in turn, haul the snow away to a dumping area. The costs of such operations are often immense when snowfall is heavy. One of the main charges is for rental and operation of the trucks. Any reduction in the number of runs the trucks must make between a snow removal site and a dumping area would result in cost savings for the operation.
[0003] One way to reduce the number of trips such trucks must make is to load the trucks with compacted snow or to compact the snow that has been loaded on the trucks. Snow compacting apparatus has been described in Richardson, U.S. Pat. No. 3,796,147; Breckbill, U.S. Pat. No. 3,791,053; Newell, Canadian Pat. No. 957,559; Broman, Canadian Pat. No. 985,951; and Huckill, Canadian Pat. No. 714,752.
[0004] These references teach compacting the snow into relatively smaller “bales” that are then loaded into the trucks for delivery to the dumping area. However, the Watson U.S. Pat. No. 4,145,824 concerns a specially-built truck which receives snow introduced by separate mechanism (not shown) into a hopper opening at the top. The truck has a rectangular box-shaped body forming a large “compacting chamber” with an openable rear gate through which the compacted snow is discharged when the truck is driven to a dumping area.
[0005] The snow is compacted by a hydraulically-operated, articulated arm with a hydraulically-movable blade at one end. The arm and blade repeatedly push the snow, received through the hopper opening, toward the rear of the truck body, compacting it with each motion cycle until the truck is full. After the truck has been driven to the dumping area, the blade pushes the compacted snow out the rear gate.
[0006] Due to the massive size and the relative complexity of the articulated arm, this apparatus is expensive to manufacture and difficult to use.
SUMMARY OF THE INVENTION
[0007] It is a principal objective of the present invention to provide apparatus which compacts snow on a transport vehicle to form a block of compacted snow the size of the load carrying space of the vehicle.
[0008] It is a further, more specific objective of the present invention to provide apparatus of the aforementioned type which is simpler to manufacture and use than snow compacting apparatus known heretofore.
[0009] These objectives, as well as further objectives which will become apparent from the discussion that follows, are achieved, according to the present invention, by providing a snow compactor and carrier device, adapted to be mounted on a transport vehicle chassis, for compacting and transporting snow, and which comprises:
[0000] (a) a rectangular box-shaped structure, having a central longitudinal axis, that is open at the top and has a floor panel, two opposite side panels, a front panel and an openable rear gate panel;
(b) a compactor plate, oriented substantially vertically in the box-shaped structure, for pushing snow inside the structure toward the rear gate panel, when closed, to compact the snow; and
(c) a device for moving the compactor plate, while maintaining its substantially vertical orientation, from a point adjacent the front panel of the structure toward the rear gate panel and back again.
[0010] The compactor plate operates to repeatedly compact snow that enters through an open top of the structure until the structure is loaded and thereafter, after opening the rear gate panel, to push and discharge the snow out the rear.
[0011] According to the invention, the device for moving the compactor plate back and forth within the structure preferably comprises:
[0000] (1) one or more elongate screw rods that extend parallel to the central longitudinal axis of the structure and transverse to the compactor plate. The screw rod(s) have an external screw thread that mates with an internal screw thread in a rod bearing on the compactor plate; and
(2) one or more drive mechanisms, such as electric motors, operative to rotate the screw rod(s) either clockwise or counter-clockwise, as required, to move the compactor plate toward or away from the rear gate panel.
[0012] According to a preferred embodiment of the snow carrier device, the rear gate panel includes a single panel that is hinged at the top and is operable to open outward from the bottom or, alternatively, two parallel panels that are hinged on their opposite sides and are operable to open outward from the center.
[0013] To prevent snow from entering the internal space between the front panel and the compactor plate, the box-shaped structure preferably further includes a top panel that extends between the front panel and the compactor plate. The top panel advantageously includes a plurality of interleaved sections that telescope outward in the longitudinal direction when the compactor plate is moved outward toward the rear panel and which retract to a single section when the compactor plate is drawn back toward the front panel.
[0014] According to a preferred feature of the invention the top panel sections include a vertically extending lip on their opposing lateral edges to form a “trough” for collecting snow that falls thereon.
[0015] The upper surface of the top panel is also preferably coated with TEFLON®.
[0016] The drive mechanisms (e.g. electric motors) are preferably housed in a rectangular enclosure that forms the front panel of the box-shaped structure.
[0017] When retracted, the top panel sections are preferably housed in a separate enclosure mounted directly above the enclosure forming the front panel.
[0018] During operation of the snow carrier device, a snow blower module, detachably mounted on the front of the transport vehicle, collects the snow and blows it through a pipe into the open top of the snow compactor and carrier device.
[0019] For a full understanding of the present invention, reference should now be made to the following detailed description of the preferred embodiments of the invention as illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 is a side view of a transport vehicle (e.g., a truck) having (1) a rectangular box-shaped structure, mounted on the rear truck chassis, with a built-in snow compactor, and (2) a snow blower module, detachably mounted on the front.
[0021] FIG. 2 is a diagram, shown partly in phantom to reveal its internal components, of the rectangular box-shaped structure shown in FIG. 1 that serves as a snow compactor and carrier.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] The preferred embodiment of the present invention will now be described with reference to FIGS. 1 and 2 of the drawings. Identical elements in the two figures are identified with the same reference numerals.
[0023] The present invention makes use of two different technologies on a single transport vehicle to greatly facilitate snow clearing in areas where space is at a premium. When equipped with the invention, the vehicle, for example a truck, can easily remove the snow entirely, in a single pass, from those locations where the snow cannot readily be pushed aside as with a conventional snow-plow. Given the growing severity of winter storms due to climate change, coupled with ever-tighter municipal budgets, there is an increasing need for such a solution, as was evidenced in Boston, Mass., during its devastating winter of 2014/15.
[0024] The two individual components, mounted on a single heavy-duty truck platform, are: (1) a detachable snow-thrower module mounted on the front that can direct the snow UP, OVER and BEHIND the truck cab, dumping it into (2) a specialized snow compactor and carrier device (“The Box”) which compacts the snow and dumps a full load at a different location. Each of the components is powered by a separate auxiliary drive mechanism.
[0025] “The Box” is a very robust, open-topped rectangular container built around a heavy-duty compacting plate driven by twin power-screws. When activated, the plate travels horizontally down the full length of the rectangular box, moving freely all the way to an openable rear panel. Attached to the top edge of the compactor plate is a telescoping TEFLON®-coated “trough” with low, reinforcing side walls, that unfolds as the plate moves toward the rear, providing a “roof” over the growing gap between the plate and the truck cab, thus preventing snow accumulation on the “wrong” side of the compactor plate, while also serving as a “conveyor belt” of sorts that itself delivers the incoming snow to the box.
[0026] The rear panel of The Box can, in fact, be a hinged gate or twin doors that are locked closed during the collection phase of the operation. This rigid gate therefore serves as the fixed surface against which the incoming compacting plate compresses the snow. The compacting function of the plate maximizes the capacity of The Box far beyond a load of loose snow, and also serves to empty The Box, discharging the snow through the rear panel when opened.
[0027] As the truck drives forward, it gathers-up and blows the snow straight back into The Box as it goes, depositing the accumulating load on the rearward side of the fully retracted compactor plate at first. Once a sufficient mound of snow has accumulated in The Box, the driver activates the compactor, which then compresses this first mound against the rigid rear panel surface. During this operation, the compactor plate pulls the telescoping trough out of its housing, which continues to capture the incoming snow as it extends. This permits the vehicle to continue moving forward without a pause. The compactor plate is then partially retracted, causing the snow that has been accumulating in the extended telescoping “trough” to be shoved toward the rear as it gets shorter, by an upward-extending central flange on the trough housing, the snow sliding easily thanks to the TEFLON® coating. As a result, the accumulated snow in the trough is itself dropped into The Box as the trough retracts, thus enhancing the collection process in The Box. This entire sequence is repeated until The Box is full. The truck driver then shuts off the snow-thrower module and drives away.
[0028] With The Box now substantially full, and with the compactor plate and the trough both fully retracted, the truck can be driven to a disposal site and backed into position. The rear gate is then opened and the compactor plate is triggered one last time. However now, as the compactor plate travels rearward, it “extrudes” the compacted snow out the back, emptying the box. The rear gate is then closed, and the truck sets out to collect a fresh load.
[0029] The present invention is not intended to supplant conventional snow-plows and/or snow-blowers in all situations. Its primary purpose is to remove snow in those environments where there is no room to shove the snow aside. This system is well-suited to large parking lots at malls and entertainment venues, and residential areas with narrow streets, where cars must park at the curb. Of course, the truck can be put to work removing snow from any other location, such as centralized collection points, where they are loaded in a more conventional fashion with front-end loaders from the side, for example, but its primary mission is for operations in tight quarters such as those described above.
[0030] A truck that incorporates the present invention is not foreseen as a special-purpose “one-season” vehicle, however, but as a flexible piece of heavy equipment adaptable to year-round use. It can retain The Box, with the snow-thrower module removed, and can then serve, for example, as a conventional snow-plow/road sander/salter in winter, or as a three-season bulk-trash/cargo hauler, with the compacting feature available when needed to empty the container. Also, the simple, low-profile compacting action of The Box eliminates the need for complex and space-stealing hydraulics needed to empty gravity-driven tilting dump trucks, for example, whose height also has to be accounted for.
[0031] Perhaps the greatest advantage of the present invention is that it entirely obviates the need for two separate machines, and two crews, that are otherwise required to collect the snow. This known solution to the problem of relocating snow typically includes a conventional open-topped hauler paired with a huge, front-end loader working alongside. This operation can be impossibly slow, agonizingly difficult, expensive to execute and fraught with insurance risks in a residential neighborhood with its narrow streets clogged with parked cars, driveways, overhead wires, overhanging trees and the like. This situation is especially prevalent in older, densely-populated cold-weather cities of the Northeastern U.S., as well as in Canada, Europe and Asia.
[0032] Referring now to the figures, FIG. 1 shows a truck 10 incorporating the two components that, together, serve to load, compact, transport and unload snow. The components are (1) an otherwise conventional snow blower/snow thrower module 12 , detachably mounted on the front of the vehicle, and (2) The Box 14 , mounted on the truck rear chassis behind the truck cab 16 . The Box receives snow blown through a pipe 18 by the module 12 .
[0033] FIG. 2 shows The Box 14 in phantom view, revealing its internal parts and structure. The Box comprises a front panel 20 , a floor 22 , two sides 24 A and 24 B and a rear gate panel 26 . The rear gate is openable, either as a single unit or in the form of two separate doors, as shown, that swing outward.
[0034] Oriented vertically, within The Box, is a compactor plate 28 that is driven rearward toward the rear gate and drawn back toward the front by two rods 30 A and 30 B with external threads. These rods extend through rod bearings 32 A and 32 B in the compactor plate, each bearing having and internal thread that mates and engages with the external thread of its respective rod.
[0035] The rods 30 A and 30 B are rotated, clockwise and counter-clockwise as the case may be, by electric drive motors 34 A and 34 B. Instead of electric motors it will be understood that the rods could also be rotated (driven) by an auxiliary power take-off from the truck engine, or by a separate gasoline engine.
[0036] The electric motors 34 A and 34 B are located within an enclosure 36 , which in part forms the front panel 20 of The Box. Mounted above this enclosure 36 is a second enclosure 38 that houses a telescoping “roof trough” 40 comprised of telescoping roof sections 40 A, 40 B, 400 , etc., covering the space between the front panel 20 and the compactor plate 28 . Because the rearmost section 40 C is connected to the compactor plate, these sections are pulled and telescope outward, extending toward the rear of The Box, when the compactor plate moves rearward. Conversely, the sections are pushed and collapse together toward the front, as the compactor plate moves back, where they are collected within the housing 38 .
[0037] The telescoping roof panel is provided with vertically extending lips 42 A and 42 B on its opposing lateral edges to form a “trough” for collecting the snow that falls or is blown onto it when the compactor plate moves rearward. The upper surface of the roof panel is coated with TEFLON® to facilitate the removal of this collected snow by the face (the central flange) of the enclosure 38 when the compactor plate moves rearward.
[0038] There has thus been shown and described a novel snow compacting and removal apparatus which fulfills all the objects and advantages sought therefor. Many changes, modifications, variations and other uses and applications of the subject invention will, however, become apparent to those skilled in the art after considering this specification and the accompanying drawings which disclose the preferred embodiments thereof. All such changes, modifications, variations and other uses and applications which do not depart from the spirit and scope of the invention are deemed to be covered by the invention, which is to be limited only by the claims which follow.
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A snow removal device, adapted to be installed on a motor vehicle, for compacting, transporting and discharging snow, includes:
(a) a rectangular box-shaped structure for carrying snow, the structure having a front panel, side panels and rear gate panel which is can be opened to permit the snow to be discharged;
(b) a compactor plate, disposed substantially vertically in the box-shaped structure, for pushing snow inside the structure toward the rear gate panel;
(c) a screw mechanism which moves the compactor plate from a point adjacent the front panel toward the rear gate panel, thereby compacting the snow, and back again; and
(d) a snow blower mechanism, preferably attachable to and detachable from the front of the motor vehicle, for collecting and blowing snow into the open top of the box-shaped structure.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This patent claims the benefit of provisional patent applications Ser. No. 60/639,428 filed 27 Dec. 2004 by the present inventor and Ser. No. 60/643,546 filed 13 Jan. 2005 by the present inventor.
FEDERALLY SPONSORED RESEARCH
None
SEQUENCE LISTING
None
BACKGROUND OF THE INVENTION—FIELD OF INVENTION
This invention generally relates to the field of earthquake defense, specifically the use of area-wide, integrated defense systems throughout the surface and subterranean extent of the defended area and, as necessary, at locations outside the area.
BACKGROUND OF THE INVENTION—PRIOR ART
When a military operation is to be conducted the area of battle is normally delineated on a map by marking its boundary. Fighting the enemy within the boundary is primarily the responsibility of the commander of the ground forces within the unit, supported by organic and external fire support. It is a major responsibility of the overall operation commander to seal off the battle area, filtering external support to the enemy engaged therein, and essentially feeding the enemy to the friendly forces within the area in manageable portions.
In a somewhat similar fashion, when bombers were sent over Europe in WW II they had their best survivability when escorted by fighters. The latter would do as much as possible to cut the enemy fighter force down to size or at least tie them up so that the defensive gunners in the bombers did not have so difficult time dealing with the threat.
The standard doctrine is to weaponize the targets themselves so they can provide for their own individual defense and then to do everything possible to prevent the enemy from reaching them in strengths beyond what they can withstand.
In general this philosophy has not been applied to earthquake defense, although earthquake protection has been the subject of numerous inventions. These advances may be grouped into six general categories as follows:
1. Measurement Techniques and Analytical Methods
2. Hardening for Items of Furniture or Fixtures
3. Structural Protection by Physical Barriers and Soil Manipulation
4. Structural Protection by Frame Hardening, Damage Resistance, and Blow-out Walls
5. Structural Protection by Structural Movement and Acceleration Compliance with or without Shock Absorbers
6. Sensors, Alarms, and Control Systems
With the exception of Measurement Techniques and Analytical Methods there are three basic shortcomings of these approaches. The first is that they tend to be oriented to individual structures or small groups. The second is that they tend to be limited to surface or shallow depth application. The third is that the range of responses is very limited. Even the control systems that recognize the importance of external communications and networking and those that can issue commands to remote devices envision a very limited set of responses. Automated decision making is envisioned at only the most basic level. Therefore with respect to an area such as Southern California as a whole these approaches represent a patchwork approach which leaves each structure to face the physical onslaught alone. While single site defenses are absolutely necessary, better results will be achieved if the shocks impinging a single point have been reconfigured for minimum effectiveness against the structure's defensive characteristics.
A brief review of the prior art with respect first to structural protection by physical barriers and soil manipulation; then structural protection by structural movement and acceleration compliance; and finally sensors, alarms, and control systems will illustrate limitations that can be removed or reduced.
With respect to physical barriers and soil manipulation four patents are relevant.
In U.S. Pat. No. 6,581,340 (2003) Orovay et al disclosed a design and building technique wherein the foundation of a structure would reside on an in-ground, modular base assembly consisting of two layers of modules separated by a deformable layer of materials. For economy they included a variety of readily available materials such as old tires and granular materials enclosed in suitable enclosures. This is a very simple and totally passive system that works to protect only one structure at a time; only operates in very shallow depths; and has very limited value in protecting the larger structures which characterize urban settings.
In U.S. Pat. No. 4,484,423 McClure, Jr., (1984) disclosed a seismic shield consisting of a generally vertical trench at least 100 meters (328 feet) deep and oriented between the structure to be protected and the source of earthquake shocks. The trench might be open to the air or covered. The trench would be filled with low shear modulus material such as a liquid. Other materials identified included the open air itself and a variety of slurries, gels, solids, and gasses. The trench might have a wall on one side extending as deep as 1,000 meters (3,280 feet). McClure, Jr., postulated that such a structure would inhibit the transmission of seismic waves, especially S waves. S waves shake the ground laterally or vertically to the direction of propagation and are more destructive than the other type of body waves, P waves, which are compressive. The limitations with this invention are that in some areas a building would require virtually a circular mote to fully protect it from known and possible sources. In an urban environment construction of such a barrier may be impossible without significant demolition first. It would provide no protection against body waves arriving directly from causative faults beneath a city or with a direct line to the city under the trench. Depending on the specific design, it may not provide much protection against compressive P waves. Also the barrier is static with fixed characteristics. Lastly the maintenance of such a structure might be rather much. Uncovered standing water tends to grow micro organisms and become foul. Any chemicals added to the water to prevent such action would have to be chosen for non-corrosive actions and economy. On the other hand recycling the water periodically would likely put a strain on local resources, especially if there were a number of these structures. A fully buried mote structure, as provided for, would alleviate much of this issue, but fully encapsulated water might transfer compression waves very effectively.
In U.S. Pat. No. 5,174,082 (1992) Martin et al disclosed the use of a plurality of islands installed around structures to be protected. They offered two general types. The first was compressed earth held between an anchor at 5 to 30 meters (16.4 to 98.4 feet) depth and a sole, or plate, on the surface. The two end devices would be connected by a connecting means under tension. The second type of island envisioned the use of wells or similar vertical openings either unlined or lined with concrete and filled with a variety of materials. In both types of structure the object was to create a maze of vertical structures whose mechanical characteristics would be different from the rest of the ground to a result that impinging seismic waves would be attenuated. The limitations of the approach are that it operates in a very shallow range, 30 meters (98.4 feet) or less. In setting that depth Martin et al do make note of studies that indicate that this is the depth within which the mechanical properties of the surface layer have their most effect on earthquake propagation. Another limitation is that it is very much oriented on single structures. A final limitation is that it is a static structure.
Berry in U.S. Pat. No. 6,659,691 (2003) discloses an approach in which a plurality of underground piles in multiple rings and depths interacts to perform two important functions at once: to reduce the tendency of the soil under a structure to liquefy and to improve deflection and dissipation of the incident shock waves. There are seven perimeters specified with 5 and 18 piles per perimeter, and their orientation is generally divided into one set at 12 to 20 degrees and another at 30 to 60 degrees. Multiple types of materials are identified as candidates for the structure, and depths of 7.6 meters (25 feet) or more are prescribed. The limitations here are similar to those of Martin et al's approach: single structure, shallow depth, and fixed structure.
With respect to structural movement and acceleration compliance literally dozens of patents can be cited.
A limited sample includes Delorenzis et al, U.S. Pat. No. 6,293,530 (2001); Kim et al, U.S. Pat. No. 6,499,170 (2002); Shreiner, U.S. Pat. No. 6,675,539 (2004); Ikonomou, U.S. Pat. No. 4,554,767 (1985); Valencia, U.S. Pat. No. 4,587,773 (1986); Staudacher, U.S. Pat. No. 4,587,779 (1986); Csak, U.S. Pat. No. 4,651,481 (1987); Caspe, U.S. Pat. No. 4,793,105 (1988); Shustov, U.S. Pat. No. 5,056,280 (1991); Bobrow et al, U.S. Pat. No. 5,984,062 (1999); Tamez, U.S. Pat. No. 6,115,972 (2000); and Robinson, U.S. Pat. No. 6,321,492 (2001). In general the advances documented involved moving joints, special bearings, advanced isolation techniques and mechanisms, active and passive vibration dampening, liquid springs, and other electro-mechanical approaches. Each one, however, displays at least one of the following limiting characteristics: limited range of motion for components or structures; designs that are difficult to integrate with traditional styles and structures; intrusive bulkiness; limited ability to be integrated with a defensive command and control network and to be remotely, dynamically controlled; or limited ability to be upgraded and modernized as technology advances.
In Sensors, Alarms, and Control Systems six patents illustrate the limitations.
In U.S. Pat. No. 5,726,637 (1998) Miyahara et al disclosed a system for automatically protecting building occupants at all times and in an economical way. First, two separate sets of sensors would be used to detect and confirm earthquakes. The reason for using two separate sets was to have independent corroboration in order to avoid false alarms. The result of the detection focused primarily on activating protective measures internal to occupied structures whereby people would automatically be protected from flying or falling debris. These measures involved inflating rapidly expanding structures to form barriers. Thus it was a passive system triggering an active but very localized defense.
Three separate patents and inventors (Drake et al, Flanagan, and Skoff) have laid down plans for collecting and analyzing sensor data, determining that earthquakes have or have not occurred, and carrying out various responses.
Drake et al in U.S. Pat. No. 6,347,374 (2002) outlined a system for event detection using networks of sensors, computers, dynamically updated databases, secure networks, and decision rules including rule-based processing and statistical processing. The output was to provide data to the human safety authorities so they could better deal with the problem.
It was a comprehensive and detailed look at how to manipulate raw data to constantly enhance earthquake detection and characterization, but the output was very limited.
Similarly Flanagan provides a very comprehensive description of data sources, networks, and reporting channels and agencies in U.S. Pat. No. 5,910,763 (1999). He also shows a method by which general alerts can be issued to large areas but detailed follow up information and evacuation instructions can be restricted to only those in the areas most affected. He also indicates that certain predetermined responses could be triggered such as to closing valves on pipelines and executing similar controls on electrical grids, for example.
Skoff adds further details in a complementary vein of a multi-event alerting system. In U.S. Pat. No. 6,518,878 (2003) he describes a system that can take reports from smoke detectors, earthquake detectors, gas detectors, and then determine the correct array of reports and alarms to activate.
What none of these systems does is actively fight the earthquake as a response; they sound alarms and execute limited predetermined activations. Two other patents take limited steps in the direction of active defenses.
In U.S. Pat. No. 6,130,412 (2000) Sizemore discloses a method and apparatus for remotely controlling devices in response to a detected condition. This expands on the responses alluded to by Drake et al, Flanagan, and Skoff. Essentially he establishes a servo relationship of a remote actuator to a detection and response system. The main beneficial result of this device is in the interruption of fire-causing conditions and materials and the control of similar damage and danger. Other patents have used local sensors to activate valves and similar controls; Sizemore does it remotely.
In U.S. Pat. No. 6,792,720 (2004) Hocking utilizes sensors, embedded electrical wires, a direct current power source, the local soil and water conditions, and the process of electro-osmosis to create a subsurface propagation inhibitor. In an area where the soil is a very fine type of clay, sand, slurry, or similar material he prescribes utilizing a subsurface layer near enough to the water table that DC power routed through the silt will draw the water table up and liquefy the layer. This will provide a seismic disconnect between the surface and any rising shock waves, an active defense. He also describes another set of circuits for reversing the situation and eliminating the liquefaction. When appropriate, he recommends the use of a standby water supply. The limitations seen in this approach are that it is not clear that this is intended to cover more than a small area; it is employed at a shallow depth in favorable soil and water conditions; and that in places where such benign conditions are absent the volume of water needed or the challenge of delivering it in a timely manner may be prohibitively expensive. This is besides the fact that shock induced soil liquefaction is one of the major damage mechanisms of an earthquake, so intentionally inducing such must be done with extreme care.
BACKGROUND OF INVENTION—OBJECTS AND ADVANTAGES
Accordingly, besides alleviating the shortcomings of the prior art, several objects and advantages of the present invention are:
(a) to provide a defense that will protect a large area with emphasis on reducing the destructive power of the overall shock waves reaching the surface to M4 on the Richter scale or less and in particular to focus on reducing the damage capabilities for shocks impinging those structures hardest to defend using single structure techniques; (b) to provide as a part of that system a wholly passive, fully integrated defensive maze that will at all times reduce the shock wave reaching individual structures on the surface with no outside intervention, command, power, or support; (c) to make such a complex able to respond immediately to successive tremors of all waveforms and intensities with minimal or no repair, refurbishment, or replenishment; (d) to provide active devices that the command and control system can configure and reconfigure as necessary to optimize the overall attenuation, redirection, and transformation of the earthquake shock waves and, uniquely, to prevent harmonic accumulations; (e) to provide a single structure defense that is compatible with current structural design practices and which will not introduce intrusive structures; (f) to provide a single structure defense which employs features amenable to continuing improvement and benefiting from the introduction of new technologies in such growth fields as electromagnetism, super-conductivity, friction reduction technology, and automated control systems; (g) to provide a single structure defense which allows for different levels of protection to accommodate different financial budgets during the installation and for different levels of electrical power available at any moment during the event; (h) to provide a single structure defense mechanism inherently compatible with internal or external data transmission systems and command networks, including command and control networks; (i) to provide a single structure defense based on electromagnetic levitation that utilizes the principle of “just enough lift” (JEL) to allow at least some defensive motion of the defended structure even when insufficient electrical power is available to a single site to support a complete set of responses; (j) to provide a single structure defensive system that can allow dislocation of the structure in an overload condition and also support relocation of the structure after the cessation of the earthquake event; (k) to provide an automated command and control system that will manage the defense system; collect and analyze reports; make decisions within the timelines necessary for effective response; reconfigure, arm, and fire selected devices of the defense as necessary to tune the system response during the earthquake event; execute the measure-predict-calculate-activate defenses cycle iteratively until the tremors have ended; deal with multiple near-simultaneous earthquakes on a systems basis; and to interface with all appropriate human command and control systems.
SUMMARY
In accordance with the present invention the system comprises a plurality of physical and electronic devices deployed within the defended area and elsewhere as necessary at various depths from the surface and its structures to the fault lines, which may be 70 kilometers (43.4 miles) or more below the surface, including wave shapers for the redirection or temporal segmentation of the shock waves; dissipation chambers for the dissipation and neutralization of the shock waves; single structure and single site defenses based on electro-magnetic levitation and propulsion and integrated with other structural defenses; and a fully automated command and control system.
The single structure system comprises a plurality of electro-magnetic levitation and propulsion devices with dynamic computer controls or presettable controls to provide active, controlled isolation. Specifically it provides the ability of structures to decouple themselves from their steady state supports and perform escape maneuvers. These involve levitation above the foundation, either passively riding out the shock waves with no attempt to control drift relative to the original spot or, by a combination of lift and propulsive actions, to levitate and to maneuver as needed. In either case the minimum standard of success is decoupling the structure from the foundation enough to avoid earthquake damage to the structure and friction or impact damage to the weight bearing surfaces between the structure and its foundation. The term single site connotes several structures joined by a common command and control system or shared electrical power systems or a combination of the two.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts a nominal cross section of a shaped charge warhead.
FIG. 2 shows how a wave shaper converts the hemispherical shock wave into a fast-moving, toroidal shock wave which is trailed by a residual, slow-moving, central shock wave component.
FIG. 3 depicts how the copper stream is formed and smashes its way through the target armor, creating spall as an intended effect.
FIG. 4 illustrates the refraction of a wave at an interface.
FIG. 5 illustrates the refraction of light into its component wavelengths.
FIG. 6 illustrates the splitting of sonar waves and the subsequent refraction of the components into two different directions.
FIG. 7 illustrates total internal reflection.
FIG. 8 illustrates wave diffraction at an iris.
FIG. 9 illustrates a wave slicer.
FIG. 10 depicts a refractor with imbedded reflectors.
FIG. 11 illustrates a horizontally acting refractor.
FIG. 12 depicts a passive dissipation chamber.
FIG. 13 depicts an active dissipation chamber.
FIG. 14 shows a side view of a nominal, integrated in-ground defense system.
FIG. 15 depicts a levitation coupling.
FIG. 16 depicts an electromagnetic structural location coupling.
FIG. 17 provides a nominal timeline from the occurrence of the earthquake until after its remnants have impacted the defended area.
DRAWINGS—REFERENCE NUMERALS
20 large, open end of the copper liner for a shaped charge warhead
22 target
24 main explosive charge
26 copper liner
28 hollow interior of shaped charge
30 wave shaper
32 initiator train including primer
34 shock wave created in the initiator train
36 initial shock wave created in the aft end of the main charge
38 center portion of the shock wave slowed dramatically and falling aft of the outer ring
40 outer ring of the shock wave moving forward in a toroid
42 liquid copper ejected from the liner walls by the energy of the shock wave
44 copper slag ball
46 molten copper stream traveling at Mach 25
48 point of impact of copper stream on target
50 spall crater on inside surface of target armor
52 radiating cloud of spall
54 initial wave vector
56 medium of travel for initial wave vector
58 different material
60 refracted wave vector
62 light vector incident to prism
62 a - 62 d light wave broken into component wavelengths by prismatic refraction
64 upper layer of ocean
66 lower layer of ocean
68 thermocline
70 sonar transmission from surface ship
72 sonar waves reflected and refracted away from deep water
74 sonar waves refracted into deeper water
76 sonar shadow zone with submarine in hiding
78 light ray incident to a prism
80 reflected ray
82 reflected ray
84 wave incident to a grating
86 grating plate
88 iris
90 emergent, diffracted wave
92 oncoming earthquake shock wave
94 , 96 outer portions of shock wave
98 center portion of oncoming earthquake shock wave
100 defended area
102 refractor vessel
104 refractor fill material
106 approach end of the earthquake shock channel
108 incident shock wave
110 wave refracted toward safe direction
112 defended area on the surface
114 shock disperser
116 line or assembly of shock reflectors in spine of refractor
118 top cap of non-transmissive materials
120 refractor vessel
122 shock reflectors
124 refractor fill material
126 incident earthquake shock wave
128 refracted portion of shock wave
130 defended area
132 dissipation chamber
134 liquid
136 gas
138 artificial spall
140 compressive P wave
142 translational S wave
144 dissipation chamber vessel
146 fluid reservoir
148 counter shock generator—transmitter
150 non-transmissive cap
152 passive dissipation chamber
154 active dissipation chamber
156 wave shapers
158 defended area
160 sky scraper district
162 electro-magnetic coil assembly
164 wall
166 electro-magnetic coil assembly
168 foundation to which wall is attached
170 male connector assembly in location coupler
172 female connector assembly in location coupler
174 location pin
176 receptacle for location pin
178 a , 178 b electro-magnetic horizontal motion control coils
180 a , 180 b electro-magnetic horizontal motion control coils
182 earthquake shock wave
184 time t 0
186 deployed subsystem of the command and control system
188 main command and control center
190 sensors and reports to the system
192 communications bus
194 local command and control systems
196 Automated Command and Control System
198 time t 1
200 establishment of emergency posture
202 passive defenses reducing and changing the shock
204 active defenses reducing and changing the shock
206 time t 2
208 activation and execution of active defenses
210 time t 3
212 earthquake residuals act on the defended area
214 time t 4
216 recover and reconstitute phase
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
What can be done to apply in an area earthquake defense the military technique of cutting the enemy down to size before he gets within range of his targets? An integrated defense can be mounted from the surface to significant depths within which the mechanism of each device and its effects are implemented to maximize the overall reduction in damage and injury.
Relevant Parameters
Two key characteristics of such a defense are extraordinary speed of operation and the ability to reduce earthquakes larger than 4 on the Richter scale to levels at or below that level in selected areas. Reducing earthquakes to M4 or lower makes them to be much more within the defensive capabilities of traditional earthquake resistance design practices for buildings, roads, and other structures.
Such a defense must be extremely fast because most dangerous earthquakes occur within 60 km (37 miles) of the surface and the area to be defended may be right over the causative rupture. Most of the California faults are within 15 km (9 miles) of the surface. Earthquake waves can travel at speeds up to 5.7 km per second (3.6 miles per second) in granite; from rupture to arrival of the shock in a site of interest can occur in less than a minute even for causative faults at some remove. The present invention uses the nature of the shock waves and the geological characteristics of the area to passively manipulate the earthquake shock in multiple ways even as it advances. The degree of reduction reflects the extent to which the affected governments and owners elect to install the devices needed.
Earthquakes present at remote sites in four different wave forms, each of which must be considered in designing the defense. Two forms are created at the rupture, P waves and S waves. These are called body waves, and they radiate in all directions throughout the earth. When body waves hit the surface they create the other two forms, Rayleigh and Love waves. Rayleigh and Love waves, unlike body waves, are strictly bound to the surface and are called surface waves.
Shock wave transit times depend on the materials to be transited and the nature of the waves. In general, all other things being equal, wave speeds are higher in material with higher rigidity, and they are lower in material that is denser. The velocity of sound, for example, in sand is 244 meters per second (800 feet per second) or less but in solid granite 6,100 meters per second (20,000 feet per second) or more.
P waves are called primary waves. They are also called pressure waves and longitudinal waves. A P wave compresses and elongates along the axis of travel. It is an acoustic wave, and under some conditions the highest frequency P waves can be heard at the bottom of the human hearing range, approximately 20 hertz. They are the fastest of the wave forms, traveling at approximately 5.7 km per second (3.6 miles per second) in granite, and from the site of the rupture they will travel to the surface both directly and by routes through the earth. P waves can cross liquid, so they are not stopped by the molten core of the earth.
S waves are secondary waves. They are also called translational waves. In S waves the amplitude moves forward in sine waves at right angles to the line of advance. S waves in the vertical plane are called S-V, and S waves in the horizontal plane are called S-H. S waves, like P waves, are created at the focus of the earthquake and travel both directly and indirectly to the surface. Unlike P waves, S-H cannot penetrate liquid and cannot cross the core of the earth. S waves travel at about 3.1 km per second (1.9 miles per second).
Rayleigh waves are formed by the intersection of P waves and S-V waves with the surface. Rayleigh, or R waves, demonstrate the vertical amplitude of S-V waves and the fore and aft motion of P waves in a manner very similar to ocean waves. R waves travel at about 2.7 km per second (1.7 miles per second), and they can cross liquid.
Love waves, or L waves, are formed by the intersection of S-H waves with the surface. They exhibit a strictly side-to-side motion in the displacement as they pass. L waves are somewhat faster than R waves, but, like S-H waves, they cannot penetrate liquid.
A typical sequence of observations at an earthquake site is a bang as the P wave arrives, followed shortly by vertical and horizontal displacements from the S waves, and then vertical, horizontal, and longitudinal effects from the surface waves.
The relative contribution of energy for the four types will depend on whether surface waves will be prominent. In general the lateral shocks are the most destructive. P waves have only about ⅓ to ⅔ of the acceleration amplitudes of S waves, plus they have shorter durations. When surface waves are strong the L waves are particularly important for their impact on foundations. The hypocenter is the site of the fault, and the epicenter is the surface area directly over the fault. The ratio of the lateral distance of the defended area from the epicenter to the depth of the hypocenter will determine whether surface waves will be significant. For relatively near quakes, where the distance from the epicenter to the point of interest is less than five times the depth of the hypocenter below the epicenter, the amplitude of Rayleigh waves is considerably lower than those of the body waves. For a defended area directly above the causative fault the directly transiting body waves will predominate.
Several relationships exist with regard to the power of earthquakes. In general the longer the fault, the greater is the energy release, the greater are the accelerations seen in the shock waves, and the longer is the duration of the shock pulses. The level of destructiveness is reflected in the acceleration pulse area, the product of the acceleration curve and the duration. The acceleration pulse area is denoted in feet per second. M5 earthquake accelerations may be on the order of 0.09 g and their duration on the order of 2 seconds. M7 earthquakes may have accelerations on the order of 0.37 g's and durations of up to 24 seconds. The 1906 San Francisco earthquake, for example, is reported to have had a duration in excess of 40 seconds in the primary shaking. The fact that the pulse area is so important probably reflects the need to allow sufficient time for the forces to integrate upon the structures encountered. Too short an integration time in some applications will result in the energy having passed over the object before there has been appreciable absorption.
Earthquake effects are measured in three parameters at the same time: accelerations, velocities, and displacements. All three of these are greatly affected by the characteristics of the ground. All other things being equal, speeds increase in rigid materials and decrease in very dense materials. Material which is not dense may be displaced more than denser material, and unconsolidated deposits actually exhibit an amplifier effect with respect to displacement when struck by shock. As the transition from granite to unconsolidated material occurs the wave speed slows and the ground motion greatly increases. Thus the size of defensive structures meant to interfere with the shock wave will depend on exactly where they are sited and what are their specific missions. Such dimensions can be predetermined, however, given the specific requirements.
Underlying Proven Techniques
Techniques for the control of pressure and translational waves are well understood and include reflection, refraction, diffraction, and absorption. Physical systems that demonstrate the techniques involved include shaped charge, anti-tank warheads; optical prisms; sonar systems; and diffraction gratings.
Shaped charge warheads provide illustrations of two mechanisms: passive control of extremely high speed shock waves and the dissipation of shock energy by passively converting it into kinetic and thermal energy.
The most widely deployed anti-tank warhead is a shaped charge warhead with a hollow, conical, copper liner. FIG. 1 illustrates. The big end of the cone 20 faces the target 22 , and the main explosive charge 24 is wrapped around the outside of the copper cone 26 . The interior of the trumpet 28 is empty, which is why this type of device is also called a hollow charge. At the aft end of the main charge is a very dense, inert device called a wave shaper 30 . Lead is a popular material for wave shapers. Aft of the wave shaper and pointed straight at the main charge is the initiator train 32 containing the primer assembly.
In order for the warhead to function properly the shock wave created when the initiator charge is detonated must be applied to the aft edges of the main in a near perfect toroid, or ring. The shock wave from the initiator travels the 15 cm (six inch) (or shorter) length of the initiation train at about 4.8 to 8 km per second (3 to 5 miles per second), depending on the explosive. This is in approximately the same speed range as earthquake waves, which, as noted, travel at speeds from 3.1 to 5.7 km per second (1.9 to 3.6 miles per second), depending on the wave form and the density of the strata.
FIG. 2 illustrates how this is accomplished. Detonation of the initiator chain causes a detonation wave to run forward 34 and detonate the main charge at its apex. Due to the active process within the detonation wave, the detonation wave is not a shock wave as strictly defined in aerodynamics and hypersonic analysis. Seismological techniques, however, have proven that shock propagation from explosive events and earthquakes generally follow similar principles. Therefore the detonation wave will hereinafter also be referred to as an explosive shock wave.
The face of the wave takes the shape of an expanding hemisphere 36 . It runs straight into the wave shaper. The wave shaper is not wide enough to block the whole blast wave, but it is wide enough to block the center of the wave. Upon striking the wave shaper the center of the wave is slowed so dramatically 38 that it is effectively eliminated from the timeline for the detonation of the main charge. The center portion does not get absorbed or disappear; it just doesn't complete its trip through the wave shaper until it doesn't matter any more. By hobbling the center of the shock wave the wave shaper changes the propagation formation into two energy entities: an extremely fast, forward moving toroid 40 that impinges the main charge at the periphery of the apex perfectly and a slower moving one which will still be transiting at the point in time when it no longer matters.
The effectiveness and reliability of shaped charge warheads and the surety of these design techniques have been proven repeatedly since World War II. They form the basis for virally all the infantry and helicopter launched anti-tank weapons in the world. The helicopter launched missile upon which both the U.S. Marine Corps and the U.S Army relies, AGM-114 HELLFIRE, uses a shaped charge with an inert wave shaper to control the initiation of the main charge as described herein. Over 60,000 of these missiles have been procured at a cost of over $1,000,000,000, and HELLFIRE reliability has proven rock solid in both Iraqi wars.
Thus an inert object can passively and surgically slice a shock wave traveling at about three miles per second into discrete segments with significantly different arrival times.
The second warhead phenomenon of interest has to do with the conversion of shock energy into kinetic and thermal energy within the target, the formation of spall. FIG. 3 depicts this. When the blast of the main charge detonation strikes 40 the copper liner 26 the liner is melted and thrown from the interior sides of the trumpet into the cavity 42 . Here the liner ejecta forms a roiling copper soup called the slag 44 , but almost instantly the pressures on this liquid mass cause it to eject a tightly focused stream of molten copper 46 at the target 22 . The stream is approximately 6 cm (¼ inch) in diameter, 538 degrees Centigrade (1,000 degrees Fahrenheit), and traveling at about 25 times the speed of sound. When the copper stream strikes the armor of the target the over-pressure at the point of impact 48 is in the millions of pounds per square inch. This creates severe hydrodynamic erosion, cutting through the tank armor like a fire hose through a paper towel and creating an enormous shock wave. Shock transmits happily within solid armor, but as it approaches the back side of the armor there is nothing to contain the energy. Accordingly the shock wave tears out chunks of the back side of the armor wall, forming the somewhat conical spall crater 50 and flinging the metal fragments 52 throughout the interior of the armored vehicle. The debris thus excavated and scattered is called spall. In transporting and transferring the considerable energy of the shock wave to the people and objects throughout the interior of the vehicle, spall formation is the secondary kill mechanism of the warhead.
A mechanism for surgically dissecting a 4.8+ km per second (3+ mile per second) shock wave has been proven using a wave shaper, and as a mechanism for dissipating an impinging shock wave has been proven in the creation and propulsion of spall.
The next mechanism to be considered is refraction. Refraction is the bending of the axis of travel of a wave as it passes from one material into another where the two materials offer different speeds for the wave relative to each other. FIG. 4 illustrates. In the figure the wave vector 54 travels through a material 56 until it impacts an interface with a less rigid material 58 . The wave crosses the interface with a new vector 60 due to refraction at the interface. The formula for the phenomenon is given by Snell's equation:
Sin
θ
1
Sin
θ
2
=
V
1
V
2
Where θ 1 is the angle of incidence; θ 2 is angle of refraction; V 1 is the speed of light in the first medium; and V 2 is the speed of light in the second medium.
If the wave speed in the second material is slower than that in the first, the wave will turn into the second material. On the other hand, if the speed in the second material is higher, then the wave will turn away from the interior of the material and back toward the interface. FIG. 5 illustrates the first pattern in a prism, where an incident wave 62 is refracted into component frequencies, rays 62 a through 62 d.
FIG. 6 , extracted from a US Navy illustration, depicts the phenomenon of wave separation followed by simultaneous refraction in opposite directions, which creates the sonar shadows. In the figure the upper water layer 64 is warmer and less dense than the lower layer 66 . They are separated by the thermocline 68 . In this Navy-created scenario the speed of sound is not constant even within the separate bodies of water. It increases steadily from the surface down to the thermocline and then decreases steadily from there into the depths. Sonar waves from the ship on the surface 70 are split and refracted in opposite directions as they encounter the two layers of water with different sound speed characteristics. The sonar rays separate into two components which each wheel toward the directions of the slower sound velocity ahead of them. Thus the original single wave is transformed into two different waves pursuing increasingly divergent paths. The waves projected toward the interface between the two layers at relatively oblique angles are reflected away from the thermocline and then refracted toward the surface 72 . The rays at steeper angles with respect to the interface cross the interface and are then refracted in an increasingly vertical pattern into the deeper water 74 . Just beyond where the two diverge is the shadow zone where submarines 76 like to hide because there they are passively hidden by the physics of the sea. The same effect is used routinely in mapping the geologic structures using seismology.
A special condition exists when a wave moves from a high speed medium into a slower one. A ratio of the speeds and a critical angle of incidence exist where the wave will not cross the interface but rather will be reflected. The critical angle is also called the angle of total internal reflection. FIG. 7 illustrates how a prism can be used as a reflector by exploiting the angle of total internal reflection. The incident ray 78 is reflected to a new vector 80 . The new vector impacts another interface, and it is also reflected 82 . With reference to FIG. 4 the critical angle can be calculated using the following formula:
θ
critical
=
Sin
-
1
(
V
1
V
2
)
By adjusting either the incident angle or the ratio of the speeds the reflected wave can be driven off the interface and away from the second medium.
An every day example of the use of total internal reflection comes from the technology of fiber optics cables. A fiber optics telecommunications cable has a core of fiber glass that carries the input light from origin to destination. It is surrounded by a layer of cladding. The cladding is composed of a material that does not allow the light that strikes the outer walls of the core to pass into the cladding. Instead the light bounces off the cladding and back into the core. This is not done with a mirrored finish; it is done by the technique of total internal reflection. Given the extraordinary durability, efficiency, and growing popularity of fiber optics communications networks, it is clear that total internal reflection is a well established optical engineering feature.
Therefore, it is clear that waves can be refracted or reflected by properly locating astride their path or at an appropriate angle a boundary which separates materials with different wave speed characteristics. This includes both longitudinal waves such as sound and translational waves such as light. Earthquake waves present in both these forms.
The last mechanism to observe is the diffraction grating. FIG. 8 illustrates this. The incident wave 84 is blocked by the rigid plate 86 except for a small portion that passes through the iris 88 . The portion of the wave passing through the iris will tend to naturally spread itself as it passes through the opening, changing from an emerging point source with one energy density across its front into a hemispherical wave front with considerably lower energy density 90 .
System Design
The overall design strategy of the present invention is to reduce the inbound earthquake waves to manageable levels and then, exercising multiple active systems, to mitigate the effects of the remaining shock. Specific methods to reduce the magnitude include the sum of multiple mechanisms: channeling some of it away from the protected area by the use of refraction and reflection; absorbing some of it within the geologic structure by means of passive and active devices; chopping it into separately arriving packets by causing speed changes within the waves themselves; and spreading the shock waves by emplacing the different devices as an integrated diffraction grating. The invention consists of a plurality of passive and active devices designed for and integrated into the geologic structures at all depths plus the command and control system that collects data; evaluates the evolving situation; determines that an earthquake may be happening or has occurred; selects and activates the active countermeasures, networks, and alarms that will for that situation best protect the area being defended; iteratively executes the measure-predict-calculate-activate defenses cycle; deals effectively with multiple near-simultaneous earthquakes on a systems basis; and reconstitutes the defensive posture on a dynamic basis autonomously. Characteristics of these devices are as follows, given that the dimensions of the devices may be huge or very small, reflecting geological conditions, including the most likely axes of advance for each site from the faults considered most dangerous. Specification of the requirements for any particular site, however, will allow the device dimensions to be fully determined during the development stage.
1. Wave Shapers. Wave shapers are in-ground objects designed to change the propagation characteristics of the shock wave vector but not necessarily reduce the total energy. They may be as large as miles across or in height, or they may be inches on a side. Size determinants will include the type of material and the size of the geological channel in which each is sited, the size characteristics of the wave to be anticipated within that channel, the mission intended, and the capabilities for the necessary mining and installation available at the time of their construction. They may or may not be homogeneous, and their density may or may not be uniform throughout.
One basic design is a wave slicer. FIG. 9 illustrates using a top-down perspective. This object works like the wave shaper in a shaped charge warhead. The wave shaper slows the center of the approaching wave 92 so much that it effectively creates three waves, two of which are on the outside and will arrive together 94 and 96 , and the third in the middle 98 which will follow them. Thus it creates a condition of temporal separation, potentially significantly reducing the energy transfer into the protected objects. The longer the dimension of the device along the earthquake axis and the greater is the wave speed differential between it and the channel in which it sits, the greater will be the temporal separation. Done carefully, this can greatly reduce the acceleration—duration area, and thus the damage potential. To the extent this device diffracts the first arriving pair toward the center and each other it will reduce their peaks without stretching out their integration time on the structures in the defended area 100 . If the two lateral components do not fully come together, an effective zero acceleration node will accompany them, thus effectively causing two zero crossings at the time of impact, one for each of the two slices at the points where the middle slice has been held back.
The second form is a refractor or channel. FIG. 10 illustrates using a side view. A vessel 102 is filled with material 104 considerably less rigid but denser than the geological channel at the approach end of the object 106 . To the greatest extent possible the filler is not uniform but rather has a shock velocity gradient that is optimized for refraction. This wave shaper passively refracts the incoming wave 108 into a safe direction 110 away from the defended area 112 . The new direction may be a bypass into a natural channel leading away from the defended area; or it may be toward an array of dissipation chambers; or it may be to a disperser 114 . A disperser is a shape on the exit end of the vessel that encourages departing waves to refract outward over a quadrant larger than a more rectangular termination would be expected to induce. The edge of the vessel toward the defended area may have an armored spine: it could be lined with shock reflectors 116 . These are devices whose shape, materials, and siting combine to foster internal reflection. The vessel may be backed with a cap of non-transmissive material 118 to absorb shocks generally and to function seismically as a giant neutral density filter would in optics.
The technical approach where the material in the vessel has a much lower shock wave velocity may offer the advantage of reusing at least some of the debris excavated during the installation, which might be mixed with additional materials rather than fully excavated. A channel of the opposite effect, one that provides a higher speed to the shock waves, would probably be much more expensive to build.
FIG. 11 illustrates a refractor sited to channel shock away from the defended area in a horizontal plane. The vessel 120 , reflectors 122 , and inner fill 124 will refract the incident shock wave 126 away 128 from the defended area 130 . A non-transmissive backplate is an option not pictured.
It may be that these deep structures could provide a use for certain materials currently considered environmental hazards. One material that might prove excellent for the dense construction if it can be securely contained would be depleted uranium. It is extremely dense, relatively workable, and of little other use in normal society. Depleted uranium, however, does have a number of negative aspects, among them that it poses a severe threat to water contamination. Additionally its use could potentially be politically unacceptable.
Advanced versions of wave shapers might utilize electronic controls for optimized self-reconfiguration. Various servo-operated valves, barriers, and other devices might be utilized to tune response, but this is highly speculative given the depth and expense of such construction and, more importantly, the overarching need for maximum durability under extreme conditions.
Where practicable, wave shapers and other devices to be described shortly would be installed in a complex that constitutes a diffraction grid with respect to both the horizontal and vertical planes. If wave shapers are placed in a relatively wide, flat matrix such that the shock energy passing these devices from below is truncated on their sides as it passes, it may essentially represent a wave being passed through a diffraction grate with multiple irises. Similarly if flat matrices are built in layers, a vertical diffraction grid would be created for defense against waves coming in at an angle from the vertical. For a given urban area the overall complex might be a subterranean, inverted, hemispherical shell. The shell would be a number of devices thick, but the actual volume of the devices themselves would be a small fraction of the bounded volume. An analogy might be a triple thick chain link fence installation around a 19,844 square meter (5 acre) storage lot: the volume of the protective structure is vastly less than the volume bounded. The interior of the shell would be the existing geologic structure essentially untouched. The reason for such a shape is that, depending on the location, and pending further studies at any given site, earthquake shock waves include surface and body waves from almost any in-ground and surface direction. Since transmission paths will vary, the potential range in angles of ingress is largely unconstrained. Therefore, except where engineering studies can conclusively define the axes of greatest threat, a hemispherical design must be considered the default approach. As previously noted, the size of each device will depend on where it is, what it is made of, and what it is supposed to do.
Many if not all of the wave shapers will be emplaced so that repairs and replenishment will be extremely difficult or impracticable, particularly if the shafting that have might originally been installed during their construction is damaged by the earthquake.
Therefore durability during extended quiet times and also during execution of the primary mission will be extremely important. Fractures anywhere in the structure may cause major discontinuities in intended paths and thereby significant reductions in effectiveness. They may, however, also create retro-reflections which would help disrupt propagation of the destructive energy. Also the interface between the structure and the surrounding geologic structure must be considered both before and after an event for consideration of changes to the physical interfaces.
2. Dissipation Chambers. Dissipation chambers are in-ground earthquake kill zones. In passive chambers, which are particularly suited to deep installation sites, they promote the conversion of very large proportion of the incident energy into kinetic and thermal energy within the chambers. In active dissipation chambers, which must be more accessible from the surface with respect to replenishment and command and control, they provide a way to strike the earthquake waves with a counter-stroke specifically created to neutralize some of the destructive power. Dissipation chambers could take many shapes, and they could be any size. It is likely they would be very much wider than high, depending on where in the complex they are sited.
Passive dissipation chambers can be used at any depth, but they are uniquely suited to deep emplacements. They have two characteristics. The first is that they would be filled with a medium like gas or water with a low shear wave transmissivity. As is well-known, by this feature those shock components acting horizontally would be eliminated automatically. For eruptions nearly directly below the defended areas this would include major components of both the S-H and S-V waves. The other characteristic is that their lower quadrants would be lined deeply with unattached materials that would absorb the upward, compressive, shock wave and then, like the back, inside wall of a tank struck by a shaped charge warhead, spontaneously accelerate from their place of repose. Thus all forms of the incident shock energy would be at least partially dissipated or blocked.
The use of two non-transmissive media together, such as a layer of water overlaid with a layer of compressed gas, would enhance the effect. Together they would reduce the horizontal shock components. The viscosity of the liquid, however, would also make the artificial ejecta dissipate its energy faster, possibly allowing for lower heights of the chambers.
FIG. 12 illustrates a chamber 132 , liquid 134 , gas 136 , and artificial spall 138 in place and awaiting the arrival of compressive shocks 140 and translational shocks 142 . Stainless steel balls are one possibility. One of the reasons for not filling the chambers with liquid would be to ensure the effective creation of the same “nowhere else to go” situation for the compressive shock wave which is the root cause of the exspalliation inside a tank hull. Thus the translational components would be largely dissipated in moving the liquid horizontally, and the compressive components would be dissipated in moving artificial ejecta vertically, dissipating the shock energy as kinetic and thermal energy. If stainless steel balls prove good for this purpose, then it may be possible to shape the bottom of the chambers so that they roll back into their ready positions after their energy has been dissipated. Thus the defense would reconstitute itself In selecting the materials for such a system the prevention of damage to the chamber and, if possible, to the projectile objects, would be a major consideration. As with the wave shapers, the use of a non-transmissive cap should be considered.
A vulnerability that must be guarded against anytime a defense relies on a body of fluid is to make sure it will be there as long as it is needed. Subterranean fissures forming in the bottom of the chamber could drain the liquid, and fissures in the ceiling could vent a gas layer. Loss of the restraining viscosity of the ambient liquid might mean the artificial ejecta might not be stopped before hitting the chamber ceiling. This might result in damage to both objects. Further, depending on the relative sizes involved, a large fissure could drain a substantial portion of the ejecta from the floor of the chamber. One way to control this is to line the chamber with impermeable liner materials that have extraordinary features with respect to stretching.
Another way to avoid the problem, at least for cities on the west Coast, is to supply a virtually endless and automatically activated source of water. For example, a non-freespan chamber kilometers across but only ten meters (32.8 feet) high could be located four kilometers (2.5 miles) below a city. To maintain structural integrity the volume of the vertical supports in the chamber might be much greater than the volume of the open chamber. All the galleries would be connected to each other by floor to ceiling openings which are occasionally restricted by slosh barriers of less than half ceiling height. The complex could be connected by multiple chimneys to the Pacific Ocean. A bubble of compressed gas at the top of the chamber would ensure the chamber does not become fully immersed. As with the floor of a chamber filled with fluid, an overhead vapor barrier with fissure resistance would be required. Instead of steel balls the artificial ejecta would be rock quarried from the floor of the chamber but not removed. Such a structure would form a vast, totally passive, automatic, self-regulating shock absorber insulating the areas above from major components of any incident wave. Pumps could be used to continuously change the water in the chamber, and gravity would cause the Pacific Ocean to refill anything lost in a fissure.
An advance well into the future that will increase the effectiveness of passive dissipation chambers would be to make the artificial ejecta from a material that would be subject to electro-magnetic repulsion and to install an electro-magnetic repulsion grid above the chamber. This would increase the strength of the force gradient against which the ejecta must advance and thus allow for lower ceiling heights without a loss of kinetic dissipation capabilities. Such a system, however, unless very ingeniously protected against the complications of overhead displacements, would be extremely susceptible to power outages and thereby reductions in both effectiveness and durability. The diversion of power from the emergency grids of the defended area may also be prohibitive in some situations.
Active dissipation chambers are emplaced relatively close to the surface of the earth. They are completely or nearly filled with fluid into which a counter shock transmitter would be immersed. FIG. 13 illustrates. The purpose is to bring the quake energy into a chamber 144 filled with a material that transmits compressive shock efficiently, in this case a fluid reservoir 146 . Then the defense will hit the incoming wave with an oppositely directed blast of energy in wavelengths that will interact with it destructively. In this figure counter shocks are transmitted from the inverted cylindrical objects 148 hanging from the ceiling of the chamber. Given the disparity between the magnitude of even an M4 earthquake shock and a man-made shock, the main purpose of shallow-sited dissipation chambers for the foreseeable future would be to provide additional protection for specific structures or complexes needing it or to break up any detected harmonic accumulation of earthquake waves emerging from the various defenses. An example of the former might be a dam or a nuclear power plant. Depending on the type of counter shock system selected, it may be necessary to install shock insulation on the top of the counter shock generator. One approach would be to top the counter shock generator with a massive non-transmissive layer as previously discussed 150 .
A critical issue of any counter shock system is getting more attenuation of the upward bound, natural shock via the active system than by not using an active system at all and just simply relying on the non-transmissive cap to absorb the compression waves. One way to do this is to deploy the individual counter shock generators in arrays with carefully timed sequential firings. It would require very precise use of harmonics into the medium to aggregate the counter shock energy for maximum cancellation of the compressive wave. It would probably require physical and temporal separation of the impulses on the protected side to limit the total upward shock at any moment and point by segmenting it into discrete packets with relatively low peaks and relatively short durations from the counter shock generators.
For example an underground, relatively shallow lake 2,000 meters (1.2 miles) below the skyscraper part of a city and dimensioned such that the whole high rise district is within its lee may achieve extraordinary reductions in the shocks with which the surface defenses have to contend. The chamber need not be a clear span; very thick natural or artificial columns with or without shock control features would allow a fully supported but effectively vast cavern. Shock transmitted through the verticals must be accounted for, but whatever does escape should diffract upon reaching the top of the support, thus reducing its energy density. Between the changes imparted by the fluid component, the counter shock component, the diffraction of the residual transmitted up the vertical supports, and the non-transmissive cap the power of the shock wave should be attenuated enough to provide critical additional margin to specific structures and sites.
Well-understood mechanisms exist to provide counter shock capabilities for the limited purposes noted. Explosives are the most obvious near-term approach. Explosives' efficiencies toward a single quadrant are low, so enormous amounts would be needed. Moreover, a most difficult aspect of the counter shock feature is adjusting the characteristics of the explosive wave in frequency and timing so that it achieves the desired effect and so the use of the active system produces a significantly better net result than would a passive one. Explosives' detonation wave speeds range from 900 meters per second (0.6 miles per second) for ammonium nitrate to approximately 8,750 meters per second (5 miles per second) for RDX. A relatively new type of munition, fuel air explosives (FAE), offers significant potential advantages in shock peaks and compactness. The use of FAE also may provide the capability to “reload” the chamber after an event in a much easier fashion than would be the case if solid explosives and detonator charges were used.
Another potential approach for creating counter shock is sonar. Sonar is well-established, but the current range of frequencies is too high by a factor of 1 00 or more, and the power is too low. The open literature reports work being done with sonars operating from 100 to 1000 hertz and using power ranges of more than 200 dB. That suggests that lower frequency and higher power sonar may be in work under secret conditions. Two major issues arise from sonar: power levels high enough to do any good and the size of the transmitter antennae. Both of these may be amenable to the previously noted option of deployment in arrays. If deployed, such arrays would receive their power from the primary emergency bus controlled by the command and control system.
Still another approach is to consider mechanical vibration generators.
Dissipation chambers with counter shock features offer the most selective of the last minute defenses that can be brought into play, a relatively surgical final cut inflicted on the inbound threat to drop its specific lethality slightly as part of the terminal defense of specific structures.
Like wave shapers, both active and passive dissipation chambers may be extremely difficult to repair or replenish.
3. The Integrated In-Ground System Structure. FIG. 14 shows one nominal installation. In creating the overall defensive complex a pattern would be to install layers of dissipation chambers 152 and 154 inside the outer shell(s) of the wave shapers 156 . In the figure device 152 is a passive dissipation chamber protecting the whole defended area 158 . Device 154 , on the other hand, is an active dissipation chamber emplaced to provide additional protection only for the sky scraper district 160 within the defended area. The layers would have enough chambers that for a significant depth the structure would like a relatively thin but giant membrane of urethane foam. As noted, the actual volume taken up in the separate devices would be a small fraction of the bounded area. Of course the separation and dimensions of the chambers would be such that the strength and rigidity of the overall geologic structure would be left at an unquestionable level of integrity. Significant, passive attenuation of the shock from all axes could be achieved, greatly enhancing the ability of single site and single structure defenses within the top 100 meters (328 feet) of the surface to cope successfully. The actual structure of the in-ground complex would be designed to optimize shock wave diffraction and overall structural integrity while minimizing excavation requirements.
4. Electro-Magnetically-Based Defenses
Defended structures can be equipped with powerful self-defense capabilities by building into them electro-magnetic (e-m) levitation and motion control systems. The use of electro-magnetic forces for the levitation and propulsion of heavy passenger trains at speeds up to 400 km per hour (250 mph) is well-established. Migration of this technology to structural systems will provide the capability for active, controlled isolation of the structures from the destructive shaking. Such adaptation of the technology to the new use of earthquake defense is low risk as long as limitations of the technology at any given period are respected, and provisions are made for reliable delivery of adequate electrical power. Further, the capabilities and cost effectiveness of this approach can be expected to grow as advances are made in super-cooling and other new technologies.
The magnetic levitation earthquake defense system comprises two basic types of structural couplings, levitation couplings and location couplings, deployed in two types of arrangement. The first is single structure. The second is single site. The latter, a single site, may be multiple structures whose individual systems are linked by a single command and control system or a combined power supply or a combination of the two. This may allow optimal deployment of semi-independent control and power systems that can operate the single site defenses despite break downs in the overall communications and power grids.
The first type of coupling is the levitation coupling, which is depicted in FIG. 15 . It includes an electro-magnetic coil assembly 162 located in the bottom portion of a wall 164 and another electro-magnetic coil 166 located in the foundation 168 directly below where the wall will sit. The coils are connected to electrical power and to control machinery. The surface between the foundation and the wall may be a low friction surface, such condition created by lubrication, surface material selection, or other approach. The wall is not fastened to the foundation but instead sits atop it. Where necessary, removable pins or other mechanical connectors may be used to provide retention against hurricane or other exceptional forces that might otherwise displace the structure from its foundation. These connectors would be automatically retractable by the earthquake command and control system as a preliminary measure upon threat of an earthquake. Careful design would ensure that shifting of the structures against the connectors would not inadvertently prevent their disengagement during an earthquake emergency. The electrical current input to the two coils will cause the electromagnets to repel each other. The repulsive force may be as little as what constitutes “just enough lift” (JEL), or it may be so much as to cause the wall to rise well clear of the support structure.
“Just enough lift” refers to the condition where the net down force on an object has been lightened to the point where it is still in contact with the surface below, but lateral motion is possible with acceptable dragging between the upper and lower objects. An analogous situation exists in a standard technique utilized by pilots of helicopters equipped with skids for landing gear instead of wheels. Sometimes these pilots need to take off when they do not have enough power to actually fully break contact with the ground, let alone hover. They increase rotor power to the point where they are light on the skids but still in contact with the ground. Then by minute forward control inputs they can very gradually and gently accelerate forward until they have reached translational lift speed, which catapults them up and into flight. During their takeoff run their skids are in contact with the ground, but the down force is sufficiently small that no serious damage is done to the skids. In the present invention the term refers to lifting the wall until its downward force does not create enough friction with the surface below to prevent motion or to cause unacceptable damage to either of the surfaces in contact.
The second type of device is the location coupler as shown in FIG. 16 . The location coupler is made of a male connector 170 and a female connector 172 . The location pin 174 on the male connector is smaller than the receptacle 176 on the female connector, with space on all sides. Both the male and female connectors have electro-magnetic horizontal motion control coils 178 a and 178 b and 180 a and 180 b . These act like the acceleration coils on magnetic levitation trains to move the trains forward. In the case of the present invention they are arrayed to induce or control motion in both horizontal axes and radially.
The building to be defended is constructed with some or all the floors not fly joined to the structure below. The structural joints between the floors at predetermined places contain levitation couplers. These are located not only at the perimeter but wherever rigidity in the lifting structure is required to prevent buckling or other damage. At the corners of each floor and elsewhere as necessary are installed location couplers. To prevent excessive wander of the levitated structure away from the fixed coils in the foundation an array of sensors and a control loop provide a gradient of increasing force against outward travel. Alternatively a physical apparatus such as a spring and shock absorber system could be used. Weather sealing and water sealing at the decoupling joints accommodate the motion without appreciable interference and are readily restorable after the event.
Primary emergency power is connected to the levitation couplers. Power to the location couplers for ground level structures may be applied by a secondary emergency bus that will be disconnected if there is not enough to energize the primary bus fully. Where the decoupled structure is an upstairs portion of a building, however, power to the location couplers must come from the primary bus. Standby power supplies are located on site or nearby. The defense system is controlled by a computer either in the building or in a remote site, or in both places in a primary and backup arrangement. The control computer(s) are compatible with the external emergency information and command and control systems. Plumbing and other utilities are installed so that they can accommodate motion of the structure. In some buildings the present invention may be of greatest use on some of the upper floors rather than for the whole structure.
Alternatively, levitation couplers and location couplers can be interspersed along the bottoms of the walls and in the corners, or motion control couplers can do additional duties as levitation couplers.
5. Automated Command and Control System. The Automated Command and Control System is a system designed to act within the timelines of the earthquake. For the most powerful of earthquakes this may encompass considerably less than a minute from rupture at the causative fault to impact at the point of defense. The system consists of redundant computers, sensors, communications busses, and networks that autonomously or semi-autonomously monitor the local situation, collect and evaluate data, execute decision loops, and integrate with the human portion of the disaster control systems. It is beyond the control and warning systems disclosed by Drake et al, Flanagan, Skoff, Miyahara et al, and Sizemore, adding new capabilities and roles not previously envisioned. Specific capabilities are as follows:
a. The Automated System collects data and alerts from sensors and from the Human Command and Control System. b. The Automated System analyses the data to determine the probability that an earthquake has occurred. c. Based upon multiple iterations of the four step response cycle (measure-predict-calculate-activate defenses), the Automated System reconfigures sensors; initiates preliminary alerts and warnings; arms arming-required systems; declares an earthquake emergency; ceases transport of or re-routes liquid flammables and activates control systems to accomplish the same; predicts propagation characteristics of the earthquake when such has been declared; monitors path and intensity of the shock wave through the defenses; issues orders to the reconfigurable elements of the defense, including, as necessary, “commence self-controlled operations” instructions to remote, subordinate command and control systems; and passes information such as the following to the Human Command and Control System: (1) Origin and characteristics of the earthquake (2) Predicted impact with continuous updates (3) Functional status and need for repair and/or replenishment of all devices in the defense system.
The system deals with multiple near-simultaneous earthquakes on a systems response basis for overall optimized defense.
A critical task for the present invention is the arming of two- or multi-staged responses beyond what has been envisioned in the prior art. For example, if electro-magnetic levitation becomes a significant approach for surface structure defense, it may be necessary to charge local energy storage devices and/or to shunt extra power to areas where such are deployed prior to activating the levitation devices themselves. This latter task itself may require automated diversion of power in the municipal grids in a shorter cycle time than within the human response system. Such, however, could easily be implemented as an outcome of the determination that an earthquake has occurred and, as provided by Flanagan, where it is most likely to hit. Another example comes from the generation of fire fighting materials on-site before the occurrence of the event. In U.S. Pat. No. 6,560,991 (2003) Kotliar discloses how a hyperbaric hypoxic environment can be created wherein an elevated atmospheric pressure allows humans to successfully breathe a gas mixture so oxygen-deficient that it will extinguish fires. This technology allows for all sorts of defensive options, but to implement them may require time to start the gas generators and build up enough supply to cover all contingencies. Activating these devices at the first confirmation of a quake would be a perfect mission for the command and control system. This in turn would even allow prophylactic deployment of such gasses where the structure to be protected is large compared to the generator and deployment apparatus.
A unique and powerful new capability for the command and control system is to actively run the defenses against the earthquake itself. The most near-term capability to demonstrate this advance would be a system comprising the command and control system operating localized electro-magnetic single structure and single site systems via communications busses. At the outset of an earthquake the command and control system would make determinations, issue warnings, and commence remote controlling of defensive systems. It would not only shut off flammables pipelines but also arm arming-required circuits, re-route electricity to start boost-charging local stores for the electro-magnetic systems to use, and activate other defenses such as Kotliar's hyperbaric hypoxic fire safety system. On a broader basis the command and control system could automatically activate or withhold activation of the active features of the wave shapers and dissipation chambers or change their characteristics to optimize the overall system response. This would function at all times and always respond inside the time lines for human situational awareness and management. Such a high speed, fully-empowered response system is largely unprecedented in current practice except in the highly accelerated world of military terminal defense systems, such as the defenses against anti-ship missiles. Defending a ship against missiles involves being able to detect, track, and destroy objects as small as approximately a foot in diameter flying just above the surface of the water, traveling at 800 km per hour (500 miles per hour) or faster, and possibly executing evasive maneuvers. When enabled, shipboard terminal defense systems offer at least one fully automated mode because sometimes there is no time for anything less. The same automated, closed loop requirement exists for some aspects of earthquake defense.
OPERATION OF THE PREFERRED EMBODIMENT
It is not necessary to employ all the elements of the present invention to gain significant advantages. The electro-magnetic single structure and single site defenses and the Command and Control system could be deployed in the near-term at modest cost and immediately provide major advances on the present conditions. The other devices could follow as appropriate, based on systems studies of the human and natural factors and options. The underlying objective of the present invention other than for the single site and single structure subsystems is to reduce the magnitude of earthquake shock in the defended area to Richter scale M4 or less. That may not require the use of all options in every situation.
Planning and Installation
As in few other systems the successful operation of the automated area earthquake defense system will require superb planning and execution. Accordingly an outline of such pre-operational work is hereinafter provided to illustrate the intricacy and magnitude of the planning and installation tasks. Without such work nothing can be predicted reliably.
1. A detailed study is conducted by or for an appropriate agency to determine the following.
a. Single point sites needing the most protection by reduction of the earthquake effects before it strikes them. This may be focused on structures that are the most difficult to protect using the single point and single site protective measures enumerated above. Such objects may include the following:
(1) Tall buildings (2) Bridges (3) Dams and water control facilities (4) Nuclear power plants (5) Significant facilities for the storage or distribution of flammable, explosive, or toxic materials such as fuels, explosives, fertilizers, ammunition, and pesticides, herbicides, and other poisons.
b. As exactly as possible the geological structure of the area to be protected and the contiguous areas, especially with regard to faults and shock channels. This would extend as far out as necessary to understand the geologic system of which the protected area is a part and to protect the objective area without creating or aggravating dangerous conditions for a neighboring area. c. The state of the art in all applicable disciplines including but limited to earthquake and shock wave sensors; earthquake-resistant, deeply buried communications systems; deep tunneling especially with regard to the use of very wide chambers and underground construction; electromagnetism and electro-magnetic levitation and propulsion; super-conductivity; friction reduction technology; and automated control systems. The current maximum depths for deep tunneling, about 10 kilometers (6.2 miles) due to the extreme pressure and heat, would allow the emplacement of a number of deep devices. Therefore that would not in itself bar a start to such a project, and the practicable depths can be expected to be increased with time.
2. The area to be defended and contiguous areas are modeled and extensive simulation is used to characterize the area with respect to earthquake occurrences and propagation.
3. Potential configurations of wave shapers, dissipation chambers, and single site complexes are designed, built, and extensively used in simulations that characterize multiple areas. It is desired to characterize their performance both as separate devices and as elements of the plurality. Determining how each acts in different geological arrangements is a critical task because some may prove more useful in some areas and less so in others. A critical fact of geometry that must be recognized involves the relationship of the depth of a device to the size of the area protected. The closer to the shock source the protective device is, the proportionately larger is the area inscribed on the surface by its lee. At the same time, the deeper an object is buried, the more likely it will not be in a good position to help with waves coming in from another area. As previously noted in that regard, a complex with a hemispherical outer surface may be required, depending on the geology.
4. For a given area a preliminary master plan is developed incorporating the results of the studies and trials. A preliminary positioning plan for buried devices is completed and preliminary designs laid out for the specific devices themselves. Repair and replacement strategies are also devised. The defended area earthquake simulations are resumed, and their results are fed at the appropriate rate into the engineering configuration control system for the system overall.
5. When the configuration of the plurality has been completed the command and control system and the single site complexes are then configured in the simulation and exercised. In these simulations the effects of triggering multi-step, arming-required processes and equipment, including charging local and backup power for the single site systems; sending alarms; closing valves and re-routing flammables; controlling the reconfigurable elements of the plurality, including levitating and driving structures at the single sites; and reconstituting the whole system after the event ends are evaluated in terms of lives saved and in the degree to which protection systems are able to be reconstituted. The final step will be to finalize the network of replenishment tunnels, networks, and other support infrastructure.
7. Formal development of the system will follow proven program management techniques well established in the large structures contracting and aerospace industries.
Operation
The operation of the system is shown in FIG. 17 by a nominal timeline. It is important to remember that from the start to the finish of the timeline may be less than one minute for cities sitting atop major faults.
The event starts with an earthquake 182 at time t 0 184 . The overall command and control system comprises the deployed system 186 and the main command and control center 188 . The earthquake is quickly detected by multiple sensors which send reports 190 on a communications bus 192 connecting them and the main command and control center and the local command and control systems 194 . The sensors will continue reporting throughout the event, and those configured for remote programming will respond as directed. In the main center the data goes to the Automated Command and Control System 196 , which commences the iterative cycle. At time t 1 198 , upon developing a high level of confidence that a significant earthquake has occurred, the System issues orders 200 to set an emergency posture throughout appropriate areas.
The emergency posture includes stopping the flow of flammables and, to the maximum extent possible, drawing them back from pipelines. Also ground transportation and air transportation into the area is halted, and bridges are closed to oncoming traffic. Trains will be stopped where they are unless they are leaving the area. Electrical power is re-routed locally with a priority to busses supporting earthquake defense, and any chargeable sources are charged or activated. A priority tap on state, regional, or national power grids is activated as appropriate. All earthquake defenses with arming switches that require being set in an armed position prior to activation are armed. Where fire fighting systems require the charging of local storage or the generation of suppressive gasses, these are activated also. This includes systems like Kotliar's hyperbaric hypoxic fire escape system. All the local command and control systems are confirmed to be online and synchronized. Warnings are sent locally and to higher emergency response headquarters.
As the earthquake advances it is depleted and reconfigured by natural and man-made forces, many of which will overlap. For simplicity the timeline depicts the reduction in the shock threat first by the refractor channels and the passive dissipation chambers 202 . Then it shows the change in the character of the waves in magnitude or timing by the wave slicers and the active dissipation chambers 204 . This convention is used in the diagram because it is necessary for this Application to portray a four dimensional sequence in two dimensions. If the fault is directly under the city, and the passive dissipation chambers are extensive, massive depletion may be achieved in both the S-H and S-V waves because they both would be moving as horizontal components which cannot cross the liquid in the chambers.
Within the command center the cycle continues. At time t 2 206 the Automated Command and Control System commences the active defense 208 . It empowers the local command and control systems to act as autonomously as has been planned for and prescribed in advance in the overall strategy. It updates predictions of the arrival time and wave characteristics of the inbound waves as they approach the separate active dissipation chambers and fires the counter shock mechanisms as appropriate. It causes the levitation and structure motion control systems to be activated. It commences active detection and fighting of fires.
At time t 3 210 the earthquake reaches the defended area 212 . By this time the magnitude of the earthquake shock has been reduced to M4 or less, levels of energy reasonably within traditional design protection capabilities. Local systems conduct terminal defense, by traditional structural defenses augmented the levitation and control systems and the enhanced fire fighting capabilities.
At time t 4 214 the earthquake main shaking has passed, and the command center activates the recovery phase 216 . Levitated structures are restored to their sites as soon as possible to reduce the extraordinary demand on the power system. Some buildings that have drifted may have to continue to be levitated or to be temporarily deposited with a very light footprint until they can be restored to their correct site. Fire suppression continues and expands while search and rescue begins. Integrity checks are run on pipelines, rail systems, roadways, bridges, and runways. As soon as integrity has been confirmed each is restored to operation. The defenses are reconstituted to the extent their designs permit, and the status of the whole system is assessed. Repair and replenishment operations are commenced.
This preferred embodiment is nominal. Many others are envisionable, and in reality each of the defense systems will be custom developed for the area to be protected.
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An area earthquake defense system is disclosed which uses military planning principles; automated command and control systems; the technology of wave manipulation demonstrated in optical engineering, sonar, and anti-tank weapons and their countermeasures; and proven electromagnetic technology. Deeply buried, specially configured, passive devices attenuate, temporally segment, and redirect earthquake shock waves. Such a system, fully integrated into the local geological structure, can reduce the shock reaching the protected area, and, within that area, channel it away from those structures most difficult to protect with single point measures. This is especially true when the plurality of passive devices is complemented by an automated decision and command loop and dynamically reconfigurable active devices embedded at a variety of depths. Further, within the defended areas those structures enhanced with electro-magnetic levitation systems can be raised from their bases and, by partial or full decoupling, isolated from the shock. Structures with electromagnetic motion control systems can further be protected by having a means for controlling their displacements during the earthquake and for restoring them to their original location on the site despite any lateral translations experienced during the event.
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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 based on provisional application Ser. No. 60/060,691 filed Sep. 23, 1997.
BACKGROUND OF THE INVENTION
The present invention relates to a fluid control device for use in an oil and/or gas well and, more particularly, to such a device for selectively controlling the flow of production fluid from a producing formation adjacent the well, through the well, and to the ground surface.
In a typical oil and gas production well, a casing is provided to line the well and is provided with perforations adjacent the formation to receive the production fluid. A tubing string is run into the casing and has an outer diameter less than that of the inner wall of the casing to form an annulus. A packer is placed in the annulus to direct the production fluid into the lower end of the tubing string for passage upwardly through the tubing string for recovery above ground.
It is often advantageous, and sometimes necessary, to utilize hydraulically-actuated packers and other ancillary devices, especially when operating in deviated or horizontal well sections. To this end, the flow of production fluid into and through the tubing string is blocked, and well fluid is introduced into the tubing string from the ground surface, to create a relatively high fluid pressure which is used to actuate these devices. After this operation is completed the tubing string must be opened to permit the flow pf production fluid through the string and to the ground surface. Therefore, pump-out plugs, or the like, are often provided in the tubing string which normally block fluid flow through the string and which are ejected from the string when the flow of production fluid is desired. However, these plugs are relatively large and, when ejected, must either be removed from the wellbore by coiled tubing or the like, which is very expensive, or left in the wellbore, which may cause problems during the life of the well.
Also, disc subs have been used which incorporate a disc that normally blocks fluid flow through the tubing string and which breaks in response to fluid pressure acting thereon when flow is desired. However, these disc subs suffer from the fact that the pressure that has to be applied to break the disc is often excessive and unpredictable. Therefore, other techniques have been devised to break the discs to permit fluid flow. For example, steel bars have been used which are dropped into the well or run on wireline or coiled tubing. This has disadvantages since the broken disc forms debris in the wellbore and, if the well has a deviated or horizontal section, a drop bar or wireline run is very unreliable.
Still other techniques for selectively blocking the flow of production fluid through the tubing string involve wireline set/retrieved tubing plugs. However, these devices require a "profile" sub that has to be added to the tubing string and require the use of wireline intervention, as well as increased risk and expense.
Therefore, what is needed is a relatively inexpensive and reliable device for selectively controlling the flow of production fluid through a tubing string in an oil and/or gas well which minimizes the amount of debris left in the wellbore yet which can be activated with a predictable and relatively low amount of fluid pressure. Also what is needed is a device of the above type which does not require a profile sub or any actuation device to be dropped into the tubing string or run into the string on wireline or coiled tubing.
SUMMARY OF THE INVENTION
The present invention, accordingly, is directed to a device for selectively controlling the flow of production fluid through a tubing string in an oil and gas well according to which one end of a housing is connected to a tubing string for insertion into the well, and well fluid is passed from the ground surface the one end of the housing. The other end of the housing is closed to establish well fluid pressure in the housing to actuate a packer and/or other ancillary devices. The other end of the housing can be opened by increasing the pressure of the well fluid in the housing above a predetermined value, thus permitting the flow of production fluid from the formation, through the housing and the tubing string, and to the ground surface.
Several advantages result from the device and method of the present invention. For example, they are relatively inexpensive and reliable, yet minimize the amount of debris left in the wellbore. Also, the device can be activated with a predictable and relatively low amount of fluid pressure, and does not require a profile sub or any actuation device that must be dropped into the tubing string or run into the string on wireline or coiled tubing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partial elevation-partial sectional view depicting an installation in an oil and/or gas well including the device of the present invention.
FIGS. 2 and 3 are vertical sectional views of the device of the present invention depicting two operational modes of the device.
FIGS. 4 and 5 are views identical to those of FIGS. 2 and 3, respectively, but depicting an alternate embodiment of the device of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The well fluid control device of the present invention is designed to be used downhole in an oil and/or gas wall depicted in FIG. 1. The reference numeral 10 refers, in general to a well casing that lines the well bore and receives a tubing string 12 having an outer diameter that is less than the casing to define an annulus 14 between the tubing string and the casing. The tubing string 12 can be lowered into the casing 10 from the ground surface in any conventional manner such as by using a wireline, coiled tubing, or the like. A packer 16 is disposed in the annulus 14 and extends around a lower portion of the tubing string 12, as viewed in FIG. 1. The packer 16 is preferably hydraulically actuated and since it is conventional, it will not be described in detail. A plurality of perforations 10a are formed through the casing 10 below the end of the tubing string 12. The perforations 10a permit production fluid from a formation zone F to flow into the casing 10 and through the tubing string to the ground surface, in a manner to be described.
The control device of the present invention is referred to, in general, by the reference numeral 20, and is attached to the lower end portion of the tubing string 12. The control device 20 is adapted to selectively control the flow of the production fluid through the tubing string 12 and to the ground surface, and to permit well fluid from the ground surface to be introduced into the tubing string 12 and pressurized sufficiently to actuate the packer, and any ancillary devices.
To this end, and with reference to FIG. 2, the control device 20 comprises a sub 22 which is internally threaded at its upper end portion 22a, as viewed in FIG. 2, to mate with a corresponding externally threaded lower end portion of the tubing string 12 (FIG. 1). The control device 20 also includes a tubular housing 24 having an internally threaded upper end portion 24a that threadedly engages a corresponding externally threaded lower end portion 22b of the sub 22. A plurality of set screws 26, one of which is shown in FIG. 2, are angularly spaced around the circumference of the upper end portion 24a of the housing 24 and extend through aligned opening in the latter end portion and the lower end portion 22b of the sub 22, to secure the sub to the housing. A seal ring 28 extends between an outer surface portion of the sub 22 and a corresponding inner surface portion of the housing 24.
A lower sub 30 is also provided which has an internally threaded upper end 30a portion that threadedly engages a corresponding externally threaded lower end portion 24b of the housing 34. A plurality of set screws 32, one of which is shown in FIG. 2, are angularly spaced around the circumference of the upper end portion 30a of the lower sub 30 and extend through aligned opening in the latter end portion and the lower end portion 24b of the housing 24, to secure the connection between the sub and the housing. A seal ring 34 extends between and outer surface portion of the housing 24 and a corresponding inner surface portion of the sub 30. The lower end portion of the lower sub 30 is externally threaded so as to enable internally threaded subs of ancillary equipment (not shown) to be attached to the device 20 as needed.
A tubular piston 40 is slidably mounted in the housing 24 and its outer surface is stepped to define an upper end portion 40a, an intermediate portion 40b extending just below the upper end portion, and a portion 40c that extends from the intermediate portion 40b to the lower end of the piston. The outer diameter of the intermediate portion 40b is greater than the diameter of the portions 40a and 40c, and a pair of axially spaced seal rings 42a and 42b extend between the outer surface portion of the intermediate portion 40b and corresponding inner surface portions of the housing 24. The lower end of the piston 40 tapers to a relative sharp point for reasons to be described.
A ring 46 is disposed in a space defined between the outer surface of the upper end portion 40a of the piston 40 and the corresponding inner surface of the housing 24. The ring 46 receives a plurality of angularly-spaced shear pins 48 that extend through aligned openings in the ring 44 and the upper end portion of the piston 40. The shear pins 48 thus normally retain the piston 40 in its upper position shown in FIG. 2, but are adapted to shear in response to a predetermined shear force applied thereto to release the piston and permit slidable movement of the piston downwardly in the housing 24, as will be explained. A plurality of angularly-spaced openings 40d, one of which is shown in the drawings, extend through the upper end portion 40a of the piston 40 just below the openings that receive the shear pins 48, for reasons that will also be explained.
The inner surface of the housing 24 is stepped so that the inner diameter of its lower portion is less than that of its upper portion to define an annular chamber 50 between the inner surface of the upper portion of the housing 24 and a corresponding outer surface of the piston 40. The relatively large-diameter intermediate portion 40b of the piston 40 defines the upper boundary of the chamber 50, and the reduced-diameter portion of the housing 24 defines its lower boundary. The chamber 50 accommodates movement of the intermediate portion 40b of the piston 40 during its downward movement. A seal ring 52 extends between an outer surface portion of the piston portion 40c and a corresponding inner surface portion of the reduced-diameter portion of the housing 24. Thus, the chamber 50 extends between the seal rings 42b and 52 to isolate the chamber from fluids and to maintain the pressure in the chamber at atmospheric pressure for reasons to be described.
The lower sub 30 has a stepped inner surface that defines a shoulder that receives a frangible disc 56, and a seal being 58 extends between the shoulder and the disc. The disc 56 is made of frangible material, such as glass that is adapted to shatter when impacted by the pointed lower end of the piston 40 with sufficient force. The end of the housing 24 abuts the disc 56, and a seal ring 60 is disposed between the latter end and the disc. A seal ring 62 extends between the outer surface of the disc 56 and the corresponding inner surface of the sub 30. The disc 56 is capable of withstanding relatively large differential pressures acting on its respective upper and lower surfaces far in excess of the amount of force required to shears the pins 48 as will be described.
In operation, a well fluid is introduced into the casing 10 from the ground surface at a sufficient pressure to block the flow of production fluid from the formation zone F (FIG. 1) through the perforations 10a and into the casing 10. When it is desired to recover the production fluid, the tubing string 12 is run into the casing 10 with the device 20 attached to the lower end of the string, and with the packer 16 provided in a section of the string just above the device 20.
The presence of the disc 56 in the lower end portion of the device 20 permits well fluid from the ground surface to be introduced into the tubing string 12 at an increased pressure to establish a hydrostatic load to allow the packer 16, and/or any ancillary devices to be hydraulically set in a conventional manner. During this operation, the pressure of the well fluid in the device 20 acts on the upper end of the piston 40 in a downwardly direction and on the lower end of the piston in an upwardly direction. Since the area of the annular upper end surface of the piston 40 is greater that the area of its annular lower end surface, a differential force is established which applies a shear force to the pins 48. However, the pins 48 are designed to normally resist the force and thus maintain the piston in its upper, static position of FIG. 2. This increased fluid pressure in the device 20 is controlled so that the resultant differential pressure across the disc 56 caused by the latter pressure acting on the upper surface of the disc 56, and the well fluid in the annulus 14 acting on the lower surface of the disc, does not exceed the design limit of the disc.
When the packer 16, and any ancillary devices, have been set in accordance with the above and it is then desired to recover production fluid from the formation zone F, the pressure of the well fluid in the tubing string 12 is increased. Since the upper end surface of the piston 40 has a larger area than its lower end, the shear force applied to the pins 48 will be increased until the pins are sheared, with the openings 40d increasing the volume of well fluid available to act on the upper surface of the piston 40. The piston 40 is thus forced downwardly and its pointed lower end strikes the disc 56 with enough force to shatter it. It is noted that the relatively low atmospheric pressure existing in the chamber 50 does not impede this downward movement of the piston 40 and that the above increase in hydrostatic load is selected so that the disc 56 can withstand the resulting differential pressure acting on its upper and lower surfaces. The pressure of the well fluid in the tubing string 12 is then reduced as necessary to allow the well fluid in the annulus, and then the production fluid from the formation zone F, to flow through the device 20 and the tubing string 12 to the ground surface and be recovered.
The device 20 thus enjoys several advantages. For example, it is relatively inexpensive and reliable, yet can withstand a great deal of differential fluid pressure and be activated with a predictable and relatively low amount of fluid pressure. Also, the amount of debris left in the wellbore is minimized since the material used in the frangible disc 56 is such that, one broken by the piston 40, it is reduced to small slivers or particles that can be flowed or circulated from the well. Further, the device 20 does not restrict the inner diameter of the well bore and thus allows other tools to pass through it and it does not require a profile sub or any actuation device that must be dropped into the tubing string or run into the string on wireline or coiled tubing.
The embodiment of FIGS. 4 and 5 is similar to the embodiment of FIGS. 2 and 3 and identical components are given the same reference numerals. According to the embodiment of FIGS. 4 and 5, a device 20' is provided which is identical to the device 20 of the embodiment of FIGS. 2 and 3 with the exception that, in the former device, a plurality of angularly-spaced ports, one of which is shown by the reference numeral 24c in FIGS. 4 and 5, are provided through the wall of the housing 24. The ports 24c are axially located relative to the housing 24 so that they register with the lower portion of the chamber 50 when the piston 40 is retained in its upper, static position by the shear pins 48 as shown in FIG. 4. Thus, the above-mentioned well fluid that is initially in the annulus 14 to maintain the production fluid in the formation zone F, as discussed above, will enter the chamber 50 through the ports 24c and exert an upwardly-directed pressure against the lower annular surface of the relative large diameter portion 40b of the piston 40.
As in the previous embodiment, the upper surface of the piston 40 has a greater surface area than the lower surface due to the relatively large diameter portion 40b. Therefore, there is one downwardly-directed force caused by the well fluid in the interior of the housing 24 acting on the upper surface of the piston 40 as described above and an upwardly directed force caused by the well fluid in the interior of the housing acting on the lower surface of the piston, also as described above. In addition, there is an additional upwardly-directed force by the well fluid in the annulus 14 acting on the lower annular surface of the relatively large diameter portion 40b of the piston. Also as in the previous embodiment, the shear pins 48 are designed to shear at a predetermined shear force applied thereto based on the difference of the above-mentioned forces acting on the piston 40. However, in this embodiment, the shear force can be much less than that of the embodiment of FIGS. 2 and 3 due to the presence of the last-mentioned upwardly directed force. Otherwise the operation of the device 20' is identical to that of the device 20 of the embodiment of FIGS. 2 and 3.
The device 20' of the embodiment of FIGS. 2 and 5 thus enjoys all of the advantages of the device 20 of the embodiment of FIGS. 2 and 3 and, in addition, the amount of shear force required to shear the pins 48, and therefore actuate the piston 40 of the former device is mush less than that of the latter device.
It is understood that variations can be made in the foregoing without departing from the scope of the invention. For example, although the tubing string 12 and the devices 20 and 20' are shown extending vertically, it is understood that this is only for the purpose of example and that, in actual use, they can extend at an angle to the vertical. Therefore, the use of the terms "upper", "lower", "upwardly", "downwardly", and the like, are only for the purpose of illustration only and do not limit the specific orientation and position of any of the components discussed above.
It is understood that other modifications, changes and substitutions are intended in the foregoing disclosure and in some instances some features of the invention will be employed without a corresponding use of other features. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the invention.
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A device and method for selectively controlling the flow of production fluid through a tubing string in an oil and gas well according to which a housing is connected to a tubing string for insertion into the well, and well fluid is passed from the ground surface into the housing. The housing is provided with a plug to establish well fluid pressure in the housing to actuate a packer and/or other ancillary devices. The plug can be removed from the hosing by increasing the pressure of the well fluid in the housing above a predetermined value, thus permitting the flow of production fluid from the formation zone, through the housing and the tubing string, and to the ground surface.
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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 material handling systems for stick-like articles, for example, railroad spikes. More specifically, the invention is a rake for moving railroad spikes from a storage location to a workstation.
2. Description of the Related Art
Railroad spikers used for assembly or repairing sections of railroad tracks typically utilize a wide variety of automatic and manual means for loading spikes into the spiker. Both automatic and manual loading methods require transport of the railroad spikes from a storage location to a location wherein they can be loaded into the spiker without causing entanglement of the spikes, and automatic spikers further require means for properly orienting the spikes and loading the properly oriented spike into the spiker.
An example of a proposed railroad spike material handling system includes a centerless auger rotating approximately 360° in the desired direction of travel for the spikes, and then backwards 45° in an attempt to untangle any tangled spikes. A vibrating storage bin may be used to feed spikes into the auger mechanism.
Another material handling system includes a horizontal conveyor leading from a spike hopper to a vertical conveyor having a plurality of projecting fingers for receiving the spikes and transporting them towards the upper portion of the spike feeder. As the spike is dropped into the spike feeder, it will strike a ridge, causing the spike to be aligned either perpendicular to the spike's direction of travel, or with the spike point facing the direction of travel. Camming walls then ensure that all spikes are oriented with the point facing the direction of travel. Once the spike is so oriented, it falls into the spike-driving assembly.
Spike material handling systems designed to vibrate, stir, tumble, or auger the spikes to the desired location typically have varying degrees of success, due to the tendency of the spikes to entangle with each other.
Yet another presently used spike distribution system includes a powered winch for lifting containers of spikes, and emptying them in a location wherein an operator may reach the spikes and load them into a spike driver.
Accordingly, a spike distribution system preventing entanglement of the spikes during transportation is desired. Additionally, a spike distribution system having greater efficiency, and not producing excessive noise, is also desired.
SUMMARY OF THE INVENTION
The present invention is a spike distribution system for delivering spikes from a storage location to a location wherein they may be reached by an operator for loading into a spiker. The spike distribution system includes a spike rake for moving the spikes from the storage location to the operator's location.
The spike rake includes a horizontally oriented rake head having a plurality of prongs on either end of the head. The prongs are dimensioned and configured to engage a spike either along its length or at the spike head. The rake is pivotally secured to an arm that may be raised or lowered to engage the spikes at the top of the storage location. An example of means for raising and lowering the arm include a hydraulic cylinder secured between the end of the arm and the shaft. The pivotal attachment of the rake permits the rake to remain horizontal due to the effects of gravity as the rake is raised and lowered and to permit the rake to pivot to correspond to the top of a pile of spikes. The arm is secured to a substantially vertical shaft that may be rotated to change the position of the rake, with an example of means for rotating the shaft being a hydraulic cylinder secured to another arm extending a short distance from the shaft.
Spikes will typically be stored in bulk behind the operator of the spike driver. The operator's workstation will typically include at least one location adjacent to the operator's seat wherein a small number of spikes may be stored within reach of the operator. A spike rake assembly will be located behind and to one side of the operator, wherein it may be used to move spikes from the storage location to the operator's work station. When additional spikes are needed at the operator's work station, the shaft may be rotated to locate the spike rake above the pile of spikes. The rake will pivot to maximize the number of prongs in contact with the spikes. The arm is then lowered to bring the spike rake into contact with the top of the pile of spikes. The shaft is then rotated to move the spike rake towards the operator's workstation while maintaining a small amount of downward pressure on the spike rake, thereby enabling the spike rake to peel some spikes from the top of the pile of spikes without causing entanglement of the spikes. Once the spike rake has reached the storage location at the operator's work station, the arm may be raised, and the spike rake again rotated towards the storage location in preparation to transfer the next set of spikes. The operator may then reach the storage location at his workstation, grab a spike, and load it into the spike driver for driving through a tie plate and railroad tie.
A preferred workstation for a spiker operator will include two small storage areas for spikes within reach of the operator, with one storage area on each side of the operator. One spike rake will be positioned to transfer spikes into each storage area, so that the operator will control a total of two spike rakes.
It is therefore an aspect of the present invention to provide a spike distribution system preventing entanglement of the spikes.
It is another aspect of the present invention to provide a spike distribution system having a high efficiency.
It is a further aspect of the present invention to provide a spike distribution system avoiding generation of excess noise.
It is another aspect of the present invention to provide a spike rake for peeling spikes from the top of a spike pile, and transferring them to a location wherein a spiker operator may reach them.
These and other aspects of the invention will become apparent through the following description and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front isometric view of a spike distribution system according to the present invention.
FIG. 2 is an isometric view of a spike rake assembly for a spike distribution system according to the present invention.
FIG. 3 is a top view of a spike distribution system according to the present invention.
Like reference numbers denote like elements throughout the drawings.
DETAILED DESCRIPTION
The present invention is a material distribution system for elongated objects. The material distribution system transfers the elongated objects from a storage location, located behind an operator's seat, to a destination location, wherein the elongated objects may be reached by the operator. Although not limited to such use, the material handling system of the present invention is particularly useful for transferring railroad spikes from a storage location to a location wherein they may be reached by the operator of a spike driver, and the invention will be described herein based on this example embodiment.
Referring to FIG. 1, a typical workstation for the operator of a spike driving apparatus is illustrated. The workstation 10 includes an operator's chair 12 , located in a position enabling the human operator to easily reach the spike driving apparatus (not shown, and well known in the art) for loading spikes into the apparatus. A bulk storage bin 14 for the spikes is located behind the operator's chair 12 . The bulk storage bin 14 includes a floor 16 , front wall 18 , rear wall 20 , and angled side walls 22 . The workstation 10 also includes at least one, and more preferably two, small operator-accessible storage bins 24 , located within easy reach of the operator's chair 12 . The illustrated example includes two small storage bins 24 , with one bin 24 on either side of the operator's chair 12 . Each bin 24 includes a floor 26 , at approximately the same height or slightly lower than the floor 16 of the bulk storage bin 14 . The small storage bins 24 also include front walls 28 , and side walls 30 . A passageway 32 is defined between the ends 34 of the spike bin's front wall 18 , and the ends 36 of the bulk spike bin's side walls 22 . The bulk spike bin 14 is therefore in communication with the small storage bins 24 , permitting passage of spikes from the bulk spike 14 to the smaller storage bins 24 . The workstation 10 also includes at least one spike rake assembly 38 for each small storage bin 24 , with a preferred total number of spike rakes 38 at a workstation 10 being two.
The spike rake assembly 38 is best illustrated in FIG. 2 . The spike rake assembly 38 includes a shaft 40 , rotatably mounted on the workstation 10 . The shaft 40 has a lower portion 42 including an arm 44 connected between the shaft 40 and the means for rotating the shaft. The illustrated example includes a hydraulic cylinder 46 pivotally secured to the arm 44 for rotating the shaft 40 . Extending the hydraulic cylinder 46 thereby rotates the shaft 40 in one direction, and retracting the hydraulic cylinder 46 rotates the shaft 40 in the opposite direction.
The top end portion 48 of the shaft 40 includes a boom assembly 50 . The boom assembly 50 includes a boom 52 , pivotally secured at the top portion 48 of the shaft 40 , so that it may pivot within a vertical plane. The outer end 54 of the boom 52 preferably includes a downwardly extending arm 56 . The boom assembly 50 also includes a hydraulic cylinder 58 , extending between the top portion 48 of the shaft 40 , and the outward end 54 of the boom 52 . The hydraulic cylinder 58 is pivotally secured at each of these locations. Extending the hydraulic cylinder of the illustrated example lowers the boom 52 , and retracting the hydraulic cylinder 58 raises the boom 52 .
A spike rake is pivotally secured to the outer end 54 of the boom 52 , preferably at the end of the arm 56 by the pivot 70 . The spike rake 60 includes a base portion 62 and at least one set 64 of prongs 66 . The illustrated example includes a horizontal, substantially planar base portion 62 , having a pair of prong sets 64 , with one prong set 64 located adjacent to the front of the base 62 , an the other prong set 64 located adjacent to the rear of the base 62 . The prongs 66 are dimensioned and configured to permit passage of the body portion of a railroad spike, but not the head portion of the railroad spike between them. The prongs 66 are preferably pointed approximately in the spike rake's direction of travel along the arcuate path between the bulk storage bin 16 and small storage bin 24 and angled downward. The pivot 70 permits the rake 60 to pivot about an axis that is substantially horizontal and substantially parallel to its direction of travel along its arced path from the bulk storage bin 14 to the operator-accessible bin 24 .
Operation of the spike rake assembly 38 is best illustrated in FIGS. 3 . The spike rake assembly is controlled by the joystick 68 . When the human operator seated in the chair 12 wishes to move additional spikes from the bulk storage bin 14 to either of the smaller storage bins 24 , the operator uses the joystick 68 to retract the hydraulic cylinder 46 , thereby rotating the shaft 40 to bring the spike rake 60 to a first position (shown by rake assembly 38 a in FIG. 3 ), corresponding to one end of its range of travel. The operator next uses the joystick 68 to extend the hydraulic cylinder 58 , thereby lowering the spike rake 60 on top of the pile of spikes within the bin 14 , and applying a small amount of downward pressure to the rake 62 . The operator may control the degree of downward pressure by the extent to which he moves the joystick 68 , thereby providing only the desired amount of downward pressure. While maintaining this downward pressure, the operator again manipulates the joystick 68 to extend the hydraulic cylinder 46 , thereby moving the spike rake 60 from a first position above the pile of spikes in the bulk spike bin 14 to a second position above the smaller storage bin 24 .
As the spike rake 60 moves from the first position to the second position (shown by rake 38 b in FIG. 3 ), railroad spikes are peeled off the top of the pile by the prongs 66 , catching between and in front of the prongs 66 , and thereby being pushed along with the spike rake 60 towards the small storage bin 24 . During this movement, the operator may choose to further extend the hydraulic cylinder 58 , lowering the spike rake 60 to maintain contact with the railroad spikes as lower portions of the spike pile are encountered. Additionally, the spike rake 60 may pivot around the pivot 70 to maximize the number of prongs 66 in contact with the spikes if the spike rake 60 contacts the pile of spikes at a position wherein the spike pile is not horizontal. Once the second position has been reached, the operator may again manipulate the joystick 68 to retract the hydraulic cylinder 58 , thereby raising the spike rake 60 , and to retract the hydraulic cylinder 46 , thereby moving the spike rake 60 to a position wherein it will be out of the way of his reaching the spikes within the small storage bin 24 , and loading them into the spike driving apparatus.
While a specific embodiment of the invention has been described in detail, it will be appreciated by those skilled in the art that various modifications and alternatives to those details could be developed in light of the overall teachings of the disclosure. Accordingly, the particular arrangements disclosed are meant to be illustrative only and not limiting as to the scope of the invention which is to be given the full breadth of the appended claims and any and all equivalents thereof.
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A material distribution system for stick-like objects such as railroad spikes includes a rake for peeling the stick-like objects from the top of a pile, and transferring them to another location, for example, where they might be reached by a human operator. Use of the rake to peel the object from the top of the pile, with minimized downward pressure applied by the rake, minimizes the tendency of the objects to entangle with each other.
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TECHNICAL FIELD OF THE INVENTION
[0001] The present invention relates in general to the field of oil recovery, and more particularly, to a process for altering wettability using altering fluids through a subterranean oil-bearing formation to enhance oil recovery therefrom.
STATEMENT OF FEDERALLY FUNDED RESEARCH
[0002] None.
INCORPORATION-BY-REFERENCE OF MATERIALS FILED ON COMPACT DISC
[0003] None.
BACKGROUND OF THE INVENTION
[0004] Without limiting the scope of the invention, its background is described in connection with oil recovery. Stimulation of subterranean hydrocarbon reservoirs and injector wells are widely carried out in the oilfield services industry and include matrix acidizing, hydraulic fracturing, acid-fracturing, sand control, enhanced oil-recovery, etc. use aqueous fluids to impact hydrocarbon productivity. However, the majority of the aqueous fluids are executed with little knowledge of or consideration for the wettability (water-wet or oil-wet) or the partial water/oil saturation of the rock being treated.
[0005] A variety of supplemental recovery techniques have been employed in order to increase the recovery of oil from subterranean reservoirs. The most widely used supplemental recovery technique is fluid flooding which involves the injection of a fluid, such as water or a miscible solvent into an oil-bearing reservoir. As the fluid moves through the reservoir, it acts to displace oil therein to a production system of wells through to recover oil.
[0006] Many oil-wet/mixed-wet fractured reservoirs employ gravity drainage to recover oil. The gravity drainage is caused by the density difference between the injected fluid (e.g., gas, steam, water, surfactant-water), and oil. The gravity drainage is often controlled by the thickness of the pay zone, even though vertical barriers are present in the matrix which is broken up into several layers. The oil drains out of the top layers into the vertical fractures, but reimbibes into the underneath layer because the matrix is oil-wet/mixed-wet. Thus, the drainage rate is inversely proportional to the total height of the whole pay zone and therefore it is slow.
[0007] U.S. Pat. No. 4,842,065, entitled “Oil recovery process employing cyclic wettability alteration,” discloses a surfactant solution injected into an oil-wet fractured formation and becomes the preferred wetting phase of the matrix blocks in the formation thereby displacing oil from the matrix blocks into the fracture network. The formation is then flooded with water to displace the oil from the fracture network to the surface while returning the matrix blocks to an oil-wet condition. The injection cycle is repeated until the formation is depleted.
[0008] U.S. Pat. No. 5,042,580, entitled “Oil recovery process for use in fractured reservoirs,” discloses a process for recovering oil from fractured formations which involves altering the wettability of the formation, particularly at the interface of the fracture and rock matrix. The process improves the ability of injected fluids flowing in the fracture to enter the rock matrix to displace oil.
[0009] U.S. Pat. No. 7,921,911, entitled “Surface-modifying agents for wettability modification,” discloses a method and composition for treating a subterranean formation with a fluid including a particulate and an organosilane with the chemical formula R n SiX 4-n , wherein n is equal to 1, 2, or 3, R is an organic functional group, and X is a halogen, alkoxy, or acetoxy group, introducing the fluid into a subterranean formation with exposed surfaces, and modifying the wettability of a surface of the particulate or subterranean formation or both. A method and composition for treating a subterranean formation with a fluid including a particulate and an organosilane, introducing the fluid into a subterranean formation with exposed surfaces, and modifying the wettability of the proppant or surfaces or both, wherein the wettability modification degrades. The entire contents of which are incorporated herein by reference.
SUMMARY OF THE INVENTION
[0010] Current gravity drainage technology in oil-wet/mixed-wet fractured rocks allows reimbibition of oil into underneath layers since the rock imbibes oil. The present invention provides methods and compositions to make the rock more water-wet so that oil reimbibition can be prevented to increase the oil drainage rate during gravity drainage.
[0011] In a gravity-drainage process, a small amount of a rate enhancer is injected into the fractures in terms of an aqueous solution or foam before or during gas or steam injection from the top (or water/surfactant-water injection from the bottom). The treatment can be repeated periodically if the effect of the chemical degrades over the long drainage time.
[0012] The present invention provides a process for enhancing oil recovery from an oil-wet/mixed-wet fractured oil-bearing formation by identifying a fractured reservoir comprising a multilayered matrix, in communication with a fracture at a matrix-fracture interface; providing an injection fluid comprising a wettability altering agent; injecting the injection fluid into the fractured reservoir; contacting the matrix at the matrix-fracture interface with the wettability altering agent; and altering the wettability of the matrix-fracture interface to a more hydrophilic state, wherein oil produced from the upper matrix flows within the fracture instead of reimbibing into the lower matrix underneath. The injection fluid may be any injection fluid with a wettability altering agent or a foam of this injection fluid and a gas. The injection fluid may be injected into the fractured reservoir at a reservoir top, a reservoir bottom or both and the injection may be before or during the gravity drainage process into the fracture. The wettability altering agents include cationic surfactants, anionic surfactants, nonionic surfactants, aqueous ions, chelating agents, sequestration agents, acids, alkali, solvents, silanes, fatty acid complexes, and aromatic/asphaltic oils. For example, the wettability altering agent is sodium polyacrylate (NaPA), ENORDET® A092 or both.
[0013] The present invention provides a method for treating a subterranean formation with a wettability altering agent by forming a fluid comprising a wettability altering agent; introducing the fluid into a subterranean formation with exposed surfaces; and modifying the wettability of the particulate or surfaces or both, wherein the wettability modification results in oil flowing within a fracture instead of reimbibing. The injection fluid may be any injection fluid with a wettability altering agent or a foam of this injection fluid and a gas. The injection fluid may be injected into the subterranean formation at a reservoir top, a reservoir bottom or both and the injection may be before or during the gravity drainage process into the subterranean formation. The wettability altering agent include cationic surfactants, anionic surfactants, nonionic surfactants, aqueous ions, chelating agents, sequestration agents, acids, alkali, solvents, silanes, fatty acid complexes, and aromatic/asphaltic oils. For example, the wettability altering agent is sodium polyacrylate (NaPA), ENORDET® A092 or both.
[0014] The present invention provides a process for increasing a gravity drainage rate for oil recovery in oil-wet/mixed-wet fractured oil-bearing formation by identifying a fractured reservoir comprising an upper matrix, a lower matrix in communication with a fracture at a matrix-fracture interface; providing an injection fluid comprising a wettability altering agent; injecting the injection fluid into the fractured reservoir; contacting the upper matrix and the lower matrix at the matrix-fracture interface with the wettability altering agent; and altering the wettability of the matrix-fracture interface to a more hydrophilic state to increase the gravity drainage rate, wherein oil produced from the upper matrix flows within the fracture instead of reimbibing into the lower matrix underneath. The injection fluid may be any injection fluid with a wettability altering agent or a foam of this injection fluid and a gas. The injection fluid may be injected into the fractured reservoir at a reservoir top, a reservoir bottom or both and the injection may be before or during the gravity drainage process into the fracture. The wettability altering agent include cationic surfactants, anionic surfactants, nonionic surfactants, aqueous ions, chelating agents, sequestration agents, acids, alkali, solvents, silanes, fatty acid complexes, and aromatic/asphaltic oils. For example, the wettability altering agent is sodium polyacrylate (NaPA), ENORDET® A092 or both.
[0015] The present invention provides a process for increasing oil recovery from a water-wet fractured oil-bearing formation employing gravity drainage techniques by identifying a fractured reservoir comprising an upper matrix, a lower matrix in communication with a fracture at a matrix-fracture interface; providing an injection fluid comprising a wettability altering agent; injecting the injection fluid into the fractured reservoir; contacting the upper matrix and the lower matrix at the matrix-fracture interface with the wettability altering agent; and altering the wettability of the matrix-fracture interface to a more hydrophilic state, wherein oil produced from the upper matrix flows within the fracture instead of reimbibing into the lower matrix underneath to increase oil recovery. The injection fluid may be any injection fluid with a wettability altering agent or a foam of this injection fluid and a gas. The injection fluid may be injected into the fractured reservoir at a reservoir top, a reservoir bottom or both and the injection may be before or during the gravity drainage process into the fracture. The wettability altering agent include cationic surfactants, anionic surfactants, nonionic surfactants, aqueous ions, chelating agents, sequestration agents, acids, alkali, solvents, silanes, fatty acid complexes, and aromatic/asphaltic oils. For example, the wettability altering agent is sodium polyacrylate (NaPA), ENORDET® A092 or both.
[0016] The present invention provides a process for recovering oil from a water-wet fractured oil-bearing formation having an injection well and production well in fluid communication with a substantial portion of the formation by identifying a fractured reservoir comprising an upper matrix, a lower matrix in communication with a fracture at a matrix-fracture interface; providing an injection well and a production well in the fractured reservoir; providing an injection fluid comprising a wettability altering agent; injecting the injection fluid into the injection well, contacting the upper matrix and the lower matrix at the matrix-fracture interface with the wettability altering agent; and altering the wettability of the matrix-fracture interface to a more hydrophilic state, wherein oil produced from the upper matrix flows within the fracture instead of reimbibing into the lower matrix underneath to increase oil recovery. The injection fluid may be any injection fluid with a wettability altering agent or a foam of this injection fluid and a gas. The injection fluid may be injected into the fractured reservoir at a reservoir top, a reservoir bottom or both and the injection may be before or during the gravity drainage process into the fracture. The wettability altering agent include cationic surfactants, anionic surfactants, nonionic surfactants, aqueous ions, chelating agents, sequestration agents, acids, alkali, solvents, silanes, fatty acid complexes, and aromatic/asphaltic oils. For example, the wettability altering agent is sodium polyacrylate (NaPA), ENORDET® A092 or both.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] For a more complete understanding of the features and advantages of the present invention, reference is now made to the detailed description of the invention along with the accompanying figures and in which:
[0018] FIG. 1 is an image of the drainage of oil by gas in a layered fractured reservoir and reimbibition of oil into underneath blocks.
[0019] FIG. 2 is an image of the drainage of oil by gas in a layered fractured reservoir without reimbibition of oil into underneath blocks.
[0020] FIG. 3 is a graph of the imbibition oil recovery profiles for the different combinations of sodium polyacrylate (NaPA) and ENORDET® A092, at 100° C. and neutral pH.
DETAILED DESCRIPTION OF THE INVENTION
[0021] While the making and using of various embodiments of the present invention are discussed in detail below, it should be appreciated that the present invention provides many applicable inventive concepts that can be embodied in a wide variety of specific contexts. The specific embodiments discussed herein are merely illustrative of specific ways to make and use the invention and do not delimit the scope of the invention.
[0022] To facilitate the understanding of this invention, a number of terms are defined below. Terms defined herein have meanings as commonly understood by a person of ordinary skill in the areas relevant to the present invention. Terms such as “a”, “an” and “the” are not intended to refer to only a singular entity, but include the general class of which a specific example may be used for illustration. The terminology herein is used to describe specific embodiments of the invention, but their usage does not delimit the invention, except as outlined in the claims.
[0023] Many oil-wet/mixed-wet fractured reservoirs employ gravity drainage to recover oil. The gravity drainage is caused by the density difference between the injected fluid (e.g., gas, steam, water, surfactant water) and oil. The gravity drainage is often controlled by the thickness of the pay zone, even though vertical barriers are present in the matrix and the matrix is broken up into several layers. The oil drains out of the top layers into the vertical fractures, but reimbibes into the underneath layer because the matrix is oil-wet/mixed-wet. Thus, the drainage rate is inversely proportional to the total height of the whole pay zone. The goal of this invention is to prevent the reimbibition of oil into underneath layers to increase the oil drainage rate. For example, in a gas-oil drainage process, a small amount of wettability altering agent will be injected periodically into the fractures in terms of an aqueous solution or foam before or during gas injection from the top. The wettability-altering agent will imbibe into the near-fracture region of the matrix and change the wettability to a more water wetting (hydrophilic) state only in that region. Thus, the oil produced from higher layers will flow in the fractures instead of reimbibing into the underneath matrix layers. The treatment of wettability agent can be repeated periodically if the wettability agent degrades over the long time. The wettability agent can be any water-wetting chemicals including surfactants (cationic, nonionic or anionic), aqueous ions, chelating agents, sequestration agents, acids, alkali, and solvents.
[0024] The gravity drainage is caused by the density difference between the injected fluid and oil and is controlled by vertical oil permeability in the matrix, viscosity of oil, and capillary forces. Hagoort (1980) describes an analytical solution for immiscible gas drainage in a homogeneous matrix block. Approximating the flow to be one-dimensional, the drainage rate is constant in the initial period followed by a decline after gas breakthrough. The initial drainage rate, q, is given by
[0000] q=Ak z ( k ro /μ o )Δρ g (1- H c /H ),
[0000] wherein A is the cross-sectional area, k z is the vertical permeability, k ro is the oil permeability at the initial condition, μ o is the oil viscosity, Δρ is the density difference, g is the acceleration due to gravity, H is the height of the matrix block, and H c is the capillary hold-up height. This analysis has been improved including the width of the matrix blocks (Clemens & Wit, 2001). Since for a given matrix block oil volume V oi , the area:
[0000] A=V oi /( HφS oi ),
[0000] the oil drainage rate is inversely proportional to the height of the matrix block.
[0025] FIG. 1 is an image of the drainage of oil by gas in a layered fractured reservoir and reimbibition of oil into underneath blocks. In layered reservoirs, oil drains out of the top layers into the vertical fractures, but reimbibes into the underneath layer because the matrix is oil-wet/mixed-wet (Firoozabadi et al., 1991). Thus, the drainage rate is controlled by the total height of the whole pay zone. In the past, several methods have been developed to increase the oil drainage rate (Boerrigter et al., 2007). Gravity drainage with steam increases the reservoir temperature and reduces the oil viscosity. This process is limited by the thermal diffusion and is energy intensive because the whole reservoir needs to be heated up. Gravity drainage by miscible gas injection increases oil recovery by reducing interfacial tension between oil and gas. Availability of miscible gas is a potential issue for this process. Surfactant water can be injected into fractures from the bottom. Surfactants can reduce the capillary holdup; this process is also slow because the density difference is smaller between oil and water than between oil and gas (Seethepalli et al., 2004). Pressurization followed by surfactant water injection has been proposed which accelerates surfactant penetration into the matrix (Adibhatla & Mohanty, 2011). The present invention provides a method and compositions to increase the oil drainage rate by preventing the reimbibition of oil into underneath layers.
[0026] The oil drained out of the top block into the fracture in FIG. 1 reimbibes into the underneath matrix block because the matrix is oil-wet or mixed-wet. If the matrix at the matrix-fracture interface can be made more water-wet, the oil would flow down the fracture instead of imbibing back into the matrix. FIG. 2 sketches such a scenario.
[0027] FIG. 2 is an image of the drainage of oil by gas in a layered fractured reservoir without reimbibition of oil into underneath blocks. In this case, the oil drainage rate would be higher because each layer will contribute oil independently. The oil rate is now inversely proportional to thickness of each layer instead of thickness of the whole pay zone. If the zone consists of 10 equal layers, then the oil drainage rate would increase 10 times.
[0028] A small amount of wettability altering agent can be injected periodically into the fractures in terms of an aqueous solution or foam before or during gas injection from the top. Similar technique can also be applied for water injection or aquifer invasion from the bottom. The wettability-altering agent will imbibe into the near-fracture region of the matrix and change the wettability to a more water-wetting (hydrophilic) state only in that region. Thus, the oil produced from higher layers will flow in the fractures instead of reimbibing into the underneath matrix layers. The treatment of wettability agent can be repeated periodically if the wettability agent degrades over the long time. The wettability agent can be any water-wetting chemicals including surfactants (cationic, nonionic or anionic), aqueous ions, chelating agents, sequestration agents, acids, alkali, and solvents.
[0029] FIG. 3 shows the imbibition oil recovery profiles for the different combinations of sodium polyacrylate (NaPA) and ENORDET® A092, at 100° C. and neutral pH. FIG. 3 shows one example of oil recovery by spontaneous imbibition of several aqueous solutions in laboratory cores (Chen & Mohanty, 2014). These core samples were saturated with oil and connate brine Immersing such cores in formation brine does not lead to any spontaneous imbibition of brine. A092 is a surfactant and reduces interfacial tension between water and oil. The addition of NaPA and use of softened sea water makes the rock more water-wet. Increase in wettability alteration increases spontaneous imbibition of water and oil drainage rate. Wettability altering agents depend on the rock, reservoir oil, and brine composition. Once the target reservoir is identified, laboratory tests can be done to identify the wettability altering materials.
[0030] Wettability alteration (without gravity drainage) is a slow process. Stoll et al. (2007) claim that it is controlled by diffusion of wettability modifiers, with an effective diffusion coefficient of about 10 −11 m 2 /s. Thus, altering the wettability of the interfacial region (near the fracture-matrix interface) can be fairly quick (hours), but that of a whole matrix block of size 10 m would take a long time (decades). The present process overcomes this time-scale difficulty by targeting the wettability alteration of the fracture-matrix interfacial region.
[0031] The present invention provides the injection of a small amount of wettability altering material before or during the gravity drainage process into the fracture. The amount of material should be sufficient to change the wettability of the matrix-fracture interfacial region to a depth of a few cm. If in a gas-oil drainage process, brine with the wettability altering agent is injected into the fracture, the brine will flow down the fracture while imbibing into the fracture. The flow in the fracture may be unstable depending on the fracture width, injection rate. For getting 100% coverage in the matrix-fracture interface, the flow of brine has to be stable. The stability could be achieved by injecting a foam of brine (with wettability altering agents) and gas. The normal gravity drainage process can be continued after the injection of the wettability alteration material. The wettability alteration material will make the fracture- matrix surface hydrophilic and prevent re-imbibition of oil produced from upper layers.
[0032] The wettability alteration material deposited in the matrix may degrade over the long life time of the reservoir. This will be detected if the oil drainage rate decreases to the before treatment level. In such cases, the wettability alteration treatment can be repeated periodically.
[0033] This wettability alteration treatment can be applied to all gravity drainage processes (e.g., gas-oil gravity drainage, steam-oil gravity drainage, water-oil gravity drainage, surfactant-water gravity drainage, etc.).
[0034] The present invention uses sodium polyacrylate (NaPA) as an example; other reagents include acrylate/alkyl-acrylate cross-polymer, e.g., acrylate/C10-30 alkyl-acrylate cross-polymer, poly C10-30 alkyl-acrylate, Potassium acrylate/C10-30 alkyl-acrylate cross-polymer, Sodium acrylate/C10-30 alkyl acrylate cross-polymer; polyacrylate, e.g., potassium aluminum polyacrylate, potassium polyacrylate, sodium polyacrylate, sodium polyacrylate starch, ammonium polyacrylate and glyceryl polyacrylate; sodium polyacrylate, polyacrylamide, sodium carboxymethylcellulose, and polyacrylonitrile.
[0035] It is contemplated that any embodiment discussed in this specification can be implemented with respect to any method, kit, reagent, or composition of the invention, and vice versa. Furthermore, compositions of the invention can be used to achieve methods of the invention.
[0036] It will be understood that particular embodiments described herein are shown by way of illustration and not as limitations of the invention. The principal features of this invention can be employed in various embodiments without departing from the scope of the invention. Those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, numerous equivalents to the specific procedures described herein. Such equivalents are considered to be within the scope of this invention and are covered by the claims.
[0037] All publications and patent applications mentioned in the specification are indicative of the level of skill of those skilled in the art to which this invention pertains. All publications and patent applications are herein incorporated by reference to the same extent as if each individual publication or patent application was specifically and individually indicated to be incorporated by reference.
[0038] The use of the word “a” or “an” when used in conjunction with the term “comprising” in the claims and/or the specification may mean “one,” but it is also consistent with the meaning of “one or more,” “at least one,” and “one or more than one.” The use of the term “or” in the claims is used to mean “and/or” unless explicitly indicated to refer to alternatives only or the alternatives are mutually exclusive, although the disclosure supports a definition that refers to only alternatives and “and/or.” Throughout this application, the term “about” is used to indicate that a value includes the inherent variation of error for the device, the method being employed to determine the value, or the variation that exists among the study subjects.
[0039] As used in this specification and claim(s), the words “comprising” (and any form of comprising, such as “comprise” and “comprises”), “having” (and any form of having, such as “have” and “has”), “including” (and any form of including, such as “includes” and “include”) or “containing” (and any form of containing, such as “contains” and “contain”) are inclusive or open-ended and do not exclude additional, unrecited elements or method steps. In embodiments of any of the compositions and methods provided herein, “comprising” may be replaced with “consisting essentially of” or “consisting of”. As used herein, the phrase “consisting essentially of” requires the specified integer(s) or steps as well as those that do not materially affect the character or function of the claimed invention. As used herein, the term “consisting” is used to indicate the presence of the recited integer (e.g., a feature, an element, a characteristic, a property, a method/process step or a limitation) or group of integers (e.g., feature(s), element(s), characteristic(s), propertie(s), method/process steps or limitation(s)) only.
[0040] The term “or combinations thereof” as used herein refers to all permutations and combinations of the listed items preceding the term. For example, “A, B, C, or combinations thereof” is intended to include at least one of: A, B, C, AB, AC, BC, or ABC, and if order is important in a particular context, also BA, CA, CB, CBA, BCA, ACB, BAC, or CAB. Continuing with this example, expressly included are combinations that contain repeats of one or more item or term, such as BB, AAA, AB, BBC, AAABCCCC, CBBAAA, CABABB, and so forth. The skilled artisan will understand that typically there is no limit on the number of items or terms in any combination, unless otherwise apparent from the context.
[0041] As used herein, words of approximation such as, without limitation, “about”, “substantial” or “substantially” refers to a condition that when so modified is understood to not necessarily be absolute or perfect but would be considered close enough to those of ordinary skill in the art to warrant designating the condition as being present. The extent to which the description may vary will depend on how great a change can be instituted and still have one of ordinary skilled in the art recognize the modified feature as still having the required characteristics and capabilities of the unmodified feature. In general, but subject to the preceding discussion, a numerical value herein that is modified by a word of approximation such as “about” may vary from the stated value by at least ±1, 2, 3, 4, 5, 6, 7, 10, 12 or 15%.
[0042] All of the compositions and/or methods disclosed and claimed herein can be made and executed without undue experimentation in light of the present disclosure. While the compositions and methods of this invention have been described in terms of preferred embodiments, it will be apparent to those of skill in the art that variations may be applied to the compositions and/or methods and in the steps or in the sequence of steps of the method described herein without departing from the concept, spirit and scope of the invention. All such similar substitutes and modifications apparent to those skilled in the art are deemed to be within the spirit, scope and concept of the invention as defined by the appended claims.
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The present invention provides a method for treating a fractured oil-wet/mixed-wet subterranean formation with a wettability altering agent by forming a fluid comprising a wettability altering agent; introducing the fluid into the fractures of a subterranean formation; and modifying the wettability of the formation near the fracture surface, wherein the wettability modification results in oil flowing within a fracture instead of reimbibing.
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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 No. 60/356,785, filed Feb. 13, 2002.
TECHNICAL FIELD
The present invention is directed to a method and apparatus for enhancing safety within a work zone and particularly directed to enhancing worker safety in the work zone associated with a work vehicle operating on a construction site.
BACKGROUND OF THE INVENTION
It is desirable to enhance worker safety particularly that of ground personnel working around the area of heavy equipment such as a construction vehicles on a construction site. If an operator of a large construction vehicle does not see a ground worker near such equipment, it is possible for a strike and run-over incident to occur.
SUMMARY OF THE INVENTION
An apparatus for enhancing the safety in a work zone surrounding operating equipment including means for identifying workers within said work zone and means for warning unauthorized workers within said work zone.
A method for enhancing the safety in a work zone surrounding operating equipment including the steps of identifying workers within said work zone and warning unauthorized workers within said work zone.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other features and advantages of the present invention will become apparent to those skilled in the art to which the present invention relates upon reading the following description with reference to the accompanying drawings, in which:
FIG. 1 is a schematic illustration of a construction vehicle and workers using a safety apparatus in accordance with the present invention;
FIG. 2 is a schematic illustration of a vehicle control unit in accordance with the present invention;
FIG. 3 is a schematic illustration of a worker's portable warning unit in accordance with the present invention;
FIG. 4 is a flow diagram of a control process for the vehicle controller in accordance with the present invention; and
FIG. 5 is a flow diagram of a control process for the worker's portable warning unit in accordance with the present invention.
DESCRIPTION OF PREFERRED EMBODIMENT
Referring to the drawings, each vehicle 20 on a construction site 22 includes an associated vehicle mounted transceiver unit 24 mounted in the operator cab 26 and accessible to the vehicle operator 28 . Each ground worker 30 , 32 , 34 wears an associated portable worker transceiver while he is on the construction site 22 .
The vehicle mounted transceiver unit 24 may be mounted within the cab 26 and connected to the vehicle battery 48 for power so that when the vehicle 20 is turned on, i.e., is operating, the vehicle mounted transceiver unit 24 is powered. Alternatively, the vehicle mounted transceiver unit can be removably mounted within the vehicle cab, e.g., magnetically, Velcro, etc., and is connectable to the vehicle battery 48 via a plug in socket such as a cigarette-type socket 50 . The vehicle mounted transceiver unit 24 could alternatively be powered by a self-contained battery.
The vehicle mounted transceiver unit 24 transmits a communication signal through an antenna 56 having a signal strength that transmits over an area having an adjustable or selectable radius 60 surrounding the vehicle 20 . This area surrounding the vehicle over which the vehicle's transmitted signal can be received is referred to as the zone of danger or work zone of the vehicle. Since the zone of danger is vehicle-type dependent, e.g., backhoe, crane, etc., the size of the zone established by the vehicle transceiver is preferably adjustable. Alternatively, a particular vehicle mounted transceiver unit can be specifically arranged to have a fixed transmission diameter if it is going to be mounted in a known vehicle. Having the transmission diameter or work zone area variable allows a more universal application of a single vehicle mounted transceiver unit that can be used in any construction vehicle type. The present invention is also applicable to other heavy operating equipment such as a crane.
The signal emitted by the vehicle mounted transceiver unit 24 can be a radio-frequency (“RF”) signal having controllable signal strength. Those skilled in the art will appreciate that other types of known communication signal may be used.
The size of the vehicle work zone or zone of danger surrounding a work vehicle is further dependent on the type and congestion of a particular construction site. In a typical congested construction site, it is anticipated that the signal strength for a front-end loader would be adjusted to provide a 15-foot danger zone around the vehicle. In a quarry operation where it is rare for ground personnel to be near the heavy equipment work vehicles, a 50-foot zone could be established.
The vehicle mounted transceiver unit 24 would include a display 70 , a data entry device 72 such as a keyboard or keypad, an audible warning device 74 , a visual warning device 76 , and a signal strength adjustment device 78 . The codes that match worker's portable units 40 that are permitted to be in the work area 80 can be entered through the data entry device 72 . Signal strength to control the size of the work or danger zone 80 can be adjusted via the control 78 or alternatively through the data entry device 72 .
The worker's portable warning device 40 is attachable to the worker's helmet or clothing in any known manner of attachment. The device 40 includes an antenna 90 for receiving and transmitting signals from and to vehicle mounted control units of vehicles or equipment within the construction site 22 . The devices 40 further include a source of electrical energy such as a battery 92 , an ON/OFF switch 94 , a battery indicating light 96 , an audible warning device 98 , and a visual warning device 100 . All persons on the construction site would be required to wear a portable worker unit 40 . A person wearing the portable unit 40 has no ability to override the functions of the unit 40 .
Certain workers are permitted or authorized to be within the work zone of selected pieces of equipment. For example, pipe-laying workers 30 would be permitted to be within the work zone of a backhoe with which they are working but may not be permitted to be within the working or danger zone of other vehicles or pieces of equipment on the work site. Other workers 32 , 34 would not be permitted to be in the working zone 80 . By way of another example, riggers or ironworkers may be permitted within the work or danger zone of a crane with which they are associated.
Each portable worker's units 40 have an associated code that identifies that unit, and, in effect, identifies that associated worker. Workers permitted to be in the work zone of a particular vehicle have their code from their associated unit programmed into the vehicle mounted control unit 24 of that vehicle. This can be preprogrammed either at the factory or through the data entry device 72 .
During operation, the vehicle transceiver of the vehicle mounted control unit 24 transmits an interrogation signal, in effect, looking for workers within its zone of danger or work zone 80 . If a worker comes within the zone, his potable unit receives the interrogation signal, transmits its code to the vehicle unit. If the vehicle mounted control unit 24 determines that the received code from a worker's portable unit 40 is that of an authorized worker, no further action is taken. If the code does not match, the alarms 74 , 76 are activated to warn the vehicle operator 28 . The unit 24 further transmits an alarm signal to the portable unit 40 of the unauthorized worker, e.g., 32 , which, in turn, activates his alarms 98 , 100 .
The vehicle operator has the ability to override the alarm if desired through the data entry device 72 or via a reset switch.
FIG. 4 shows a flow diagram of a control process 200 for the vehicle mounted controller 24 . The process starts at step 202 . At step 204 , codes or communication information to identify authorized workers are entered. This can be accomplished via the data entry 72 or preprogrammed at the time of manufacture. In step 206 , the vehicle based unit transmits a signal to communicated with any worker carried portable unit 40 that is within it's work zone. The signal strength is adjusted to define the work zone based on the vehicle and the type of work site. In step 208 , a determination is made as to whether a return signal is received. This may be in the form of a signal having a code that identifies the worker carried portable unit 40 . If the determination is negative meaning no worker is within the work area 80 , the process loops back to step 206 . The steps 206 and 208 are continuously performed until a return signal is received. From an affirmative determination is step 208 , a determination is made in step 210 as to whether the return signal identifies an authorized worker or not. If the determination is affirmative, the process loops back to step 206 . The steps 206 , 208 and 210 continuously repeat until an unauthorized worker is identified as being within the work zone of the vehicle based unit. An unauthorized worker leads to an affirmative determination in step 210 . From an affirmative determination in step 210 , the process proceeds to step 212 in which the alarm is activated in the vehicle based unit 24 to warn the vehicle operator of the unauthorized worker in the work zone 80 . The vehicle based unit sends a signal to the portable unit to activate the portable unit alarm to also warn the worker that he is in a work zone in which he is not authorized to be in. In step 214 , a determination is made as to whether the work zone area 80 has been cleared of the unauthorized worker. If the determination is negative in step 214 , a determination is made in step 216 as to whether the vehicle operator has manually overridden the alarm. If the determination in step 216 is negative, the process loops back to step 212 and both alarms remain activated. From affirmative determinations in either steps 214 or 216 , the process proceeds to step 218 in which the alarm of the vehicle based unit is reset. The process then loops back to step 206 .
FIG. 5 shows a flow diagram of a control process 250 for the worker's portable warning unit 40 . The process starts at step 250 and proceeds to step 254 in which a determination is made as to whether an interrogation signal has been received from a vehicle based unit. If the determination is negative, the process loops back upon itself and continues to monitor for receipt of an interrogation signal. From an affirmative determination in step 254 , the process then transmits its identification code to the vehicle based system in step 256 . The process then proceeds to step 258 in which the portable unit determines if an alarm signal has been received from the vehicle based unit. If the determination is negative, this means that the worker must be an authorized worker for that work zone and the process loops back to step 254 without an alarm being activated. If the determination is step 258 is affirmative, the process proceeds to step 260 in which the alarm of the worker unit 40 is activated. The process then loops back to step 254 . If no further interrogation signal is received, i.e., the worker has left the work zone 80 , its alarm would be reset and then again continuously monitor for another interrogation signal.
From the above description of the invention, those skilled in the art will perceive improvements, changes and modifications. For example, other type of signal communication arrangements between a vehicle based unit and the portable worker unit can be used other than that describe above in the exemplary embodiment to identify workers within a work zone and to warn unauthorized workers and the equipment operator of the unauthorized worker within the work zone. Such improvements, changes and modifications within the skill of the art are intended to be covered by the appended claims.
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A method and apparatus for enhancing the safety in a work zone surrounding operating equipment including identifying workers within said work zone and warning unauthorized workers within said work zone.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is the National Stage of International Application No. PCT/CN2010/079550, filed Dec. 8, 2010, which claims the benefit of Chinese Application No. 200910250793.1, filed Dec. 11, 2009, the disclosures of which are incorporated herein by reference in their entireties.
FIELD OF THE INVENTION
The present application relates to a flow control method in an oil-gas well exploitation field, and in particular to a sectional flow control method using a flow control filter string in an oil-gas well having a perforated pipe.
BACKGROUND OF THE INVENTION
An oil-gas well generally refers to a production well in the oil-gas field development in a broad sense, including an oil well, a gas well, an injection well and so on. In the production process of the oil-gas well, due to the heterogeneous characteristic of the oil reservoir, the oil-gas well, regardless of a vertical well or a horizontal well, has to be sealed off and separated into multiple independent zones for production. The oil-gas well production mentioned herein includes the production and injection of the fluid in the oil-gas well production process, for example, injecting water and vapor into the formation in the petroleum exploitation or production process, and injecting chemical agents for improving the oil field recovery ratio, and also includes the injection of acid liquor into the formation in some operation processes, etc.
During the process of sealing off and separating the oil-gas well into multiple independent zones for production, a device for controlling flow rate in sections (for example, a flow control filter string), and a device for separating the production section of the oil-gas well into several flow units along the axial direction of the oil-gas well (for example, a packer) are generally used to realize the seal and separation of the zones, so as to realize relatively independent production.
FIG. 1 is a schematic view illustrating the flow control by using a flow control filter string and a packer in an open hole. In FIG. 1 , reference numeral 1 indicates a borehole wall of the oil-gas well, reference numeral 2 indicates a flow control filter string, reference numeral 3 indicates an annular space between the flow control filter string and the borehole wall, reference numeral 4 indicates a packer hung with the flow control filter string, and reference numeral 5 indicates a flow control packer.
The process of sectional flow control is briefly described hereinafter with reference to FIG. 1 . FIG. 1 shows a non-oil-bearing formation, an oil-bearing formation and bottom water under the oil-bearing formation. Various formations are schematically indicated by horizontal lines in FIG. 1 , though the person skilled in the art may understand that these formations may not be horizontal, which depends on the geologic structure of the locality where the oil-gas well is located. The oil-gas well as shown in the figure includes a vertical section and a horizontal section. The horizontal section substantially extends along the oil-bearing formation so as to increase the contact area between the borehole wall and the oil-bearing formation. FIG. 1 illustratively shows two zones having different permeability, i.e. a high permeability zone and a low permeability zone. Under the situation without flow control in the oil-gas well (i.e. no packer 5 is provided in FIG. 1 ), since the permeability of the two zones is different, a flow rate of the fluid in the high permeability zone is larger than a flow rate of the fluid in the low permeability zone. In this case, due to the difference between the pressure of the bottom water and the pressure inside the oil-gas well, the bottom water under the oil-bearing formation may firstly pass through the high permeability zone and enter into the oil-gas well, which may cause the decrease of oil and gas and the increase of water in the production of the oil-gas well. This should be avoided in the production.
Currently, as shown in FIG. 1 , the sectional flow-rate control production in many oil-gas wells is realized as follows. A flow control filter string 2 is lowered into the production section inside the oil-gas well, and the flow control filter string 2 and the packer 5 are used to effectively seal off and partition an annular space between the flow control filter string 2 and the production section inside the oil-gas well, i.e. axial channeling passage of fluid outside the flow control filter string is blocked, thereby realizing a better sectional flow-rate control production. Generally, the packer is provided between two zones having different permeability. Since the flow control filter can play a role of flow-rate control, the packer is used to pack off the zones having different permeability so as to perform independent control or sectional control of various zones having different permeability. Therefore, it is possible for the oil-gas well to achieve a good production, and to effectively control the quantity of the bottom water entering into the oil-gas well.
However, the current well completion of the oil-gas well is achieved by running a perforated pipe into an open hole, and an annular space between the perforated pipe and the open hole wall is not sealed by filling cement or other materials between the perforated pipe and the borehole wall. The well completion method has an advantage of the low cost, and a disadvantage that the annular space becomes a passage for fluid channeling, so that it is difficult to realize the sectional flow control in the later production. Each meter of the perforated pipe is provided with several to dozens of holes with a diameter about 10 mm. The perforated pipe is mainly used in the oil-gas well to support the borehole wall and prevent lumps in the well from entering into the perforated pipe so as to ensure that the whole flow passage of the oil-gas well is not blocked by lumps.
As shown in FIG. 2 , if the flow control technology using the packer in the open hole as shown in FIG. 1 is directly applied in the existing oil-gas well having the perforated pipe, the annular space between the perforated pipe and the borehole wall cannot be packed off. Thus, the bottom water entering into the oil-gas well may flow axially in the annular space between the perforated pipe and the borehole wall. Thus, the annular space between the perforated pipe and the borehole wall forms an axial channeling passage, which destroys the pack-off effect between the flow control filter string in the perforated pipe and the perforated pipe, and cannot control the amount of water satisfactorily. In FIG. 2 , reference numeral 11 indicates a borehole wall of the oil-gas well, reference numeral 12 indicates a perforated pipe, reference numeral 13 indicates an annular space between the perforated pipe and the borehole wall, reference numeral 14 indicates a packer hung with the perforated pipe, reference numeral 15 indicates a flow control filter string, reference numeral 16 indicates a flow control filter on the flow control filter string, reference numeral 17 indicates a packer provided in the annular space between the flow control filter string and the perforated pipe, and reference numeral 18 indicates a packer hung with the flow control filter string. A direction of arrows in the figure indicates the fluid channeling direction. As shown in FIG. 2 , the fluid in the formation passes through the borehole wall and enters into the annular space between the borehole wall and the perforated pipe, so that the axial channeling is formed in the annular space between the borehole wall and the perforated pipe, and then passes through the flow control filter and enters into the flow control filter string. This axial channeling destroys the pack-off effect of the packer provided between the flow control filter string and the perforated pipe, thus a good water control effect can not be realized.
SUMMARY OF THE INVENTION
A technical problem to be solved by the present application is to provide a sectional flow control method using a flow control filter string in an oil-gas well having a perforated pipe, in which the annular space between the flow control filter string and the perforated pipe and the annular space between the perforated pipe and the borehole wall are filled with anti-channeling pack-off particles, so as to realize a good pack-off effect, thereby realizing a good sectional flow control production.
For solving the above problem, one embodiment of the present application provides a sectional flow control method in an oil-gas well, wherein the oil-gas well includes a first annular space formed between a borehole wall of the oil-gas well and a perforated pipe, and a second annular space formed between the perforated pipe and a flow control filter string. The perforated pipe is located inside the oil-gas well and extends along an axial direction of the oil-gas well. The flow control filter string is located inside the perforated pipe and extends along the axial direction of the oil-gas well. The method includes the step of: filling anti-channeling pack-off particles into the first annular space and the second annular space such that fluid can flow in a penetration manner in the first annular space and the second annular space filled with the anti-channeling pack-off particles.
Preferably, filling the anti-channeling pack-off particles into the first annular space and the second annular space is performed by injecting particle-carrying fluid with the anti-channeling pack-off particles into the first annular space and the second annular space.
Preferably, the particle-carrying fluid has a density substantially equal to a density of the anti-channeling pack-off particles.
Preferably, the particle-carrying fluid is water or aqueous solution.
Preferably, the anti-channeling pack-off particles are high molecular polymer particles with an average particle size ranging from 0.05 mm to 1.0 mm and a density ranging from 0.8 g/cm 3 to 1.4 g/cm 3 .
Preferably, the anti-channeling pack-off particles are high molecular polymer particles with an average particle size ranging from 0.1 mm to 0.5 mm and a density ranging from 0.94 g/cm 3 to 1.06 g/cm 3 .
Preferably, the anti-channeling pack-off particles are high-density polyethylene particles with an average particle size ranging from 0.1 mm to 0.05 mm and a density ranging from 0.90 g/cm 3 to 0.98 g/cm 3 .
Preferably, the anti-channeling pack-off particles are styrene and divinylbenzene crosslinking copolymer particles with an average particle size ranging from 0.05 mm to 1.0 mm and a density ranging from 0.96 g/cm 3 to 1.06 g/cm 3 .
Preferably, the anti-channeling pack-off particles are polypropylene and polyvinyl chloride high molecular polymer particles with an average particle size ranging from 0.05 mm to 1.0 mm and a density ranging from 0.8 g/cm 3 to 1.2 g/cm 3 .
Preferably, the anti-channeling pack-off particles are filled into the first annular space and the second annular space until the first annular space and the second annular space are substantially full of the anti-channeling pack-off particles, and the first annular space and the second annular space are closed. Preferably, the oil-gas well is a horizontal well or an inclined well.
Preferably, a difference between a density of the particle-carrying fluid and a density of the anti-channeling pack-off particles is within a range of ±0.4 g/cm 3 or a range of ±0.2 g/cm 3 .
According to another embodiment of the present application, a sectional flow control system for an oil-gas well is provided, including: a first annular space formed between a borehole wall of the oil-gas well and a perforated pipe; a second annular space formed between the perforated pipe and a flow control filter string; and anti-channeling pack-off particles. The perforated pipe is located inside the oil-gas well and extends along an axial direction of the oil-gas well. The flow control filter string is located inside the perforated pipe and extends along the axial direction of the oil-gas well. The anti-channeling pack-off particles are filled in the first annular space and the second annular space such that fluid can flow in a penetration manner in the first annular space and the second annular space filled with the anti-channeling pack-off particles.
Preferably, the first annular space and the second annular space are filled by injecting particle-carrying fluid with the anti-channeling pack-off particles into the first annular space and the second annular space.
Preferably, the particle-carrying fluid has a density substantially equal to a density of the anti-channeling pack-off particles.
Preferably, the particle-carrying fluid is water or aqueous solution.
Preferably, the anti-channeling pack-off particles are high molecular polymer particles with an average particle size ranging from 0.05 mm to 1.0 mm and a density ranging from 0.8 g/cm 3 to 1.4 g/cm 3 .
Preferably, the anti-channeling pack-off particles are high molecular polymer particles with an average particle size ranging from 0.1 mm to 0.5 mm and a density ranging from 0.94 g/cm 3 to 1.06 g/cm 3 .
Preferably, the anti-channeling pack-off particles are high-density polyethylene particles with an average particle size ranging from 0.1 mm to 0.5 mm and a density ranging from 0.90 g/cm 3 to 0.98 g/cm 3 .
Preferably, the anti-channeling pack-off particles are styrene and divinylbenzene crosslinking copolymer particles with an average particle size ranging from 0.05 mm to 1.0 mm and a density ranging from 0.96 g/cm 3 to 1.06 g/cm 3 .
Preferably, the anti-channeling pack-off particles are polypropylene and polyvinyl chloride high molecular polymer particles with an average particle size ranging from 0.05 mm to 1.0 mm and a density ranging from 0.8 g/cm 3 to 1.2 g/cm 3 .
Preferably, the first annular space and the second annular space are substantially full of the anti-channeling pack-off particles, and are closed.
Preferably, the oil-gas well is a horizontal well or an inclined well.
Preferably, a difference between the density of the particle-carrying fluid and the density of the anti-channeling pack-off particles is within a range of ±0.4 g/cm 3 or a range of ±0.2 g/cm 3 .
According to another embodiment of the present application, a sectional flow control method using a flow control filter string in an oil-gas well having a perforated pipe is provided, wherein the oil-gas well having the perforated pipe includes a borehole wall of the oil-gas well and the perforated pipe running in the oil-gas well, one end of the perforated pipe adjacent to a wellhead is fixedly connected to the borehole wall, and an annular space is formed between the perforated pipe and the borehole wall.
The sectional flow control method using a flow control filter string includes the following steps:
1) running the flow control filter string into the perforated pipe via a running string, wherein the flow control filter string is provided with a flow control filter, one end of the flow control filter string adjacent to the wellhead is fixedly connected to the borehole wall, and an annular space is formed between the flow control filter string and the perforated pipe;
2) injecting particle-carrying fluid with the anti-channeling pack-off particles into the annular space between the flow control filter string and the perforated pipe, wherein the particle-carrying fluid carrying the anti-channeling pack-off particles passes through holes in the perforated pipe and into the annular space between the perforated pipe and the borehole wall, the anti-channeling pack-off particles are accumulated both in the annular space between the flow control filter string and the perforated pipe and in the annular space between the perforated pipe and the borehole wall, so that the annular space between the flow control filter string and the perforated pipe and the annular space between the perforated pipe and the borehole wall are filled with and full of the anti-channeling pack-off particles, a part of the particle-carrying fluid enters into the flow control filter and then flows back to the ground, and another part of the particle-carrying fluid passes through the borehole wall and penetrates into the formation;
3) closing the annular space full of the anti-channeling pack-off particles between the flow control filter string and the perforated pipe; and
4) disengaging the running string which is connected to the flow control filter string, and forming a well completion structure in which the annular space between the flow control filter string and the perforated pipe and the annular space between the perforated pipe and the borehole wall are filled with the anti-channeling pack-off particles.
The particle density mentioned in the present application is the true density of the individual particles, rather than the packing density of the particles.
The present application uses water or aqueous solution with a density about 1 g/cm 3 as the particle-carrying fluid to carry anti-channeling pack-off particles, and the present application uses anti-channeling pack-off particles having almost the same density as the particle-carrying fluid, thus the particle-carrying fluid may easily carry the anti-channeling pack-off particles to fill in the annular space between the flow control filter string and the perforated pipe and the annular space between the perforated pipe and the borehole wall. The anti-channeling pack-off particles are accumulated both in the annular space between the flow control filter string and the perforated pipe and in the annular space between the perforated pipe and the borehole wall, so that the annular space between the flow control filter string and the perforated pipe and the annular space between the perforated pipe and the borehole wall are filled with and full of the anti-channeling pack-off particles. A part of the particle-carrying fluid enters into the flow control filter and then flows back to the ground, and another part of the particle-carrying fluid passes through the borehole wall and penetrates into the formation. Finally, a well completion structure is formed, in which the annular space between the flow control filter string and the perforated pipe and the annular space between the perforated pipe and the borehole wall are filled with the anti-channeling pack-off particles. The anti-channeling pack-off particles are filled tightly and there is almost no channeling. The oil-gas well may effectively be sealed off and separated into multiple independent zones with combination of the flow control filter string, so as to perform oil-gas well production, realize the object of flow control, and facilitate the flow-rate sectional management, thereby bringing good effects of the oil-gas well production, for example, improving the production efficiency of the oil-gas well.
Furthermore, even there still has channeling after filling with the anti-channeling pack-off particles, in production axial channeling of small flow rate of fluid may bring the anti-channeling pack-off particles to move and to be accumulated towards the channeling direction and then to fully fill the channeling passage, thereby achieving a very good anti-channeling pack-off effect and realizing the object of sectional flow control using a flow control filter string in an oil-gas well with the combination of a flow control filter string.
The formation fluid flows in media formed by the accumulation of the anti-channeling pack-off particles in the penetration manner. According to the principle of the penetration fluid mechanics, the penetration resistance is proportional to the penetration distance, and is inversely proportional to the penetration area. The accumulation body of the anti-channeling pack-off particles has a thin thickness, a small section and a long axial length. Accordingly, a channeling resistance of the formation fluid flowing in the anti-channeling pack-off particles along the axial direction of the oil-gas well is very high. However, when the formation fluid flows along the radial direction of the oil-gas well, the penetration area is big and the penetration distance is short, thus the flow resistance is very small. The resistance flowing in the accumulation body for several meters or tens of meters along the axial direction of the oil-gas well is hundreds times even thousands times more than the resistance flowing in the accumulation body for several centimeters along the radial direction of the oil-gas well. Due to the great difference between the resistance flowing in the accumulation body along the axial direction of the oil-gas well and the resistance flowing in the accumulation body along the radial direction of the oil-gas well, the flow rate flowing in the accumulation body along the axial direction of the oil-gas well is far less than the flow rate flowing in the accumulation body along the radial direction of the oil-gas well under the same pressure difference. Thus, under the difference between the resistance flowing in the accumulation body of the anti-channeling pack-off particles along the axial direction of the well and the resistance flowing in the accumulation body along the radial direction of the well, the smooth flow of the formation fluid in the accumulation body along the radial direction of the oil-gas well may be ensured, and the flow of the formation fluid along the axial direction of the oil-gas well may be limited, thereby functioning as a packer.
The present application provides a convenient and useful sectional flow control method using a flow control filter string in an oil-gas well having a perforated pipe, which may pack off the annular space between the flow control filter string and the perforated pipe and the annular space between the perforated pipe and the borehole wall, thereby having a good pack-off effect, realizing the sectional flow control production well, and satisfying the actual production requirements of the oil field, for example, improving the oil recovery ratio.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view illustrating the flow control by using a flow control filter string and a packer in an open hole in the prior art;
FIG. 2 is a schematic view of a hypothetical state where the flow control technology using the flow control filter string and the packer as shown in FIG. 1 is applied to an oil-gas well having a perforated pipe, the flow control filter string is lowered into the perforated pipe, an annular space between the flow control filter string and the perforated pipe is packed off, while an annular space between the perforated pipe and a borehole wall is not packed off;
FIG. 3 is a schematic view of a sectional flow control method using a flow control filter string in an oil-gas well having a perforated pipe according to an embodiment of the present application; and
FIG. 4 is a schematic view of a well completion structure according to an embodiment of the present application, in which an annular space between the flow control filter string and the perforated pipe and an annular space between the perforated pipe and a borehole wall are both filled with anti-channeling pack-off particles.
DETAILED DESCRIPTION OF THE EMBODIMENTS
Overall, the present application provides a sectional flow control method using a flow control filter string in an oil-gas well having a perforated pipe. The oil-gas well having the perforated pipe therein includes a borehole wall of the oil-gas well and the perforated pipe running into the oil-gas well. One end of the perforated pipe adjacent to a wellhead is fixedly connected to the borehole wall, and an annular space is formed between the perforated pipe and the borehole wall.
The sectional flow control method using the flow control filter string includes the following steps:
1) running the flow control filter string into the perforated pipe via a running string, wherein the flow control filter string is provided with a flow control filter, one end of the flow control filter string adjacent to a wellhead is fixedly connected to the borehole wall, and an annular space is formed between the flow control filter string and the perforated pipe;
2) injecting a particle-carrying fluid into the annular space between the flow control filter string and the perforated pipe; wherein the particle-carrying fluid carries the anti-channeling pack-off particles, the particle-carrying fluid carrying the anti-channeling pack-off particles passes through holes in the perforated pipe and enters into an annular space between the perforated pipe and the borehole wall, the anti-channeling pack-off particles are accumulated both in the annular space between the flow control filter string and the perforated pipe and the annular space between the perforated pipe and the borehole wall, so that the annular space between the flow control filter string and the perforated pipe as well as the annular space between the perforated pipe and the borehole wall is filled with and full of the anti-channeling pack-off particles, a part of the particle-carrying fluid enters into the flow control filter and then flows back to the ground, and another part of the particle-carrying fluid passes through the borehole wall and penetrates into the formation;
3) closing the annular space full of the anti-channeling pack-off particles between the flow control filter string and the perforated pipe; and
4) disengaging the running string which is connected to the flow control filter string, and forming a well completion structure in which the annular space between the flow control filter string and the perforated pipe and the annular space between the perforated pipe and the borehole wall are filled with the anti-channeling pack-off particles.
The particle-carrying fluid carrying the anti-channeling pack-off particles is water or aqueous solution.
The anti-channeling pack-off particles may be high molecular polymer particles with a particle size ranging from 0.05 mm to 0.7 mm and a density ranging from 0.8 g/cm 3 to 1.2 g/cm 3 .
The anti-channeling pack-off particles may be high molecular polymer particles with an average particle size ranging from 0.05 mm to 1.0 mm and a density ranging from 0.8 g/cm 3 to 1.4 g/cm 3 .
The anti-channeling pack-off particles may be high molecular polymer particles with an average particle size ranging from 0.1 mm to 0.5 mm and a density ranging from 0.94 g/cm 3 to 1.06 g/cm 3 .
The anti-channeling pack-off particles may be high-density polyethylene particles with an average particle size ranging from 0.1 mm to 0.5 mm and a density ranging from 0.90 g/cm 3 to 0.98 g/cm 3 .
The anti-channeling pack-off particles may be styrene and divinylbenzene crosslinking copolymer particles with an average particle size ranging from 0.05 mm to 1.0 mm and a density ranging from 0.96 g/cm 3 to 1.06 g/cm 3 .
The anti-channeling pack-off particles may be polypropylene and polyvinyl chloride high molecular polymer particles with an average particle size ranging from 0.05 mm to 1.0 mm and a density ranging from 0.8 g/cm 3 to 1.2 g/cm 3 .
The embodiments of the present application will be described in detail with reference to the drawings hereinafter.
First Embodiment
The embodiment of the present application provides a sectional flow control method using a flow control filter string in an oil-gas well having a perforated pipe. As shown in FIG. 3 , the oil-gas well structure having the perforated pipe includes a borehole wall 101 of the oil-gas well and a perforated pipe 102 running in the oil-gas well. Each meter of the perforated pipe 102 is provided with multiple small holes. For example, the number of the small holes is 30 . The diameter of the small holes is configured to be able to prevent lumps from entering into the perforated pipe 102 , for example 10 mm. A packer 104 hung with the perforated pipe 102 is provided between an upper portion of the perforated pipe 102 and the borehole wall 101 . An annular space 103 is formed between the perforated pipe 102 and the borehole wall 101 .
The water control pack-off method according to the embodiment of the present application is described in detail with reference to FIG. 3 hereinafter, which includes the following steps.
A flow control filter string 105 is run into the perforated pipe 102 via a running string (not shown). A flow control filter 106 is provided on the flow control filter string 105 . A packer 108 hung with the flow control filter string 105 is provided between an upper portion of the flow control filter string 105 and the borehole wall 101 . An annular space 103 is formed between the flow control filter string 105 and the perforated pipe 102 .
A particle-carrying fluid 110 carrying the anti-channeling pack-off particles is injected into the annular space 103 between the flow control filter string 105 and the perforated pipe 102 . The particle-carrying fluid 110 carrying the anti-channeling pack-off particles passes through small holes in the perforated pipe 102 and enters into the annular space 111 between the perforated pipe 102 and the borehole wall 101 . The anti-channeling pack-off particles are accumulated both in the annular space 103 between the flow control filter string 105 and the perforated pipe 102 and in the annular space 111 between the perforated pipe 102 and the borehole wall 101 , so that the annular space 103 between the flow control filter string 105 and the perforated pipe 102 and the annular space 111 between the perforated pipe 102 and the borehole wall 101 are filled with and full of the anti-channeling pack-off particles. A part of the particle-carrying fluid penetrates through the flow control filter 106 and enters into the flow control filter string 105 and then flows back to the ground, and another part of the particle-carrying fluid passes through the borehole wall 101 and penetrates into the formation. The direction of arrows in FIG. 3 is the flowing direction of the particle-carrying fluid. The anti-channeling pack-off particles are high-density polyethylene particles with an average particle size ranging from 0.1 mm to 0.5 mm and a density ranging from 0.90 g/cm 3 to 0.98 g/cm 3 . The particle-carrying fluid is water.
The packer 108 hung with the flow control filter string 105 is set so as to close both the annular space 103 between the flow control filter string 105 and the perforated pipe 102 and the annular space 111 between the perforated pipe 102 and the borehole wall 101 which are filled with the anti-channeling pack-off particles.
The running string (not shown) connected to the flow control filter string 105 is disengaged and a well completion structure is formed. In the well completion structure, the annular space 103 between the flow control filter string 105 and the perforated pipe 102 and the annular space 111 between the perforated pipe 102 and the borehole wall 101 are filled with the anti-channeling pack-off particles, as shown in FIG. 4 . In FIG. 4 , reference numeral 101 indicates the borehole wall of the oil-gas well, reference numeral 102 indicates the perforated pipe, reference numeral 104 indicates the packer hung with the perforated pipe, reference numeral 105 indicates the flow control filter string, reference numeral 106 indicates the flow control filter on the flow control filter string, reference numeral 107 indicates the anti-channeling pack-off particles filled the annular space between the flow control filter string and the perforated pipe, reference numeral 108 indicates the packer hung with the flow control filter string, and reference numeral 109 indicates the anti-channeling pack-off particles filled the annular space between the perforated pipe and the borehole wall.
Second Embodiment
In the embodiment of the present application, the anti-channeling pack-off particles are polypropylene and polyvinyl chloride high molecular polymer particles with an average particle size ranging from 0.1 mm to 0.5 mm and a density being 0.97 g/cm 3 .
The other steps of the method are the same as the first embodiment.
Third Embodiment
In the embodiment of the present application, the anti-channeling pack-off particles are styrene and divinylbenzene crosslinking copolymer particles with an average particle size ranging from 0.05 mm to 1.0 mm and a density ranging from 0.96 g/cm 3 to 1.06 g/cm 3 .
The other steps of the method are the same as the first embodiment.
In the first, second and third embodiments of the present application, water is used to carry the anti-channeling pack-off particles. The density of water is 1 g/cm 3 . The density of the anti-channeling pack-off particles selected in the present application is almost the same as the density of water. Therefore, the water may easily carry the anti-channeling pack-off particles to fill in the annular space 103 between the flow control filter string 105 and the perforated pipe 102 and the annular space 111 between the perforated pipe 102 and the borehole wall 101 . The anti-channeling pack-off particles are accumulated both in the annular space 103 between the flow control filter string 105 and the perforated pipe 102 and in the annular space 111 between the perforated pipe 102 and the borehole wall 101 , so that the annular space 103 between the flow control filter string 105 and the perforated pipe 102 and the annular space 111 between the perforated pipe 102 and the borehole wall 101 are filled with and full of the anti-channeling pack-off particles. A part of the water passes through the flow control filter 106 and enters into the flow control filter string 105 and then flows back to the ground, and another part of the water passes through the borehole wall 101 and penetrates into the formation. Finally, a well completion structure is formed, in which the annular space 103 between the flow control filter string 105 and the perforated pipe 102 and the annular space 111 between the perforated pipe 102 and the borehole wall 101 are filled with the anti-channeling pack-off particles.
The formation fluid flows in media formed by the accumulation of the anti-channeling pack-off particles in a penetration manner. According to the principle of the penetration fluid mechanics, the penetration resistance is proportional to the penetration distance, and is inversely proportional to the penetration area. The accumulation body of the anti-channeling pack-off particles is a medium having a thin thickness, a small section and a long axial length, thus the channeling resistance of the formation fluid flowing in the accumulation body of the anti-channeling pack-off particles along the axial direction of the oil-gas well is very high. However, when the formation fluid flows along the radial direction of the oil-gas well, the penetration area is big and the penetration distance is short, thus the flow resistance is very small. The resistance flowing in the accumulation body for several meters or tens of meters along the axial direction of the oil-gas well is hundreds times even thousands times more than the resistance flowing in the accumulation body for several centimeters along the radial direction of the oil-gas well. Due to the great difference between the resistance flowing in the accumulation body along the axial direction of the oil-gas well and the resistance flowing in the accumulation body along the radial direction of the oil-gas well, the flow rate flowing in the accumulation body along the axial direction of the oil-gas well is far less than the flow rate flowing in the accumulation body along the radial direction of the oil-gas well under the same pressure difference. Under the difference between the resistance flowing in the accumulation body of the anti-channeling pack-off particles along the axial direction of the well and the resistance flowing in the accumulation body along the radial direction of the well, the smooth flow of the formation fluid in the accumulation body along the radial direction of the oil-gas well may be ensured, and the flow of the formation fluid along the axial direction of the oil-gas well may be limited, thereby functioning as a packer.
The present application provides a convenient and useful sectional flow control method in an oil-gas well having a perforated pipe, which may pack off both the annular space between the flow control filter string and the perforated pipe and the annular space between the perforated pipe and the borehole wall. The sectional flow control production may be realized due to the good pack-off effect, so as to improve the oil recovery ratio and satisfy the actual production requirements of the oil field.
The production section referred in the present application is a generalized production section. There may be some non-flowing sections (for example, an interlayer, a sandwich layer and an imperforated interval after the casing cementing) along the length of the production section.
The flow control filter string in the present application includes filtering sections and blank sections which are arranged alternately. The blank section is a pipe without holes on its wall surface. The anti-channeling pack-off particle ring outside the blank sections plays a major role in preventing the axial channeling. The blank sections are provided in two ways. On the one hand, each filter itself includes a filtering section and blank sections provided at two ends of the filter and provided with screw threads, so that two filters may be connected via the screw threads on the blank sections of the two filters. When screwing and connecting the filters above the well, the blank section is a place for setting the pliers. On the other hand, an additional blank section may be connected between two filters. Under the situation that a relatively long flow control filter string is desired, the flow control filter string may be formed by connecting multiple flow control filters in series.
The anti-channeling pack-off particles in the present application is preferably circular.
In the embodiments of the present application, a sectional flow control method using a flow control filter string in an oil-gas well having a perforated pipe is provided, wherein the oil-gas well having the perforated pipe includes a borehole wall of the oil-gas well and the perforated pipe running into the oil-gas well, one end of the perforated pipe adjacent to a wellhead is fixedly connected to the borehole wall, and an annular space is formed between the perforated pipe and the borehole wall.
The sectional flow control method using a flow control filter string is characterized by including the following steps:
1) running the flow control filter string into the perforated pipe via a running string, the flow control filter string being provided with a flow control filter, the flow control filter string being fixed connected to the borehole wall, and an annular space being formed between the flow control filter string and the perforated pipe;
2) injecting particle-carrying fluid, which carries the anti-channeling pack-off particles, into the annular space between the flow control filter string and the perforated pipe; wherein the particle-carrying fluid carrying the anti-channeling pack-off particles passes through holes in the perforated pipe and enters into an annular space between the perforated pipe and the borehole wall, the anti-channeling pack-off particles are accumulated both in the annular space between the flow control filter string and the perforated pipe and in the annular space between the perforated pipe and the borehole wall, so that the annular space between the flow control filter string and the perforated pipe and the annular space between the perforated pipe and the borehole wall are filled with and full of the anti-channeling pack-off particles;
3) closing the annular space full of the anti-channeling pack-off particles between the flow control filter string and the perforated pipe, and closing the pack-off medium in the annular space between the perforated pipe and the borehole wall;
4) disengaging the running string which is connected to the flow control filter string; and forming a well completion structure in which the annular space between the flow control filter string and the perforated pipe and the annular space between the perforated pipe and the borehole wall are filled with the anti-channeling pack-off particles.
The particle-carrying fluid carrying the anti-channeling pack-off particles is water or aqueous solution.
The anti-channeling pack-off particles may be high molecular polymer particles with an average particle size ranging from 0.05 mm to 1.0 mm and a density ranging from 0.8 g/cm 3 to 1.4 g/cm 3 .
The anti-channeling pack-off particles may be high molecular polymer particles with an average particle size ranging from 0.1 mm to 0.5 mm and a density ranging from 0.94 g/cm 3 to 1.06 g/cm 3 .
The anti-channeling pack-off particles may be high-density polyethylene particles with an average particle size ranging from 0.1 mm to 0.5 mm and a density ranging from 0.90 g/cm 3 to 0.98 g/cm 3 .
The anti-channeling pack-off particles may be styrene and divinylbenzene crosslinking copolymer particles with an average particle size ranging from 0.05 mm to 1.0 mm and a density ranging from 0.96 g/cm 3 to 1.06 g/cm 3 .
The anti-channeling pack-off particles may be polypropylene and polyvinyl chloride high molecular polymer particles with an average particle size ranging from 0.05 mm to 1.0 mm and a density ranging from 0.8 g/cm 3 to 1.2 g/cm 3 .
Although the present application has been described with reference to the preferred embodiments of the present application, it should be understood that, the present application is not limited to the disclosed embodiments or structures. On the contrary, it is intended that the present application covers various modifications and equivalent solutions. In addition, various elements of the present application disclosed herein are shown in various exemplary combinations and structures, but other combinations and structures including more or less elements or only one element are also deemed to fall into the protection scope of the present application.
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A method and a system for segmental flow control in an oil-gas well are disclosed. The oil-gas well includes a first annular space ( 111 ) and a second annular space ( 103 ). The first annular space ( 111 ) is formed with the space between the borehole wall ( 101 ) of the oil-gas well and a perforated tube ( 102 ) which is in the oil-gas well and extends along an axial direction of the oil-gas well; The second annular space ( 103 ) which is formed with the space between the perforated tube ( 102 ) and a flow-control filter string ( 105 ) which is in the perforated tube ( 102 ) and extends along the axial direction of the oil-gas well. The method includes filling anti-channeling isolating particles ( 109 ) in the first annular space ( 111 ) and the second annular space ( 103 ) to enable fluid to flow in the first annular space ( 111 ) and the second annular space ( 103 ) filled with the anti-channeling isolating particles ( 109 ) in the manner of seepage.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally motor control systems, and more specifically to a vehicle door control system that detects and responds to abnormal door operation.
2. Background of the Invention
Automatic vehicle door opening and closing mechanisms are in widespread use in public transportation systems such as trains and buses, as well as in private vehicles adapted for use by the handicapped. The control of the operation of a vehicle door is typically performed by an electronic control system that determines the position and speed of a moving element of an electric motor that operates the door positioning mechanism. The control system typically stops the electric motor when an abnormality is detected in the operation of the door positioning mechanism by observing position and speed signals from a position detector coupled to the motor and/or positioning mechanism. The control system responds to the detection of the abnormality by removing power from the electric motor in order to prevent breakage of the positioning mechanism, the vehicle door or damage to the electric motor.
Japan Patent Application JP-A-5-344775 discloses a vehicle door control system that provides a signal that is generated when abnormal position or speed of the positioning system is detected. The signal causes the servo motor to stop operating. Japan Patent Application JP-A-5-98867 discloses a vehicle door control system that restricts operation of an electric motor that moves a vehicle door for a predetermined time period when abnormal operation is detected. In both of the systems described in the above-referenced patent applications, the electric motor is ultimately stopped when abnormal operation is detected.
In addition to detecting abnormal door/door positioner operation, indications of continuous abnormal operation in the above-mentioned systems occur when a disconnection or failure of a feedback signal from the position detector occurs and indications of temporary abnormal operation occur when electrical noise is present on the position detector feedback signal(s), such noise due to electrical storms or electrical noise generated by operation of the electric motor. In either case, if the electric motor is controlled in position and speed in conformity with an erroneous feedback signal, the electric motor, positioning system and/or the vehicle door may be damaged. Therefore, in the above-mentioned control systems, operation of the electric motor is stopped in order to prevent damage.
However, stopping operation of a vehicle door control system when no actual possibility of damage exists is undesirable, as delays or complete shutdown prevent the use of the vehicle door and in public transportation applications, prevent persons from entering or exiting the vehicle.
Therefore, it would be desirable to provide a vehicle door control system and method whereby operation of the vehicle door may be continued after detection of an abnormality if a determination is made that the vehicle door control mechanism may be damaged or broken, while preventing operation that may cause damage to the vehicle door, door positioning mechanism or the electric motor.
SUMMARY OF THE INVENTION
The above objectives of providing for continued operation of a vehicle door control system after detection of an abnormality if a determination is made that the vehicle door, positioning system or electric motor will not be damaged is accomplished in a method and system for controlling a vehicle door position.
The system is an electronic control system coupled to an electric motor that operates the vehicle door and is further coupled to an abnormality detector that determines when the position and/or velocity of the door indicates that operation of the door is abnormal. The system further includes a control circuit coupled to the abnormality detector that ceases operation of the electric motor when abnormal operation is detected and resumes operation after a predetermined amount of time has elapsed if the abnormality is no longer present. The control circuit may further include a counter for counting a number of times that operation is resumed and cease resumption of operation if the number of attempts to resume operation exceeds a predetermined count value.
When the vehicle door positioning system or the electric motor include a locking device for locking the position of the vehicle door at one or more positions, the control system may further include a locked state detector for detecting that the vehicle door or motor is in one of the locked positions. The control circuit may be coupled to the locked state detector for storing an indication of the locked state position and may compare a position of a next locked state and cease operation of the electric motor if the magnitude of the difference exceeds a predetermined value.
The vehicle door control method is a method of operation of the above-described control system and may be embodied therein.
The foregoing and other objectives, features, and advantages of the invention will be apparent from the following, more particular, description of the preferred embodiment of the invention, as illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram depicting a vehicle door control system in accordance with an embodiment of the present invention.
FIG. 2 is a flowchart depicting a method in accordance with an embodiment of the present invention.
FIG. 3 is a flowchart depicting a method in accordance with another embodiment of the present invention.
FIG. 4 is a block diagram depicting a vehicle door control system in accordance with yet another embodiment of the present invention.
FIG. 5 is a flowchart depicting a method in accordance with yet another embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention is directed toward an electronic control system and method for controlling the position of a vehicle door. The control system operates an electric motor that opens/closes the vehicle door, which may be a public transportation vehicle door such as on a train or bus, or may be an automobile door. The control system includes a detector for detecting the position and/or velocity of door via a detector mechanically coupled to the electric motor. The control system further includes an abnormality detector that determines when the position and/or velocity deviate from an expected position and/or speed. If an abnormality is detected, motor operation is ceased for a predetermined period of time determined by a timer in the control system and then the control system resumes operation of the electric motor if the abnormality detector indicates that the abnormality is no longer present. The control system thereby provides for continued operation when the abnormality is a transient abnormality, e.g., when noise or intermittent operation of the control system causes an indication of an abnormality. The control system also thereby provides for shutdown of the vehicle door positioning system when a continuous abnormality is indicated, e.g., when a disconnection of the motor speed/position feedback signal has occurred. The control system thus provides a means for providing continued vehicle door operation when there is no possibility of damaging the door, the electric motor or other portions of the door positioning mechanism.
Referring now to FIG. 1 , a vehicle door control system 20 in accordance with an embodiment of the invention is shown. Control system 20 includes a position calculator 6 , a speed calculator 7 , an abnormality detector 8 , a driving command calculator 9 and a power converter 10 . Control system 20 is electrically connected via wiring 12 to a linear motor 2 , which is mechanically coupled to door 1 in order to open and close door 1 and further electrically coupled via connection 13 to a position detector 5 for detecting the position of a moving part of linear motor 2 .
Vehicle door 1 is mechanically connected to the moving part of the linear motor 2 by a connector 3 , and a locking device 4 for mechanically fixing door 1 in one or more positions. Position detector 5 detects the position and/or velocity of the moving part the linear motor 2 and provides detection signals to position calculator 6 , speed calculator 7 and abnormality detector 8 via connection 13 . Position calculator 6 calculates the position of door 1 from the detection signal provided by position detector 5 . Speed calculator 7 also calculates the opening and closing speed of door 1 from the detection signal.
Abnormality detector 8 provides an abnormality detection signal to driving command calculator 9 when an abnormality is detected. An abnormality is indicated by the detected position provided by position calculator 6 and/or speed calculated by speed calculator 7 based on the signals provided by position detector 5 have values that deviate values corresponding to the position and speed control values.
Driving command calculator 9 includes a timer, a serious failure flag, an abnormal state flag and an abnormality start flag and controls the timer and flags, in response to door position information calculated by the position calculator 6 , door speed information calculated by the speed calculator 7 and abnormality indications provided by abnormality detector 8 . Driving command calculator determines driving commands for door 1 thereby controlling power converter 10 for controlling power supplied to linear motor 2 . Power converter 10 supplies power to linear motor 2 in accordance with a power supply command calculated by driving command calculator 9 .
Next, a method for controlling opening closing door 1 as performed by door control system 20 will be described with reference to the flowchart shown in FIG. 2 . First, at step S 1 , driving command calculator 9 determines whether the serious failure flag is set (logical 1) or not (logical 0). If the serious failure flag is set (due to a previous abnormal condition exceeding a predetermined period of time, for example, due of disconnection of electrical connection 13 ), then the opening/closing driving of door 1 is stopped at step S 2 . Door 1 is stopped by sending a power supply command to stop the linear motor 2 , which is sent to power converter 10 . Otherwise, if the serious failure flag is not set, then abnormality detector 8 determines whether or not an abnormal condition exists in the position signal provided by position detector 5 (step S 3 ). If no abnormality is present, the abnormal state flag is reset to “0” at step S 4 . If there is an abnormality in the detection signal, the abnormal state flag is set to “1” at step S 5 . Then, step S 6 determines whether or not the abnormality start flag is set and if not, step S 7 sets the abnormality start flag.
Next, the abnormality start flag is tested at step S 8 . If the abnormality start flag is not set, normal opening/closing of door 1 is continued at step S 9 , by sending a power supply commands sent to power converter 10 that cause linear motor 2 to operate at an opening/closing speed corresponding to the opening/closing position of door 1 .
If the abnormality start flag is set at step S 8 , a timer is started at step S 10 and at step S 11 it is determined whether or not the measured time of the timer has reached a predetermined time period. If the predetermined time has not been reached, opening/closing of door 1 is stopped at step S 12 . If the predetermined time has been reached, the timer is reset (=0) and the abnormality start flag is reset to “0” at step S 12 . Then, the abnormal state flag is tested in step S 13 . If the abnormal state flag is not set, opening/closing operation of door 1 is continued at step S 9 . However, if the abnormal state flag is set, the serious failure flag is then set at step S 14 and the opening/closing of door 1 is stopped at step S 2 .
By the above-described action, in the vehicle control system of FIG. 1 , when an abnormality in the detection signal provided by position detector 5 is detected by abnormality detector 8 , driving command calculator 9 stops the movement of door 1 . If the abnormality is still detected after the lapse of a predetermined time from when the abnormality was initially detected, the stopped state is maintained. But, if the abnormality is no longer detected, opening/closing operation of door 1 is resumed.
Thus, if the abnormality is eliminated after the lapse of a predetermined time, it is determined that the abnormality is a temporary malfunction of position detector 5 or a minor transient fault and that there is no possibility of damage or breakage of linear motor 2 and the devices driven by linear motor 2 . Therefore, opening/closing operation of the door is resumed and can be continuously carried out. Therefore, inconvenience due to the fault such as delay in getting on/off a vehicle and operation of the vehicle can be eliminated in general.
Referring now to FIG. 3 , a flowchart depicting operation of a vehicle door control system in accordance with another embodiment of the invention is depicted. Steps corresponding to the steps in the flowchart shown in FIG. 2 are denoted by the same reference designator and will not be described further in detail, as their operation has been described above. Therefore, only differences between the embodiment of FIG. 3 and the embodiment of FIG. 2 are described below.
Driving command calculator 9 is further provided with a driving resumption counter for counting the number of times the opening/closing driving of door 1 is resumed. At step S 13 , if the abnormal state flag is not set, the value of the driving resumption counter is incremented in step S 15 . Then, in step S 16 , the driving resumption counter value is compared to a predetermined threshold count value. If the count is less than the threshold, opening/closing operation of door 1 is continued in step S 9 . However, if the operation resumption counter value is greater than or equal to the threshold, the serious failure flag is set to “1” in step S 14 and opening/closing operation of door 1 is ceased in step S 2 .
Therefore, according to the above-described embodiment, which can be performed within the system depicted in FIG. 1 , driving command calculator 9 includes a counter that counts the number of times opening/closing operation of door 1 is resumed, and stops the opening/closing driving control when the count value reaches a predetermined threshold. If an abnormality is detected in the signal provided by position detector 5 and operation is thereby ceased for a predetermined number of times, the method and system determine that the abnormality is not a temporary malfunction of the position detection means or a certain minor transient fault but is due to a continuous failure such as disconnection of connection 13 and that damage or breakage of linear motor 2 and the devices driven thereby is possible, so opening/closing operation of door 1 is stopped. The above-described action thereby prevents such damage or breakage of the devices.
Referring now to FIG. 4 , a block diagram is presented depicting a vehicle door control system according to yet another embodiment of the present invention. In the embodiment shown in FIG. 4 , components corresponding to the parts in the embodiment shown in FIG. 1 are denoted by the same reference numerals and operate in the same manner. Therefore the common components will not be described further in detail and only differences between the embodiments will be described.
The embodiment of FIG. 4 differs from that of FIG. 1 in that driving command calculator 9 detects that the door 1 has been brought into a locked state (e.g., mechanically fixed), by locking device 4 , which is controlled by a detection signal provided by position detector 5 . A locked state detector 11 for detecting the locked state of door 1 (and thereby the locked position) is provided in door driving control apparatus 20 , so that driving command calculator 9 performs control as will be described hereinafter with reference to the flowchart shown in FIG. 5 . The control is performed in response to the values of the locked state and the locked position as detected by the locked state detector 11 .
Referring now to FIG. 5 , a flowchart illustrating operation of a vehicle door control system in accordance with the embodiment depicted in FIG. 4 is depicted. Steps corresponding to the steps in the flowchart shown in FIG. 3 are denoted by the same reference designator and will not be described further in detail, as their operation has been described above. Therefore, only differences between the method illustrated in FIG. 5 and the method illustrated in FIG. 3 will be described below.
If, it is determined in step S 3 that there is an abnormality indicated by abnormality detector 8 , driving command calculator 9 sets the abnormal state flag to “1” and resets a locked position confirmation flag to “0” in step S 5 . In step S 16 , if the driving resumption counter value is less than the predetermined threshold, then in step S 17 a determination is made whether or not a locked state of the vehicle door has been detected by locked state detector 11 . If a locked state was not detected, opening/closing operation of door 1 is continued at step S 9 .
Otherwise, if a locked state was detected and determined in step S 17 , then the locked position confirmation flag is tested in step S 18 . If the locked position confirmation flag is “1”, the locked position is stored at step S 19 and the opening/closing operation of door 1 is continued at step S 9 . If, however the locked position confirmation flag is “0” and if, as determined in step S 20 , the absolute value of difference between the previously stored locked position and the locked position as presently indicated by locked state detector 11 is less than a preset range, then the locked position confirmation flag is set to “1”. Otherwise, if the locked position confirmation flag was “0” in step S 18 , then the serious failure flag is set to “1” in step S 14 and opening/closing operation of door 1 is stopped at step S 2 .
The above-described operation provides for proper operation when a DC offset occurs in the detection signal of position detector 5 so that the detection signal may deviate from the actual detection value. If driving command calculator 9 controls the locking of door 1 by locking device 4 in response to a deviated detection signal, the locked position will be deviated from the original proper position. If the deviation in the locked position increases or frequently occurs, door 1 and devices mechanically coupled to door 1 will be damaged or broken. Therefore, step S 20 determines whether or not there is a deviation in the locked position due to a DC offset, and the opening/closing driving of the door is stopped when there is a deviation.
On the other hand, if the result of the determination in step S 20 shows that the absolute value of difference is less than the preset range, there is no deviation in the locked position or the deviation is within an allowable range. Therefore, the locked position conformation flag is set to “1” at step S 21 and the locked position is stored at step S 19 . The opening/closing operation of door 1 is continued at step S 9 .
Thus, the control system of FIG. 4 operating according to the method illustrated in FIG. 3 provides protection against offset or other deviation in the position detector 5 signal in order to avoid damage to door 1 or other device mechanically coupled to door 1 .
As an alternative to the above described operation, driving command calculator 9 may perform the operations of step S 5 , setting the abnormal state flag to “1” and the locked position confirmation flag to “0”, and may perform the control steps S 17 to S 21 after step S 13 determines that the abnormal state flag is “0”. The above-described alternative order can realize the same effects as those of the third embodiment, performing steps S 15 and S 16 after determination of any locked state, or the resumption counter steps of S 15 and S 16 may be omitted in accordance with another embodiment of the invention that incorporates locked position detection within the embodiment of the invention illustrated in FIG. 2 .
This application claims the benefit of priority of Japanese application 2003-165424, filed on Jun. 10, 2003, the disclosure of which is incorporated herein by reference.
While the invention has been particularly shown and described with reference to the preferred embodiments thereof, it will be understood by those skilled in the art that the foregoing and other changes in form, and details may be made therein without departing from the spirit and scope of the invention.
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A method and system for controlling vehicle door position in improved reliability of a vehicle door electromechanical positioning components. The vehicle door control system includes an abnormality detector for detecting abnormal operation of the vehicle door by a deviation of expected door position and/or velocity. If abnormal operation is detected, operation of the electrical motor driving the door is ceased for a predetermined time period. Operation is then resumed if the abnormal condition has been removed. The control system may include a counter for counting a number of attempts to resume operation and further attempts to resume may be ceased if the counter exceeds a predetermined count value. The motor or door positioning system may include a locking device that locks the vehicle door at various positions and the control system use indications of a locked position indicator to determine whether or not to resume operation of the electric motor.
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BACKGROUND OF THE INVENTION
1. Field of the Present Disclosure
This disclosure relates generally to protective sleeves and more particularly to a sleeve for protecting the end of a fence post.
2. Description of Related Art including information disclosed under 37 CFR 1.97 and 1.98.
Fisher, U.S. Pat. No. 94,195, discloses a design for a post support, such design showing a box-like construction with a chiseled lower edge and an open top for receiving a square post. Side fins extend from two opposing sides of the support.
Banks, U.S. Pat. No. 1,402,561, discloses a post support providing a cylindrical receiver, chisel lower edge, disk shaped cap portion, and outwardly and downwardly extending stabilizing teeth.
Knowles, U.S. Pat. No. 5,082,231, discloses a post support for permanent installation at or below ground level including a post receiving collar affixed to fins. The fins have collar supporting shoulders against which a post may rest. A driver/cap/marker has a cap and sleeve with sleeve length the same as the collars length so that when the driver/cap/marker is inserted into the collar the lower edge of the sleeve rests on the shoulders and the underside of the cap/marker rests on top of the collar. The driver/cap/marker serves firstly as a tool for inserting the support into he ground and secondly as a cover for an unused support, and thirdly for marking the location of an unused collar.
Wells, U.S. Pat. No. 5,165,663 discloses a ground anchor for a post including an elongated vertically extending cylindrical PVC tube and including at the lower end of the tube an end member having a cylindrical portion snugly and frictionally fit within the tube and a conical portion projecting downwardly from the tube to a point, the end member having thereon within the tube an upwardly facing drive surface. An elongate driving member is removable insertable into the tube and has at one end a driving which is engagable with the free surface on the end member. In a variation, the tube has at the upper end a collar which includes an axially extending annular flange snugly fir within the upper end of the tube and a further annular flange projecting radially outwardly from the support end of the axial flange.
Boyd et al., U.S. Pat. No. 5,535,555, discloses a breakaway post coupling with a hollow, tubular sleeve which accommodates a ground-mounted stub post and a top, sign-supporting post. The sleeve is held onto the posts by a plurality of pins which engage a corresponding plurality of slots in the sleeve. Collars slidably engage the sleeve and force the pins into the post material as the collars are drawn over the sleeve and pins. A plurality of cutouts in the sleeve define a shear point in the coupling. When the top post is struck by a vehicle, the coupling breaks at the shear point, leaving an intact stub post upon which a new top post can be joined.
Fitzsimmons et al., U.S. Pat. No. 5,571,229, discloses a support structure or ground sleeve for supporting a pole including a cap threadably engagable with an open end of a sleeve body. The ground sleeve includes a sleeve body adapted to be positioned in a ground surface for receiving and supporting a pole and includes at least one flange extending outwardly from the sleeve body for preventing the sleeve from rotating in the ground, a collet for engaging the pole, and an inwardly tapered closed end of the sleeve body for centering an end of the pole. An inwardly tapered race surface of the cap and a plurality of circumferentially-spaced tabs of the sleeve body cooperate to define the collet. In addition, the ground sleeve is formed of a weather resistant non-corrosive material.
Killick, U.S. Pat. No. 5,625,988, discloses a support assembly for a roadside or traffic signpost includes a mounting socket cylinder fixed in the ground for receiving a support post therein. A resilient support means in the form of a pair of O-rings is interposable between the post and the mounting cylinder. A reinforcing collar prevents deformation of adjacent portions of the mounting cylinder and the post.
Aberle, U.S. Pat. No. 5,632,464, discloses a ground pocket support device for removably mounting a post having variable cross-section shape and size. The ground pocket support device includes an elongate ground engaging member having upper and lower end portions. The member is adapted for placement in the ground and defines a hollow post-receiving portion for receiving and supporting a post in a substantially upright position. The ground engaging member further includes elongate wall members and a post wedging mechanism positioned toward the lower end portion for firmly engaging the lower end of a post inserted therewithin. A post-engaging member is disposed at the upper end portion of the ground engaging member. The post-engaging member includes members for removably anchoring a post inserted within the ground engaging member and for adjusting the vertical alignment of the post independent of the vertical alignment between the ground engaging member and the ground in which it is placed.
Peery, Jr., U.S. Pat. No. 5,704,580, discloses a method and apparatus for assembling a selected street pole to a standard sized base. The method includes the step of selecting a street pole of a predetermined configuration. Encircling portions, preferably rings consisting of two semi-circular portions, each having a nestable section with each other and a complementary section with the selected street pole are then provided. The encircling portions are nested together on the standard sized base to connect the standard sized base to the selected street pole thereby continuing the appearance finish of the standard sized base while preventing unauthorized access to an interior of the standard sized base. The apparatus includes the encircling portions to connect the standard sized base to the selected street pole.
Zuares, U.S. Pat. No. 5,832,675, discloses a prefabricated flashing for post bases intended for installation in new or existing construction comprising two different pieces. One piece having a nailing flange which fits snugly around a post whose dimension is five-sixteenths of an inch square, and has a total of eight nail holes and four tapered sides that terminate in a bottom flange. The second piece is shaped and sized similarly to the first except that it is split vertically straight across the nailing flange and on one side has an extension of material which creates a seam.
Doeringer et al., U.S. Pat. No. 5,901,525, discloses an elevated column base for supporting a wood column subjected to high mechanical loads and protecting the column lowermost portion from rot and other deterioration due to exposure to a tropical environment. The column base includes a stanchion, a diaphragm, and a cap, each monolithically molded from a thermoplastic. A first embodiment of the stanchion adapted for a 6.times.6 or 8.times.8 column includes a solid base portion with a cavity which is filled with concrete and plugged with the diaphragm. The stanchion has two pairs of side walls attached to the base portion. Opposed gussets attached to the upper portions of one pair stiffen the side walls against transverse loads. Most of the load carried by the wood column is borne by the concrete and by two horizontal bolts. The diaphragm acts to spread the load force to the base portion and side walls. The load on the diaphragm acts to create a seal against moisture entering the cavity. A second embodiment of the stanchion adapted for a 4.times.4 column does not include gussets. The cap has four lateral faces fitting closely over the stanchion side walls, and a top face with a square aperture formed by four flexible web portions pressing against the wood column. After the column lowermost portion is secured within the stanchion by the bolts, the cap is slid downwardly until the ends of slots in the lateral faces contact the bolts. Each cap bottom corner edge and trough then bound an aperture through which water collected above the diaphragm can drain.
The prior art teaches various means for mounting and protecting a buried end of a post or beam. However, the prior art does not teach a peripheral elastomeric seal that has means for accepting one end of a protective sleeve and that is able to compressed by a molding against a post to attain a water and insect proof enclosure. The present invention fulfills these needs and provides further related advantages as described in the following summary and detailed description and as shown in the accompanying corresponding figures.
BRIEF SUMMARY OF THE INVENTION
This disclosure teaches certain benefits in construction and use which give rise to the objectives described below.
Wooden posts are widely used for outdoor fences and similar applications. Such posts are subject to the elements and insect attack so that they typically need to be replaced periodically. Additionally, such posts are mounted by burying one end into the earth or mounting one end to a concrete footing with metal brackets. These approaches are not aesthetically pleasing and tend to leave the lower end of the post vulnerable to water damage and insect infestation. The above defined prior art devices provide improvements in this field, but clearly, further improvements and post mounting solutions are needed and the present invention is one approach that provides such benefit that is clearly novel and which provides practical benefits over the prior art.
In a preferred embodiment of the present invention, the post has a rectangular cross-sectional shape, typically four inches square, and is mounted within a protective sleeve. The sleeve provides a cylindrical sidewall and a bottom cap closing the end of the sidewall and sealing the end of the post. An elastomeric seal is engaged with the sidewall peripheral to the post, and a pair of L-shaped moldings are mounted exterior to the seal providing engagement within a groove of the elastomeric seal and exerting a sealing force against the elastomeric seal and the post to achieve a waterproof assembly that also is aesthetically pleasing.
A primary objective inherent in the above described apparatus and method of use is to provide advantages not taught by the prior art.
Another objective is to seal the lower end of a post so as to prevent insect attack and water damage.
A further objective is to provide an improved seal between the posts' mounting and the post itself so as to exclude water from the lower end of the post.
A still further objective is to provide a post mounting that is easily installed and later removed as necessary.
A still further objective is to provide a seal that provides mechanical and weather resistant engagement between a sleeve and the post.
Other features and advantages of the present invention will become apparent from the following more detailed description, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of the presently described apparatus and method of its use.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)
Illustrated in the accompanying drawing(s) is at least one of the best mode embodiments of the present invention In such drawing(s):
FIGS. 1 , 2 and 3 are perspective views of an elastomeric seal of the presently described apparatus as seen from one side, above and below respectively;
FIGS. 4 and 5 are perspective views of a cylindrical sidewall closed at one end by a cap of the apparatus as seen from above and from below respectively;
FIG. 6 is a perspective view of the sidewall and cap engaged with an elastomeric seal as seen from above;
FIGS. 7 and 8 are perspective views of the elastomeric seal engaged with a pair of L-shaped moldings as seen from below and from above respectively;
FIG. 9 is a perspective view of the sidewall and cap of FIG. 4 with the elastomeric seal and moldings of FIG. 8 mounted on the sidewall; and
FIG. 10 is a cross sectional view showing the constructional details of the engagement of the elastomeric seal with the molding, sidewall and the post as taken along line 10 - 10 in FIG. 9 .
DETAILED DESCRIPTION OF THE INVENTION
The above described drawing figures illustrate the described apparatus and its method of use in at least one of its preferred, best mode embodiment, which is further defined in detail in the following description. Those having ordinary skill in the art may be able to make alterations and modifications to what is described herein without departing from its spirit and scope. Therefore, it must be understood that what is illustrated is set forth only for the purposes of example and that it should not be taken as a limitation in the scope of the present apparatus and method of use.
Described now in detail is the present invention, a protective sleeve which is mounted on and engages one end of a post, as shown in FIGS. 1-10 . An elongate post 10 ( FIG. 10 ), has a rectangular cross-sectional shape and opposing terminal ends. Such a post 10 is widely used and very well known in the art. A protective sleeve 20 is an assembly made up of several components including: a cylindrical sidewall 22 ( FIG. 4 ); a bottom cap 24 ( FIG. 5 ), a pair of identical L-shaped moldings 26 ( FIGS. 8 and 10 ); and a rectangular peripheral elastomeric seal 28 ( FIGS. 1-3 ). Additionally, fastening hardware 30 is used to interconnect the moldings 26 at opposing corners.
The cap 24 is engaged with a bottom end 23 of the cylindrical sidewall 22 by a bonding adhesive or other well known attachment means that is able to provide a sealed joint, weather and insect proof. A top edge 25 of the sidewall 22 is positioned within a downwardly directed first groove G 1 of the elastomeric seal 28 so that moisture and insects are not able to pass through this joint. To further assure that this joint is impermeable, a bonding adhesive may be inserted into groove G 1 . This joint is best shown in FIG. 10 .
Moldings 26 are positioned around the elastomeric seal 28 , as shown in FIGS. 7 and 8 , with terminal ends 27 of the moldings 26 mutually joined in such manner as to secure the moldings 26 to the elastomeric seal 28 , thereby securing the elastomeric seal 28 to the sidewall 22 , and forcing the elastomeric seal 28 against the post 10 thereby securing the protective sleeve 20 to the post 10 for preventing moisture to enter between the elastomeric seal 28 and the post 10 . The elastomeric seal 28 provides an outwardly directed second groove G 2 which receives an interior ridge or ridges 29 present on each of the moldings 26 , i.e., on all four sides thereof. Please see FIG. 10 for details.
Preferably, the elastomeric seal 28 provides a slopped surface 40 terminating upwardly at a peripheral ridge 42 . Likewise, the moldings preferably provide an interior slopped surface 44 in contact with the slopped surface 40 of the elastomeric sea 28 . These surfaces 40 and 44 lead water that tends to move between the molding 26 and the elastomeric seal 48 away from post 10 , and as shown in FIG. 10 , such moisture cannot enter the space between sidewall 22 and the post 10 .
Preferably, fasteners 30 are directed across the terminal ends 27 of the moldings 26 so as to provide for cinching the moldings tightly around the molding 26 as shown in FIG. 9 . Preferably, the fasteners 30 comprise a female threaded receiver pressed into hole 45 in one of the moldings 26 , and a common machine screw inserted into a clearance hole 46 in the adjoining one of the moldings 26 . In their positions, angled across the ends 27 , the fasteners 30 are positioned within the second groove G 2 of the elastomeric seal.
It should be noted, that the moldings 26 may alternately comprise four linear sections instead of two L-shaped portions or one U-shaped portion and one linear portion. Also, the apparatus may take an alternate shape other than square or rectangular as is shown in the illustrations. For instance the apparatus may be round or oval for accepting a post of that shape.
The enablements described in detail above are considered novel over the prior art of record and are considered critical to the operation of at least one aspect of the apparatus and its method of use and to the achievement of the above described objectives. The words used in this specification to describe the instant embodiments are to be understood not only in the sense of their commonly defined meanings, but to include by special definition in this specification: structure, material or acts beyond the scope of the commonly defined meanings. Thus if an element can be understood in the context of this specification as including more than one meaning, then its use must be understood as being generic to all possible meanings supported by the specification and by the word or words describing the element.
The definitions of the words or drawing elements described herein are meant to include not only the combination of elements which are literally set forth, but all equivalent structure, material or acts for performing substantially the same function in substantially the same way to obtain substantially the same result. In this sense it is therefore contemplated that an equivalent substitution of two or more elements may be made for any one of the elements described and its various embodiments or that a single element may be substituted for two or more elements in a claim.
Changes from the claimed subject matter as viewed by a person with ordinary skill in the art, now known or later devised, are expressly contemplated as being equivalents within the scope intended and its various embodiments. Therefore, obvious substitutions now or later known to one with ordinary skill in the art are defined to be within the scope of the defined elements. This disclosure is thus meant to be understood to include what is specifically illustrated and described above, what is conceptually equivalent, what can be obviously substituted, and also what incorporates the essential ideas.
The scope of this description is to be interpreted only in conjunction with the appended claims and it is made clear, here, that each named inventor believes that the claimed subject matter is what is intended to be patented.
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A post has a rectangular cross-sectional shape and mounted on one end of the post is a protective sleeve. The sleeve provides a cylindrical sidewall within which one end of the post is engaged. A bottom cap closes the end of the sidewall sealing the end of the post. A rectangular elastomeric seal is engaged with the sidewall peripheral to the post. A pair of L-shaped moldings are mounted exterior to the elastomeric seal providing engagement within a groove of the elastomeric seal and exerting a sealing force against the elastomeric seal and the post.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims benefit of U.S. Provisional Patent Application Ser. No. 60/655,289,filed Feb. 22, 2005,which is herein incorporated by reference.
BACKGROUND OF THE INVENTION
1.Field of the Invention
The present invention generally relates to systems and methods for drilling and completing a wellbore. More particularly, the invention relates to systems and methods for mitigating trouble zones in a wellbore in a managed pressure condition and completing the wellbore in the managed pressure condition.
2.Description of the Related Art
Historically, wells have been drilled with a column of fluid in the wellbore designed to overcome any formation pressure encountered as the wellbore is formed. This “overbalanced condition” restricts the influx of formation fluids such as oil, gas or water into the wellbore. Typically, well control is maintained by using a drilling fluid with a predetermined density to keep the hydrostatic pressure of the drilling fluid higher than the formation pressure. As the wellbore is formed, drill cuttings and small particles or “fines” are created by the drilling operation. Formation damage may occur when the hydrostatic pressure forces the drilling fluid, drill cuttings and fines into the reservoir. Further, drilling fluid may flow into the formation at a rate where little or no fluid returns to the surface. This flow of fluid into the formation can cause the “fines” to line the walls of the wellbore. Eventually, the cuttings or other solids form a wellbore “skin” along the interface between the wellbore and the formation. The wellbore skin restricts the flow of the formation fluid during a production operation and thereby damages the well.
Another form of drilling is called managed pressure drilling. An advantage of managed pressure drilling is the ability to make bottom hole pressure adjustments with minimal interruptions to the drilling progress. Another related drilling method of managed pressure drilling is underbalanced drilling. In this drilling method, the column of fluid in the wellbore is designed to be less than the formation pressure encountered as the wellbore is formed. Typically, well control is maintained by using a drilling fluid with a predetermined density to keep the hydrostatic pressure of the drilling fluid lower than the formation pressure. As the wellbore is formed, drill cuttings and small particles or “fines” are created by the drilling operation and circulated out of the wellbore resulting in minimal formation damage.
Managed pressure drilling and underbalanced drilling maximizes the production of the well by reducing skin effect and/or formation damage during the drilling operation. However, the maximization of production is negated when the well has to be killed in order to mitigate a trouble zone encountered during the managed pressure or underbalanced drilling operation. Further, the maximization of production is negated when the well has to be killed in order to complete the wellbore after the drilling operation. Presently, snubbing is a method for tripping a drill string in a constant underbalanced state. Snubbing removes the possibility of damaging the formation, but increases rig up/rig down and tripping times, adding to the operational expense. In addition, the snubbing unit cannot seal around complex assemblies, such as a solid expandable drilling liner which is typically used to mitigate a trouble zone encountered during a drilling operation. Further snubbing units cannot seal around slotted liners or conventional sand screens which are typically used in completing a wellbore.
There is a need, therefore, for an effective method and system to mitigate trouble zones encountered during an underbalanced or managed pressure drilling operation. There is a further need, therefore, for an effective method and system to complete the wellbore in an underbalanced or managed pressure condition.
SUMMARY OF THE INVENTION
The present invention generally relates to methods and systems for mitigating trouble zones in a wellbore in a preferred pressure condition and completing the wellbore in the preferred pressure condition. In one aspect, a method of reinforcing a wellbore is provided. The method includes locating a valve member within the wellbore for opening and closing the wellbore. The method further includes establishing a preferred pressure condition within the wellbore and closing the valve member. The method also includes locating a tubular string having an expandable portion in the wellbore and opening the valve member. Additionally, the method includes moving the expandable portion through the opened valve member and expanding the expandable portion in the wellbore at a location below the valve member.
In another aspect, a method of forming a wellbore is provided. The method includes separating the wellbore into a first region and a second region by closing a valve member disposed in the wellbore. The method also includes reducing the pressure in the first region and lowering a tubular string having an earth removal member and an expandable portion into the first region of the wellbore to point proximate the valve member. The method further includes establishing and maintaining a preferred pressure condition in the wellbore and opening the valve member. Additionally, the method includes moving the earth removal member and the expandable portion through the opened valve member and forming the wellbore.
In yet another aspect, a system for drilling a wellbore is provided. The system includes a tubular string having an earth removal member and an expandable portion. The system also includes a valve member located within the wellbore for substantially opening and closing the wellbore. Additionally, the system includes a fluid handling system for maintaining a portion of the wellbore in one of a managed pressure condition and an underbalanced pressure condition.
BRIEF DESCRIPTION OF THE DRAWINGS
So that the manner in which the above recited features of the present invention can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
FIG. 1 is a view of a drilling assembly being lowered in a wellbore on a drill string.
FIG. 2 is a view of the wellbore with a valve member in a closed position.
FIG. 3 illustrates the drilling assembly forming another section of the wellbore during an underbalanced or a managed pressure drilling operation.
FIG. 4 illustrates the drilling assembly forming another section of the wellbore after an expandable portion has isolated a trouble zone from the surrounding wellbore.
FIG. 5 illustrates the placement of a second expandable portion at another trouble zone.
FIG. 6 illustrates a portion of the wellbore being formed by drilling with a string of casing.
FIG. 7 illustrates a completed wellbore with an expandable filter member.
FIGS. 8A-8D illustrate different forms of the expandable portion.
DETAILED DESCRIPTION
In general, the present invention relates to systems and methods for completing a wellbore in a preferred pressure condition in order to reduce wellbore damage. As will be described herein, the systems and methods are employed in a wellbore having a preferred pressure condition, such as an underbalanced or managed pressure condition. It must be noted that aspects of the present invention are not limited to these conditions, but are equally applicable to other types of wellbore conditions. Additionally, the present invention will be described as it relates to a vertical wellbore. However, it should be understood that the invention may be employed in a horizontal or deviated wellbore without departing from the principles of the present invention. To better understand the novelty of the apparatus of the present invention and the methods of use thereof, reference is hereafter made to the accompanying drawings.
FIG. 1 is a view of a drilling assembly 100 being lowered in a wellbore 10 on a drill string 105 . The drilling assembly 100 includes a drill bit 110 or other earth removal member, a first carrying assembly 115 with an expandable portion 125 and a second carrying assembly 120 with an expandable portion 130 . As illustrated, the wellbore 10 is lined with a string of steel pipe called casing 15 . The casing 15 provides support to the wellbore 10 and facilitates the isolation of certain areas of the wellbore 10 adjacent hydrocarbon bearing formations. The casing 15 typically extends down the wellbore 10 from the surface of the well to a designated depth. An annular area 20 is thus defined between the outside of the casing 15 and the wellbore 10 . This annular area 20 is filled with cement 25 pumped through a cementing system (not shown) to permanently set the casing 15 in the wellbore 10 and to facilitate the isolation of production zones and fluids at different depths within the wellbore 10 .
At the surface of the wellbore 10 , a rotating control head 75 is disposed on a blow out preventer (BOP) stack 80 . Generally, the rotating control head 75 isolates pressurized annular returns and diverts flow away from the surface of the wellbore 10 to a choke manifold (not shown) and a separator (not shown). The rotating control head 75 , which is mounted on top of the BOP stack 80 , seals the drill string 105 creating a pressure barrier on the annulus side of the drill string 105 while the drill string 105 is being tripped in or out of the wellbore 10 or while it is being rotated during drilling operations. Additionally, the rotating control head 75 and the choke manifold together act as a fluid control system and are used to manage the wellbore's annular pressure, such as in a managed pressure condition or an underbalanced pressure condition.
During the underbalanced drilling operation, the reservoir fluids are allowed to flow. Therefore a surface pressure is ever present in the annulus formed between the drill string 105 and the casing 15 . The rotating control head 75 is used to control the pressure at the surface of the wellbore 10 . As tripping begins, and the drill string 105 is stripped through the rotating control head 75 , the pressure must be managed to prevent well pressures uncontrollably forcing the drill string out 105 of the wellbore in a pipe-light situation. Generally pipe-light occurs at the point where the formation pressure across the pipe cross-section creates an upward force sufficient to overcome the downward force created by the pipe's weight.
A downhole deployment valve 50 is disposed at the lower end of the casing 15 . The downhole deployment valve 50 is commonly used to shut-in oil and gas wells. The downhole deployment valve 50 may be installed in the casing 15 as shown in FIG. 1 or the downhole deployment valve 50 may be installed on a tie-back string which can be retrieved following the drilling operation. Generally, the downhole deployment valve 50 is configured to selectively block the flow of formation fluids upwardly through the casing 15 should a failure or hazardous condition occur at the well surface. Additionally, the downhole deployment valve 50 allows a wide range of systems and bottom hole assemblies to be safely and effectively deployed in an underbalanced or a mangaged pressure drilling operation. Typically, the downhole deployment valve 50 is maintained in an open position by the application of hydraulic fluid pressure transmitted to an actuating mechanism. The actuating mechanism (not shown) is charged by application of hydraulic pressure. The hydraulic pressure is commonly a clean oil supplied from a surface fluid reservoir through a control line. A pump (not shown) at the surface of the wellbore 10 delivers regulated hydraulic fluid under pressure from the surface of the wellbore 10 to the actuating mechanism through the control line. Typically, the bore through the downhole deployment valve 50 is equal to or greater than the drift diameter of the casing 15 when the downhole deployment valve 50 is in the open position.
As illustrated in FIG. 1 , the drilling assembly 100 is lowered into the wellbore 10 on the drill string 105 to a point proximate the downhole deployment valve 50 . Pressure within the drill string 105 is controlled by closing an inner diameter of the drill string using a valve member within the drill string or a retrievable plug. Thereafter, the downhole deployment valve 50 is closed as illustrated in FIG. 2 by applying hydraulic pressure from the surface fluid reservoir through the control line.
After the downhole deployment valve 50 is closed, the wellbore 10 is separated into a first region 85 and a second region 90 . The wellbore pressure in the first region is then reduced to substantially zero by manipulating the rotating control head 75 and the choke manifold system. In one embodiment, the downhole deployment valve 50 is equipped with downhole sensors 250 , as shown in FIG. 1 , that transmit an electrical signal to the surface, allowing measurement and reading of real-time downhole pressures.
When the wellbore pressure in the first region 85 is reduced to substantially zero, the balance of the drill string 105 is tripped out of the wellbore 10 in a similar manner as the procedure for tripping pipe in a dead well. During the trip into the wellbore 10 , the drill string 105 is rerun to a depth directly above the downhole deployment valve 50 , where a pipe-heavy condition exists. Subsequently, pressure is applied to the wellbore 10 to equalize the pressure in the first region 85 and the second region 90 . When the pressures in the regions 85 , 90 are substantially equal, hydraulic pressure from the surface fluid reservoir is applied through the control line to open the downhole deployment valve 50 , thereby opening the pathway into region 90 of the wellbore 10 .
FIG. 3 illustrates the drilling assembly 100 forming another section of the wellbore 10 during an underbalanced or a managed pressure drilling operation. Generally, the wellbore 10 is formed by rotating the drill bit 110 while urging the drilling assembly 100 downward away from the mouth of the wellbore 10 . Typically, the drill bit 110 is rotated by the drill string 105 or by a downhole motor arrangement (not shown).
The wellbore 10 will be formed by the drilling assembly 100 until the drilling assembly 100 encounters a trouble zone 160 . The trouble zone is a section or zone of the wellbore that negativity affects the drilling operation and/or subsequent production operation. For instance, the trouble zone may be a permeable pay zone which drains the drilling fluid from the wellbore 10 . The trouble zone may also be a high pressure water flow zone which communicates high pressure water into the wellbore 10 . The trouble zone may consist of a loss circulation zone that causes sloughing intervals or pressure transistions.
Once the trouble zone 160 is encountered during the drilling operation, the trouble zone 160 must be mitigated in order to effectively continue the drilling operation. In one embodiment, the trouble zone is mitigated by isolating the trouble zone from the wellbore by placing the expandable portion 125 over the trouble zone 160 . The expandable portion 125 may be an expandable clad member, an expandable liner as shown in FIGS. 8A-8C , or any other form of expandable member.
As illustrated in FIG. 3 , the drilling assembly 100 is positioned in the wellbore 10 such that the first carrying assembly 115 is positioned proximate a trouble zone 160 . In one embodiment, the portion of the wellbore 10 by the trouble zone 160 is enlarged or under-reamed by an under-reamer (not shown) or an expandable drill bit (not shown) prior to placing the carrying assembly 115 proximate the trouble zone 160 . Thereafter, the carrying assembly 115 is activated and the expandable portion 125 is expanded radially outward into contact with the under-reamed portion of the wellbore 10 . Next, the expandable portion 125 is released from the carrying assembly 115 and the drilling operation is continued.
The expandable portion 125 isolates the trouble zone 160 without loss of wellbore diameter. In other words, after expansion of the expandable portion 125 , the inner diameter of the expandable portion 125 is greater than or equal to the inner diameter of the casing 15 , thereby resulting in a monobore configuration. Further, the expandable portion 125 may have an anchoring member on an outside surface to allow the expandable portion 125 to grip the wellbore 10 upon expansion of the expandable portion 125 . The expandable portion 125 may also have a seal member 135 disposed on an outside surface to create a sealing relationship with the wellbore 10 upon expansion of the expandable portion 125 . Additionally, the expandable portion 125 may be set in the wellbore 10 with or without the use of cement.
The carrying assembly 115 may include a hydraulically activated expansion member 145 with extendable members 140 (see FIG. 3 ) or another type of expansion member known in the art such as solid swage or a rotary tool. Additionally, the expansion member may expand the expandable portion 125 in a top to bottom expansion or in a bottom to top expansion without departing from principles of the present invention.
In one embodiment, the expandable portion 125 is a pre-shaped or profiled tubular. After the carrying assembly 115 is positioned proximate the trouble zone 160 , the carrying assembly 115 applies an internal pressure to the expandable portion 125 to substantially deform or reshape the expandable portion 125 to its original round shape and into contact with the wellbore 10 . Thereafter, a rotary expansion tool or another type of expansion tool may be used to further radially expand the expandable portion 125 .
FIG. 4 illustrates the drilling assembly 100 forming another section of the wellbore 10 after the expandable portion 125 has been placed in the wellbore 10 . As shown, the drilling assembly 100 is urged further into the wellbore 10 and the expandable portion 130 moves through the inner diameter of the expandable portion 125 . The drilling assembly 100 continues to form the wellbore 10 until another trouble zone 165 is encountered. At that point, the trouble zone 165 is mitigated by isolating the trouble zone 165 from the wellbore by placing the expandable portion 130 over the trouble zone 165 as illustrated in FIG. 5 .
Similar to the process described above, the carrying assembly 120 is located in the wellbore 10 such that the expandable portion 130 is positioned proximate the trouble zone 165 . Thereafter, an expansion member 150 in the carrying assembly 120 is activated and the expandable portion 130 is expanded radially outward into contact with the under-reamed portion of the wellbore 10 by extendable members 155 in the expansion member 150 (see FIG. 5 ) and then the expandable portion 130 is released from the carrying assembly 120 . Similar to expandable portion 125 , the expandable portion 130 isolates the trouble zone 165 without loss of wellbore diameter. In other words, after expansion of the expandable portion 130 , the inner diameter of the expandable portion 130 is greater than or equal to the inner diameter of the casing 15 and the inner diameter of the expandable portion 125 , thereby resulting in a monobore configuration.
After both expandable portions 125 , 130 have been deployed, the drill string 105 is retrieved from the wellbore 10 until the lower end of the drilling assembly 100 is above the deployment valve 50 . The deployment valve 50 is then closed and the annular seal is then disengaged. Thereafter, the drill string may be removed from the wellbore 10 . Although the deployment of only two expandable portions has been described, more than two may be drilled in and deployed using the steps described without departing from principles of the present invention. Additionally, the Figures illustrate the drill bit 110 and the expandable portions 125 , 130 lowered on the drill sting 105 at the same time. It should be understood, however, that the drill bit 110 and the expandable portions 125 , 130 may be used independently without departing from principles of the present invention. In other words, the drill bit 110 may be used to form the wellbore 10 and then removed from the wellbore 10 while maintaining the preferred pressure condition. Thereafter, the expandable portion 125 may be lowered and disposed in the wellbore 10 as described herein while maintaining the preferred pressure condition.
In another embodiment the drill string 105 is deployed as described above until the first expandable portion 125 deployment is complete. At that point the drill string 105 is retrieved from the wellbore 10 until the lower end of the drill string 105 is above the deployment valve 50 . The deployment valve 50 is then closed and the annular seal is then disengaged. Retrieval of the drill string 105 is then continued until the carrying assembly 115 of the drill string 105 is accessible. A second expandable portion 130 is then affixed to the carrying assembly 115 .
The deployment valve 50 is then closed and the drill string 105 is reinserted into the wellbore 10 until at least the drilling assembly 100 is within the wellbore 10 . The annular seal is engaged between the wellbore inner diameter and the drill string 105 and the deployment valve 50 is opened. The drill string 105 is progressed into the wellbore through the deployment valve 50 and the drill bit 110 engaged in drilling below the previously deployed expandable portion 125 . The second expandable portion 130 is deployed proximate a second formation requiring control when drilling has progressed to that point. Following deployment of the second expandable portion 130 drilling may progress further or the drilling assembly 100 may be retrieved as previously described herein.
FIG. 6 illustrates a portion of the wellbore 10 formed by drilling with a string of casing 175 . Another type of trouble zone is a sloughing shale zone. One cause of unstable hole condition can occur in certain formations when the hydrostatic pressure of the fluid column is not sufficient to hold back the formation, resulting in sloughing of the wall of the wellbore 10 . For this reason sloughing formations, especially shale sections, are somewhat common in underbalanced drilling operations. There are several different methods of remediating these type of trouble zones, such as managed pressure drilling techniques, solid expandable liners (either tied-back or not) through the use of conventional liners, or by drilling with casing or liners. Each method has its own limitations. However, drilling with casing technology has been used for both drilling through problem formations and ensuring the casing or liner can be set on bottom through unstable hole conditions.
Drilling with casing (or liners) are useful tools for drilling in difficult drilling conditions. Drilling with casing can be a relatively simple operation if the operator knows of a problem zone. For instance, a conventional assembly can be used to drill the wellbore 10 to a point just above a trouble zone 170 . Thereafter, the conventional assembly may be removed and a casing string 175 with a drill bit 180 attached is introduced into the wellbore 10 . Similar to the procedure previously discussed, the casing string 175 and the drill bit 180 are lowered into the wellbore 10 on the drill string 105 to a point proximate the downhole deployment valve 50 . Thereafter, the downhole deployment valve 50 is closed. Next, the wellbore pressure in the first region above the valve 50 is reduced to substantially zero by manipulating the rotating control head 75 and the choke manifold system. When the wellbore pressure in the first region 85 is reduced to substantially zero, the balance of the drill string 105 is tripped out of the wellbore 10 in a similar manner as the procedure for tripping pipe in a dead well. During the trip into the wellbore 10 , the drill string 105 is rerun to a depth directly above the downhole deployment valve 50 , where a pipe-heavy condition exists. Subsequently, pressure is applied to the wellbore 10 to equalize the pressure in the first region and the second region below the valve 50 . When the pressures in the regions are substantially equal, hydraulic pressure from the surface fluid reservoir is applied through the control line to open the downhole deployment valve 50 , thereby opening the pathway into the region of the wellbore 10 below the valve 50 . Then the casing string 175 and the drill bit 180 are lowered into the wellbore 10 past the expandable portions 125 , 130 to form another portion of the wellbore 10 and isolate the trouble zone 170 .
Generally, drilling with casing entails running the casing string 175 into the wellbore 10 with the drill bit 180 attached. The drill bit 180 is operated by rotation of the casing string 175 from the surface of the wellbore 10 . Once the wellbore 10 is formed, the attached casing string 175 is cemented in the wellbore 10 . Thereafter, a drilling assembly (not shown) may be employed to drill through the drill bit 180 at the end of the casing string 175 and subsequently form another portion of the wellbore 10 .
In drilling the wellbore 10 , the drilling assembly 100 with a directional drilling member (not shown) is tripped into the wellbore 10 through the valve 50 (and hole angle is built to horizontal). The reservoir is drilled underbalanced to a total depth. Pressure while drilling and gamma ray sensors in the guidance system, in addition to the normal directional tool face, inclination and azimuth readings, aid in maintaining proper underbalance margin and geologic settings. Multiphase flow modeling prior to and during the drilling operation insures desired equivalent circulating density (ECD) and sufficient circulation rates required for cuttings removal and good hole cleaning during Under Balanced Drilling operations. Additionally, fluid density may be adjusted, as can the injection rates of nitrogen and liquid to achieve the desired mixture density.
FIG. 7 illustrates the wellbore 10 with an expandable filter member 185 or a screen. For purposes of sand control, the expandable filter member 185 commonly referred to as an Expandable Sand Screen (ESS®) is useful in controlling sand and enhancing the productivity of both vertical and horizontal wells. In a similar manner as previously discussed, the expandable filter member 185 is lowered into the wellbore 10 on the drill string 105 to a point proximate the downhole deployment valve 50 . Thereafter, the downhole deployment valve 50 is closed. Next, the wellbore pressure in the first region above the valve 50 is reduced to substantially zero by manipulating the rotating control head 75 and the choke manifold system. When the wellbore pressure in the first region 85 is reduced to substantially zero, the balance of the drill string 105 is tripped out of the wellbore 10 in a similar manner as the procedure for tripping pipe in a dead well. During the trip into the wellbore 10 , the drill string 105 is rerun to a depth directly above the downhole deployment valve 50 , where a pipe-heavy condition exists. Subsequently, pressure is applied to the wellbore 10 to equalize the pressure in the first region and the second region below the valve 50 . When the pressures in the regions are substantially equal, hydraulic pressure from the surface fluid reservoir is applied through the control line to open the downhole deployment valve 50 , thereby opening the pathway into the region of the wellbore 10 below the valve 50 . Then the expandable filter member 185 is lowered into the wellbore 10 past the expandable portions 125 , 130 and the casing string 175 to a previously formed section of the wellbore 10 in a completion operation. The ability of performing a drilling operation and completion operation in an underbalanced environment will cause less damage to the reservoir formations.
Generally, the expandable filter member 185 comprises an overlapping mesh screen, sized for the particular sieve analysis solution and sandwiched between two slotted metal tubulars, an inner base pipe and an outer shroud that covers and protects the screen. As expandable filter member 185 is expanded, the pre-cut slots in both the base and shroud pipes expand and the screen material slides over itself to provide an uninterrupted screen surface on the wellbore 10 . The expandable filter member 185 maybe expanded by a rigid cone expander, a variable compliant expansion, or any other type expansion device.
In the past the greatest challenge of completing an underbalanced well using the expandable filter member 185 is deploying the porous unexpanded sand screen into a live, pressured wellbore 10 . Conventional snubbing options available to solid pipe will not work with the expandable filter member 185 . Killing the well to deploy the completion hardware likewise does not work because that defeats the objective of the underbalanced completion. The underbalanced drilling was possible, using snubbing equipment to trip under pressure to avoid pipe light conditions, but running sand screens was the challenge. However, the development of the valve 50 made the use of the expandable filter member 185 as an underbalanced completion system possible. As previously discussed, the valve 50 is used to drill the well underbalanced and to deploy the expandable filter member 185 . Typically, the expandable filter member 185 employs a modified Axial Compliant Expansion (ACE) tool for underbalanced compliant expansion. The modified Cardium liner hanger or an expandable liner hanger is used to hang the expandable filter member 185 before expansion begins. Membrane nitrogen or another gas is used to set the hanger and then to expand the screen using the pressure translation sub between the gas and the ACE tool.
FIGS. 8A-8D illustrate the different forms of the expandable portion. For instance, FIG. 8A illustrates an expandable portion 205 disposed at an end of a casing string 200 . As shown, the expandable portion 205 has an inner diameter (D 1 ) smaller than an inner diameter (D 0 ) of the casing string 200 . FIG. 8B illustrates an expandable portion 210 disposed in a shoe portion of the casing string 200 . As shown, the expandable portion 210 has an inner diameter (D 1 ) substantially equal to an inner diameter (D 0 ) of the casing string 200 , thereby resulting in a monobore configuration. FIG. 8C illustrates an expandable portion 220 disposed in a shoe portion of the casing string 215 which is mounted in a shoe portion of the casing string 200 . As shown, the expandable portion 220 has an inner diameter (D 2 ) substantially equal to an inner diameter (D 1 ) of the casing string 215 and an inner diameter (D 0 ) of the casing string 200 , thereby resulting in a sequential monobore configuration.
FIG. 8D illustrates an expandable portion 225 disposed below an end of the casing string 200 . As shown, the expandable portion 225 has an inner diameter (D 1 ) smaller than an inner diameter (D 0 ) of the casing string 200 . Similar to expandable portions 125 , 130 as shown in FIGS. 1-7 , one advantage of this embodiment is that only the trouble zone is being remediated rather than forcing the expandable casing to be installed from the trouble zone all the way back to the previous string of casing. Therefore, the expandable portion 225 requires a much shorter liner to be installed, creating a more cost effective expandable system to cure the trouble zone.
While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.
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The present invention generally relates to methods and systems for mitigating trouble zones in a wellbore in a preferred pressure condition and completing the wellbore in the preferred pressure condition. In one aspect, a method of reinforcing a wellbore is provided. The method includes locating a valve member within the wellbore for opening and closing the wellbore. The method further includes establishing a preferred pressure condition within the wellbore and closing the valve member. The method also includes locating a tubular string having an expandable portion in the wellbore and opening the valve member. Additionally, the method includes moving the expandable portion through the opened valve member and expanding the expandable portion in the wellbore at a location below the valve member. In another aspect, a method of forming a wellbore is provided. In yet another aspect, a system for drilling a wellbore is provided.
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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 drain plug structure for use in opening or closing a drain port of a bath tab.
2. Related Art
As the related art, drain plug structure for a bath tub, it is well known in the art to provide a system in which the supporting member having a plug lid pivotally supported therein, for example, is held in the drain port and an operating part arranged at a position spaced apart from the supporting member is connected to the supporting member through a release wire, for example, Gazette of Japanese Patent Laid-Open No. Hei 9-60073.
Further, in the case of such a drain plug structure as described above, as shown in FIG. 5 , a packing 102 arranged at a rear surface 101 of a plug lid 100 is closely contacted with a packing close-contact surface 103 of a drain port C to hold a water-tight state, so that there occurs a possibility that the plug lid 100 may protrude substantially from the bottom surface 104 of the bath tub and become a hindrance material when a person takes a bath.
In view of the foregoing, although the packing close-contact surface 103 is lowered by a certain step from the upper surface of the drain port C and a height of the plug lid 100 is made low a little as shown in the figure, practically it is lowered by an amount corresponding to a height lower than a thickness of the packing 102 and its practical effectiveness is quite low because of a wall thickness of a drain fitting for constituting the drain port and holding the supporting member, and a holding of the drain port diameter and the like.
Further, when it is desired to generate a clearance between the rear surface 101 of the plug lid and the upper surface of the drain port C and assure an amount of collapse of the packing 102 required for holding a water-tightness at this clearance under a state in which the packing 102 is closely contacted with the packing close-contact surface 103 because of the highest priority of assuring of the water-tightness, this clearance may become a cause for oppositely increasing an amount of protrusion of the plug lid 100 and the plug lid 100 becomes a step without a fail.
SUMMARY OF THE INVENTION
In view of the foregoing, it is a subject matter of the present invention to restrict a protrusion of the plug lid from the bottom part of the bath tub and decrease a possibility in which the plug lid becomes a hindrance and it is an object of the present invention to provide a drain plug structure resolving the subject matter described above.
Further, it is a subject matter of the present invention to improve a water-tightness in addition to the aforesaid subject matter and it is an object of the present invention to provide a drain plug structure solving the subject matter described above.
In order to accomplish the aforesaid objects, the present invention employed some technical means described below.
The technical means provides a drain plug structure for a bath tub using a remote-controlling type drain plug device, wherein this drain plug structure has a feature that at least a circumferential edge of the plug lid is set to be lower than the bottom surface of the bath tub under a drain port closed state (first aspect).
With such an arrangement as above, at least the circumferential edge of the plug lid is dropped into the drain port in such a way that it may not be contacted with a skin of a person and it becomes possible to position the top point of the plug lid in flush with the bottom surface of the bath tub or less than that in response to an amount of dropping. In this case, this plug does not become a hindrance and a safe and comfortable taking a bath can be assured.
The practical structure according to first aspect is a drain plug structure for a bath tub using a remote-controlled type drain plug device, for example, wherein the drain port is comprised of a notch part where it is dropped to become lower than the bottom surface of the bath tub under a closed state of the drain port and a packing close-contact surface placed lower than the bottom surface of the notch and having a smaller diameter than a diameter of the plug lid, and the packing is closely contacted with the packing close contact surface under a state in which the plug lid is dropped into the notch part (second aspect).
According to second aspect, the plug lid is dropped into the notch formed in such a way that the circumferential edge of the plug lid becomes lower than the bottom surface of the bath tub, the packing is closely contacted with the packing close-contact surface lower than the bottom surface of the notch.
Due to this fact, although the plug lid is dropped into the notch part, an amount of collapsing of the packing required for holding a water-tightness does not become a hindrance against dropping of the plug lid into the notch part.
Although the packing close-contact surface includes all the constitutions having the aforesaid actions, it is preferable that this packing close-contact surface has a constitution in which the surface is a narrow inclined surface where it is narrowed from the bottom surface of the notch in a downward direction (third aspect).
According to third aspect, a returning force of the packing itself from its deformation is added to a pushing force against the packing close-contact surface acting to the packing to increase a close-contact force because the packing is closely contacted with the packing close-contact surface while it is being crashed by the inclined surface and deformed.
In addition, it is the best way for the notch part to set a horizontal plane having the plug lid mounted thereon as a bottom surface (fourth aspect).
According to fourth aspect, the plug lid is supported at the horizontal plane without being inclined under application of a load (either a hydraulic pressure or an artificial pressure applied by a user) and a crushing force more than a requisite force is not acted on the packing.
As to a close contact characteristic, the packing is set such that the main body extending from the base part to its extremity end in narrow form is integrally arranged and at the same time, one or a plurality of more than two annular protrusions closely contacted with the packing close-contact surface are protruded at the main body and formed (fifth aspect), and the annular protrusions are closely contacted with the packing close-contact surface in a linear-contact form and this is effective in realizing a much higher close-contact characteristic.
In this case, it is preferable that the main body is formed such that its outer surface becomes a fine narrow shape having a convex curved surface from the upper edge of the end part to the bottom part, and annular protrusions are protruded at the convex curved surface (sixth aspect).
Then, a depth of the notch is set to such a value as one enabling the plug lid to be dropped into it in such a way that its top part may become in flush with the bottom surface of the bath tub or less than that (seventh aspect), thereby the plug lid is installed at the bottom part of the bath tub without being protruded.
In addition, the plug lid is removably fitted to the supporting shaft of the drain plug device (eighth aspect), thereby the plug lid can be removed through one-finger touch for performing a convenient repairing management.
As a practical example of the engagement or disengagement structure between the plug lid and the supporting shaft of the drain plug lid, there is provided a structure in which some axial slits are arranged at a fitting cylinder arranged at the plug lid and some protrusions are protruded inside the resilient pieces formed at several locations in a circumferential direction of it, fitting grooves where the protrusions are adapted to be fitted are set at the supporting shaft, the supporting shaft is inserted into the fitting cylinder, thereby the supporting shaft is contacted with the protrusions to expand and open the resilient pieces, when the protrusions are positioned at the fitting grooves, the resilient pieces are recovered from the expanded and opened state due to their resiliency to cause the protrusions to be fitted to the fitting grooves, wherein under a normal state of use, the plug lid is connected in such a way that it may not be removed from the supporting shaft, the plug lid is pulled out of the supporting shaft to cause the resilient pieces to be expanded and opened and the protrusions are escaped from the fitting grooves and the plug lid is removed (ninth aspect).
Additionally, when the anti-vibrating member sliding on the outer circumferential surface of the supporting member supporting the supporting shaft in such a way that it can be moved up and down is vertically installed at the plug lid, the plug lid is prevented from being vibrated and inclined (tenth aspect) and further the plug lid is provided with a foreign material mixing preventive cover sliding on the outer circumferential surface of the supporting member supporting the supporting shaft in such a way that it can be moved up and down, the foreign material mixing preventive cover has a cylinder part with its lower end being opened or released, the cylinder part has a length extending along the outer circumferential surface of the supporting member when the drain port is opened and when the drain port is closed, and then the foreign material is prevented from advancing into the supporting member when the drain port is opened (eleventh aspect).
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view for showing a drain plug structure of the present invention.
FIG. 2 is a sectional view for showing an opened state of a drain port.
FIG. 3 is a sectional view for showing a plug lid.
FIG. 4 is a sectional view for showing another preferred embodiment.
FIG. 5 is a sectional view for showing the related art drain plug structure.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, some preferred embodiments of the present invention will be described as follows.
Further, an illustration and a description of an operating unit for the drain plug device of the present invention will he eliminated because basically the device has a well-known structure.
The supporting member 2 is held in a drain fitting A 1 by a holding means A 3 placed in the drain fitting A 1 constituting the drain port B in such a way that it can be inserted into to or removed from it. However, as to the holding structure of the supporting member 2 , this is not limited to a structure illustrated in the drawings.
A practical description about the constitution of the holding means A 3 will be eliminated because the present applicant has already proposed in Gazette of Japanese Patent Laid-Open No. Hei 11-099077.
Further, the holding means A 3 is integrally provided with a holding rind A 32 removably attached to the drain fitting A 1 through a rib A 31 arranged in a radial direction from an outer circumferential surface of the supporting member 2 , and a fitting means A 33 is arranged over the holding ring A 32 and the drain fitting A 1 so as to hold the supporting member 2 in the drain fitting A 1 in such a way that it can be inserted into or removed from it.
Next, the drain plug structure of the present invention will be described more practically.
A drain port B is constituted by a notch 4 having a depth where a circumferential edge 11 of the plug lid 1 is embedded at its upper surface, and a packing close-contact surface 5 becoming a narrow extremity end slant surface from a horizontal surface 41 of a bottom part of the notch 4 to a downward direction.
The horizontal surface 41 acting as the bottom part of the notch 4 and the packing close-contact surface 5 are positioned lower than the bottom surface A 2 of the bath tub, thereby the circumferential edge 11 of the plug lid 1 and a packing 6 to be described later are positioned at a lower place than the bottom surface A 2 of the bath tub.
The packing 6 for being closely contacted with the packing close-contacted surface 5 to keep a water-tight state is arranged below the plug lid 1 .
The packing 6 is arranged to be spaced apart from the rear surface 12 of the plug lid 1 , a clearance between the packing 6 and the rear surface 12 becomes a deformed space for the packing 6 , wherein the packing 6 is deformed to be peeled up through inclination of the packing close-contacted surface 5 under a closed state of the plug lid 1 and then its recovering force from its deformation may also act as the close contact force.
The packing 6 is made such that its main body 61 is formed to have a shape narrowing toward its extremity end from its base part and at the same time its outer surface ranging from the upper edge of the end part to the bottom part is formed as a convex curved surface.
In addition, two annular protrusions 62 coaxial with the packing 6 are provided at the rear surface of the packing 6 and the water-tight state is held while the annular protrusions 62 may closely be contacted with the packing close-contacted surface 5 in a line-contact state.
A connected structure between the plug lid 1 and the supporting shaft 21 of the supporting member 2 is set such that a fitting cylinder 7 integrally protruded at the rear surface 12 of the plug lid 1 is removably fitted to the supporting shaft 21 .
More practically, a large number of axial slits 71 are arranged at the fitting cylinder 7 to form resilient pieces 8 at several locations in a circumferential direction, protrusions 81 are protruded inside the extremity ends of the resilient pieces 8 and in turn the supporting shaft 21 is provided with fitting grooves 9 to which the protrusions 81 may be fitted in an adapted state.
In the case that the plug lid 1 is fixed to the supporting shaft 21 in such a connected structure as above, the fitting cylinder 7 is pushed against the extremity end of the supporting shaft 21 and pushed into it while it is being kept, resulting in that the resilient pieces 8 are recovered from their expanded and opened state due to their resiliency when the protrusions 81 are positioned at the fitting grooves 9 to cause the protrusions 81 to be fitted to the fitting grooves and the plug lid 1 is fixed.
Under a state in which the plug lid 1 is fixed to it, the extremity end of the supporting shaft 21 is inserted into the fitting cylinder 7 , the protrusions 81 of the resilient pieces 8 are fitted to the fitting groove 9 and the connected state is held with the resilient force of the resilient pieces 8 under a normal opening or closing operation of the plug lid 1 .
When the plug lid 1 is removed, the plug lid 1 is pulled out of the supporting shaft 21 , resulting in that a force escaping from the fitting groove 9 may act against the protrusions 81 to cause the resilient pieces 8 to be expanded and opened and further cause the protrusions 81 to be removed from the fitting groove 9 and the plug lid 1 is removed from it.
That is, under the closed state of the plug lid 1 , it is possible to cause a tension force of the thrust lock mechanism acting against the supporting shaft 21 to act as a pushing force against the packing close-contacted surface 5 of the packing 6 and at the same time, a pulling-out the plug lid 1 from the supporting shaft 21 enables its repairing or maintenance work to be easily carried out.
An anti-vibrating member 13 sliding at an outer circumferential surface of the supporting member 2 is arranged vertically at the rear surface of the plug lid 1 .
The anti-vibrating member 13 has a cylindrical part 131 having such an inner diameter as one to be fitted to the supporting member 2 and slid against it. Axial slits 14 of which number corresponds to that of the ribs A 31 so as to avoid the ribs A 31 during a moving-up and/or moving-down operation of the supporting shaft 21 are formed at the lower end of the cylindrical part 131 (refer to FIG. 4 ).
The anti-vibrating member 13 is moved up or down and guided by the supporting member 2 as the plug lid 1 is moved up or down by the supporting shaft 21 .
Even if the plug lid 1 is lifted up by the supporting shaft 21 (the drain port is in an opened state), a length of the cylindrical part 131 is set to such a length as one extending along an outer circumferential surface of the supporting member 2 to prevent either vibration or inclination of the supporting shaft 21 from being produced.
Additionally, this anti-vibrating member 13 may also act as a foreign material mixing preventive cover 23 for preventing some foreign materials mixed in the drain water from entering through a supporting guide hole (not shown) opened at the supporting member 2 into the supporting member 2 .
With the foregoing, although it has been described that the anti-vibrating member 13 may also act as the foreign material mixing-preventive cover 23 , it is optional that some guide legs (not shown) extending along the outer circumferential surface of the supporting member 2 from the plug lid 1 are spaced apart in a circumferential direction and vertically installed to accomplish only the anti-vibrating action and then the anti-vibrating member is constituted by a plurality of guide legs.
The preferred embodiment described above has been illustrated under a state in which the circumferential edge of the plug lid is embedded into the notch part. However, in addition to this form, it is also possible to attain a form in which a depth of the notch is set to such a depth as one having a top point of the plug lid in flush with the bottom surface of the bath tub and the entire plug lid is embedded into the notch (not shown) or another form in which as shown in FIG. 3 , a height of the plug lid 1 is made low, the upper surface of the plug lid 1 is made flat or gradual arc (not shown) to cause the entire plug lid 1 to be embedded and the bottom surface A 2 of the bath tub is made flat or substantially flat.
Further, the similar reference numerals are applied to the structure shown in FIG. 3 because its components other than those of the plug lid are similar to those of the structure shown in FIG. 1 .
As described above, the present invention has some superior effects as follows.
According to first aspect of the invention, the plug lid is constructed to have a configuration in which the plug lid is dropped into the drain port under a closed state of the drain port, so that it is also possible to prevent the circumferential edge of the plug lid from being exposed, an operator's hand or fingers from being engaged with the circumferential edge and further the plug lid from being protruded out of the bottom surface of the bath tub in response to an amount of dropping of the plug lid, resulting in that a person taking a bath can enjoy it in a comfortable manner without having any irregular feeling caused by some hindrances.
In addition, according to second aspect of the invention, a recovering force of the packing itself is added to a pushing force against the packing close-contact surface acting on the packing.
Accordingly, a close-contact force of the packing against the packing close-contact surface is reinforced and a superior water-stopping characteristic is realized.
Additionally, the circumferential edge of the plug lid is dropped into the notch formed to be lower than the bottom surface of the bath tub; the packing is closely contacted with the packing close-contact surface lower than the bottom surface of the notch, thereby a load applied to the plug lid (a hydraulic pressure or an artificial pressure provided by a user) can be accepted while being divided by the plug lid and the packing.
Accordingly, it is possible to prevent a load from being concentrated on one of the plug lid or the packing, it may substantially contribute to an improvement of durability of the plug lid and the packing.
In addition, according to third aspect of the invention, the packing is closely contacted with the packing close-contact surface while it is being crushed by the inclined surface and deformed, so that its close-contact force is increased while the returning force of the packing itself from its deformation is added to the pushing force against the packing close-contact surface acting on the packing and a more positive water stopping state can be realized.
In addition, according to fourth aspect of the invention, the plug lid is not inclined to open the drain port and no useless load is applied to the packing to perform a positive stopping of water because the plug lid is supported by a horizontal plane with an applied load (a hydraulic pressure or an artificial pressure applied by a person) and a crushing force more than a requisite force is not acted on the packing, resulting in that there is no possibility that a durability of the packing is deteriorated.
Further, according to fifth and sixth aspects of the invention, a further higher contribution can be applied to an improvement of water-tightness because the annular protrusions of the packing are closely contacted with the close-contact surface of the packing in a line-contact state.
Additionally, according to seventh aspect of the invention, the plug lid can be installed at the bottom part of a bath tub without being protruded because a depth of the notch part is set to such a value as one in which the plug lid can be dropped into the bottom part of the bath tub while its top part is in flush with or less than the bottom part of the bath tub.
Further, in the case of the inventions according to eighth aspect and ninth aspect, a more superior water stopping characteristic can be attained because a tension force of the supporting shaft can also be acted as a pushing force of the packing against the packing close-contact surface, and a repairing or maintenance work can be easily carried out if the plug lid is pulled out of the supporting shaft in an artificial manner.
In addition, according to tenth aspect of the invention, the plug lid is prevented from being vibrated or inclined to make a positive guiding of its opening or closing operation because the anti-vibrating member sliding on the outer circumferential surface of the supporting member for supporting the supporting shaft in such a way that it can be moved up and down, resulting in that the plug lid may not close the drain port due to its vibration or inclination, the water stopping does not become incomplete and a predetermined water stopping characteristic can be maintained stably until its durable limit time. Further, according to eleventh aspect of the invention, some foreign materials mixed into the drain water are not flowed into the supporting member and there is no possibility that neither trouble nor poor operation may be produced because the plug lid is provided with a foreign-material mixing preventive cover sliding on the outer circumferential surface of the supporting member supporting the supporting shaft in such a way that it can be moved up and down, the foreign material mixing preventive cover has a cylindrical part with its lower part being opened or released, and the cylindrical part has a length extending along the outer circumferential surface of the supporting member when the drain port is opened and when the drain port is closed (eleventh aspect).
Having described specific preferred embodiments of the invention with reference to the accompanying drawings, it will be appreciated that the present invention is not limited to those precise embodiments, and that various changes and modifications can be effected therein by one of ordinary skill in the art without departing from the scope of the invention as defined by the appended claims.
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A protrusion of the plug lid out of a bath tub is restricted to prevent the plug lid from being a hindrance, and water-tightness of the plug is improved. The plug lid is dropped into a notch formed in such a way that the circumferential edge of the plug lid becomes lower than the bottom surface of the bath tub. The packing closely contacts a packing close-contact surface narrowed from the bottom surface of the notch in a downward direction. The bottom part of the notch is formed into the horizontal plane and the plug lid is supported while it is not inclined under application of weight (such as a hydraulic pressure or an artificial pressure applied by a user) and the packing is protected from unnecessary crushing force.
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REFERENCE TO RELATED APPLICATIONS
[0001] The present invention claims the benefit of German Patent Application No. 102 53 643.0, filed Nov. 18, 2002.
TECHNICAL FIELD
[0002] The present invention relates to a window lifter control system for a motor vehicle and a method of controlling at least two window lifter motors.
BACKGROUND OF THE INVENTION
[0003] When an electric window lifter motor of a window lifter fully closes a window pane, the window lifter motor is rotationally driven to close the window pane until the window pane presses against an associated seal on the window frame with a desirably high amount of force, causing the window pane to come to a stop. The window lifter motor is blocked when the window pane is stopped by the seal, causing a high blocking current (e.g., 30 A) to flow through the window lifter motor. This is acceptable as long as the blocking current flows through only one window lifter motor in the vehicle.
[0004] However, currently available comfort functions in vehicles are able to close all of the window panes of the vehicle simultaneously. In fact, some consumers find it disturbing when, in spite of identical starting positions, different window panes in the vehicle reach the fully closed position at different times even though the associated window lifters received the instruction to close the window panes at the same time. But if all of the window panes are actually closed at the same time, this can result in as many as four window lifter motors being supplied with the blocking current at the same time. The high amount of blocking current to the window lifter motors leads to a noticeable voltage drop in the power supply of the vehicle. This voltage drop is especially critical if the vehicle is provided with other electric systems which have high power requirements themselves, such as an electrical steering system (“steer-by-wire”) or an electrical brake system (“brake-by-wire”). As soon as a control unit in such systems detects the voltage drop, the system may be momentarily disconnected until the voltage drop is over. Obviously, however, it is undesirable in an electrical steering system or an electrical brake system for a functional interruption to occur.
[0005] There is a desire for a window lifter system in which, on the one hand, can meet the demands in relation to comfort (e.g., simultaneous window closing) made by the ultimate customers and, on the other hand, avoids voltage drops in the on-board supply when meeting those demands.
SUMMARY OF THE INVENTION
[0006] One embodiment of the invention is directed to a method of controlling at least two window lifter motors. When at least one of the window lifter motors is instructed to close the window pane associated with the motor to it, the method determines whether the window pane is approaching its fully closed position. The method then checks whether any other window pane is approaching its own fully closed position. If any other window pane is approaching its fully closed position, the original window pane is moved only as far as to an approximately closed position rather than its fully closed position. If, on the other hand, no other window pane is approaching its fully closed position, the window pane is moved to its fully closed position.
[0007] The invention generally prevents a plurality of window lifters from fully closing their respectively assigned window panes at the same time. Instead, only the window lifter that is the first one to close the window pane is allowed to close the window pane fully, causing the window lifter motor to block and blocking current to flow. All other window lifter motors in the vehicle are turned off so that the window pane does not reach its fully closed position and only reaches an approximately closed position in which it contacts its associated seal with a low force. The contact gives a vehicle user the impression that the window pane is already fully closed and that all window panes were closed simultaneously.
[0008] Once the first window pane is fully closed, all the remaining window panes will then also be fully closed, occurring in a staggered relationship with respect to one another so that only one single window lifter motor is blocked at any given time when the window pane presses against its corresponding seal. The short time interval between the time the first window pane closes fully and the time the other window panes closes fully will go unnoticed by the user. The minimum adjustment of the window pane from the approximately closed position to the fully closed position will not be detectable by the user of the vehicle, and as a result the invention will not impair user comfort.
[0009] The moment at which each window pane enters a previously defined end zone portion of its travel distance may be used as a criterion for the decision of which window pane should be allowed to be fully closed. This end zone may cover, for instance, the last 4 mm of the distance traveled before reaching the fully closed position. As soon as a window pane enters this end zone, a blocking signal is transmitted by a controller of the respective window lifter and transferred via a bus system to all other window lifter controllers in the vehicle. If any other controller receives the blocking signal when the window pane assigned to it arrives at the end zone, the other controller will not close the window pane fully, but move it only into the approximately closed position.
[0010] As soon as a window lifter has shifted the window pane into its approximately closed position, it is checked in a loop to see whether the previously received blocking signal continues to be applied. As soon as the blocking signal is no longer applied, a counter starts, initiating a waiting time corresponding to each window controller. After the waiting time has elapsed, the window lifter motor for a given window is driven to move the window pane into its fully closed position while a blocking signal is sent at the same time. This prevents any of the other window lifters from simultaneously shifting their respectively assigned window panes from the approximately closed position to the fully closed position. The blocking signals and waiting times stagger the times at which each window is moved to the fully closed position so that only one window is moved to the fully closed position at a time.
[0011] In one embodiment of the invention, the method suppresses detection of multiple window pane closings when the engine of the vehicle is not running because, in this case, there are no expected negative effects if the multiple window closings create a voltage drop in the on-board voltage supply.
[0012] Another embodiment of the invention is directed to a window lifter control system comprising at least two window lifter motors, at least one controller for driving the window lifter motors, and a sensor that detects the position of a window pane assigned to the window lifter motor. The controller includes a checking circuit that checks whether any other window lifter is a transmitting a blocking signal. The system further includes a blocking signal generator, which generates a blocking signal when the window lifter motor causes its corresponding window pane to approach its fully closed position, and a counter that can detect an expiration of a predetermined waiting time. The description below explains the advantages that may be gained using a window lifter control system of this type in more detail.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The invention will now be described with reference to a preferred embodiment which is illustrated in the accompanying drawings, in which:
[0014] [0014]FIG. 1 is a representative diagram of a window lifter system including two window lifters according to one embodiment of the invention; and
[0015] [0015]FIG. 2 is a representative flow diagram of a method that may be sequenced in one of the window lifters of FIG. 1.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0016] [0016]FIG. 1 is a representative diagram of a window lifter system according to one embodiment of the invention and FIG. 2 is a flow diagram of a method according to one embodiment of the invention. Note that although FIG. 1 shows only two window lifters 5 , 7 for illustrative purposes, the system may include more than two window lifters without departing from the scope of the invention.
[0017] In the embodiment shown in FIG. 1, each window lifter 5 , 7 has a window lifter motor 10 which acts on a window pane 14 of a vehicle via an adjustment mechanism 12 . The window pane 14 is adapted to be shifted within a window frame 16 , which is provided at least at its upper edge with a seal 18 , shown schematically in FIG. 1. The window pane 14 can be moved in the window frame 16 by the window lifter motor 10 .
[0018] A controller 20 is provided for driving the window lifter motor 10 . The controller 20 is usually disposed inside the vehicle door in which the window pane 14 is guided and is therefore frequently referred to as a door control module. Each controller 20 drives the window lifter motor 10 by, for example, pulse width modulation. A sensor 22 is provided on the window lifter motor 10 through which a position recognition circuit 24 inside the controller 20 may sense the absolute position of the window pane 14 . In one embodiment, the sensor 22 may be a Hall effect sensor.
[0019] The controller 20 further includes a counter 26 that generates a waiting time. In one embodiment, the counters associated which each controller 20 differ from one another so that each controller 20 in the vehicle each has its own unique waiting time.
[0020] Each controller 20 further contains a blocking signal checking and generating circuit 28 , each of which is able to generate a blocking signal and to sense whether any other controller generates such blocking signal.
[0021] The controllers 20 are connected to a bus system 30 , such as a CAN bus.
[0022] The operation of the window lifter system will now be described when it is intended to close the window panes 14 , reference being also made to the flow chart of FIG. 2.
[0023] When a vehicle user wishes to close a particular window pane 14 such as, for example, the window pane associated with the right-hand window lifter 7 in FIG. 1, the user actuates the appropriate window lifter switch so that the controller 20 drives the window lifter motor 10 in the proper direction for the window pane 14 to be closed. During the closing process of the window pane 14 , the absolute position of the window pane 14 sent to the controller 20 at all times since the sensor 22 continuously supplies information about the position of the window lifter motor 10 .
[0024] When the window pane 14 arrives at an end zone E, which is defined as, for example, the last 4 mm of the closing travel before reaching the fully closed position, the blocking signal checking and generating circuit 28 checks, by way of the bus system 30 , whether any other controller 20 is transmitting a blocking signal 32 . The blocking signal may be, for example, one bit that is encoded in a specific way corresponding to a given controller 20 with the bus system 30 , with each bit encoded in a unique manner to correspond with its associated controller 20 . In the example shown in FIG. 1, the blocking signal checking and generating circuit 28 of the controller 20 of the left-hand window lifter 5 does not send a blocking signal. Therefore, the blocking signal checking and generating circuit 28 of the controller 20 associated with the right-hand window lifter 7 will now generate a blocking signal, which is transmitted to all other controllers 20 in the vehicle via the bus 30 .
[0025] At the same time, since the blocking signal checking and generating circuit 28 of the right-hand window lifter 7 is not currently receiving a foreign blocking signal, the right-hand window lifter motor 10 continues to be supplied with power until the window pane 14 comes up against the seal 18 at full power and comes to a stop. As a result of this, the right-hand window lifter motor 10 is also braked to a standstill and the window lifter motor 10 consumes its blocking current. The high torque produced by the window lifter motor 10 in this condition ensures that the right-hand window pane 14 is pressed against the seal 18 with a desirably high force to ensure that the window pane 14 is fully closed tightly.
[0026] The window pane of the left-hand window lifter 5 is also closed at approximately the same time as the window pane 14 of the right-hand window lifter 7 . However, since the window pane of the left-hand window lifter 5 slightly lags behind the window pane of the right-hand window lifter 7 , the window pane 14 of the left-hand window lifter 5 will enter the end zone slightly later than that of the right-hand window lifter 7 . At the moment the controller 20 detects that the left-hand window pane 14 has arrived at the end zone E, the blocking signal checking and generating circuit 28 detects that a foreign controller 20 is generating a blocking signal, namely the controller 20 of the right-hand window lifter 7 . The left-hand window lifter motor 10 is therefore stopped before the window pane 14 rides up on the seal 18 and is braked by the window pane 14 ; in other words, the left-hand window lifter motor 10 is stopped so that the window pane 14 is in an approximately closed position in which it contacts the seal 18 with a low force.
[0027] The controller 20 subsequently checks whether any foreign blocking signal is continuing to be received. As soon as the controller 20 no longer detects a foreign blocking signal, the counter 26 is activated, which generates a specific time delay or waiting time. After expiration of this time delay, the blocking signal checking and generating circuit 28 transmits its own corresponding blocking signal while the left-hand window lifter motor 10 is at the same time supplied with power so that the left-hand window pane travels from the approximately closed position to the fully closed position until it is braked by the seal 18 and until the left-hand window lifter motor 10 is blocked.
[0028] While only two window lifters are shown in FIG. 1, it is readily apparent that the window panes can be closed in a time-staggered as described above and as shown in FIG. 2 when more than two window lifters are provided. In the case of systems having more than two window panes and more than two associated window lifters, only the window pane that is the first to enter the end zone E is closed fully without interruption, whereas all other window panes will be stopped at the approximately closed position and closed one after the other in a staggered fashion into the fully closed position based on the different waiting times as generated by the counter 26 of each respective controller 20 .
[0029] It should be understood that various alternatives to the embodiments of the invention described herein may be employed in practicing the invention. It is intended that the following claims define the scope of the invention and that the method and apparatus within the scope of these claims and their equivalents be covered thereby.
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A window lifter system and method coordinates closing of multiple windows by detecting when more than one window pane is approaching a fully closed position and moving one window pane to only an approximately closed position while the other window pane is moved to the fully closed position. By staggering the closure of window panes to the fully closed positions, the system and method provides the illusion that all of the window panes are being closed at the same time while avoiding voltage drops in the vehicle power supply caused by excessively high blocking currents generated when multiple window panes are moved to the fully closed position.
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BACKGROUND
[0001] Contaminants in aquatic sediments and detritus can include oil and hazardous materials, toxic metals, and nutrients like phosphorus, nitrates and sulfates. Some of these contaminants readily absorb to suspended organic and inorganic materials or seston in water. Some of the contaminants, particularly the nutrient phosphorus, can be taken up and used by aquatic biota including benthic and pelagic algae, cyanobacteria, and plants. Eventually, the contaminants of interest to this invention are those that settle out of the water column to form a very loose, detritus layer on sediment that can be easily resuspended, dispersed or released in a soluble, solid, or colloidal form back into the water column by physical disturbance, diffusion, microbial and geochemical processes, or the actions of aquatic biota.
[0002] For the purpose of this invention algae, cyanobacteria, and invasive, noxious and nuisance densities of aquatic plants or animals are also considered contaminants that can be targeted by this invention for control or removal from water bodies.
[0003] Contaminants in sediments and detritus can also concentrate in ecologically sensitive, littoral regions of water bodies that could be adversely impacted by other dredging methods or application of chemicals or clay to treat or bind contaminants. Similarly, contaminants can also be located in shallow water containing invasive, noxious, or nuisance densities of aquatic plants, algae and biota that could be spread further throughout the water body if other dredging methods or treatment with chemicals were used. Shallow water areas are also not conducive to the use of chemicals to treat contaminants or for clay to bind or cover contaminants due to wave action and water turbulence often found in shallow water areas.
[0004] This collapsible enclosure for removal of contaminants in water bodies is a light, ecologically-sensitive structure that can be deployed by a limited number of trained people without the need for barges, cranes or heavy equipment operators. The collapsible enclosure itself is constructed primarily with soft layers of waterproof fabric in order to minimize potential damage to sensitive ecological receptors like shellfish and snails. The contaminant removal processes can allow for either the release of dissociable contaminants or biotic cells containing contaminants from sediments into enclosed water, or the physical removal of contaminated sediments and detritus by raising and lowering the top of the enclosure and plunger to suspend loose sediments and detritus within the enclosure. The dissolved and suspended contaminants within the isolated, interior portion of the enclosure could then be pumped out and brought to shore for either treatment and return of treated water to the water body or offsite reuse or recycling of water and recovered sediments and detritus. While pumping out the contents of the collapsible enclosure, the top of the enclosure can be allowed to collapse. The collapsibility of the enclosure keeps contaminant removal volumes to a minimum without having to add water or air to the enclosure during pumping.
SUMMARY OF THE INVENTION
[0005] This invention serves as a means to capture and remove contaminants contained in very loose sediments and detritus by enclosing targeted contaminant areas in water bodies. The primary advantages of this invention compared to other contaminant response actions in water bodies is that it both minimizes physical disturbance and dispersion of the almost smoke-like sediment and detrital layer, and it is also primarily a soft apparatus that can limit the amount of potential damage to benthic fauna such as snails and shellfish when compared to other dredging techniques or the use of hard or rigid, containment structures or vessels on the sediment surface. Aquatic fauna could also be selectively removed from targeted contaminant areas and relocated elsewhere in the same water body before deploying the invention enclosures.
[0006] Once enclosed, areas of targeted contaminants can be removed either by dissociation of contaminants from the solid to soluble form within the enclosure then removal of the enclosed, and now contaminated water, or by direct physical disturbance and resuspension of contaminated sediments and detritus within the enclosure followed by removal of this now contaminated water volume. Similarly, some biotic cells containing contaminants may rise up within the enclosure during deployment thus facilitating their removal.
[0007] Contaminants within the enclosure that are amenable to dissociation from solid to soluble form by microbial and geochemical processes, such as the nutrient phosphorus or the metals arsenic or mercury, can be targeted for removal by allowing naturally-occurring or enhanced biogeochemical processes to occur within the enclosure. Enhancement of biogeochemical processes to help dissociate solid contaminants to soluble forms could include increasing temperature, dissolved oxygen content, carbohydrate or electron acceptor substrate content within the enclosure.
[0008] Another advantage of the soft structure invention is that the volume of extracted contaminated water and suspensions removed from the enclosure can be kept to a minimum by allowing the structure to collapse or shrink without having to replace water removed with clean water or air during pumping of the enclosures' contents.
[0009] Physical disturbance of very loose sediment and detritus within the enclosure can be brought about by raising and lowering a suspension cable, pump intake piping and plunger attached to the top center of the enclosure either manually or from wave action on a floating buoy attached to the suspension cable and plunger. The plunger and pump intake piping would also serve to remove air trapped within the collapsible enclosure.
[0010] Removal of the enclosures' contents by pumping can utilize commercially-available pumps such as a diaphragm pump and piping connected to the plunger and pump intake piping located in the interior of the enclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The accompanying drawings, FIG. 1 through 6 , which are incorporated herein by reference and constitute part of this specification, exemplify the embodiments of the present invention and in conjunction with written descriptions, serve to illustrate and explain principles of this invention.
[0012] FIG. 1 is a side view and schematic diagram of invention. This figure illustrates a deployed situation for the invention as it gently rests on the detritus and sediment surfaces of a water body. The soft layers of collapsible enclosure are in the fully engaged position.
[0013] FIG. 2 is a side view and schematic diagram of the invention being deployed. The figure illustrates the general configuration of the invention while it is being lowered or pushed downward to the detrital and sediment surface. The soft layers of the collapsible enclosure are down or in the full pre-deployment position. Once the plunger and pump piping intake section contact the sediment surface, the remaining portions of the invention will continue to drop and eventually will capture and contain the targeted detrital and sediment layers beneath the extent of the collapsible enclosure as represented in FIG. 1 .
[0014] FIG. 3 is an illustrative schematic of several collapsible enclosures subject to this invention being deployed but linked together on the detrital/sediment surfaces in a body of water. The individual invention collapsible enclosures are scalable, they can be linked together to simultaneously provide larger areas of coverage for removal of contaminants. For convenience and to limit the number of overall buoys, discharge piping from each collapsible enclosure can be piped through a single buoy access point.
[0015] FIG. 4 depicts the invention with the outer or top layer of soft enclosure layer or fabric removed. The inner collapsible enclosure layer serves to form an initial barrier wall to help retain detritus, sediment or contaminants during operation of the invention. The lower edge of this layer, in contact with the detritus and sediment layers is weighted around the internal circumference or opening of this enclosure layer. The weighted edge also has sufficient additional material or slack to extend below the deployed elevation of the main structure.
[0016] FIG. 5 depicts the invention deployed but for illustrative purposes without the soft, waterproof enclosure layers. The structure is kept in place by both a weighted center piece, the Weight and Support Connector, and by stakes or weights at the sediment contact end of each Support Structure. This figure also depicts an internal, circumferential perforated pipe that can be used to add fluid, air, or treatment fluids to the interior of the enclosure. The perforated piping also aids in keeping the interior of the soft enclosure fully open or exposed to the targeted detritus and sediment layers during operation of the invention.
[0017] FIG. 6 depicts a cross-section of the inner, soft enclosure layer. The perforated pipe and weighted, lower, edge of this enclosure layer is illustrated.
DETAILED DESCRIPTION OF THE INVENTION
[0018] Embodiments of the invention operate to effectively resolve four problems related to removal of contaminants in detritus and sediment of water bodies. First, the top layer of contaminated sediment and detritus is often very loose and can be easily disturbed and redistributed into the water column when using dredging techniques, heavy equipment or during application of chemicals and binders. The invention is a collapsible enclosure with a high ratio of aerial coverage to interior volume that can capture and isolate the targeted area of contaminants with minimal deployment disturbance to targeted contaminant areas. Second, contaminated detritus and sediment can be located in ecologically sensitive, littoral regions of water bodies that can be adversely impacted by other dredging techniques and apparatus or by the addition of chemicals or clays to bind or treat contaminants. The invention is primarily a light, soft structure that is ecologically sensitive enough to be deployed on top of shellfish beds or emergent plants for a short period of time without causing immediate or long term damage. Third, other removal methods for contaminated detritus and sediment can generate large volumes of contaminated water and suspended sediment and detritus requiring additional special handling, treatment, storage and disposal considerations and higher costs. The invention includes a unique process whereby the soft enclosure layers actual collapse as contaminated water and suspended sediment and detritus are pumped out of the enclosure. This collapsible aspect allows for removal of the interior volume of the enclosure without having to add air or additional water to replace the volume pumped out. And, fourth, contaminants can be located in shallow water, in small water bodies, or on top of significant thicknesses of very soft sediment and detrital layers which are not well suited to the use of larger, heavier or more rigid dredging techniques, or application of chemicals or binders. This collapsible enclosure invention has a high aerial coverage to internal volume ratio, is scalable in size, and can be effectively used in shallow water, on sloped surfaces, in small water bodies such as landscape water features, and on top of thick sequences of very soft sediment while minimizing overall disturbance to non targeted contaminated sediment, detrital layers and surrounding environments.
[0019] An additional problem solved by this invention when compared to the use of chemicals or binders to treat or bind contaminants in place is that the collapsible enclosure invention can permanently remove targeted contaminants from water bodies without the use of toxic or harsh chemicals, repeated applications and recurring costs of same over time, or harm to aquatic biota related to the use of chemicals and binders.
[0020] The invention and components disclosed herein, as illustrated on FIGS. 1 , 2 , 3 , 4 , 5 and 6 comprises a two layer, soft, collapsible enclosure 10 constructed of either flexible polyethylene sheeting, nylon, polyester or similar waterproof or water resistant fabric layers. Polyester and nylon fabrics are preferred both for their workability, flexibility, strength and durability. The collapsible enclosure is constructed by sewing sections of fabric together to form a pyramid shape for rectangular enclosures or a conical shape for circular enclosures. Seams and points of contact are reinforced for added strength and durability. The height of the enclosure 10 is determined in a way that minimizes the volume of water isolated in the enclosure 10 while at the same time maximizing the aerial coverage over the targeted contaminated sediment or detritus area. The enclosure can be any three dimensional shape but either pyramidal or conical are preferred for their ease of construction, uniform collapsibility of the enclosure and symmetrical load distribution.
[0021] Support structures 11 provide support and shape to the enclosure 10 and can be constructed of solid or hollow metal or plastic piping or solid rods. Preferably, the supporting structure rods 11 are made of polyvinyl chloride pipe for their strength, lightness, workability, durability and commercial availability. If metal is used, aluminum or stainless steel are preferred. Bracing structures 12 are constructed of the same piping material as the support structures 11 and are used to add strength to the overall supporting structure 11 by connecting each supporting structure 11 with each other near the outside edge of the enclosure 10 . Stakes or weights 13 at the end of each supporting structure 11 pole are used to help maintain the position and integrity of the enclosure. A circular weight and support connector 14 is also used at the top of the support structures 11 to help maintain the position and integrity of the enclosure. The circular weight and support connector 14 has an open hole in the center to allow for movement of the suspension cable and pump intake piping 15 .
[0022] The bracing structure 12 connecting points to the supporting structures 11 also serves as the connecting point to the inner, soft barrier wall 16 of the enclosure 10 . The soft barrier wall 16 is where the innermost enclosure layer drops down to form the first contact seal with the detritus and sediment surface 17 . This inner enclosure layer and barrier wall is illustrated on FIG. 4 . As illustrated in a partial cross section in FIG. 6 , the lower, sediment contact edge of the barrier wall 16 is weighted to help maintain contact with sediment and detritus surfaces 14 . The lower edge of the interior barrier wall 16 can also be designed to extend vertically slightly beyond the targeted contaminant removal depth. The same lower edge of the barrier wall 16 is also constructed so as to extend further laterally into the center of the enclosed area than the overlying bracing structure 12 . In this manner, as water contained within the enclosure is agitated by an up and down motion on the enclosure 10 top and the plunger and pump piping intake structure 18 , water flow paths are redirected toward the center base of the enclosure rather than lifting the barrier wall 16 and leaking out of the inner enclosure layer.
[0023] The outer layer of the soft enclosure 10 extends over the inner layer and soft barrier wall 16 and beyond the limits of the support structures 11 and stakes or weights 13 . The perimeter of the outer layer is also weighted in a manner similar to the inner barrier wall 16 edge. Preferably, weights in the edges of the enclosure 10 fabric are sewed in place and consist of a soft weighted roping, a light chain or sand. The weighted edges of the enclosure 10 should remain flexible and light enough for easy transport, placement, and to maintain the ecological sensitivity of the invention to aquatic biota while at the same time maintaining sufficient contact with the detrital and sediment surface 17 to keep contaminants in the enclosure until they can be removed.
[0024] The plunger 18 is constructed of a rigid to semi-rigid plastic or metal with perforations along the exterior edges to allow for water and suspended sediment flow to the pump intake even if the plunger 18 is resting on the detrital or sediment surface 17 . If metal is used, aluminum or galvanized steel is preferred for construction of the plunger 18 . The plunger is connected to the pump intake piping and suspension cable 15 and top layers of the enclosure 10 by commercially-available brackets. All edges of the plunger are rounded and smooth to limit the potential for tearing or catching of the collapsible enclosure 10 during operation. The suspension cable 15 can be made of either coated stainless steel cable, polypropylene or nylon rope. Polypropylene roping is preferred as it has some stretch and is otherwise resistant to deterioration while in contact with water. The piping 15 connecting the interior pump intake in the plunger 18 to the exterior of the enclosure 10 can be made of either rigid polyvinyl chloride pipe or semi-rigid, high density polyethylene pipe. In either case, the piping must not interfere with the up down motion of the plunger 18 and top of the enclosure 10 . The piping 15 can be capped near the floating buoy 19 when not in use and secured against the suspension cable 15 which is attached to the buoy 19 .
[0025] The invention is light enough to be deployed and used without the need for heavy equipment, barges or in some instances even boats. Once constructed, the supporting 11 and bracing structures 12 form a self standing structure to which the enclosure 10 is attached just prior to placement in the water body. Once constructed, multiple collapsible enclosure units can be stacked on top Of each other for ease of transport and deployment. As illustrated in FIG. 2 , during deployment through the water column, the invention is lowered into place by pushing downward on the plunger 18 and pump piping 15 . In this way, the plunger 18 would be the first component of the invention to contact the targeted contaminant area. Once contact is made, the remaining portions of the invention would continue to fall until they come to rest on, and capture the targeted contaminated sediment and detritus layer. If warranted, additional support to the invention can be provided by adding stakes or weights 13 at the ends of the support structures 11 . For the preferred embodiment of this invention, a minimum of four support structure 11 poles or rods are used to form the exterior skeleton of the enclosure 10 . The placement of the invention on the targeted contaminant area can be confirmed by those skilled or trained in the art and science including those licensed or trained to work underwater. Once sufficient contact is made with the contaminated sediment and detritus, the invention can be used either to dissociate solid contaminants into a soluble form by microbial and geochemical processes or contaminants can be removed by their physical disturbance and suspension within the enclosure. Followed by removal of the collapsible enclosure's contents using a temporary piping connected to the enclosure's piping and a pump on a boat on or land.
[0026] Depending upon the contaminant types present, the isolated interior portion of the collapsible enclosure 10 can be used to alter or enhance microbial and geochemical dissociation of contaminants from solid to soluble form. Those skilled in the art and science of contaminant remediation would be able to alter and monitor dissolved oxygen, temperature, oxidation reduction potential, pH, carbon substrate, and nutrient content of water within the enclosure to facilitate removal of contaminants in sediment and detritus by dissociation and degradation. The invention is equipped with perforated interior piping 20 to facilitate addition or removal of treated water combined with the use of the pump intake piping 18 . Treatment to dissociate contaminants could continue until the contaminant concentration in water decreases over time, as confirmed by field and laboratory testing and analysis.
[0027] Contaminated sediments and detritus can also be removed by physically agitating the top of the enclosure 10 and plunger 18 with an up and down motion either created by hand by raising and lowering the suspension cable and pump piping 15 or by wave action on the buoy 19 . Water could also be injected into the perforated interior piping 20 while being removed at the plunger and pump piping intake 18 to physically disturb water, sediment and detritus within the collapsible enclosure 10 . The perforated interior piping 20 can be connected to the water surface either by extending piping to the main buoy 19 or by extending it to a separate and dedicated buoy at the water surface (not shown but otherwise identical to the primary buoy 19 ). Removal of the contaminated sediment, detritus and water mixture would continue until the turbidity of extracted water decreased sufficiently as measured by field or laboratory testing. After fully collapsing the enclosure 10 during water extraction, additional water, sediment and detritus mixture extraction could commence once sediment pore water and water exterior to the enclosure 10 was allowed to slowly reenter the enclosure by raising the top of the enclosure 10 and plunger 18 .
[0028] Once contaminants are sufficiently removed the invention can either be removed or the soft, collapsible enclosure 10 portion of the invention can be detached from supporting structures 11 , bracing 12 , and the plunger and pump piping intake 18 and left in place as a long term barrier to aquatic plant growth where control or removal of nuisance, noxious or invasive plants are desired. Additionally, the enclosure can be left in place to control or remove invasive biotic species such as zebra mussels.
[0029] As illustrated in FIG. 3 , another embodiment of this invention would be to use more than one collapsible enclosure 10 and related structure at a time. The enclosures can be used side by side to effectively capture larger areas of targeted contaminants while minimizing potential disturbance to contaminated sediments outside the deployed invention area. As contaminated sediments and detritus are removed, individual collapsible enclosures can be redeployed onto remaining areas of contaminated detritus and sediment.
[0030] Another embodiment of the invention is its use to control or eliminate nuisance, noxious or invasive aquatic flora and fauna; also referred to as contaminants relative to this invention. Once these areas are targeted, the invention can be used to control light penetration or to create an isolated water volume above these targeted flora and fauna. The isolated water volume could then be used to apply substances approved for use in the control or removal of these flora and fauna or to alter the geochemistry of the water such as it's dissolved oxygen, pH or carbon dioxide content such that the flora and fauna within the enclosure 10 could no longer thrive.
[0031] While the narrative and illustrations included with this application serve to describe the preferred form and function of various embodiments and components of the invention, it will nevertheless be understood by others that various other modifications may be made without departing from the basic principles, intent and scope of the invention. Accordingly, other modifications and embodiments are within the invention scope for the following claims.
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The primary function of the collapsible enclosure is to capture, isolate, and allow for the permanent removal of otherwise easily dispersed contaminates in aquatic sediments and detritus of water bodies. Once deployed, the collapsible enclosure creates an isolated volume of water above these media. Contaminated sediments and detritus covered by the enclosure can then be efficiently removed either by their dissociation from sediment and detritus and into a soluble form within the enclosed water volume or by suspension of contaminated sediments and detritus within the enclosure. The dissolved or suspended contaminants within the enclosure could then be removed by an external pump, for treatment or disposal of recovered water and solids.
This invention can also control invasive, noxious or nuisance densities of aquatic plants and animals (such as zebra mussels) by placing enclosures over the area of concern and creating appropriate physical or chemical conditions within the enclosure.
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RELATED APPLICATIONS
This application claims priority under 35 U.S.C. § 119(e) to U.S. Provisional Application Ser. No. 60/483,565, entitled “UTILITY POLE REPAIR SYSTEM,” filed on Jun. 27, 2003, which is herein incorporated by reference in its entirety.
BACKGROUND OF INVENTION
The present invention relates generally to stabilization, support, repair and clamping systems and kits and other mounted supports, supported appliances, transformers, connections, etc. used in connection with poles. More particularly, the present invention relates to such systems and kits used in connection with utility poles of various materials and geometries, especially, but no limited to, wooden utility poles having generally circular cross sections.
Utility poles, especially those made of pre-stressed concrete or wood, are considered to be durable, reliable components of the outside physical plant of various utilities, such as electric systems and telephone systems. High reliability and durability is very desirable in utility poles, and other applications of vertical support, because such poles are often used in locations or in ground where they are difficult and expensive to repair or replace. The difficulty and expense can arise from difficulties in reaching a broken or damaged pole, the condition of the ground after a break and the cost of sending one or more repair crews and equipment to remote locations which may be experiencing adverse conditions such as bad weather, fire, flood, earthquakes, landslides, etc.
Despite their high reliability and durability, utility poles are susceptible to various types of damage. Wooden poles may be susceptible to “dry rot” or bacterial attack from the ground. Similarly, concrete poles may be susceptible to chemical leaching and thus weakening from materials naturally found in the ground. Other poles may be susceptible to other forms of natural attack, including chemical, wind, other storm forces, ice and snow accumulation, etc. Poles are frequently placed along roadsides, making them susceptible to damage by vehicle impact, snowplow impact, or simply impacts from objects kicked up by a snowplow or other vehicle.
Repair or replacement is conventionally effected by sending a crew to the affected pole, disconnecting all of the utility facilities connected to the pole, e.g. wires and transformers, removing the pole from the ground and placing a new pole in the ground. Sometimes, the old pole is not removed, but is merely reinforced by a new, adjacent pole or other ad hoc temporary repairs.
Also, when a pole is subjected to an impact, sometimes the damage is not immediately evident. For example, if a pole to which a transformer is clamped receives a strong impact, the pole itself may not shatter or break. However, mechanical resonances set up over the length of the pole, with the transformer itself providing the resonating mass, can cause extraordinary stress to the transformer clamping apparatus. The clamping apparatus can be weakened or broken, ultimately resulting in a dangerous condition where the transformer falls to the ground causing an environmental hazard, personal or property injury, or even death.
SUMMARY OF INVENTION
What is desired is an inexpensive, reusable support system that can be applied to a pole by a minimal sized crew after the pole has received some type of damage as an interim repair until the pole can more conveniently be replaced, in due course. Also desired is an inexpensive, reusable support system that can be applied to a pole that may be at risk of an impact or other damage, before the impact or other damage, to prevent or mitigate damage. Yet further desired is an inexpensive, reusable support system that can be applied to a pole holding a transformer, or other massive object, that can reduce or prevent mechanical resonances in the pole from causing damage to the pole or to the apparatus holding the massive object to the pole when those mechanical resonances are excited by an impact or the like.
According to aspects of embodiments of the invention, a pole support system comprises a metal sleeve that generally conforms to an outer surface of the pole; an elastic liner disposed between the metal sleeve and the pole; and a clamping band that circumscribes and compresses the metal sleeve over the elastic liner against the pole. The metal sleeve may further comprise a generally flat back portion, and may yet further comprise two generally arcuate wings, one disposed to each side of the generally flat back portion. The generally arcuate wings may comprise a series of adjacent linear breaks separated by narrow flats. One of the generally arcuate wings may further comprise a bevel lip bent at an angle inwardly and the other of the generally arcuate wings may comprise a generally unbent slip lip, whereby when the sleeve is applied, the slip lip passes over the bevel lip at an overlap.
The sleeve can also include other features, such as at least one nail hole for receiving a nail whereby the sleeve is temporarily suspended during installation, at least one lifting slot whereby the sleeve is lifted to an installation location, and/or at least one grounding hole for receiving an earth ground. The sleeve may be 2 feet long, and may be up to about 4 feet, about 6 feet, about 8 feet or even about 12 feet long. The sleeve may further comprise weather resistant steel, for example stainless steel, galvanized steel, powder coated steel or polymer coated steel.
According to various aspects of embodiments of the invention, the elastic liner may have various features. The elastic liner may have about a 50–80 durometer. The elastic liner may have a coefficient of friction sufficient to hold the system in place when clamped to a pole. The elastic liner may be about ¾ inches thick. The elastic liner may be resistant to natural deteriorating agents, for example the elastic liner may be sufficiently porous to permit water to flow through the elastic liner, the elastic liner is resistant to biologic action, the elastic liner may be resistant to insect damage, the elastic liner may be resistant to bacteriologic damage and the elastic liner may be resistant to fungal damage. The elastic liner may comprise bonded crumb rubber.
According to various aspects of embodiments of the invention, the clamp may have various features. The clamp may be adjustable to accommodate poles having different circumferences and perimeter lengths. In embodiments where the generally arcuate wings meet at a joint or opening, which may be secured or not, and wherein the clamp has an opening drawn together by an adjustable fastener, the opening of the clamp and the joint or opening may be arranged to be unaligned when assembled. The clamp may be weather resistant, for example comprising powder coated steel or polymer coated steel.
According to other aspects of embodiments of the invention, a pole reinforcement or repair kit comprises a sleeve having a generally axial opening opposite a generally flat rear wall, the generally flat rear wall framed on two sides by generally arcuate side walls, the sleeve lined by an elastic layer; and a clamping band having an adjustable circumference that, in use, will be placed to circumscribe and compress the metal sleeve over the elastic liner against the pole. The generally arcuate wings may comprise a series of adjacent linear breaks separated by narrow flats. One of the generally arcuate wings may further comprise a bevel lip bent at an angle inwardly and the other of the generally arcuate wings may comprise a generally unbent slip lip, whereby when the sleeve is applied, the slip lip passes over the bevel lip at an overlap.
The sleeve can also include other features, such as at least one nail hole for receiving a nail whereby the sleeve is temporarily suspended during installation, at least one lifting slot whereby the sleeve is lifted to an installation location, and/or at least one grounding hole for receiving an earth ground. The sleeve may be 2 feet long, and may be up to about 4 feet, about 6 feet, about 8 feet or even about 12 feet long. The sleeve may further comprise weather resistant steel, for example stainless steel, galvanized steel, powder coated steel or polymer coated steel.
According to various aspects of embodiments of the invention, the elastic liner may have various features. The elastic liner may have about a 50–80 durometer. The elastic liner may have a coefficient of friction sufficient to hold the system in place when clamped to a pole. The elastic liner may be about ¾ inches thick. The elastic liner may be resistant to natural deteriorating agents, for example the elastic liner may be sufficiently porous to permit water to flow through the elastic liner, the elastic liner is resistant to biologic action, the elastic liner may be resistant to insect damage, the elastic liner may be resistant to bacteriologic damage and the elastic liner may be resistant to fungal damage. The elastic liner may comprise bonded crumb rubber.
According to various aspects of embodiments of the invention, the clamp may have various features. The clamp may be adjustable to accommodate poles having different circumferences and perimeter lengths. In embodiments where the generally arcuate wings meet at a joint or opening, which may be secured or not, and wherein the clamp has an opening drawn together by an adjustable fastener, the opening of the clamp and the joint or opening may be arranged to be unaligned when assembled. The clamp may be weather resistant, for example comprising powder coated steel or polymer coated steel.
BRIEF DESCRIPTION OF DRAWINGS
The accompanying drawings, are not intended to be drawn to scale. In the drawings, each identical or nearly identical component that is illustrated in various figures is represented by a like numeral. For purposes of clarity, not every component may be labeled in every drawing. In the drawings:
FIG. 1 shows a plan or top view of a sheath, having a cushioning layer and a metal strap, with the sheath nailed to a pole;
FIG. 2 shows a plan or top view of a sheath, having a cushioning layer and a metal strap that clamps the sheath into a closed position around a pole;
FIG. 3 shows a front perspective view of a sheath, having a cushioning layer and a metal strap that clamps the sheath into a closed position around a pole;
FIG. 4 shows a rear perspective view of a sheath, having a cushioning layer nailed to a pole, and a metal strap that clamps the sheath into a closed position around the pole;
FIG. 5 shows a rear elevation view of a sheath, having a cushioning layer, nailed to a damaged utility pole, and a metal strap that clamps the sheath into a closed position around the pole;
FIG. 6 shows a top view of the strap flange with reinforcement by bending back the end of the strap and welding it to the flange and strap;
FIG. 7 shows a top view of the strap flange with reinforcement by providing a separate bent metal piece that is welded to the outside surface of the flange and strap;
FIG. 8 shows a top view of the strap flange with reinforcement by providing a separate bent metal piece that is welded to the outside surface of the flange and strap;
FIG. 9 shows a top view of the strap flange with reinforcement bending back the end of the strap to a brace position and welding the end in place;
FIG. 10 shows a front perspective view of the strap of FIG. 9 as used;
FIG. 11 shows a top view of the strap of FIG. 9 as bolted in place;
FIG. 12 shows a front view of the strap of FIG. 9 and the bolt system by which it is cinched tight; and
FIG. 13 shows a rear view of the strap and the bolt system by which the two halves of the strap are joined at the rear.
DETAILED DESCRIPTION
This invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having,” “containing”, “involving”, and variations thereof herein, is meant to encompass the items listed thereafter and equivalents thereof as well as additional items.
Aspects of embodiments of the invention include a pole stabilization, support or repair system or kit that is safe and inexpensive to apply, and that is reusable. As discussed above, in the Summary of Invention, the system or kit includes a sleeve, lined with an elastic member, the sleeve and liner held in place when in use by an adjustable clamp. The components are all made from materials that are inexpensive, readily available from stock or recycled sources. As will be explained, the system can be quickly installed by a crew of one or two at ground level with the assistance of a small crane or lifting aid above six feet.
Reference is now made to FIGS. 1 , 2 and 3 .
The sleeve 101 is the strength member that will distribute the forces applied by the clamp 102 , 103 through the elastic member 104 to the pole 105 to provide the desired stabilization or support. The elastic member 104 , through its resilience, absorbs the energy of impacts to the pole 105 , and flexibly absorbs movements of an underlying defect due to prior damage that has been stabilized when subjected to environmental stresses such as compression, tension and torsion, such as wind. After the system has been temporarily secured, as will be explained below, the clamp 102 , 103 is applied to secure the system for an extended period of time. Each of these elements of the system are now described in detail, after which it is explained how the system is applied to a pole, and some further advantages and applications of the system are explained.
The sleeve 101 is preferably made of a strong material that will have some degree of elasticity when used in practical applications, as explained below. Sleeves suitable for use with utility poles, especially wooden utility poles, are preferably made of 12 or 14 gauge steel, with 14 gauge steel being more preferred. The invention is not, however, limited to a particular gauge of steel. Since wooden utility poles come in a wide range of diameters, and often are tapered, the sleeve should have sufficient elasticity that a sleeve having a fixed axial opening 106 can be worked around a pole having any of a range of diameters and then tightened as described below, without undergoing permanent deformation.
In order to prevent oxidation, the steel can be galvanized or otherwise suitably coated for protection. Alternate suitable coatings may include a flexible powder coating or chip-resistant polymer coating. In order to sustain multiple reuses and resist environmental assault, the coating should be flexible, chip-resistant and well-bonded to the underlying steel.
The sleeve may be made in any suitable length. Naturally, it will be preferred by contractors using the system to stock a limited number of standard-sized kits, for example including sleeves of 4, 6, 8 and 12 foot lengths.
The sleeve 101 has a substantially flat back 107 and two generally arcuate wings 108 , 109 . The flat back defines an elastic spring that provides an opening force to maintain an axial opening 106 of the sleeve sufficiently wide to permit the sleeve 101 to be worked around poles of various diameters. After the sleeve 101 has been used, and when it is later unclamped, the flat back 107 will again open the axial opening 106 of the sleeve to permit the sleeve to be removed from the pole and subsequently reused. The arcuate wings 108 , 109 roughly trace the circumference of the poles to which the sleeve is designed to be applied. The arc of the wings should be defined by a radius slightly larger than the largest pole for which the sleeve is designed, so that the wings, like the flat back, are slightly flexed as the sleeve is tightened around the pole.
The arcuate wings 108 , 109 can be made by any suitable technique, such as roll forming, progressive dies or, as preferred, by a series of parallel breaks at small angles, separated by thin, flat strips, approximating a smooth arc. For very long sleeves, such as those 12 feet long, or longer, the preferred method provides additional strength. In any case, it is a very low cost method of manufacture in the expected volumes required.
The edges of the arcuate wings that face each other to form the axial opening are shaped as follows. The edge of one arc 108 is bent inwardly to form an angled bevel 110 . The opposing arc simply continues right to its edge; this edge is referred to as a slip edge 111 . When the sleeve 101 is closed around a pole 105 , the slip edge 111 is guided by the bevel 110 over the outside of the opposing arc if the pole is of a small enough diameter that there is no gap between the edges when the sleeve is closed.
The sleeve 101 is punctured in one or more locations, as now described in connection with FIGS. 4 and 5 , by any suitable method, to provide a number of useful features. Preferably, each of the punctures is made in the flat back 107 , in order to maximize their utility while minimizing the impact of the punctures on the strength of the sleeve 101 .
At least one of the punctures should be a hole having a size suitable to receive a nail 401 for temporarily securing the sleeve to the pole at the location where it is to be installed. Preferred are 16P galvanized duplex nails, also known as double-headed nails, because duplex nails are easy to remove when no longer needed. Since the nails are only a temporary measure, used for safety when installing the system, they should be easy to remove when no longer needed.
At least one of the punctures should be a hole having a size suitable to receive a fastener 402 to hold the elastic layer to the inside of the sleeve. Although other means and methods of fastening the elastic layer to the sleeve, including clips, adhesive and friction could be used, one or two mushroom-head screws are preferred because this type of fastening combines a degree of permanence with a degree of sliding and flexing freedom that allows the elastic layer to conform to both the inside of the sleeve and the outside of the pole without wrinkling or other undesired stress.
At least one of the punctures should be a hole or slot 403 suitable for receiving a hoist hook or chain, so that the sleeve and elastic layer (attached to the inside of the sleeve) can be hoisted into place, where the sleeve is temporarily held there by the duplex nails mentioned above. Having a hoist hole or slot 403 permits the system to be installed by a crew as small as a single person, using a hoist to assist with lifting the system into place. The size, shape and orientation of the hoist hole may vary depending on the desire lifting apparatus.
Finally, at least one of the punctures should be a hole 404 for receiving an earth ground. In installations where an earth ground is desired or necessary, there may be provided a conductive stake driven into the ground, to which a wire is attached. The wire is then attached to the provided hole 404 in the sleeve by any suitable fastener.
The elastic layer 104 is preferably a ¾ inch sheet of bonded crumbed rubber, for example made from recycled tires. Any other suitable elastic material could be used, however, bonded crumbed rubber of the following description has several advantages, as will be noted. In some applications, such as where the elastic layer 104 is likely to be subject to long-term exposure to oil, other elastic materials may be more suitable.
Bonded crumbed rubber has a high coefficient of friction, which assists with holding the system in place once installed. The high coefficient of friction also helps keep broken parts of a pole from pulling out of the stabilization and support system under normal use stresses, holding the parts of a broken pole in alignment, while allowing stress movement.
Bonded crumbed rubber with a modulus of elasticity of about 50–80 durometer has sufficient elasticity to compensate for differential expansion and contraction of the various components with temperature variations over time and to absorb the energy of future impact stress, wind stress, and the like. The elasticity of the elastic layer also helps spread the clamping force applied to the sleeve to all parts of the pole roughly equally because the elastic layer conforms on the one side to the inside of the sleeve and on the other to the surface of the pole, even if the pole has surface irregularities. When removed from an installation, a ¾ inch sheet of bonded crumbed rubber of 50–80 durometer will substantially return to its original form upon release of the compression forces.
Bonded crumbed rubber can further be manufactured to have durability and resistance to degradation by common environmental elements in typical applications. For example, bonded crumbed rubber can be made with sufficient porosity to allow water to percolate through without collecting in the elastic layer. Thus, ice will be less likely to form between the sleeve and pole, particularly in the interstices of the elastic member, reducing stress on the system. Moreover, crumbed rubber is naturally resistant to bacteria, fungus and insects, properties that can be easily enhanced with suitable additives.
The clamp includes two curved steel strips about 2–5 inches wide. One end of each strip has one or more holes for joining the strips together into a clamp configuration. Preferably, as shown in FIG. 13 , two rows of plural holes 1301 are provided. Four small carriage bolts 1302 inserted from the inside join the strips into one clamp strap of the proper length for the pole to which the sleeve is to be applied.
The opposite end of each strip is bent to form a generally triangular flange 1001 as shown in FIGS. 10 , 11 and 12 . The flanges each have one face 1002 with a hole through which a carriage bolt 1101 is passed to cinch the clamp. At least one of the holes is square 1201 , to receive the square shank 1202 of the carriage bolt 1101 . The threaded end 1203 of the carriage bolt 1101 is received through the hole in the other bracket face, through a flanged spacer 1205 and captured by a flange nut 1204 . When the clamp strap has been adjusted to the correct length, the clamp applied to the system and the cinching bolt tightened, the faces of the flanges 1001 will lie parallel, about 1–2 inches apart. The flanged spacer allows an installer to apply a wrench to the nut 1204 without interfering with brace 1003 .
The arrangement including the flanges 1001 , the flanged spacer 1205 and the flange nut 1204 have been found to make assembly easier by aligning the components without significant effort by the assembler, while also distributing well the clamping forces though the clamp, however, any suitable cinching mechanism could also be used.
The system described is installed as now described.
Suppose, for the sake of this example, that a pole has received damage about 4–5 feet above the ground level. The installer might select a 4 foot sleeve, depending on the extent of the damage. The sleeve is stood on the ground adjacent the pole, with the axial opening facing the pole. The installer then pushes or kicks one end of the sleeve onto the pole and slides the sleeve the rest of the way onto the pole. The sleeve, which weighs about 71 pounds, can then be lifted by the installer to a position where the damage is approximately centered between the ends of the sleeve. Using his body weight, the installer can then stabilize the sleeve against the pole (the high coefficient of friction of the elastic member makes this easier) while the installer hammers home a first and then a second duplex nail. Next, the installer applies a ratchet strap to close the sleeve around the pole. Clamps are then positioned about 1 foot from each end, with the openings of the clamps out of alignment with the axial opening by about 45–90 degrees. The clamps are finally tightened to about 35–60 foot-pounds of torque using a torque wrench, or until a firm resistance is met if a torque wrench is unavailable. A more badly split pole will require higher torque values to close up the split.
The system can be unbolted and removed, and most of the components reused on another stabilization. To remove the system, the uninstaller should first apply a ratchet strap around the sleeve to secure the sleeve. Without the ratchet strap, when the bolts are undone, the spring force of the sleeve can create a hazard by ejecting parts of the system at high rates of speed. However, once the sleeve is properly strapped, the clamp bolts can be loosened and removed, together with the clamps. The sleeve can be gently lowered by a hoist or crane, or by simply slowly loosening the strap. Allowing the sleeve to fall in an uncontrolled manner can be hazardous due to the weight, at 71 pounds per 4 foot section, and thin edge. Once used once, the bolts, nuts and nails are not reusable.
Several additional variations and other concepts should be noted.
The system can be pre-installed on new poles before they are installed in the ground at any convenient location desired to protect the pole against damage. The system can be pre-installed at a level below ground or above ground, depending on the conditions desired to be protected against. For example, the system can be installed at a level to protect from snowplow damage, or below ground where it can protect from insect and water damage. When installed below ground, the entire pole and system portion inserted in the ground can further be encased in concrete. Moreover, the system can be used in construction and marine applications where the system is buried, encased in concrete or below the waterline. For example, the system may be used to stabilize piers.
The system can be used in connection with mounting heavy apparatus to a pole, such as mounting transformers to utility poles. The sleeve can further include brackets welded or bolted on, which in turn receive the brackets customarily used on pole-mounted electrical transformers. The brackets of the apparatus could alternatively be clamped directly to the sleeve using clamping straps such as used to attach the sleeve. Because the system spreads the force of mounting the apparatus over a larger area of the pole, the apparatus and its mounting is less susceptible to damage by harmonic oscillation, shock, shear, and torsion, which can otherwise cause such heavy apparatus to fall, creating a severe crushing hazard when a pole is struck by a vehicle, for example. In this type of application, in order to prevent electrical arcing, the sleeve is preferably coated with a non-conductive polymer coating.
The bolts, nuts and nails can be part of a kit of parts, together with the sleeve, elastic member and clamp straps. High strength duplex nails should be used. All of the metal parts, including the steel, the bolts and the nuts should be certified as to their gauge and strength. The sleeve and clamp straps should be marked with the sizes of poles for which they are suitable. The marking should preferably be in terms of the circumference of the pole at the installation location, as this value is easily measured with a flexible tape measure at the job site.
Having thus described several aspects of at least one embodiment of this invention, it is to be appreciated various alterations, modifications, and improvements will readily occur to those skilled in the art. Such alterations, modifications, and improvements are intended to be part of this disclosure, and are intended to be within the spirit and scope of the invention. Accordingly, the foregoing description and drawings are by way of example only.
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A pole support system comprises a metal sleeve that generally conforms to an outer surface of the pole; an elastic liner disposed between the metal sleeve and the pole; and a clamping band that circumscribes and compresses the metal sleeve over the elastic liner against the pole. A pole reinforcement or repair kit comprises a sleeve having a generally axial opening opposite a generally flat rear wall, the generally flat rear wall framed on two sides by generally arcuate side walls, the sleeve lined by an elastic layer; and a clamping band having an adjustable circumference that, in use, will be placed to circumscribe and compress the metal sleeve over the elastic liner against the pole.
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PRIORITY
[0001] This application is a continuation of U.S. application Ser. No. 12/655,228, filed Dec. 26, 2009.
FIELD OF THE INVENTION
[0002] The present invention relates to the field of closure assemblies that are used in the pool industries. The closure assemblies have generally been used for pool maintenance and closing the swimming pool skimmer for winter (winterizing).
[0003] The field of endeavor for this invention is directed towards in-ground pools and above ground pools that have a skimmer attached to the pool and the pump.
BACKGROUND OF THE INVENTION
[0004] U.S. Pat. No. 4,281,422 by Simonelli discloses a winterizing kit that includes a socket plug that fits into a female receptacle of a filtered water inlet. The socket plug includes a check valve and a nipple to impede the flow of water from the swimming pool and also disconnect an air compressor attached to the pool water line. This invention is not anticipated to be used in a skimmer, but specifically placed into the inlet/outlets in the wall of a pool.
[0005] U.S. Pat. No. 4,825,605 by Weir discloses a closure device for pre-formed wall openings in swimming pool side wall panels that includes the insertion of either rectangular or circular-shaped plugs into the wall openings. The plugs are used to close unwanted openings in the wall of the swimming pool. The plugs are attached to the side wall of the pool.
[0006] U.S. Pat. No. 4,903,351 by Dengel et al. discloses a winterizing faceplate kit for the side wall of the swimming pool. The kit includes a cover plate, faceplate, and a pair of gaskets, where the cover plate is adapted to be removable and to be secured to the sidewall, thus facilitating spring season opening and fall season closure of the swimming pool
[0007] U.S. Pat. No. 4,285,358 by Hodak discloses a sealing assembly similar to U.S. Pat. No. 4,903,351 by Dengel and includes a gasket frame, faceplate and a cover panel which are all attachable to the inside surface of a pool wall in order to shut the water flow from the pool to the skimmer.
[0008] What is needed and has never been disclosed or described in the prior art is an apparatus for pools that have been completed and will allow the skimmer to be sealed from the side drain of the pool, but still allow communication between the pool pump and the main drain through the fittings that are attached at the bottom of the skimmer.
SUMMARY OF THE INVENTION
[0009] The present invention discloses a conventional swimming pool skimmer that is known in the art for many years and has been adapted to receive a removable pool skimmer plug. The removable pool skimmer plug has been designed and adapted to be inserted into the bottom portion of the skimmer that has already been installed in a pool. The removable pool skimmer plug is located below the side drain inlet for the pool or throat.
[0010] The removable pool skimmer plug will have at least one O-Ring or gasket that will provide a vacuum seal to allow the pump to more easily draw water from the main drain of the pool. Since the swimming pool skimmer housing has already been installed, and may be several years old, the removable pool skimmer plug has been designed to provide a vacuum seal to eliminate the pump from drawing water from the throat of the skimmer, which is located on the side wall of the pool.
[0011] The removable pool skimmer plug will be inserted near the bottom of the swimming pool housing on a flange of the pool skimmer body, but still provide a gap to allow water from the main drain port to maintain a constant fluid communication with the port to the pump system.
[0012] It is therefore a primary object of the invention to provide a removable pool skimmer plug that can be used in skimmers that have already been installed into pools, or for existing unmodified skimmers to pump water from these pools to assist in extinguishing fires by using the pool water in those states that are prone to wildfires such as in California, and Florida.
[0013] It is therefore an object of the invention to provide a simple device for previously installed pool systems to provide an easily removable pool skimmer plug for the swimming pool skimmer that will allow the main drain to be in direct fluid communication with the pump system.
[0014] A second object of the invention is that the insertion of the plug into the skimmer will prevent the pump from burnout when the water level drops below the skimmer level.
[0015] Another object of the invention is that when there is a freeze, specifically in the midwest and northern states, it will still be possible to drain water from the main drain, even if there is ice covering the skimmer.
[0016] Another object of the invention, is the elimination of the requirement for a sump pump to drain the pool, which also implies that there are no electrical connections near the pool water site.
[0017] Another object of the invention is to assist in winterizing the pool by inserting the plug into the skimmer and draining the pool water.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 shows a cross section of the pool skimmer attached to an inground pool.
[0019] FIG. 2 shows a detailed view of the cap, plug body and pool skimmer.
[0020] FIG. 3 shows an exploded perspective of the plug assembly.
[0021] FIG. 4 shows an alternative removable pool skimmer plug.
DETAILED DESCRIPTION
[0022] FIG. one ( 1 ) shows an environmental view of an industry standard pool skimmer ( 1 ). The pool skimmer ( 1 ) is common within the industry of swimming pools, and differs in generic shapes between the various manufacturers of pool skimmers, based upon the manufacturer's specific design criteria. The pool skimmer ( 1 ) is shown imbedded in the side of a pool ( 2 ), where the water line ( 4 ) is shown, depicting the water level, which allows the water to flow into the pool skimmer ( 1 ) and hence be drawn into the pump system. The pool skimmer ( 1 ) is comprised of a body ( 6 ), where the body ( 6 ) may be composed of multiple components either solvent welded or glued together. The body ( 6 ) of the pool skimmer has a centrally located hollow portion ( 8 ). The body also has a throat ( 10 ) attached thereon, where the throat ( 10 ) projects outward from the body ( 6 ) and provides a direct conduit from the pool ( 2 ) to the hollow portion ( 8 ) of the pool skimmer ( 1 ). The throat ( 10 ) has a large central through opening or mouth ( 12 ) that allows the water in the pool ( 2 ) and communicates with the hollow portion ( 8 ) of the body ( 6 ).
[0023] The body ( 6 ) has an upper portion ( 40 ). The pool skimmer ( 1 ) is provided with a lock down lid or cap ( 42 ). The cap ( 42 ) is generally lightly press fit, with a light snap to secure the cap ( 42 ) from easily being dislodged from the upper portion ( 40 ) of the pool skimmer ( 1 ). As can be seen in FIG. 1 , the pool skimmer ( 1 ) comprises an upper portion ( 18 ) and a lower portion ( 20 ). The upper portion ( 18 ) comprises the throat ( 10 ). As is common in the pool skimmer industry, the throat ( 10 ) has a front portion ( 36 ), where the front portion ( 36 ) of the throat ( 10 ) has a weir ( 38 ). The weir ( 38 ) is pivotably mounted to a lower portion ( 40 ) and biased towards the front portion ( 36 ) of the throat ( 10 ). The weir ( 38 ) has positive buoyancy, and prevents debris from migrating from the pool skimmer ( 1 ) back into the pool ( 2 ).
[0024] The lower portion ( 20 ) of the pool skimmer ( 1 ), has, co-located at the bottom of the pool skimmer ( 1 ), a pool drain inlet ( 14 ) and a pump outlet ( 16 ). The pool drain inlet ( 14 ) and pump outlet ( 16 ) are internally sized to accept pvc (poly-vinyl chloride) piping, which is common in the pool and garden industry. An additional feature is to externally size the diameter of the pool drain inlet ( 14 ) and pump outlet ( 16 ) for larger piping, such as 3.0″ pvc pipes. The reason for using larger diameter piping is that the newer pumps need a larger diameter pipe to provide increased efficiency, due to the higher pump flows generated. As is commonly done in the pool industry, the pipes that are either internally or externally attached would be fusion welded or glued into place.
[0025] FIGS. 1, 2, and 3 show that the pool skimmer ( 1 ) is provided with a removable pool skimmer plug ( 22 ). The removable pool skimmer plug ( 22 ) comprises a plug cap ( 32 ) and a plug body ( 28 ). As is common in the industry, the plug body ( 28 ) may be tapered, or may be cylindrically shaped. The plug body ( 28 ) has an upper portion ( 24 ), wherein the upper portion ( 24 ) of the plug body ( 28 ) has a continuous outwardly extended flange or ledge ( 26 ). The ledge ( 26 ) rests upon a correspondingly shaped shoulder ( 44 ) placed towards the lower portion ( 20 ) of the pool skimmer ( 1 ). The plug body ( 28 ) has an internally defined through hole ( 30 ), where the through hole ( 30 ) has means to secure a plug cap ( 32 ). Generally the means to secure the plug cap ( 32 ) would be by threadably attaching the plug cap ( 32 ) to the plug body ( 28 ), or by providing a pin and groove system common in many industries, to secure the plug cap ( 32 ) to the plug body ( 28 ).
[0026] The plug cap ( 32 ) has at least one raised boss ( 34 ). The raised boss(s) ( 34 ) provides a grip surface to the plug cap ( 32 ) and allows a user to easily install or remove the plug cap ( 32 ) from the pool removable pool skimmer plug ( 22 ). The plug body ( 28 ) has an outer surface ( 46 ). The outer surface ( 46 ) of the plug body ( 28 ) has a groove ( 48 ) defined therein. The groove ( 48 ) allows an o-ring ( 50 ) to be placed therein. The o-ring ( 50 ) may be adhesively positioned into the groove ( 48 ) preventing dislocation of the o-ring ( 50 ) when the removable pool skimmer plug ( 22 ) is placed into the pool skimmer ( 1 ).
[0027] As depicted in FIG. 2 , the plug assembly may be provided with a gasket ( 52 ), the gasket ( 52 ) being placed between the ledge ( 26 ) of the plug body ( 28 ) and the shoulder ( 44 ) of the pool skimmer ( 1 ). A second gasket ( 54 ) may be provided and be placed between the ledge ( 26 ) of the plug body ( 28 ) and the cap ( 26 ).
[0028] As shown in FIG. 3 , the cap ( 26 ) may be adapted to receive at least one poppet valve ( 56 ). The poppet valve will be used to alleviate any vacuum developed during the plug assemblies ( 22 ) use.
[0029] The external construction of the pool skimmer ( 1 ) is generally defined by the specific company fabricating the pool skimmer ( 1 ). They attempt to provide improved fixity to the gunnite or concrete by creating some form of ribbing that aids in adhesion. This invention does not revise the external ribbing of the original pool skimmer ( 1 ).
[0030] FIG. 4 shows an alternative construction of the removable pool skimmer plug ( 60 ). The removable pool skimmer plug ( 60 ) has an upper cap portion ( 62 ) where the cap portion ( 62 ) may have an external ledge ( 64 ). The external ledge ( 64 ) would rest upon the shoulder ( 44 ) placed towards the lower portion ( 20 ) of the pool skimmer ( 1 ). The upper cap portion ( 62 ) has a downward protruding boss ( 66 ), where the downward protruding boss ( 66 ) extends into the lower portion ( 20 ) of the pool skimmer ( 1 ) and may have a light friction fit to provide an air tight seal when under vacuum. The downward protruding boss ( 66 ) may have a groove ( 68 ) defined therein, the groove ( 68 ) being adapted to seat an o-ring ( 70 ) between the downward protruding boss ( 66 ) and the lower portion ( 20 ) of the pool skimmer ( 1 ). The downward protruding boss ( 66 ) can be designed with a centrally positioned hollow portion ( 72 ). The upper cap portion ( 62 ) has a grip means ( 74 ), where the grip means ( 74 ) can have a variety of shapes to suit the manufacturer. Such shapes may be cruciform, a singular straight bar, a metallic handle or stirrup to be gripped by a users hand, etc.
[0031] This removable pool skimmer plug ( 60 ) operates as follows. The user places the downward protruding boss ( 64 ) into the lower portion ( 20 ) of the pool skimmer ( 1 ). The downward protruding boss ( 64 ) is sized to provide a light friction fit to the pool skimmer ( 1 ), while the upper cap portion ( 62 ) will rest upon the shoulder ( 44 ) of the pool skimmer ( 1 ). Vacuum from the pool pump will draw the removable pool skimmer plug ( 60 ) so that an air tight seal will be formed providing the pump with the maximum available suction to draw water from the main drain of the pool ( 2 ).
[0032] If no external ledge ( 64 ) is used in the design, upper cap portion ( 62 ) of the removable pool skimmer plug ( 60 ) would have a tapered downward protruding boss ( 66 ) and frictionally fit in the pool skimmer ( 1 ). When the pool pump is in operation, vacuum will draw the removable pool skimmer plug ( 60 ) tighter in the pool skimmer ( 1 ) making a tight seal. At least one o-ring ( 70 ) is used in the removable pool skimmer plug ( 60 ) design. If necessary the downward protruding boss ( 66 ) may have a groove ( 68 ) defined therein for each o-ring ( 70 ). As defined previously, the downward protruding boss ( 66 ) can be designed with a centrally positioned hollow portion ( 72 ). The upper cap portion ( 62 ) has a grip means ( 74 ), where the grip means ( 74 ) can have a variety of shapes to suit the manufacturer. Such shapes may be cruciform, a singular straight bar, a metallic handle or stirrup to be gripped by a users hand, etc.
[0033] Although the foregoing includes a description of the best mode contemplated for carrying out the invention, various modifications are contemplated.
[0034] As various modifications could be made in the constructions herein described and illustrated without departing from the scope of the invention, it is intended that all matter contained in the foregoing description or shown in the accompanying drawings shall be interpreted as illustrative rather than limiting.
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This application describes a device to convert an existing pool skimmer assembly into a pressurizable pool skimmer assembly, which allows the existing pool skimmer assembly to act with this existing pool pump in emergency situations, such as assisting firefighters with pool water for extinguishing local wildfires or house fires. This method utilizes a removable plug cap and o-rings to allow the pool pump to draw the pool water from the pool main drain using the existing pool skimmer. This device can also be used to drain the pool for cleaning the pool or for winterizing the pool, with out the need for an electrical sump pump.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] Benefit is claimed to U.S. Provisional Patent Application No. 62/317,645, filed Apr. 4,2016, the contents of which are incorporated by referenced herein in their entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to the field of water faucets and water taps.
BACKGROUND
[0003] A water faucet or water tap is a device able to control the flow of water. A water faucet may allow a user to commence and to stop the flow of water from a plumbing system or from a water-delivery system. A water faucet may further allow a user to modify the pressure of water flow, or the volume of water that flows per time unit.
[0004] Some water faucets may be implemented as a “mixer tap”, for example, featuring a single handle enabling the user to mix hot water supply with cold water supply, to achieve a desired temperature.
[0005] Also known are mixer faucets having a nozzle incorporating a spray function in the spout are also known, the nozzle often being attached by a hose which is long enough to permit it to be pulled out.
[0006] The size of the hole or bore required to accommodate a mixer faucet is usually about 35 mm, while the outside dimensions of the faucet body are typically 35-50 mm While the sizes of hose used depends on the desired water flow exiting the faucet, its external diameter will normally be no less than 8 mm
SUMMARY OF THE INVENTION
[0007] In accordance with an embodiment of the invention, there is provided a mixer water faucet for installation through a bore in a work surface in proximity to a water supply, which includes a stationary housing extending transversely through the bore; a faucet body mounted onto the housing, rotatable relative thereto; a main spout and an auxiliary spout extending from the housing; a main water supply hose for conveying water to the main spout and an auxiliary water supply hose for conveying water to the auxiliary spout, the main water supply hose and the auxiliary water supply hose extending through the housing; and a diverter for selectably directing a supply of water to the main spout and the auxiliary spout.
[0008] Additionally in accordance with an embodiment of the invention, the auxiliary spout is removably mounted onto a rear portion of the faucet body for use at a location relatively remote from the main spout, and the auxiliary water supply hose is adapted for extension through the housing when the auxiliary spout is removed from the faucet body, and for retraction through the housing when re-mounted onto the faucet body.
[0009] Further in accordance with an embodiment of the invention, the main spout is rotatable about a rotation axis extending through the faucet body.
[0010] Additionally in accordance with an embodiment of the invention, the housing has a base and an upper portion, the base having formed therein a shaped opening, and the upper portion having formed therein a main opening aligned with the shaped opening, and an auxiliary opening communicating with the shaped opening aligned along an auxiliary axis, eccentric from the main axis, wherein the main water supply hose enters the housing through the shaped opening, and exits the housing though the main opening, and wherein the auxiliary water supply hose enters the housing through the shaped opening adjacent to the main water supply hose, and exits the housing through the auxiliary opening, the alignment of the auxiliary water supply hose translating from a first auxiliary axis on entry into the shaped opening to a second auxiliary axis on exit from auxiliary opening, wherein the first and second auxiliary axes are eccentric with respect to the rotation axis.
[0011] Further in accordance with an embodiment of the invention, the main water supply house is aligned along a main axis which is eccentric with respect to the rotation axis.
[0012] Additionally in accordance with an embodiment of the invention, the housing has a base and an upper portion, the base having formed therein a shaped opening, and the upper portion having formed therein a main opening aligned with the shaped opening, and an auxiliary opening communicating with the shaped opening aligned along an auxiliary axis, eccentric from the main axis, wherein a rotation of the main spout about a rotation axis causes a partial twisting of the main water supply hose and the auxiliary water supply hose with respect to each other, and wherein the shaped opening is formed to allow relative lateral movement of the main water supply hose and the auxiliary water supply hose with respect to each other, thereby to allow extension and retraction of the auxiliary spout and the auxiliary hose.
[0013] Further in accordance with an embodiment of the invention, the auxiliary spout is a pull-up water spraying element which is located and mounted behind the faucet body and is held or mounted generally-vertically therebehind; and wherein the pull-up water spraying element is releasable from the faucet body by being pulled upwardly, and not by being pulled sideways and/or downwardly.
GENERAL DESCRIPTION OF THE INVENTION
[0014] The term “faucet” or “water faucet” as used herein may include, for example, any suitable faucet or tap or valve that controls the flow of water or other liquids; including, but not limited to, a water faucet intended for installation and utilization in a home, a household, a dwelling, an office, a business venue, a factory, a kitchen, a bathroom, a restroom, indoors, outdoors, and/or other suitable places or venues; such faucet having or utilizing or being controlled by a single handle, or two handles, or a knob, or two knobs, or by other user interface elements or controlling elements; and including, but not limited to, a pull-out faucet, a pull-down faucet, a single-handle faucet, a double-handle faucet, a bar faucet, a wall mount faucet, a pot filler faucet, a touch-less faucet or hands-free faucet (e.g., activated by sensing a motion of a hand or a gesture of the user), and/or other suitable types of faucets or taps.
[0015] Applicants have realized that in conventional systems, a main water faucet is sometimes accompanied by a separate side-spray or side-spray element, which is separate and independent from the main water faucet. Applicants have realized that this configuration may suffer from one or more problems or disadvantages, for example: (a) the need to drill two separate holes in a surface or platform (e.g., granite, marble, artificial marble, or other kitchen platform or surface); (b) increased form-factor, and reduced utilization of the kitchen platform due to the fact that two separate units occupy space, side-by-side or next to each other; (c) the need to maintain, clean and/or repair two separate units; (d) reduced convenience for some users, who need to reach sideways to grasp the side-spray unit, while the user is standing in proximity to (or in front of) the main water faucet.
[0016] Applicants have realized that it may be beneficial or advantageous to provide an integral or integrated device, which comprises in the same integrated unit, referred to as water faucet 10 below: (i) a main water faucet, referred to hereinbelow as main spout 20 , including a single handle that controls the flow of both cold water and hot water; (ii) a spraying unit or a spout unit or spout, referred to hereinbelow as auxiliary spout 26 , which is located and/or stored and/or mounted generally behind the main water faucet (e.g., immediately adjacent to the main water faucet; or immediately on its right side or its left side, immediately adjacent to the main water faucet), and utilizes the same single-hole drilled in the kitchen platform (e.g., granite, marble, artificial marble); and (iii) a diverter unit, responsive to manual actuation or manual selection of the user via a diverter switch or diverter lever or diverter button or diverter slider or other diversion interface, to divert or to direct the flow of water, in a selective manner, to either the main water faucet or the spraying unit, and vice versa.
[0017] In some embodiments, the combined faucet 10 receives incoming water from a cold water pipe (or tube), referred to as below as cold water hose 32 , and from a hot water pipe (or tube), referred to below as hot water hose 30 ; and the diverter mechanism or diverter unit, based on the manual position or actuation thereof, diverts or directs the mixed water (or the single stream of water) to either the spraying unit 26 or the main faucet 20 .
[0018] In some embodiments, the spraying or auxiliary 26 is connected to an elongated and flexible pipe or tube, which allows the user to pull-out or to pull-up the spraying unit 26 , and to distance it from the water faucet or main spout 20 , in order to reach locations or areas that the main water faucet 20 (which lets the water flow downwardly and generally vertically) cannot reach; and which also enables the user to utilize the spraying unit 26 for a variety of tasks, for example, cleaning the sink or the sink area or the platform next to the faucet, filling-up water into a coffee-maker machine or a soda-maker machine or into a pot or a pan or a cooking appliance, or the like.
[0019] Optionally, the auxiliary spout or spraying-unit 26 may have an actuation button 24 , such that only when the user presses the button does water flow out of the auxiliary spout or spraying-unit 26 ; and such that water does not flow out of the spout or spraying-unit once the button is depressed or un-pressed or is not touched (or not pressed) any more by the user. Optionally, the spout or spraying-unit may comprise one or more buttons or user-interface elements (e.g., a lever, a slider, a rotating selector, or the like), which may switch or modify the operational characteristics of the spout or the spraying unit; for example, between a regular flow, a “spray” type flow or scattered-flow, an “aerated” flow, a “pause”/“un-pause” button. In some embodiments, the auxiliary spout 26 may have a button to trigger or to cause diversion of the water flow, from flowing exclusively through the main faucet 20 , to be diverted into and to flow outwardly exclusively through the spouting unit or spraying unit. For example, if the lever or handle of the main faucet is pulled or moved by a user to enable flow of water, then as a “default route”, the water flows out through the main faucet and not to the spraying unit; and only if or when the user presses the actuation button in the spraying unit, the diversion mechanism is triggered to operate and the flow of water is diverted to flow out through the pulled-out spraying unit, instead of through the main faucet.
[0020] In some embodiments, the main water faucet may comprise, on its rear side 28 (e.g., the side that is located away from the user, or is located between the faucet and a wall that typically exists behind the faucet, a particular cavity or channel or crater or rib, that enables the secure placement or mounting or holding-in-place of the spout unit or spraying unit, when not in use or after its utilization is over. In some embodiments, the pulled-out flexible pipe or flexible tube of the spout or spraying-unit, may be inserted back downwardly and may be stored within or under the kitchen platform or under the sink, hidden away from the user when not in use.
[0021] In some embodiments, the water-outlet of the auxiliary spout 26 , when the spout is mounted or held-in-place behind the main faucet 20 , may face backwardly or rearward, away from the user, or towards a back-wall that may be located behind the water faucet. In other embodiments, the water-outlet of the auxiliary spout 26 , when mounted or held-in-place behind the main faucet 20 , may face the front, towards the user, or towards the rear-side of the main faucet 20 which “hides” or blocks that water outlet from the user.
[0022] In some embodiments, the pull-up auxiliary spout or spraying unit 26 of the present invention, is not merely a pull-out unit that is pulled out (or away) from the main faucet 20 , in a downward direction or in a horizontal direction in order to be released from the grip of (or from the holding by) the main water faucet. Rather, the pull-up auxiliary spout or spraying unit 26 of the present invention is a pull-up unit that can be pulled up, or upwardly, or only upwardly, or exclusively upwardly, in order to be released from the grip of (or from the holding by) the main faucet 20 ; and only after such upward-only pull-up for the safe release of the spout from the rear-side of the water faucet that holds it, only then may the auxiliary spout unit 26 be moved around the area flexibly while being connected to the water system via the flexible pipe or flexible tube thereof.
[0023] In some embodiments, optionally, the entirety of the auxiliary spout or spraying-unit 26 may be a generally flat unit, or a rectangular unit, or a box or cuboid or rectangular cuboid unit; and may not comprise any L-shaped ending or edge or protrusion or spout-area; thereby keeping the form-factor of the unit small, and/or thereby allowing smoother holding by the user which may hold the unit similar to holding a flat handle and without an L-shaped ending or protrusion, and/or thereby enabling the auxiliary spout or spraying-unit 26 to spray water in an un-obstructed manner from a flat or generally-flat water outlet of the auxiliary spout 26 and without being restricted or obstructed by a protrusion or an L-shaped ending of the spout. In other embodiments, the spraying unit or the auxiliary spout element 26 may be generally flat but may also have a slightly protruding water-outlet at or near its distal end (e.g., away from the base of the faucet), through which the water flows out or is sprayed out or is spouted out.
[0024] In some embodiments, the auxiliary spout element or the spraying element 26 may be structured to exactly complement a generally-vertical crater or insert or crater than is indented into the rear-side of the main water faucet 20 ; such that the integrated device 10 , namely the main water faucet 20 in the front and the held-in-place auxiliary spout unit 26 in the back, together form a perfect or generally-perfect cylinder or rectangular cuboid or other shape which is generally straight and lacks protrusions or craters.
[0025] In some embodiments, the water faucet system 10 of the present invention and/or its units or elements, may be utilized in (or may be implemented as): a pull-up water faucet system, a single-state or dual-state pull-out water faucet system, and/or other suitable types of water faucet systems.
[0026] In some embodiments, optionally, a user may permanently or temporarily remove or cancel the operation of the auxiliary spraying unit 26 ; for example, by adding or inserting or appending or inserting a suitable seal or blocking-element or cover or water-blocker or similar element, at or near the externally-facing water-outlet of the spraying unit and/or at the base-area of the spraying unit and/or within the spraying unit and/or at (or near) the connection between the spraying unit and the main water faucet and/or at (or near) the diverting mechanism that diverts water from the main water faucet to the pull-up spraying unit. In some embodiments, optionally, the entire pull-up spraying unit may be removed from the water faucet system (e.g., permanently or temporarily); and/or may be replaced in a modular manner with other suitable water-outlet units, for example, thereby converting the water faucet system into a fixed-outlet system or a non-moving-outlet system, or thereby converting the water faucet system into a pull-out system, or the like.
[0027] Functions, operations, components and/or features described herein with reference to one or more embodiments, may be combined with, or may be utilized in combination with, one or more other functions, operations, components and/or features described herein with reference to one or more other embodiments, or vice versa.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] The present invention will be more fully understood and appreciated from the following detailed description, taken in conjunction with the drawings, in which:
[0029] FIG. 1A is a pictorial representation of a water faucet constructed in accordance with an embodiment the present invention, as viewed from above a work surface in which the faucet is installed, wherein the auxiliary spout is in a retracted position;
[0030] FIG. 1B is similar to FIG. 1A , but wherein the auxiliary spout is in an extended position;
[0031] FIG. 2 is a plan view of the faucet of FIG. 1 ;
[0032] FIG. 3 is a partial side view of the faucet of FIG. 1 ;
[0033] FIG. 4 is an exploded, schematic diagram showing the flow and distribution of water supplied to the faucet of FIG. 1 ;
[0034] FIG. 5 is a side-sectional, partially exploded view of a faucet body 16 and main spout 20 constructed in accordance with an embodiment of the invention;
[0035] FIG. 6 is a schematic plan view of main spout when rotated from a first position to a second position;
[0036] FIG. 7A is a bottom view of the faucet body of the invention, showing a shaped opening for the hoses through which water is provided to the main spout and the auxiliary spout, the eccentric positioning of both the main spout supply hose and the auxiliary spout supply hose relative to the axis of rotation of the main faucet body, and their movement consequent to the rotation of the main spout as shown in FIG. 6 ; and
[0037] FIG. 7B is an enlarged view of the shaped opening and its position relative to the axis of rotation of the main faucet body.
DETAILED DESCRIPTION
[0038] Referring now to FIGS. 1-3 , there is seen a water faucet, referenced generally 10 , generally as described above, installed in a single hole 12 , formed in a work surface or platform 14 . Typically, but way of non-limiting example only, hole 12 has a diameter which is typically 35 mm as known in the art. Faucet 10 includes a faucet body 16 which may have an outside diameter of 35-50 mm as known in the art, and is supported on platform 14 via a housing 18 and shank 29 . Body 16 is rotatable relative to housing 18 which has a fixed position relative to platform 14 , and both are held in position via a suitable system of fasteners as illustrated and as generally known in the art. Faucet body 16 has a main spout 20 to which water is supplied as shown and described herein, inter alia, in conjunction with FIG. 4 , by suitable operation of selector handle 5 and mode selector switch 24 , mounted onto auxiliary spout 26 . Operation of handle 5 and mode selector switch are generally as known in the art and are thus not described herein in detail, Auxiliary spout 26 is extendably mounted onto a rearward facing portion 28 ( FIG. 1B ) of faucet body 16 . As described above, mode selector switch 24 may be any suitable switch, lever, button or slider to operate diverter 40 (seen in FIGS. 3 and 4 ), also as known in the art.
[0039] Referring now also to FIGS. 4, 5, 6, 7A and 7B , the incorporation of main spout 20 and auxiliary spout 26 into a single, integrated faucet, requires a novel, bundled water flow circuitry into a single cluster of five hoses within shank 29 ( FIG. 4 ) as described below in more detail in conjunction with FIG. 5 .
[0040] As seen in the exploded view of FIG. 4 , a pair of hot and cold water hoses, respectively referenced 30 and 32 , are connected to hot and cold water supplies, respectively referenced 34 and 36 . A water mixer cartridge 38 ( FIG. 4 ), as known in the art, is located within housing 18 in operative association with selector handle 5 . Hot and cold water is supplied to cartridge 38 via hot and cold water hoses 30 and 32 , and a mixed water supply is delivered from cartridge 38 to external diverter 40 , via intermediate hose 42 . Water reaching diverter 40 may then be supplied either to main spout 20 or to auxiliary spout 26 , via main spout hose 44 or auxiliary spout hose 46 , respectively, depending on the operation of the mode selector switch 24 .
[0041] Referring now particularly to FIG. 7A , the respective positions of the five hoses are shown, wherein hot water hose 30 , cold water hose 32 and intermediate hose 42 are seen to extend through suitable openings formed in the base 48 of housing 18 . Main spout hose 44 and auxiliary spout hose 46 extend up into main body 16 through the housing 18 , as described below.
[0042] A well-known problem of extendable hoses of spray faucets is that the extendable hose, which is required to move freely through the main faucet body, frequently becomes stuck, even though it is the only hose which extends through the faucet housing. For this reason, it is known to make use of a counterweight to assist in pulling the hose back through the main body of the faucet when seeking to retract the spray head.
[0043] Due to the desire to limit the overall external diameter of the faucet housing to those generally accepted within the field, typically, 35-50 mm, as well as the requirement to provide a flow of water by both the main spout and the auxiliary spout, thus limiting the minimum external diameter of their associated hoses to no less than 8 mm, a specially formed shaped opening 50 is formed in base 48 to accommodate the two hoses. It will be appreciated that main spout hose 44 is static and auxiliary spout hose 46 is arranged for extension and retraction.
[0044] The main spout hose 44 is positioned along a main axis 102 , which is parallel to but spaced from the axis of rotation 103 of the main body 16 and main faucet 20 , by a distance or eccentricity denoted as ‘e 1 ’ ( FIG. 5 ). Furthermore, the auxiliary spout hose 46 , extends through housing 18 along a first auxiliary axis 104 which is parallel to but spaced from the rotation axis 103 by a distance or eccentricity denoted as ‘e 2 ’.
[0045] As seen in FIG. 5 , the auxiliary spout hose 46 extends through an auxiliary opening 52 formed in an upward facing base portion 56 connecting faucet body 16 to housing 18 , thereafter to connect to the auxiliary spout 26 . Auxiliary opening 52 defines a second auxiliary axis 106 along which the auxiliary spout hose 46 connects to the auxiliary spout 26 . Second auxiliary axis 106 is parallel to but spaced from the axis of rotation 103 by a distance or eccentricity denoted as ‘e 3 ’.
[0046] In order to facilitate extension of the auxiliary spout 26 , auxiliary spout hose 46 is provided with an additional length of hose which is adapted to hang down beneath the faucet and work surface 14 when auxiliary spout 26 is in an at rest, retracted position. When auxiliary spout 26 is extended from the main body 16 , as seen in FIG. 1B , all or some of the additional length of hose is pulled through shaped opening 50 and auxiliary opening 52 , as required.
[0047] When main spout 20 is at an initial “zero” position relative to the faucet body 16 , as illustrated in FIG. 2 and as shown schematically as position “ 0 ” in FIG. 6 , auxiliary spout hose 46 is retracted substantially along axes 104 and 106 , being accommodated by a U-shaped depression portion 54 ( FIG. 7B ) of shaped opening 50 , seen in FIGS. 7A and 7B .
[0048] However, when main spout 20 is rotated to the position indicated as “I”, for example, thus rotating faucet body 16 relative to housing 18 , this has the effect of applying a rotational force to both main spout hose 44 and auxiliary spout hose 46 , pulling them to one side or another, as shown by arrows 58 and 60 in FIG. 7A , depending on the direction in which main spout 20 is rotated. The extent of the pulling on each of the hoses is a function of the eccentricities e 1 , e 2 and e 3 , and of the angle of rotation of main spout 20 . Shaped opening is thus formed with additional end depressions 62 and 64 , to accommodate the relative twisting motion of auxiliary spout hose 46 relative to main spout hose 44 , while still allowing sufficient freedom of movement therebetween when auxiliary spout hose 46 is extended or retracted when extending or retracting auxiliary spout 26 .
[0049] While certain features of some embodiments have been illustrated, and described herein, many modifications, substitutions, changes, and equivalents may occur to those skilled in the art. Accordingly, the claims are intended to cover all such modifications, substitutions, changes, and equivalents.
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A mixer water faucet for installation through a bore in a work surface in proximity to a water supply, includes a stationary housing extending transversely through the bore; a faucet body mounted onto the housing, rotatable relative thereto; a main spout and an auxiliary spout extending from the housing; a main water supply hose for conveying water to the main spout and an auxiliary water supply hose for conveying water to the auxiliary spout, the main water supply hose and the auxiliary water supply hose extending through the housing; and a diverter for selectably directing a supply of water to the main spout and the auxiliary spout.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of application Ser. No. 09/890,771 submitted on Mar. 5, 2002 by Peter Robert Flux with the title SAFETY LINE ANCHOR under 35 U.S.C. 371 from Patent Cooperation Treaty Application PCT/GB00/00371 which was filed on Feb. 8, 2000.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to height safety equipment and, in particular, to an anchoring arrangement suitable for anchoring the lower end of a temporary installation of a flexible elongate safety line disposed in a substantially vertical orientation on a tall structure.
[0004] 2. Background Art
[0005] Tall structures such as electricity pylons and radio or satellite communication masts are periodically inspected to determine whether any maintenance work is required. These structures are purposely built to be low maintenance and, because many of them stand in remote locations, they may require inspection only once every ten years, perhaps longer.
[0006] Also, in the interests of public safety, such structures are constructed to discourage easy ascent by non-authorised personnel. Hence, the lower leg portions of metal towers of this type are usually plain metal to a height of at least three meters from ground level, with no foot- or hand-holds. In fact, if such structures were built with access-ways or the like, the access-ways themselves would require periodic inspection for compliance with safety regulations. The interval between routine safety inspections is shorter than the required interval between routine maintenance inspections, so it would significantly increase the frequency of inspection for any kind of permanent access-way to form part of the tall structure.
[0007] Traditionally, personnel who have carried out maintenance inspections on metal towers, pylons, or the like have used rope-access techniques for ascent and making themselves fast at the top. In an effort to minimise some of the hazards associated with such work, the present applicants have devised a fall arrest system that can be installed temporarily on a tall structure for the duration of a routine maintenance inspection, then removed and installed on another tall structure and so on. The advantage of a temporary installation is that it does not require safety inspection in situ. Rather, the system can be removed to a convenient inspection site and inspected whenever necessary.
[0008] The above-mentioned temporary fall arrest system uses known components for the most part, but includes a new bottom anchor assembly for securing a substantially vertically-oriented safety line to the lower portion of a tall structure. The anchor assembly is a quick-release device that is significant in being manually operable to working tension. The new bottom anchor also allows a safety line of indeterminate length to be installed, with the excess line being held on a spool beyond the bottom anchor. The bottom anchor is designed to grip the safety line in a non-destructive fashion so that it can be reused repeatedly for a series of inspections on many tall structures. It can also accommodate differences in height between successive tall structures by allowing a different length of safety line to be passed through it before the gripping action is made.
[0009] In achieving the aforementioned objects, it should be borne in mind that the critical tension in a substantially vertically-disposed safety line is in its upper portion. The lower portion needs to be secured against the effects of buffeting by wind, but the safety line is inherently under tension below the top anchor by virtue of its own weight.
SUMMARY OF THE INVENTION
[0010] The invention is a fall arrest bottom anchor assembly for use with a substantially vertically-oriented elongate safety line. The bottom anchor assembly includes a safety line gripper, a safety line tensioner, and a bracket that is adapted to be fixedly mounted. The gripper includes a manually adjustable clamp that can be clamped to the safety line at an adjustable position along its length. The tensioner includes a hollow shaft connected to the gripper. The hollow shaft is adapted to receive the safety line with the safety line extending therethrough and extending both upwardly and downwardly therefrom, and the hollow shaft extends vertically through the fixed bracket downwardly and upwardly from the fixed bracket. The hollow shaft has an externally screw-threaded portion. A load setter of the anchor assembly is threadingly adjustable on the screw-threaded portion of the hollow shaft below the fixed bracket to bear against the underside of said fixed bracket for adjusting the safety line tension to a predetermined value.
[0011] The manually adjustable clamp as disclosed is secured to the safety line below the fixed bracket below the hollow shaft.
[0012] Preferably, the manually adjustable clamp includes of a pair of clamp blocks adapted to be placed in face-to-face opposing relationship around the safety line immediately beneath the hollow shaft. Most preferably, the clamp blocks are provided with mutually-aligned grooves or recesses substantially conforming to the profile of the safety line. The clamp blocks may be loosely clamped to each other using screw-threaded fastening means for initial assembly and may include a further screw-threaded fastener for applying the final clamping torque.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The invention will now be described by way of example only with reference to the drawings, in which:
[0014] FIG. 1 is a perspective view of an embodiment of the present invention in fully-assembled form.
[0015] FIG. 2 is a perspective view of a first manually-adjustable clamping arrangement in accordance with the present invention.
[0016] FIG. 3 is an exploded perspective view of the arrangement depicted in FIG. 2 .
[0017] FIG. 4 is an exploded perspective view of a tensioning device suitable for use in the present invention.
[0018] FIG. 5 is a close-up perspective view of a tensioning device in the Process of being installed on a bracket in accordance with a preferred embodiment of the invention.
[0019] FIG. 6 is a perspective view of a second manually-adjustable clamping arrangement in accordance with the present invention.
[0020] FIG. 7 is an exploded perspective view of the arrangement of FIG. 6 .
[0021] FIG. 8 is a perspective view of a third manually-adjustable clamping arrangement in accordance with the present invention.
[0022] FIG. 9 is an exploded perspective view of the arrangement depicted in FIG. 8 .
[0023] FIG. 10 is a further perspective view of the arrangement depicted in FIG. 8 .
[0024] FIG. 11 is a further exploded perspective view of the arrangement depicted in FIG. 8 .
[0025] FIG. 12 is a perspective view of a fourth manually-adjustable clamping arrangement in accordance with the present invention.
[0026] FIG. 13 is a partial exploded perspective view of the arrangement depicted in FIG. 12 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0027] Referring firstly to FIG. 1 , there is shown a perspective view of a bottom anchor assembly 10 attached to a safety line 70 in the form of a multi-stranded metal cable. Typically, the cable diameter for a vertical fall arrest system is 8 mm.
[0028] The bottom anchor assembly consists of a bottom-mounted clamp 20 , an externally screw-threaded hollow shaft 40 projecting upwardly from an upper surface of the clamp 20 , a bracket 50 for attaching the anchor assembly to the lower portion of a tall structure such as an electricity pylon (not shown) and a load-setting device 80 a portion of which is adapted to bear against the underside of the jaws of the bracket 50 . The hollow shaft 40 may include a circlip 49 at its upper end for ensuring that the load-setting device, once installed on the hollow shaft 40 , does not become inadvertently lost.
[0029] Referring now to FIGS. 2 and 3 , the clamp 20 comprises a pair of clamp blocks 21 , 31 adapted to be butted together in face-to-face opposing relationship around the safety line 70 . The safety line 70 is omitted from these views for clarity. The clamp blocks 21 , 31 each have a semi-circular groove 22 , 32 formed in their respective opposing faces. The grooves 22 , 32 may be provided with surface formation such as serrations, or a surface finish such as a metal spray for roughening, to enhance the gripping action on the safety line 70 . As shown, one of the clamp blocks 21 is provided with a pair of countersunk bores 23 , 24 whilst the other clamp block 31 is provided with a pair of threaded bores 33 , 34 adapted to be in alignment with the countersunk bores 23 , 24 when the clamp blocks are in opposing relationship. The bores 23 , 24 , 33 , 34 receive respective threaded bolts 25 , 35 which are used to assemble the clamping unit loosely for initial installation. The clamp block 21 further includes a plain through-hole 26 , whilst the clamp block 31 further includes a third threaded hole 36 adapted to be in alignment with the through-hole 26 when the clamp blocks are in opposing relationship. The holes 26 , 36 receive a wing nut 27 which is manually tightened to achieve the desired clamping force on the safety line 70 .
[0030] The exploded view of FIG. 3 does not allow this feature to be shown, but wing nut 27 is preferably captive in one of the clamp blocks, most preferably in the clamp block 31 having the threaded hole 36 .
[0031] Still with reference to FIGS. 2 and 3 , the clamp blocks 21 , 31 each have a semi-circular recess 28 , 38 in their uppermost surfaces, said recesses forming shoulder means 29 , 39 at the junction of the recesses 28 , 38 with the grooves 22 , 32 . The shoulder means 29 , 39 form a plat form upon which the hollow shaft 40 is positioned during installation of the anchor assembly.
[0032] The hollow shaft 40 is preferably held captive in the recesses 28 , 38 when the clamp blocks 21 , 31 are in opposing relationship by virtue of an undercut formation 28 a, 38 a provided at the base of recesses 28 , 38 . The undercut formation 28 a, 38 a is dimensioned to receive a flange 48 at the base of hollow shaft 40 . Preferably, the hollow shaft 40 is still capable of rotation relative to the clamp blocks 21 , 31 . This enables torsional stresses in the safety line 70 to be relieved whilst maintaining the desired tension.
[0033] Once fully installed, the anchor device behaves like a unitary assembly owing to the capture of the hollow shaft 40 in the clamping means 20 . This also means that the device can be installed the other way up from the orientation shown in the drawings, since the hollow shaft 40 is held captive relative to the safety line 70 by virtue of its engagement in the clamping means 20 .
[0034] The hollow shaft 40 has an external screw thread 41 , the purpose of which is explained in detail below, and a through-bore 42 dimensioned to receive the safety line 70 as a loose sliding fit. The safety line 70 must not be an interference fit in the through-bore 42 , otherwise it becomes difficult to control the tension in the system with precision. Neither is it desirable for the through-bore 42 to be very much wider than the diameter of the safety line 70 since this results in the device being more bulky than necessary and may also increase the likelihood of the safety line chafing at the ends of the hollow shaft 40 .
[0035] Turning now to FIG. 4 , there is shown an embodiment of a load-setting means 80 in exploded perspective view. The load-setting means 80 comprises, in order from the bottom upwards, a first wing nut 81 having a screw threaded through-hole 81 a of complementary thread pattern to the external screw thread 41 of the hollow shaft 40 , an annular rubber block 82 , and a second wing nut 83 , also having a screw threaded through-hole 83 a of complementary thread pattern to the external screw thread 41 of the hollow shaft 40 . In use, the first wing nut 81 acts as a locking nut to secure the second wing nut 83 in position on the hollow shaft 40 when the load-setting means 80 has been adjusted to the desired tension. The rubber block 82 between the first and second wing nuts 81 , 83 ensures that the assembly does not become locked up.
[0036] Next in order above the second wing nut 83 is a flanged collar 84 having an annular circlip-retaining groove 84 a at its upper end. Above the collar 84 is a wave spring 85 , then a thrust washer 86 and a spacer 87 . In alternative embodiments, the wave spring may be substituted by a crest spring, a disc spring, or even a compression spring. Also, the thrust washer 86 and the spacer 87 may be an integrally-formed single component. Above the spacer 87 is a tenser disc 88 , typically in the form of a M24, Form D washer. The spacer 87 has a longitudinal dimension such that the jaws of bracket 50 are receivable between the upper surface of thrust washer 86 and the underside of tenser disc 88 . The load-setting means 80 is completed by a retaining circlip 89 at the upper end as viewed in the Figure.
[0037] The components denoted by the reference numerals 85 to 89 form a unitary assembly on the shank of the flanged collar 84 , the circlip 89 being received in the circlip-retaining groove 84 a of the flanged collar 84 . The flanged collar 84 has a plain bore that enables it to slide freely over the external screw thread 41 of the hollow shaft 40 . The arrangement of the assembled load-setting means 80 is such that the wave spring 85 exerts a compressive force urging the tenser disc 88 into frictional engagement with the upper rim of the spacer 87 and the underside of circlip 89 . This prevents rotation of the tenser disc 88 relative to its immediate neighbours, until the desired tension has been imparted to the system in the manner to be described in more detail below.
[0038] Referring now to FIG. 5 , this view shows a load-setting means 80 being slotted into the jaws 51 , 52 of bracket 50 . Here, the load-setting means 80 is shown in an inverted orientation relative to the exploded view of FIG. 4 . However, inversion of orientation does not affect the working principle of the load-setting means 80 . As previously described, the ends of the bracket jaws 51 , 52 have down-turned portions in the form of lugs 53 , 54 (see also FIG. 1 ) which serve to prevent the accidental removal of the load-setting means from between the jaws 51 , 52 by inhibiting lateral movement of the load-setting means 80 once the system is adjusted to its predetermined tension. For the sake of clarity, the hollow shaft 40 and the safety line 70 have been omitted from FIG. 5 , but it will be understood from the explanation below that these features are present when the load-setting means 80 is installed in the bracket 50 .
[0039] Referring once again to FIG. 1 , bracket 50 is releasably secured to the lower portion of a leg (not shown) of a tall structure such as a metal tower, a pylon, or the like in a known manner. Hollow shaft 40 carrying the load-setting means 80 is fed onto the safety line 70 from the direction of its free end indicated by the reference numeral 71 and positioned roughly adjacent the jaws 51 , 52 of the bracket 50 . The manually adjustable clamp 20 is then installed on the safety line 70 just beneath the hollow shaft 40 and is fastened to the safety line 70 by manually tightening the wing nut 27 . At this moment during installation of the bottom anchor assembly 10 , the safety line 70 is still free and sufficiently flexible that the load-setting device 80 can be tilted for insertion past the lugs 53 , 54 of the bracket 50 and thence into the jaws 51 , 52 thereof. The jaws 51 , 52 of the bracket 50 are positioned between the thrust washer 86 and the tenser disc 88 . The wing nut 83 is then rotated (by hand) to urge the flanged collar 84 upwards, forcing thrust washer 86 hard against the underside of the jaws 51 , 52 of the bracket 50 . The flanged collar 84 is moved upwardly relative to the thrust washer 86 by compressing the wave spring 85 until a point is reached when the tenser disc 88 is no longer held captive between the spacer 87 and the circlip 89 , but is rotatable relative thereto. The point at which rotation of the tenser disc 88 is just possible indicates attainment of the desired tension in the system.
[0040] The first wing nut 81 can then be rotated (again by hand) against the resilience of rubber block 82 to lock second wing nut 83 and thereby ensure against relaxation of the tension in the safety line 70 .
[0041] To release the safety line 70 from the bottom anchor assembly 10 , the above procedure is reversed.
[0042] Because the bottom anchor assembly 10 uses a hollow shaft 40 and a non-terminal clamping block 20 , the safety line 70 is permitted to extend beyond the bottom anchor assembly 10 . There is no need to cut the safety line 70 to suit the height of the particular tall structure to which it is being fastened. Rather, the excess (that portion which extends in the direction of arrow 71 ) safety line can be coiled on a spool or drum onto which it can be rewound when the inspection is complete and the safety line installation is dismantled.
[0043] Referring to FIGS. 6 and 7 , a second alternative clamp 90 which can be used to replace the clamp 20 described above is shown. The clamp 90 operates with an externally screw threaded hollow shaft 91 which functions similar to the hollow shaft 40 described previously to allow the load on the safety line 70 to be set.
[0044] The clamp 90 comprises a partially conical collet grip 92 , a winged nut 93 and circlip 94 . The threaded main body section 93 a and wing section 93 b of the winged nut 93 can conveniently be manufactured separately and accordingly are shown exploded apart in FIG. 7 . However, the main body section 93 a and wing section 93 b will be permanently joined, for instance by welding, to form the winged nut 93 and are not intended to be separable in use.
[0045] The collet grip 92 is retained within the end of the hollow shaft 91 by the winged nut 93 , the winged nut 93 having an internal thread arranged to engage the external thread on the hollow shaft 91 .
[0046] The winged nut 93 has a circlip groove 93 c and a groove 91 a is formed as a gap in the external threads on the hollow shaft 91 . The circlip 94 is held in the circlip groove 93 c and the circlip groove 91 a to retain the collet grip 92 and winged nut 93 on the hollow shaft 91 and prevent their accidental loss. The width of the circlip groove 91 a must be sufficient to allow the circlip 94 to float within the circlip groove 91 a to allow the full range of movement of the winged nut 93 .
[0047] In operation, the safety line 70 , which is omitted from the figures for clarity, passes through the hollow shaft 91 as before and through the collet grip 92 and winged nut 93 . Manual tightening of the winged nut 93 drives the collet grip 92 into the end of the hollow shaft 91 , urging the collet grip 92 to close and so grip the safety line 70 .
[0048] Preferably, the collet grip 92 is capable of rotation relative to the hollow shaft 91 and winged nut 93 in order to allow torsional stresses in the safety line 70 to be relieved whilst maintaining the desired tension.
[0049] The hollow shaft 91 , like the hollow shaft 40 , may include a circlip 49 at its upper end to ensure that the load setting device, once installed on the hollow shaft 91 , does not become inadvertently lost.
[0050] At the opposite end of the hollow shaft 91 to the clamp 90 a short section at the end of the hollow shaft 91 has no external threads and at least one pair of opposed flat faces 91 b. The flat faces 91 b allow the hollow shaft 91 to be gripped by a spanner or similar tool to hold the hollow shaft 91 against rotation so that the winged nut 93 can be tightened or loosened.
[0051] Once fully installed, the anchor device behaves like a unitary assembly owing to the capture of the hollow shaft 91 in the clamping means 90 . This means that, in principle, the device can be installed the other way up from the orientations shown in the drawings. However, it will normally be preferred to only install the device in the orientation shown where the tension applied to the safety line 70 tends to pull the collet grip 92 into tighter engagement with the hollow shaft 91 . The advantage of this orientation is that if a fall arrest event occurs the additional load on the safety line will tend to pull the collet grip 92 into tighter engagement with the hollow shaft 91 . If the orientation were reversed the excess load caused by a full arrest event would have to be carried by the winged nut 93 .
[0052] A third alternative clamping arrangement is shown in FIGS. 8 to 11 .
[0053] In this arrangement an alternative clamp 100 is used, attached to one end of a hollow shaftlol similar to the hollow shaft 40 .
[0054] The clamp 100 comprises a collet grip 104 located within a clamp body 102 . The clamp body 102 has an internal thread (not shown) which engages the external thread on the hollow shaft 101 . Further, the clamp body 102 has a pair of internally threaded radial bores 102 a. Bolts 103 screw into the bores 102 a and into corresponding recesses 101 a on the outer surface of the hollow shaft 101 to retain the clamp body 102 on the end of the hollow shaft 101 .
[0055] The collet grip 104 is retained within the clamp body 102 with the narrow end of the collet grip 104 passing through an aperture 102 b in the clamp body 102 . The collet grip 104 is urged though the aperture 102 b and held in contact with the clamp body 102 by a spring 105 which is held in compression between the end of the hollow shaft 101 and a washer 106 in contact with the wider end of the collet grip 104 .
[0056] A hollow cover 107 is arranged to have a sliding fit over the outer surface of the clamp body 102 and has two slot shaped apertures 107 a in its side surface. The bolts 103 and cover 107 are arranged so that the head ends of the bolts 103 which are exposed above the surface of the clamp body 102 pass into the apertures 107 a to retain the cover 107 over the gripping body 102 while allowing the cover 107 to move axially relative to the clamp body 102 and the hollow shaft 101 .
[0057] The cover 107 has an end aperture 107 b through which the safety line 70 can pass and is arranged so that the collet grip 104 bears against an inner end surface of the cover 107 around the aperture 107 b.
[0058] In operation, the safety line 70 passes through the clamp 100 and hollow shaft 101 as before. The collet grip 104 is biased by the spring 105 against the clamp body 102 so that the collet grip 104 is biased to grip the safety line 70 . In order to release the collet grip 104 from the safety line 70 , the cover 107 must be urged towards the hollow shaft 101 , that is downwards in the figures, so that the cover 101 urges the collet grip 104 away from the clamp body 102 so that the grip of the collet grip 104 on the safety line 70 is released.
[0059] The collet grip 104 can rotate relative to the hollow shaft 101 in order to enable torsional stresses in a safety line 70 to be relieved while maintaining the desired tension. A circlip 109 may be placed on the end of the hollow shaft 101 opposite the clamp 100 to ensure that the load setting device, once installed on the hollow shaft 101 , does not become inadvertently lost.
[0060] The clamp 100 is further shown in FIG. 10 which shows the clamp assemble together with the load setting device 80 and safety line 70 and in FIG. 11 which shows the assemble clamp 100 with the cover 107 removed to show the end of the collet grip 104 protruding from the collet body 102 . For clarity, the safety line 70 is omitted in FIG. 11 .
[0061] The clamp 100 shown in FIGS. 8 to 12 allows the safety line 70 to be freely pulled through in one direction, downward in the figures, because movement of the cable in this direction will automatically pull the collet grip 104 out of engagement with the clamp body 102 and so release the grip of the collet grip 104 on the safety line 70 , while movement of the safety line 70 in the opposition direction, upwards in the figures, will be prevented because forces applied to the safety line 70 in this direction will urge the collet grip 104 against the gripping body 102 and increase the gripping force exerted on the safety line 70 . This automatic one way action has the advantage of allowing easier adjustment of the assembly to pull though excess safety line. However, the one way gripping action means that the clamp 100 can only be used on one end of the threaded shaft 101 , the top end in the figures.
[0062] A fourth alternative clamp arrangement 110 is shown in FIGS. 12 and 13 .
[0063] In this clamp 110 a collet grip 112 is urged into one end of a hollow shaft 111 by a winged nut 113 similarly to the arrangement shown in FIGS. 6 and 7 .
[0064] In the clamp 110 the hollow shaft 111 has at least one flat 111 a extending along most of its length. The flat 111 a stops short of the end of the hollow shaft 111 where the winged nut 113 is located so that the external threads are continuous in this region.
[0065] A second wing nut or hand grip 114 is provided having an engagement mechanism (not shown) arranged to selectively lock the rotational position of the hand grip 114 relative to the hollow shaft 111 and an internal thread able to cooperate with the external thread of the hollow shaft 111 . The gripping mechanism is controlled by two push buttons 114 a on the hand grip 114 .
[0066] In order to tighten or loosen the clamp 110 the buttons 114 a are pressed to release the hand grip 114 from the hollow shaft 111 and the hand grip 114 is then rotated along the thread of the hollow shaft 111 to a convenient position. The buttons 114 a are then released to lock the rotational position of the hand grip 114 relative to the hollow shaft 111 . The hand grip 114 can then be used to hold the hollow shaft 111 in position while the winged nut 113 is rotated to engage or release the collet grip 112 from the safety line 70 .
[0067] The advantage of this arrangement over the arrangement shown in FIGS. 6 and 7 is that no spanner or other separate tool is required to tighten or release the clamp 110 .
[0068] Although the invention has been particularly described above with reference to specific embodiments, it will be understood that modifications and variations are possible without departing from the scope of the claims which follow.
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A bottom anchor assembly ( 10 ) for a substantially vertically-oriented elongate safety line ( 70 ) comprises safety line gripping means ( 20 ), safety line tensioning means ( 80 ) and a bracket ( 50 ). The gripping means ( 20 ) includes a manually adjustable clamp ( 20 ) and the tensioning means ( 80 ) includes a hollow shaft ( 40 ) through which the safety line ( 70 ) passes. The hollow shaft ( 40 ) is externally screw-threaded and carries the load-setting means ( 80 ) on its screw-threaded portion ( 41 ). The load-setting means ( 80 ) is adapted to bear against the underside of the bracket ( 50 ) for adjusting the safety line tension to a predetermined value.
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BACKGROUND
[0001] During the production or injection life of a borehole in an earth formation in the completion industry, for example, it is expected that borehole and formation conditions can change over time and that these changes can alter production or injection. Examples of such changes include increases and decreases in fluid flow rates created by changes in the formation and/or changes in fluid composition (Fluid composition here being defined as relative percentages of gas, oil and water and changes in fluid composition referring to changes in the relative percentages). Different zones along the borehole often change at different times. Changes in one zone can negatively affect production or injection of that zone, of other zones, and of the borehole as a whole. Knowing when changes occur and how such changes affect production or injection through each inflow control device can allow an operator to make changes that could increase overall production or injection of the borehole. Unfortunately, gathering such knowledge can be expensive since it typically includes halting production or injection and running logging tools into the borehole to capture data sufficient to determine what changes in fluid flow rates and fluid composition at different inlet zones has occurred. Methods that permit an operator to gain such knowledge without intervention would be well received in the industry.
BRIEF DESCRIPTION
[0002] Disclosed herein is a method of diagnosing flow through an inflow control device. The method includes, producing or injecting fluid through an inflow control device, measuring temperatures near or at the inflow control device over time while producing or injecting fluid therethrough, and attributing temporal changes in temperature to changes in the fluid that is produced or injected.
[0003] Further disclosed herein is a method of determining compositional changes of a fluid flowing through an inflow control device. The method includes, measuring temperatures at selected points relative to the inflow control device at a first time, measuring temperatures at the selected points relative to the inflow control device at a second time, determining differences in temperature at the selected points between the first time and the second time, and attributing temporal temperature differences at the selected points to changes in composition of the fluid flowing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] The following descriptions should not be considered limiting in any way. With reference to the accompanying drawings, like elements are numbered alike:
[0005] FIG. 1 depicts a schematic representation of a portion of a downhole completion application wherein methods disclosed herein are deployed;
[0006] FIG. 2 depicts relationships between pressure, temperature and flow rates through various flow devices;
[0007] FIG. 3 depicts a flow chart of a process disclosed herein to calibrate a mathematical model to a simulator; and
[0008] FIG. 4 depicts a flow chart of a process disclosed herein to diagnose a completion operation through comparison to a mathematical model or a simulator.
DETAILED DESCRIPTION
[0009] A detailed description of one or more embodiments of the disclosed apparatus and method are presented herein by way of exemplification and not limitation with reference to the Figures.
[0010] Referring to FIG. 1 , a completion liner 10 as illustrated is positioned within a borehole 14 of an earth formation 18 in a downhole completion operation. The completion liner 10 is sealably engaged to the borehole 14 via a packer 22 . The completion liner 10 includes a basepipe 26 with a distributed temperature sensor (DTS) 30 , or multiple discrete sensors, positioned, inside or outside the basepipe 26 , to monitor temperature therealong in real time either upstream or downstream of a plurality of inflow control devices (ICD) 34 . The plurality of inflow control devices 34 , with three being illustrated in this embodiment, are longitudinally spaced along the basepipe 26 with a node 38 being positioned to either longitudinal side of each of the ICDs 34 thereby designating separation of adjacent zones 42 . Flow rates from various positions along the formation 18 through each of the ICDs 34 can depend upon various factors. For example, permeability of the formation 18 can vary at different positions as well as the ratio of oil to water to gas from each zone 42 . It should be understood, that although examples disclosed herein are directed to production through the drill string 10 , alternate embodiments could just as well be directed to injecting fluids through the completion liner 10 , out through the ICDs 34 and into the formation 18 .
[0011] Although inflow control devices 34 can help to balance production from the various zones 42 along the completion liner 10 , it may be desirable for an operator to alter production through particular zones 42 even further than what is possible through the ICDs 34 . For example, if one of the zones 42 is producing mostly water, it may be desirable to fully close off production from that zone 42 . Additionally, if a zone 42 is producing too fast, partially closing the zone 42 can minimize erosion of the ICD 34 thereby extending the life of the ICD 34 and likely increasing total production from the well in the process.
[0012] Knowing when to make alterations, however, requires knowledge of what is happening at the various zones 42 . Typically this has meant running logging tools within the completion liner 10 to take measurements therealong. Such intervention, however, is costly in terms of labor, equipment and lost production. Consequently, these interventions are used sparingly, possibly resulting in delays that could, if implemented sooner, have had significant benefits to the operation, including increasing production therefrom. Embodiments disclosed herein allow an operator to gain knowledge regarding flow through the ICDs 34 , positioned along the completion liner 10 , without interfering with production therethrough.
[0013] Referring to FIG. 2 , embodiments disclosed herein build on the fact that specifics of geometry 50 of the ICDs 34 determine flow performance characteristics 46 A, 46 B and 46 C therethrough. For example, the Joule Thompson effect 46 C (change in temperature divided by change in pressure) is a function of the geometry 50 of the ICD 34 and flow rates for any particular fluid having specific fluid properties, such as density and viscosity. Geometry of standard screens 54 and slotted liners 58 , by contrast, do not have pressure drops 62 or cause differential temperatures 66 that could be employed in the techniques disclosed herein.
[0014] Since flow performance characteristics of pressure drop versus flow rate 46 A, temperature differential versus flow rate 46 B and Joule Thompson Effect versus flow rate 46 C are determined by the geometry 50 of the ICD 34 for a specific fluid these flow performance characteristics 46 A, 46 B, 46 C can be both empirically mapped and mathematically calculated. Mapping them may entail measuring actual temperatures at selected points 70 , downstream and upstream of ICDs 34 , and actual pressures at selected locations 74 , along the completion liner 10 while flowing fluids of known ratios of oil to water to gas at known flow rates. The density and viscosity of these fluids, being a function of the oil to water to gas ratio, is also known and is included in the mapping database. By taking such measurements at a variety of different fluids and flow rates the flow performance characteristics 46 A, 46 B, 46 C can be accurately mapped.
[0015] Referring to FIG. 3 , a process for calibrating the mathematical model to a simulator is shown in flow chart 78 . Schematically, the simulator is configured similar to the completion configuration of FIG. 1 , the primary difference being that parameters affecting flow through each of the zones 42 of the simulator are controllable and selectable. As discussed, these parameters, among other things, include, fluid ratios of oil to water to gas, fluid viscosity, fluid density and flow rate. The mathematical model includes adjustable variables that when properly calibrated will accurately calculate temperature profiles that strongly correlate with temperature profiles measured. The model is based on mass, momentum and energy equations including Joule Thompson Effect equations.
[0016] In a first step 82 of the flow chart 78 , the simulator is run with selected fluid properties and selected flow rates. A temperature profile is measured with the DTS 30 in the second step 86 . In a third step 90 the mathematical model is run and a temperature profile is calculated. The fourth step 94 involves comparing the measured temperature profile to the calculated temperature profile. In the fifth step 98 , a decision is made as to whether the model is calibrated based on whether the measured and calculated temperature profiles match. If they do not match, the variables of the model are iterated and temperature profiles recalculated until they do match. Step 102 permits iteration of the foregoing steps until all desired operational conditions have been simulated and correlated with the mathematical model.
[0017] Referring to FIG. 4 , a process for diagnosing a completion operation by comparison to the mathematical model or the simulator is shown by flow chart 106 . In a first step 110 of the process the completion liner 10 is operated in a completion operation as schematically illustrated in FIG. 1 . A temperature profile is measured with the DTS 30 in a second step 114 . In a third step 118 the simulator is analyzed to find parameters that result in a matching temperature profile to that measured in the completion operation. Alternately, the model can be analyzed to find variables that result in a matching profile to that measured in the completion operation. A fourth step 122 attributes fluid properties and flow rates at matched settings from the model or simulator to actual completion operational conditions. With such knowledge the operator of the completion can perform the fifth step 126 and make adjustments to the completion, such as, through closure of valves, for example, to increase longevity of the completion and total production recoverable therefrom, as discussed above. Step six 130 allows the foregoing steps to be repeated over time as differences in the measured temperature profile change. Additionally, when changes to the measured temperature profile occur over time the process allows for diagnosing what has changed, i.e. fluid density, fluid viscosity, fluid oil to water to gas ratios or flow rates, so that appropriate corrective actions can be taken.
[0018] While the invention has been described with reference to an exemplary embodiment or embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the claims. Also, in the drawings and the description, there have been disclosed exemplary embodiments of the invention and, although specific terms may have been employed, they are unless otherwise stated used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention therefore not being so limited. Moreover, the use of the terms first, second, etc. do not denote any order or importance, but rather the terms first, second, etc. are used to distinguish one element from another. Furthermore, the use of the terms a, an, etc. do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item.
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A method of diagnosing flow through an inflow control device includes, producing or injecting fluid through an inflow control device, measuring temperatures near or at the inflow control device over time while producing or injecting fluid therethrough, and attributing temporal changes in temperature to changes in the fluid that is produced or injected.
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BACKGROUND
1. Field of the Invention
The present invention relates to pipe connectors, particularly, but not exclusively, for use in connecting sections of a pipe string for use in drilling. More specifically, it relates to the design of a pin and box connection of the type used in oil well tubing, casing, and the like. The invention provides a driveable threaded joint with dual mating shoulders and nose faces on the pin and box members. The dual mating shoulders substantially improve the joint's ability to withstand the intense axial compression loading that occurs when driving the pipe into the ground.
2. Description of the Related Art
Threaded connections between pipe members are typically made by providing one end of one pipe member with a male connector in the form of an externally threaded pin member, and providing one end of second pipe member with a female connector in the form of an internally threaded box member which receives the pin member. The pin and box members may be integral parts of their respective pipe members, or may be added thereto by welding or threaded engagement.
In the past, several different types of threaded connections have been designed to manage the extreme compressive, tensile, and bending forces to which the connection is exposed. Several prior art designs incorporate internal and/or external mating shoulders and end faces on the pin and box members. As used in this description, the terms "end face" and "nose face" are interchangeable. In several designs, the mating shoulders are used as torque shoulders to stop axial advancement of the pin and box members during make-up of the joint. In many designs, the shoulders are also used to provide resistance to axial compression during pile driving. Although many prior art designs use a combination of external and internal shoulders, these designs are usually configured such that only one of the shoulders will mate with its corresponding nose face upon initial make-up of the joint. These designs rely on either the external or the internal shoulder alone to mate with its corresponding nose face upon initial make-up of the joint, with the other shoulder remaining axially spaced from its corresponding nose face. The shoulder that is axially spaced from its corresponding nose face at initial make-up may not actually mate until final make-up of the joint, and in some designs may never mate, or only make contact with its corresponding nose face after the threads or other portions of the joint begin to yield. It is one object of the present invention to provide a threaded connection design that uses dual mating shoulders in which both internal and external shoulders mate with their corresponding nose faces during initial make-up of the joint. By providing dual mating shoulders, the shoulders share axial compression loads and provide the joint with improved performance in resisting the extreme axial compression loads encountered during pile driving.
In addition to providing resistance to axial compression loading, the dual mating shoulders in the present invention also function as torque shoulders to stop axial advancement of the pin and box members during make-up of the joint. In several prior art designs, the threaded connections use converging or wedge-type thread flanks rather than shoulders to act as a torque stop. As used in this description, the terms "converging" and "wedge-type" are interchangeable. In general, the pin and box threads in a converging thread flanks connection have progressively changing axial widths. The axial thread width of the pin member progressively decreases in the direction of the mouth of the pin member over the length of the thread structure. The axial thread width of the box member, on the other hand, progressively decreases in the opposite direction, such that a pair of pin and box members in the fully made up condition have a mutually wedging interfit. When converging threads are screwed together and wedging between the flanks takes place, the torsional resistance of the connection increases as the thread flanks act as a torque stop to halt axial advancement of the pin and box members. Several other threaded connection designs use tapered buttress-type thread forms that rely on radial interference to stop axial advancement of the pin and box members during make-up. In a tapered threads configuration, the radial interference fit forms as the crests and roots of the pin and box threads converge upon make-up of the joint
Although these thread form designs may succeed in providing a torque stop to halt axial advancement of the pin and box members during make-up, and also allow the threads to provide resistance to axial compression loading, taking pressure off any pin and box shoulders that may be used in the design, such use of an interference fit in the thread form has its drawbacks. Such uses of interference fits in the thread form may create high surface contact stress on the threads, which can cause galling and other localized thread damage that can severely limit the number of times the connection can be made up. In addition to limiting the repetitive use of the threads, the areas of high surface contact stress are susceptible to stress corrosion cracking, known as sulfide stress cracking, that occurs in petroleum well conduits. It is one object of this invention to provide a threaded joint connection that uses the shoulders of the pin and box members rather than the threads to function as a torque stop.
Conventionally, the pin member of the joint is tapered inwardly from the proximal end of the threaded portion to the distal end to mate with a similarly tapered female threaded box member. The taper facilitates entry of the pin member into the box member. Although the taper facilitates entry of the pin member, the wall thickness at the nose face end of a tapered thread form is often very small, especially in a flush joint configuration. Although the wall thickness at the shoulder of the pin and box member may be a substantial portion of the pipe wall thickness, with the shoulder occupying only a small portion of the wall, the wall thickness at the nose face end may be very small. This tapered configuration leaves the nose face end with a reduced wall thickness that must withstand the extreme axial compression during pile driving, as well as the extreme tensile, compressive, and bending forces to which the pipe is exposed downhole. It is one object of the present invention to provide a threaded pin and box joint in which the thread form is straight rather than tapered, to allow substantially the full one-half thickness of the wall of the pin and box members for sustaining compressive, tensile, and bending forces to which the pipe is exposed.
Although a tapered thread form may facilitate entry of the pin into the box member during make-up of the joint, tapered threads are still susceptible to cross-threading if the pin and box members are not properly aligned at the point of threaded engagement. One example of an apparatus designed to prevent cross-threading is found in U.S. Pat. No. 4,407,527, issued to Mr. Larry E. Reimert. The Reimert patent discloses a guide surface axially spaced from the internal threads of the box member to constrain the relative orientation between the pin and box members prior to threaded engagement. Although the Reimert design may be successful in preventing cross-threading, we have found that the guiding means may also be integrated into a mating shoulder configuration by axially spacing the nose face from the threads on the pin and box members. It is therefore one object of this invention to provide a guiding means for preventing cross-threading that is integrated into the shoulders and nose faces of a pin and box connection.
Several further objects of the present invention include providing means for preventing separation of the pin and box members, providing a thread form configuration that allows quick make-up of the joint, as well as several other objects and advantages that will become apparent from a reading of the attached claims and description of the preferred embodiments.
SUMMARY
These and other objects of the invention are attained by providing one end of one pipe member with a male connector in the form of an externally threaded pin member, and providing one end of second pipe member with a female connector in the form of an internally threaded box member which receives the pin member. The pin and box members may be integral parts of their respective pipe members, or may be added thereto by welding or threaded engagement. In the preferred embodiment of the present invention the pin and box members are integral parts of their respective pipe members, but it should be understand that the inventive design may also be used by mounting the pin and box members on their respective pipe members, or could be used in any of the various forms of collars or nipples known in the art featuring combinations of two box ends, two pin ends, or a box end with a pin end for threaded connection to appropriate ends of two pipe members sought to be mutually connected.
The threaded connection has dual mating shoulders in which both the internal and the external shoulder mates with its corresponding nose face during initial make-up of the joint. By providing dual mating shoulders, the shoulders share axial compression loads and provide the joint with improved performance in resisting the extreme axial compression loads encountered during pile driving. In addition to providing resistance to axial compression loading, the dual mating shoulders in the present invention also function as torque shoulders to stop axial advancement of the pin and box members during make-up of the joint. The thread form on the pin and box members is straight, rather than tapered, and does not have converging thread flanks, so the threads do not act as a torque stop, nor do they provide any substantial portion of the resistance to the extreme axial compression loading encountered during pile driving.
By providing dual mating shoulders that share axial compression loads, and by using a thread form having straight threads with uniform axial thread widths, the compressive loads on the pin and box members are transferred substantially through the shoulders rather than through the thread form. This configuration allows the shoulders to take the brunt of the axial compression loading and spare the threads. This configuration avoids high surface contact stress on the threads to prevent galling and other localized thread damage that would severely limit the number of times the connection can be made up. This configuration also helps to prevent stress corrosion cracking that occurs in areas of high surface contact stress that are exposed to sulfide in petroleum wells. The use of a straight thread form, rather than tapered, provides substantially the full one-half thickness of the wall of the pin and box members for sustaining compressive, tensile, and bending forces to which the pipe is exposed.
The straight thread form provides substantially the full one-half thickness of the wall of the pin and box members for sustaining the forces to which the pipe is exposed, but the ideal design of the pin and box members results in the wall thickness of the pin and box members being not precisely one-half the connector thickness. The optimal design provides that the pin and box members will be of equal strength. In order to design the pin and box members to be of equal strength, the pin and box members are configured to have equal annular cross-sectional areas. Because the inner diameter of the box member is aligned with the outer diameter of the pin member, the medial diameter of the box member is larger than the medial diameter of the pin member. To design the pin and box members to be of equal strength, the wall thickness of the pin member (the member with a smaller medial diameter) is increased to slightly greater than one-half the total wall thickness of the connection, and the wall thickness of the box member (the member with a larger medial diameter) is decreased to slightly less than one-half the total wall thickness of the connection. This optimal design provides substantially the full one-half thickness of the wall of the pin and box members for sustaining the forces to which the pipe is exposed, but also provides that the wall thickness of the pin and box members will be slightly other than precisely one-half the connector thickness, in order to provide that the pin and box members will be of equal strength.
The present invention also provides an integrated guiding means to facilitate entry of the pin into the box member. This integrated guiding means also functions as a self-centering means to align the pin and box members upon threaded engagement to avoid cross-threading. The integrated guiding and self-centering means is achieved by providing a design in which the shoulders and nose faces of the pin and box members are axially spaced from their most adjacent thread flanks. This configuration facilitates entry of the pin into box member, and constricts the relative orientation of the pin and box members at the point of threaded engagement, thus avoiding cross-threading.
Another feature of the present invention is the use of trapped thread flanks to prevent separation of the pin and box members. Conventional pin and box connections are susceptible to separation, often called "jumpout," when the connection is subjected to extensive axial tension and/or bending type loads. Under axial loading in tension, the pin member will shrink due to the "Poisson's" effect, and the box member will expand or "bell out," a condition known as "belling." To counteract these conditions, the thread form is provided with reverse angle load flanks, often referred to as "trapped" or "hooked" thread flanks. When the connection is subjected to axial loads in tension, the trapped load flanks cause the pin member to be pulled radially outward toward the box member, and the box member to be pulled radially inward toward the pin member. This feature secures the pin and box members together and prevents jumpout that could otherwise cause failure of the joint. By placing the box member in a state of hoop compression and the pin member in hoop tension, the trapped load flanks also serve to counteract induced assembly stresses and improve the joint's strength in sulfur environments that could otherwise make the joint susceptible to stress corrosion or hydrogen embrittlement fracture.
In addition to providing trapped thread flanks to prevent jumpout, the present invention provides trapped nose faces as well. Some prior art designs provide mating shoulders and nose faces having dissimilar angles so that the shoulder traps the nose face. One example is found in U.S. Pat. No. 4,822,081, issued to Thomas L. Blose. The Blose patent discloses a shoulder and nose face having dissimilar angles so that the shoulder traps the nose face and the nose face will not slip out upon the application of axial driving force. The present invention improves on this type of feature by providing a trapped nose face that is radially balanced to provide a radially balanced resistance to axial loading in compression. The radially balanced nose face efficiently distributes compressive forces and allows the nose face to withstand increased compressive loading without yielding.
Another feature of the present invention is a thread form configuration that provides a quick make-up of the joint. As can be seen in the drawings more fully described below, the preferred embodiment provides complete make-up of the joint in approximately one and one-half turns, a feature which offers great advantages in the field. The present invention will be more fully understood from the following description of the preferred embodiments, given by way of example only, with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a cross-sectional view of a tool joint constructed in accordance with this invention.
FIG. 2 shows a partial cross-section of a box member.
FIG. 3 shows a partial cross-section of a pin member.
FIG. 4 shows a partial cross-section of the threaded connection prior to make-up of the joint.
FIG. 5 shows a partial cross-section of the threaded connection in the fully made-up condition.
FIG. 6 shows the lower end of a pin member.
FIG. 7 shows a cross-section of the upper end of a box member.
FIG. 8 shows an inner diameter surface flat layout view of a box member.
DETAILED DESCRIPTION
FIG. 1 shows a cross-sectional view of a threaded connection according to the present invention with the pin and box members in a fully made up condition. FIG. 1 shows upper pin member 10 secured into a lower box member 11 to form a connection designated generally as 12 along axis 13. In a preferred embodiment, the threaded connection 12 has mating pin and box members having outside diameters and inside diameters substantially identical for each of the two members. This is commonly referred to as a flush connection when assembled. The flush connection is preferred in practice to avoid irregularities on the outer surface of the joint that cause resistance when driving the casing into the ground or when running the pipe through the well bore. Although the flush connection is preferred, the present invention is not limited to flush connections. Nor is the invention limited to the pin and box members being integral parts of their respective pipe members. The pin and box members may be integral parts of their respective pipe members, or may be added thereto by welding or threaded engagement. Still referring to FIG. 1, the threaded connection 12 includes pin member threads 16 that are adapted to be made-up with box member threads 17. Also shown in FIG. 1 are pin member nose face 18, box member shoulder 19, box member nose face 20, and pin member shoulder 21.
FIG. 2 shows a partial cross-section of the box member 11. The box member 11 includes box member threads 17 having box thread crests 26 and roots 27. The box member threads 17 also include stab flanks 28 and load flanks 29. The term stab flank refers to the side of the thread facing inwardly towards the joint, and the term load flank refers to the side of the thread facing away from the joint.
FIG. 3 shows a partial cross-section of the pin member 10. The pin member 10 includes pin member threads 16, which have pin thread crests 22 and roots 23. Also shown are pin member stab flanks 24 and load flanks 25.
FIG. 4 shows a partial cross-section of the threaded connection prior to final make-up. The figure shows the connection at the point of threaded engagement at which the first stab flank 30 on the pin member contacts the first stab flank 31 on the box member. In this position, one can see that the axial spacing between the nose face 18 and the first stab flank 30 on the pin member, and the axial spacing between the nose face 20 and the first stab flank 31 on the box member, form guiding surfaces 32 on the pin member and 33 on the box member. These guiding surfaces facilitate entry of the pin into the box member and function as self-centering means to align the pin and box members upon threaded engagement to avoid cross-threading. This configuration prevents cross-threading by constricting the relative orientation of the pin and box members at the point of threaded engagement.
FIG. 5 shows the threaded connection in a fully made-up condition. The tolerances of the thread form are designed so that when the joint is fully made-up, although the load flanks are in intimate contact, the clearances remain between the stab flanks to ensure that compressive loads on the pin and box members are transferred substantially through the pin and box shoulders rather than through the thread form. FIG. 5 shows stab flanks 24, 28, 30, and 31 as substantially square. Load flanks 25 and 29 form angle B with respect to a line drawn perpendicular to the longitudinal axis 13 of the connection. Load flanks angle B is preferably between 0 degrees and about 30 degrees, but may vary outside the upper limit of this range depending on the application. This is referred to as a "nonpositive" or "reverse" angle, or, if the angle is greater than 0 degrees, a "trapped" flank. A "trapped" flank also is known as a "hooked" thread. In this configuration, the thread crest extends over the thread root. The nonpositive angled load flanks help ensure that the threads do not slip out and become disengaged during axial loading in tension.
In addition to providing trapped thread flanks to prevent jumpout, the present invention provides trapped nose faces as well. FIG. 5 shows annular shoulders 19 and 21 trapping nose faces 18 and 20 as the threaded connection achieves its fully made-up condition. Nose faces 18 and 20 are radially balanced to provide a radially balanced resistance to axial loading in compression. The radially balanced nose face efficiently distributes compressive forces and allows the nose face to withstand increased compressive loading without yielding. The preferred embodiment represented shows a generally rounded nose face, but it should be understood that several alternative configurations such as a "V" shape or a square plug configuration may be used to achieve a radially balanced trapped nose face. The configuration may also be reversed such that the nose face receives a squared plug shoulder, or a rounded or "V" shape shoulder extension. Several alternative configurations such as these may be used without departing from scope and spirit of the invention.
FIG. 6 shows the lower end of a pin member 10. FIG. 7 shows a cross-section of the upper end of box member 11. Seal groove 44 is identified in FIGS. 6 and 7. Seal groove 44 on the pin member is located proximate the shoulder of the pin member and seal groove 44 on the box member is located proximate the shoulder of the box member. Each of these seal grooves may be used to contain an elastomer ring or metal seal to seal the pin and box members from leakage. The connection may be designed to include one or both of these seal grooves, or may be configured to not include either seal groove. Regardless of whether a seal groove is included in the design, the annular shoulder region 47 of the pin member functions as a seal against the annular end region 48 of the box member, and the annular shoulder region 49 of the box member seals against the annular end region 50 of the pin member. As described above, the annular shoulder region in each member functions as a guiding surface as well as a sealing surface.
FIG. 8 shows an inner diameter surface flat layout view of a box member. The preferred double lead thread form can be seen more clearly in this flat layout view. As can be seen from this figure, the threads are configured to allow the joint to be fully made-up in approximately one and one-half turns. This quick make-up feature provides significant advantages in the field. The present invention can be configured with a single lead thread form or a multiple (two or more) lead, but the preferred embodiment uses a multiple lead thread design because it has been found to provide a stronger connection. The multiple lead thread design also contributes to the quick make-up feature of the present invention because a double thread will advance twice as far as a single thread for each turn of the connection.
The above disclosure and description is illustrative and explanatory of the present invention, and it is understand that various changes in the method steps as well as in the details of the illustrated apparatus may be made within the scope of the following claims without departing from the spirit of the invention.
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A tool joint for use in connecting sections of pipe string for use in drilling. The joint is a pin and box connection of the type used in oil well tubing, casing, and the like. The driveable threaded joint has dual mating shoulders and nose faces on the pin and box members. The connection is designed so that compressive loads on the pin and box members are transferred substantially through the pin and box shoulders rather than through the thread form. The dual mating shoulders substantially improve the joint's ability to withstand the intense axial compression loading that occurs when driving the pipe into the ground.
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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 the benefit of priority of co-pending U.S. Utility Provisional Patent Application No. 62/010,356, filed 10 Jun. 2014, the entire disclosure of which is expressly incorporated by reference in its entirety herein.
[0002] It should be noted that where a definition or use of a term in the incorporated patent application is inconsistent or contrary to the definition of that term provided herein, the definition of that term provided herein applies and the definition of that term in the incorporated patent application does not apply.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] One or more embodiments of the present invention relate to cost effective structural rehabilitation and enhancement.
[0005] 2. Description of Related Art
[0006] Structural integrity of reinforced concrete structures is severely compromised due to spalling. In general, spalling is caused due to corrosion of the reinforcement, which is generally a reinforcing bar (or rebar for short) that is a metal or a metallic alloy most likely comprised of steel. When the reinforcement corrodes, it rusts (and crumbles) and therefore, expands in volume within the concrete structure, causing spalling. Additionally, loose pieces of rust particles (or crumbles) of the reinforcement also cause the concrete structure to lose its mechanical bond with the reinforcement, making the reinforcement ineffective. A further issue with corrosion of the reinforcement is that as the reinforcement corrodes into crumbling rust, the amount of reinforcement left is degraded, weakening the structural integrity of the reinforced concrete structure.
[0007] Conventional methods for repairing of spalled reinforced concrete structures vary greatly dependent on the amount of spalling of the reinforced concrete structure, the amount of corrosion of the reinforcement, and overall budgeted cost for repair. In general, the conventional repairing processes of spalled reinforced concrete structures involved many labor-intensive steps that are complex and require skilled labor, which adds to the overall cost of the structural rehabilitation.
[0008] In general, conventional methods of repair require excavation of the concrete structure to reach the corroded rebar. It should be noted that the size of the excavation (the cavity) should be sufficiently large to expose rebar beyond the corroded portion. That is, the excavation size should be large to reach the portion of the rebar where no corrosion is observed. Additionally, if the extent of the corrosion of the rebar observed is severe (e.g., where the integrity of the rebar is fully compromised, making it ineffective), the cavity should be further extended axially along the rebar to expose even more of the non-corroded portion thereof to enable augmentation of the rebar using well known splicing methodologies (detailed below).
[0009] Once the appropriate axial length of rebar is fully exposed, the formed cavity is cleaned from debris such as loose concrete. Further, the rebar is also completely cleaned from debris, loose rust, and any visible corrosion. That is, the rebar must be completely cleaned from any corrosion until a non-corroded portion of the rebar (the actually clean, bare steel portion) is reached. Therefore, to completely clean the rebar from rust or any corrosion, excavated cavity must also be of sufficient depth to enable access and reach to the entire surface of the exposed rebar from all directions and not just the “front” viewable portion. It should be noted that completely cleaning of the rebar from corrosion and removal of all rust (e.g., by scraping) is very time consuming and labor intensive. If the rebar is fully compromised, the compromised portion must be cut out completely and augmented.
[0010] The augmentation of a rebar is a complex, labor intensive, and time-consuming process that uses well known splicing methodologies, resulting in a lap spliced rebar. In general, the conventional methods for augmentation of a rebar require that the fully compromised portion of the rebar to be cut-off, and the remaining non-corroded exposed portions thereof be of sufficient axial length to allow for splicing (e.g., lap splicing). Therefore, the cavity itself must be enlarged to expose sufficient axial length of the non-corroded portion of the rebar to allow for proper lap splicing, resulting in continuous line of reinforcement that meet the required tensile strengths.
[0011] After cleaning the rebar and cavity from loose debris (rust or loose concrete), and if required, augmenting the rebar, corrosion protection (anti-corrosion) is applied to the rebar (and the augmented rebar). Thereafter, a primer (sealant/adhesive bonding material) is applied to the surface of the excavated cavity to seal and provide a bonding surface, which facilitates bonding of mortar (detailed below) with the surface of the cavity.
[0012] Thereafter, various methods are used to actually close off the cavity. For conventional methods, if the cavity is small, it is generally more cost effective to patch the cavity using well-known methodologies such as multi-lift patching, which itself is very time consuming, especially if the number of repairs is large. The quality of multi-lift patching process is generally poor due to potentially weak bonding properties between patched layers. Weak bonding properties are generally caused by variations in densities of the patching layers, temperature variation between a patched layer and a next layer, moisture variations, which affect viscosity of subsequent layers, etc.
[0013] In conventional methods, if the cavity is large, it is generally more cost effective to pour mortar into a larger excavated cavity to close off the exposed rehabilitated rebar. However, prior to pouring of the mortar, forming structures are used for forming the poured mortar to fill the excavated cavity and allow the mortar to be cured flush with exterior surface of the concrete structure, which requires time and materials to construct.
[0014] In general, the forming structures used to form (or shape) the mortar are comprised of structures that are built to fit over and cover the excavated cavity. Accordingly, if the forming structure is comprised of wood for example, the appropriate thickness and size of wood must first be selected. Thickness and size depend on the amount of load to be supported by the forming structure. In addition to selecting the correct thickness and size, the actual wooden forming structure constituting the wood form itself must be engineered and built to enable the correct forming or shaping of the mortar. This is especially difficult for non-flat surfaces such as reinforced concrete support columns that are generally cylindrical and hence, the wood forming structure must somehow be built to enable the mortar to be flush with the surface of the cylindrically or other odd-shaped structures.
[0015] After selection of the thickness, size, and building of the forming structure, a means must be devised to actually securely position and place the wooden forming structure over the cavity opening. This phase of the overall conventional rehabilitations process becomes complex if the opening is oriented at a direction where the forming structure must be secured against gravity. For example, the excavated cavity opening may be under a bridge where the opening faces “down” below the bridge or it may be vertically oriented at the side of support column. Accordingly, the process of securing the forming structure over the opening must account for supporting it in a secure position. As importantly, the securing means must also support the loads of both the forming structure and the mortar when poured within the cavity (detailed below). Therefore, the securing means must take the weight of the mortar in addition to the forming structure to support both.
[0016] Conventional methods of mounting and positioning forming structures depend on the type of material from which the forming structure is made (e.g., wood, steel, plastic, etc.). Normally, setting up a forming structure on a vertical or overhead surface requires support and mechanisms that include intricate bracing, wales, studs, stakes, pegs, screws, clamp supports, bars, etc. The work usually requires tying various pieces together, as well.
[0017] After designing a forming structure for the cavity and installing or mounting it to cover over the cavity, a hole is made on the forming structure itself to allow mortar to be poured within the excavated cavity via the hole. This phase becomes complex when the opening of cavity and or the hole is overhead (i.e., oriented such that the pour is against the gravity). Thereafter, there is a wait time until the mortar is cured after which, the forming structure must be removed. The removal of the forming structure is not a simple task as it may require heavy machinery and skilled labor.
[0018] It should be noted that in addition to the numerous labor-intensive operations to rehabilitate the reinforced concrete structure, additional care must be taken to ensure compatibility between materials used when rehabilitating the structure. For example, the type of corrosion protection material applied must be compatible with the type of mortar material used to fill the cavity or the type of primer used on the surface of the cavity. For example, the corrosion protection material used should not chemically interact with the mortar material, which may result in a degraded the integrity of both.
[0019] Accordingly, in light of the current state of the art and the drawbacks to current rehabilitation methods mentioned above, a need exists for a rehabilitation process that is much simpler, requires much less labor-intensive/skilled operations, and uses compatible material for most rehabilitation projects.
BRIEF SUMMARY OF THE INVENTION
[0020] A non-limiting, exemplary aspect of an embodiment of the present invention provides a method for rehabilitation and enhancement of structural integrity of a reinforced structures, comprising:
exposing beyond a deteriorated portion of a reinforcement where a non-deteriorated portion is visible;
[0022] covering a surround of the exposed reinforcement by a tensile member that is coupled with an exterior surface of the reinforced concrete structure; and
encapsulating the exposed reinforcement, with the encapsulation formed by the tensile member.
[0024] Another non-limiting, exemplary aspect of an embodiment of the present invention provides a system for rehabilitation and enhancement of structural integrity of a reinforced structures, comprising:
[0025] a tensile member that functions as a forming structure for forming a filler within a substrate;
[0026] the filler encapsulates a deterioriated reinforcement, binds to all surfaces with which the filler contacts, and provides compressive strength for the reinforced structure while the tensile member provides a tensile strength.
[0027] These and other features and aspects of the invention will be apparent to those skilled in the art from the following detailed description of preferred non-limiting exemplary embodiments, taken together with the drawings and the claims that follow.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] It is to be understood that the drawings are to be used for the purposes of exemplary illustration only and not as a definition of the limits of the invention. Throughout the disclosure, the word “exemplary” may be used to mean “serving as an example, instance, or illustration,” but the absence of the term “exemplary” does not denote a limiting embodiment. Any embodiment described as “exemplary” is not necessarily to be construed as preferred or advantageous over other embodiments. In the drawings, like reference character(s) present corresponding part(s) throughout.
[0029] FIG. 1 is non-limiting, exemplary illustration of a reinforced concrete structure with deteriorating reinforcement that is exhibiting spalling;
[0030] FIG. 2 is non-limiting, exemplary illustration of a substrate of the reinforced concrete structure with exposed reinforcement in accordance with one or more embodiments of the present invention;
[0031] FIG. 3A is non-limiting, exemplary illustration of a substrate with exposed reinforcement and cavity prepared in accordance with one or more embodiments of the present invention;
[0032] FIG. 3B is a non-limiting, exemplary illustration of various marking methods for proper rehabilitation of reinforce concrete structure in accordance with one or more embodiments of the present invention;
[0033] FIG. 4 is a non-limiting, exemplary illustration of substrate with an applied primer in accordance with one or more embodiments of the present invention;
[0034] FIG. 5 is a non-limiting, exemplary illustration of substrate with an applied primer and adhesive material in accordance with one or more embodiments of the present invention;
[0035] FIG. 6 is a non-limiting, exemplary illustration of substrate covered with tensile member in accordance with one or more embodiments of the present invention;
[0036] FIGS. 7A to 7C are non-limiting, exemplary illustration of vertically oriented substrate filled with filler in accordance with one or more embodiments of the present invention;
[0037] FIGS. 8A and 8B are non-limiting, exemplary illustration of overheard substrate filled with filler in accordance with one or more embodiments of the present invention; and
[0038] FIGS. 9A to 9C are non-limiting, exemplary illustrations of a method and system for full rehabilitation of reinforced concrete structures that exhibit extensive spalling in accordance with one or more embodiments of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0039] The detailed description set forth below in connection with the appended drawings is intended as a description of presently preferred embodiments of the invention and is not intended to represent the only forms in which the present invention may be constructed and or utilized.
[0040] It is to be appreciated that certain features of the invention, which may, for clarity, be described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the invention that may, for brevity, be described in the context of a single embodiment may also be provided separately or in any suitable sub-combination or as suitable in any other described embodiment of the invention. Stated otherwise, although the invention is described below in terms of various exemplary embodiments and implementations, it should be understood that the various features and aspects described in one or more of the individual embodiments are not limited in their applicability to the particular embodiment with which they may be described, but instead can be applied, alone or in various combinations, to one or more of the other embodiments of the invention.
[0041] One or more embodiments of the present invention provide method and system of rehabilitation processes for reinforced concrete structures that are much simpler, require much less labor-intensive/skilled operations, and use compatible materials for most rehabilitation projects. Non-limiting examples of reinforced concrete structures may include reinforced concrete structural members such as walls, slabs, beams, columns, etc. at various orientations (e.g., vertical, horizontal, inclined, etc.).
[0042] One or more embodiments of the present invention provide method and system that simplify repairs and enhance structural integrity of reinforced concrete structures that have compromised tensile and compressive strengths. Compromised or loss of tensile strength of reinforced concrete structure may be generally due to compromised or deteriorated reinforcement because of corrosion. Further, the deterioration of the reinforcement due to corrosion may lead to delaminated and or spalling of the reinforced concrete structures, leading to weakening of compressive strength.
[0043] One or more embodiments of the present invention provide method and system for strengthening and enhancement of a structure based on a combination of composite laminate forms constructed of a fiber reinforced polymer composite laminate and a corrosion resistant mortar. The strengthening and enhancement provided by the method and system of the one or more embodiments of the present invention include reinforcements that are less invasive than conventional reinforcement systems such as augmentation, replacement, splicing, or welding of reinforcing steel, or dowelling, at a fraction of complexity, space, and time taken to implement conventional systems.
[0044] The repair system in accordance with one or more embodiments of the present invention includes preferred use of a pre-cured fiber reinforced polymer (FRP) laminate bonded by adhesive paste on a prepared surface surrounding a cavity created from removing rust, dust, and loose pieces of concrete resulting from corrosion/rusting of the reinforcement inside the structure. The repair method and system also includes the use of waterproof and generally chemical resistant polymer mortar introduced inside the cavity directly through a port/hole made in FRP laminate after it is fixed to a surface, to completely fill up the cavity and encapsulate the exposed reinforcement, including the corroded portion. The FRP laminate replaces or enhances missing/compromised tensile strength component of reinforced concrete structure and filler enhances compressive and tensile strength components thereof, including providing corrosion protection for the reinforcement.
[0045] FIGS. 1 to 8B are non-limiting, exemplary illustrations of method and system for structural rehabilitation and enhancement of structural integrity of a reinforced concrete structure, and progressively illustrate a non-limiting, exemplary method of systematic rehabilitation and enhancement operations in accordance with one or more embodiments of the present invention. In particular, FIG. 1 is non-limiting, exemplary illustration of a reinforced concrete structure with deteriorating reinforcement that is exhibiting spalling, and FIGS. 7 , 8 A and 8 B are a non-limiting, exemplary illustration of a fully rehabilitated structure with an enhanced structural integrity in accordance with one or more embodiments of the present invention.
[0046] As illustrated in FIG. 1 , a method for rehabilitation and enhancement of structural integrity of a reinforced concrete structures commences with detecting a blemished surface 102 (e.g., spalling) of the reinforced concrete structure 104 , which as indicated above, may be a result of a corroded and rusting reinforcement 106 . As best illustrated in FIG. 2 , to rehabilitate and enhance the structural integrity of a spalling reinforced concrete structures 104 , blemished surface 102 must be excavated until reinforcement 106 is reached. That is, method for rehabilitation and enhancement of structural integrity of reinforced concrete structures 104 includes excavating a portion of the reinforced concrete structure 104 at the blemished surface 102 to reach reinforcement 106 of the reinforced concrete structure 104 , with the excavation forming a cavity 108 on the reinforced concrete structure 104 .
[0047] As illustrated in FIG. 2 , cavity 108 may have sufficient size wherein the reinforcement 106 is exposed from all sides as illustrated and further, the exposed and visible portions of reinforcement 106 includes at least a deteriorated portion 110 of reinforcement 106 and a non-deteriorated portions 112 . Well-known and conventional mechanical means such as chisel, grinder, hammer, wire brush, etc. may be used to remove all debris and lose pieces of concrete from cavity 108 to reach a sound surface 114 thereof (e.g., a solid surface with no loose particles). All surfaces 114 of cavity 108 may be cleaned from oil, grease, dust, residue, paint, and any other material not part of the substrate 118 .
[0048] As best illustrated in FIG. 3A , once exposed, reinforcement 106 is preferably cleaned by removing the loosely corroded portions thereof using conventional mechanical abrasions. It should be noted that cleaning reinforcement 106 from corrosions is optional and is not required. However, as detailed below, cleaning reinforcement 106 from loosely corroded portions (for example, loose and crumbling rust) is required and would further enhance the overall compressive strength of the rehabilitated reinforced concrete structure in accordance with one or more embodiments of the present invention. That is, in general, loose, crumbling rust may potentially lower the overall compressive strength of filler that would be encapsulating the remaining reinforcement 106 (detailed below), if crumbling rust is not removed. In other words, the filler would be encapsulating loose, crumbling rust rather than the clean reinforcement 106 , with the crumbling rust positioned between filler and reinforcement 106 , which would obviously lower compressive strength of the filler in relation to the remaining reinforcement. It should be noted that although loose, crumbling rust is removed, unlike conventional methods, it is generally preferred to only remove the crumbling, dusty rust of the reinforcement and need not remove all visible corrosion. This substantially reduces time and labor to clean the reinforcement 106 compared with time and labor required using conventional methods described above, where cleaning reinforcement 106 was required to a point where non-corroded, clean reinforcement steel is reached. Further as detailed below, with one or more embodiments of the present invention, there is no need or requirement to apply anti-corrosion to the reinforcement 106 because the filler used (detailed below) is waterproof and fully encapsulates the reinforcement 106 , isolating it from potential moisture penetrations and further corrosions.
[0049] In general, it is also preferred that cavity 108 and face area 116 be also cleaned from dust and loose particles. Dimensions of face area 116 are dictated by the dimensions of FRP laminate form required and used (as detailed below). To improve adhesion of Fiber reinforced Polymer (FRP) onto face area 116 as detailed below, surface defects of face area 116 may be reduced by reducing surface profile thereof to a maximum of about ⅛ inch or less (depending on application). Stated otherwise, visible protuberances in face area 116 may be smoothed by mechanical abrasion, and visible concave defects may be filled (or patched) with a material that has physical characteristics at least equal to that of substrate 118 . Other residues, oils, grease, coatings, sealers, and other contaminants may also be cleaned and if necessary, oil contamination may be removed using a degreaser, and the surface should in general be afterwards thoroughly rinsed free of degreaser and other chemicals such as etching material.
[0050] After a thorough preparation of substrate 118 , an FRP laminate form may be selected with appropriate shape and dimensions (thickness, length, width) corresponding to the extent and geometry of the spalled area as well as size, spacing, and loss of strength of the reinforcement. That is, size of reinforcement 106 and the extent of loss of reinforcement 106 at portion 140 due to corrosion may be determined to determine correct dimensions and strength properties required for FRP laminate form, which would be used to determine the minimum size of face area 116 required. In general, the FRP laminate form must at minimum cover over the entire cavity 108 and also the entire face area 116 (which may be flat, curved, or other configurations) to provide sufficient strength to replace or supplement the amount of strength of reinforcement 106 lost due to corrosion, and also ensure to maintain filler within cavity. Accordingly, once the extent of loss of tensile strength of reinforcement 106 is determined, the appropriate FRP laminate form, including correct dimensions required to supplement or replace any tensile loss is selected and thereafter, based on the determined FRP laminate form dimensions, size of the face area 116 is determined. It should be noted that as is well known, the fibers of the FRP laminate form used must be oriented parallel to the tensile strength provided (or that would have been provided) by the reinforcement (unidirectional or multidirectional).
[0051] As further illustrated in FIG. 3A and as part of continued preparation of substrate 118 , once cavity 108 is cleared, boundaries 120 for mounting and installation position of the FRP laminate form may be visibly marked on face areas 116 . Further, since cavity 108 would be covered by FRP laminate form prior to filling cavity 108 with the appropriate filler (detailed below), an additional marking 122 may be provided for one or more fill-point openings or holes (detailed below).
[0052] As illustrated in FIG. 3B , if face area 116 is horizontal and facing up, two perpendicular lines 301 and 305 may be drawn on the outside of the area that includes the cavity 108 and face area 116 . The lines 301 and 305 should be drawn in a manner that the intersection 313 of their traces is located generally over the deepest part of cavity 108 . If face area 116 is vertical or nearly vertical, crosswise lines 301 and 305 may be drawn outside of the area that includes cavity 108 and face area 116 such that the intersection of their traces 301 and 308 points to a spot immediately above a top extreme 307 of cavity 108 . If face area 116 is overhead and facing down, a first line 305 is drawn passing through one end of cavity of 108 and a projection of the deepest point of the cavity 108 onto plane of face area 116 , which (line 305 ) may be extended outside the face area 116 . Thereafter, a pair of crosswise lines 301 a and 301 b may be drawn on the outside of the area that includes cavity 108 and face area 116 such that an intersection 309 a of the lines 305 and 301 a points to a spot immediately under an end of cavity 108 . Further, the intersection 309 b (of lines 305 and 301 b ) points to a spot immediately under the deepest point of cavity 108 (providing a crosshair for the projected deepest point). If a reinforcement component happens to lie directly between the intersection 309 b and the deepest point of cavity 108 , the line 305 is redrawn to connect the end of cavity and a point over the deepest part of the cavity 108 and slightly away from of the rebar, so that the new path between intersection 309 b and the deepest part of the cavity 108 is clear of any rebar. Alternatively, the original set of lines may be kept unchanged and the insertion point is marked and drilled slightly away from the side of the line 305 and long the line 301 b so that the path between the insertion point and the deepest part of the cavity 108 is clear of any rebar obstruction.
[0053] After preparing substrate 118 and as best illustrated in FIG. 4 , a primer 124 is applied to coat the entire surface 114 inside cavity 108 , including the entire exposed portion of the reinforcement 106 and also the face area 116 . Primer 124 provides and enhances bonding between filler (detailed below) and cavity surface 114 , and also, reinforcement 106 . In addition, since the same primer 124 is used to prepare the adhesive material 126 (detailed below), application of primer 124 to face area 116 would further enhance bonding properties of the FRP laminate form with face area 116 . It should be noted that (as detailed below), given that filler itself has bonding capability and would fully pack inside cavity 108 and completely encapsulate reinforcement 106 , priming may not be necessary. However, since reinforcement 106 is inside cavity 108 and near surface 114 , it would not be disadvantageous to prime cavity 108 , reinforcement 106 , and surface area 116 , which would simply enhance bonding of the filler with all surfaces with which it contacts and encapsulates.
[0054] Primer 124 is a polymer that may be an epoxy resin comprised of well known thermosetting polymers, non-limiting, non-exhaustive listing of examples of which may include primer RN075 epoxy system from FRP SOLUTION, INC., or the like. The polymer primer 124 may also optionally be polyurethane or polyester based and need not be epoxy-based resin. In general, primer 124 used should be able to bind to surface 114 with sufficient strength that when cured, primer 124 cannot be mechanically separated from surface 114 without causing cohesive or other damages to the surface 114 . That is, mechanically removal of primer 124 will induce or cause cohesive failure on the surface 114 . Cured primer 124 should be solid, chemically inert, and impervious to water. Primer 124 should also be sufficiently strong to not peel, crack, wrinkle, shrink or undergo any other deformation due to movements, contractions, expansions or other thermal or mechanical effects that are generally accepted as “normal” for surface 114 . Primer 124 should be sufficiently viscous to allow for it to be conveniently applied as a liquid without dripping or sagging down surface 114 after application. In other words, primer 124 has a sufficiently low viscosity to allow primer 124 to coat every surface (and groove, pores, or cracks) of the surface 114 , but unlike water, it has sufficiently high viscosity to allow it to remain within the cavity 108 . It should be noted that primer 124 is fully compatible with other materials that are used. In fact, primer 124 is the same binder material that is used in making the filler (detailed below) for the cavity 108 , FRP laminate forms, and the paste adhesive (detailed below).
[0055] Primer 124 may be applied at a rate that it may coat the entire surface 114 uniformly and without blushing. Primer 124 may be applied by spraying or with roller/brush made of solid materials that are inert to primer 124 . Afterwards, there is a wait time until primer 124 is not fluid but still tacky before moving to the next operations, which includes operations related to installing the FRP laminate form.
[0056] As illustrated in FIG. 5 , as part of the installation operation of the FRP laminate form, after a thorough preparation of substrate 118 , a layer of prepared adhesive material 126 is applied on face areas 116 around cavity 108 that will be covered with FRP laminate form. Adhesive material 126 may be spread evenly and smoothly, and ensure that there are no voids, pinholes, bubbles, bumps or other surface irregularities present in the adhesive paste 126 applied to face areas 116 . Adequate amount of adhesive material 126 is applied to face areas 116 to ensure complete bonding between the FRP laminate (detailed below) and face areas 116 .
[0057] Adhesive material (paste) 126 should bind to face areas 116 with sufficient strength that when cured, adhesive paste 126 cannot be mechanically separated from the substrate surface 116 without causing cohesive or other damages to the substrate. That is, mechanical removal of adhesive material 126 will induce or cause cohesive failure on the face areas 116 . The cured adhesive material 126 should be solid, generally chemically inert, and impervious to water. Adhesive material 126 should also be sufficiently strong to not peel, crack, wrinkle, shrink or undergo any other deformation due to movements, contractions, expansions or other thermal or mechanical effects that are generally accepted as “normal” for substrate 118 . Adhesive material 126 should be sufficiently viscous to allow for it to be conveniently applied as a paste without dripping or sagging down face areas 116 after application. During and after curing, adhesive paste 116 must firmly hold and fixedly maintain in place the FRP laminate form that is mounted over it.
[0058] Adhesive material (paste) 126 used in accordance with one or more embodiments of the present invention is a well-known off the shelf product made of high strength polymers, for example, epoxy resin paste adhesive material comprised of thermosetting polymers in non-sag form that include added dry ingredients that increase a viscosity of the epoxy resin to form an epoxy resin paste. Non-limiting, non-exhaustive listing of examples of adhesive material 126 that may be used may include GS 100 epoxy from FRP SOLUTIONS, INC or the like. As with the primer 124 , adhesive material 126 is also fully compatible with other materials that are used immediately over or under it.
[0059] As best illustrated in FIG. 6 , thereafter, and within the working time of the applied adhesive 126 , FRP laminate form 130 is mounted on face areas 116 to entirely cover cavity 108 . That is, FRP laminate form 130 is placed over face areas 116 covered with adhesive paste 126 within the area markings 120 for application of FRP laminate form 130 , with fibers of the FRP 130 oriented in the proper direction. Preferably, fibers are oriented parallel to the direction of reinforcement 106 inside cavity 108 . FRP laminate 130 is pressed onto adhesive 126 and face areas 116 using adequate pressure to ensure an intimate contact between FRP laminate 130 and adhesive 126 . Using a hard roller, FRP laminate form 130 may be firmly pressed on to adhesive paste 126 to drive the excess adhesive 126 out and create an intimate contact and bond between FRP laminate form 130 and adhesive paste 126 . Using a spatula, paint knife or other similar tools, the oozed adhesive 126 from face area 116 may be removed to maintain a neat surface. Care should be taken not to disturb adhesive paste 126 by rotating, twisting, lifting FRP laminate form 130 or other actions that may introduce voids in the bond area or create variations in adhesive paste 126 thickness. In general, the assembled FRP laminate 130 is left intact until adhesive 126 is hardened.
[0060] FRP laminate form 130 is a well-known off-the-shelf composite product constructed of fibers of carbon or glass, steel, or other high strength materials, which are impregnated and bonded together with a high strength impregnation polymer resin that is compatible with adhesive 126 and filler (detailed below). The FRP laminate form 130 , which constitutes the forming structure as well as the tensile member in accordance with the present invention, may comprise of material (composite material) made of polymer matrix reinforced with fibers. In other words, FRP laminate form 130 is comprised of well-known reinforcing fibers embedded and cured in well-known binder polymer matrix resin using well known methodologies. Non-limiting, non-exhaustive listing of examples of FRP laminate form 130 that may be used may include C-Clad, SC352, etc. from FRP SOLUTIONS, INC., or the like. It should be noted that the binder matrix used is comprised of a polymer matrix with a component thereof being the same material that is used for primer 124 . Non-limiting, non-exhaustive listing of examples of a polymer matrix resin used is RN075 epoxy from FRP SOLUTIONS, INC, or the like. Non-limiting, non-exhaustive listing of examples of fibers used for forming an FRP may include FC061 from FRP SOLUTIONS, INC, or the like. FRP and all its constituent components may be obtained from third party manufacturers such as FRP SOLUTIONS, INC. Further details related to FRP laminate form 130 (for example, use of unidirectional laminate forms versus multi-directional laminate forms, use dry versus wet layup, etc.) used is disclosed in U.S. Pat. No. 8,479,468 to Abbasi, the entire disclosure of which is expressly incorporated by reference in its entirety herein. FRP laminate form 130 may be prefabricated in various shapes, dimensions, and thicknesses suitable for most common situations. In general, the number of layers of fiber that are laid over one another (and cannot be physically reduced or removed once fabricated) may determine the thickness of FRP laminate form 130 .
[0061] Depending on the manufacturing process, the fibers used in constructing the FRP laminate 130 can be either in the form of free strands or woven/bonded fabrics. In the case of using woven/bonded fabrics, a single or multiple layers of fabric may be needed for constructing the FRP laminate 130 to a desired thickness. Also, in the case of using woven/bonded fabrics, only one layer of lighter weight fabric may be placed in a general 90-degree fiber orientation to the main fibers to prevent the cured sheet from splitting and breakage during handling and installation. If required by the design and engineering, the fibers can also be laid in equal amounts in both 0- and 90-degree, or any other amount and directions.
[0062] When permissible, the fibers—in fabric form—may be saturated with high strength impregnation polymer to form an uncured and unseeded form of FRP laminate 130 , which may be applied to surface 116 by the well-known wet layup method. In the case of using the wet layup method, after cavity 108 and reinforcement 106 are cleared and cleaned as previously stated, face areas 116 surrounding cavity 108 is cleaned and primed with the same high strength impregnation polymer matrix used in saturating the fibers of the FRP in the welt layup method (detailed in the incorporated U.S. Pat. No. 8,479,468 to Abbasi). While the primed face areas 116 are tacky and prior to being hardened, and while the fibers saturated with the high strength impregnation polymer matrix still in the wet state, the saturated fibers of fabric (the uncured form of the FRP laminate 130 ) may be pressed on face area 116 to form a cover over cavity 108 . The saturated fibers of fabric (in the uncured form of the FRP laminate 130 ) is placed on face areas 116 in a manner that it is bonded completely to face areas 116 all around cavity 108 to the extent determined by design and engineering requirements. In the case that the wet layup application requires using multiple layers of saturated fabrics in the uncured form of the FRP laminate 130 , the subsequent layers are applied in the manner that each new layer is in complete and intimate contact and bond with the previous layer. The final assembly is left to cure before proceeding to subsequent operations.
[0063] In general, manufactured FRP laminate forms 130 are very hard, smooth and non-porous and hence, it is preferred if they are modified so that their smooth surfaces may adhere to structures and other finishes. Accordingly, in the non-limiting, exemplary instance illustrated in FIG. 6 , prior to complete curing of adhesive paste 126 , FRP laminate 130 may be coated with an additional layer of the high strength impregnation polymer matrix resin used in its manufacture, non-limiting, non-exhaustive listing of examples of which may include the above mentioned polymer matrix resin RN075 epoxy, or the like. While the additionally applied resin is still liquid, one side of the FRP laminate 130 may be seeded by sprinkling of an adequate amount of clean and dry fine silica aggregate onto it. As indicated above, since the high strength polymer matrix resin applied to the surface of FRP laminate 130 becomes very hard, smooth and non-porous, the seeding process provides a suitable surface for other additional finishes to be applied over the installed system, such as paint, protective coating, plaster, other architectural or protective finishes, etc. The opposite, unseeded side of the cured FRP laminate 130 sheet may be lightly abraded to dull the surface for better bonding with the polymer adhesive paste 126 . It should be noted that FRP laminate 130 can be manufactured without being seeded. In such cases, both sides of the FRP laminate 130 can be lightly abraded (either at the manufacturing plant or installation site).
[0064] Bonding FRP laminate form 130 with structure 104 using adhesive paste 126 enables the tensile properties of FRP to be transferred to structure 104 . Accordingly, FRP laminate form 130 functions as a forming structure for the filler (as detailed below) and adds tensile strength to compensate for loss in tensile strength due to deteriorated reinforcement 106 .
[0065] In general, reinforcements 106 are positioned near periphery or edges 142 ( FIG. 1 ) of structures 104 and not at the center thereof. Accordingly, an FRP generally compensates for the reinforcement 106 closest thereto. That is, the tensile force that was supposed to have been absorbed and counter-acted by particular reinforcement 106 is now absorbed and counteracted by the installed or mounted and fixed FRP. In fact, FRP may completely replace the reinforcement and hence, no further need is required for augmentation of a reinforcement that is fully compromised (as was required by conventional systems). The number and orientations of reinforcement(s) determine FRP thickness and fiber orientations or tensile strength orientation direction of FRP. That is, if two or more reinforcements are used that are oriented crosswise, an FRP may be used that has fibers that are oriented crosswise to mimic tensile strength orientation directions of the original reinforcements.
[0066] Upon curing adhesive 126 , or curing of all layers of FRP laminate 130 applied by wet layup (as detailed above), filling point mark(s) are placed on FRP laminate form 130 at the intersection of lines marked as detailed above. As best illustrated in FIG. 7A , a hole 132 is made in FRP laminate form 130 (with care not to damage FRP laminate form 130 ) at the marked filling point 122 . The position of the hole 132 is chosen to be at the highest part of cavity 108 when face areas 116 is vertical. If FRP laminate form 130 is in vertical position, hole 132 is drilled at an angle such that drill travels slightly downward towards the inside of cavity 108 . The size of hole 132 is chosen to allow introducing filler 134 inside cavity 108 without compromising the strength and integrity of FRP laminate 130 . Thereafter, sufficient quantity of filler 134 is prepared and introduced inside cavity 108 through hole 132 . Non-limiting, exemplary methods of introducing filler 134 inside cavity 108 may include the use of injection or pumping with manual or automated devices such as hand operated pumps, caulking guns, injection pumps, grout pumps, and other similar devices.
[0067] Filler 134 used is waterproof and generally chemical resistant polymer mortar introduced inside cavity 108 directly through a port/hole made in FRP laminate 130 after it is fixed to surface 116 , to completely fill up cavity 108 and encapsulate the exposed reinforcement 106 , including the corroded portion 110 and partially exposed non-corroded portions 112 . This prevents moisture from reaching reinforcement 106 , which prevents further corrosion and deterioration of reinforcement 106 . As indicated above, getting rid of corrosion is not important because reinforcement 106 is encapsulated within the waterproof filler 134 , which prevents further corrosion and also, any loss in tensile strength due to corrosion of reinforcement 106 is more than compensated by FRP laminate form 130 . However, waterproof filler 134 must fully cover any corroded portion 110 , including a small portion 112 of non-corroded reinforcement 106 . The depth of cavity 108 also need not be so deep to enable access for removing rust from reinforcement 106 , but must be sufficient to allow filler 134 to fully encapsulate reinforcement 106 from all sides.
[0068] It should be noted that filler 134 used fully encapsulates reinforcement 106 and therefore, reinforcement 106 need not be rehabilitate to the level required by conventional processes where the cleaning of all corroded portion must be full to reach the clean steel part of the rebar. The reason for this is because reinforcement 106 will be prevented from further corrosion due to it being encapsulated by the waterproof mortar 134 . This also means that there is no need or requirement to apply anti-corrosion to existing rebar. In other words, waterproof filler 134 encapsulating reinforcement 106 would actually protect reinforcement against moisture and hence, future oxidation and corrosion.
[0069] Filler 134 is a well-known off-the-shelf polymer-based mortar that is self-leveling and has high compressive and tensile strength properties, with compressive strength thereof at least equal to or greater than that of the substrate 108 . Non-limiting, non-exhaustive listing of examples of filler 134 that may be used may include HCM-25R from FRP SOLUTIONS, INC or the like. As with primer 124 , adhesive material 126 , and FRP constituents, filler 134 is also fully compatible with other materials that are used.
[0070] In general, filler 134 used should be able to bind to primed surface 114 with sufficient strength that when cured, filler 134 cannot be mechanically separated from primed surface 114 without causing cohesive or other damages to primed surface 114 . That is, mechanically removal of filler 134 will induce or cause cohesive failure on primed surface 114 . Cured filler 134 should be solid, chemically inert, and impervious to water. Filler 134 should also be sufficiently strong to not peel, crack, wrinkle, shrink or undergo any other deformation due to movements, contractions, expansions or other thermal or mechanical effects that are generally accepted as “normal” for substrate 118 . Filler 134 should be sufficiently viscous to allow for it to be conveniently applied (introduced into cavity 108 ) and to allow filler 134 to fill every surface (and grooves or cracks) of the cavity 108 and reinforcement 106 (if any is left). In other words, filler 134 should be viscous enough to allow for it to be conveniently placed in cavity 108 and fill all empty spaces in the cavity and bind to all contacting surfaces. It should be noted that filler 134 is fully compatible with other materials that are used and with which it comes to contact. In fact, filler 134 uses the same binder material that is used in making the primer for the cavity 108 , FRP laminate forms, and the paste adhesive. the filler has a tensile strength that is greater than the tensile strength of the concrete structure, but less than the tensile strength of FRP.
[0071] As illustrated in FIG. 7B , if cavity 108 is to be filled by gravity filling, the tip of the manual or powered grout pump nozzle may be inserted inside cavity 108 thorough hole 132 and filler 134 is pumped until cavity 108 is filled completely, and the filler 134 is in complete, intimate contact with all surfaces 114 inside cavity 108 , including reinforcement 106 , and FRP laminate form 130 . Once cavity 108 is filled, nozzle tip may be removed and hole 132 in FRP laminate form 130 may optionally be plugged with a plastic cap 156 . The plug/cap 156 is a well-known off the shelf product, non-limiting examples of which may include rubber, plastic, wood, and other appropriate materials. The cap 156 may be optionally cut off after filler 134 is cured.
[0072] As best illustrated in FIG. 7C , if cavity 108 is to be filled by pressure grouting method, conventional injection port 150 a /b are inserted within respective opening 152 a /b and the prepared filler 134 is injected inside cavity 108 in well-known method using well known injection equipment, with port 150 b being the ingress port and 150 a , the egress port. Ports 150 a /b are a well-known off the shelf product, non-limiting examples of which may include surface mounted ports, drill ports, weeping type, one way port, check valve types, and others. Once cavity 108 is filled and filler is 134 oozing out of the egress port 150 a , the injection may be stopped and ports 150 a /b closed and/or capped to allow filler 134 to cure. Once filler 134 is cured, injection ports 150 a /b may be cut off and removed without damaging FRP laminate form 130 .
[0073] It should be noted that as an intermediate operation, as soon as cavity 108 is filled with filler 134 , a brief vibration may be applied to the outside surface of FRP laminate 130 to drive out any air entrapped inside filler 134 . Vibration also helps the filler 134 to settle, flow, and reach all surfaces 114 inside cavity 108 . When filler 134 is completely cured, the plug 132 or the port 150 a /b may be removed and the hollow area of the hole 132 and 152 a /b may be patched with an adequate amount of prepared and uncured adhesive 126 or other suitable material and left to cure before applying any finishes as needed. If needed, FRP laminate form 130 or a parts thereof may further be patched (e.g., due to uneven surfaces, voids, etc.) with compatible patching material, and apply finish as required.
[0074] As best illustrated in FIG. 8A , in the case of overhead cavities, a venting port 164 is inserted inside the hole 152 b that is away from the end of the cavity 108 and bored into the FRP laminate from 130 through the point marked by intersection 309 b ( FIG. 3B ). The venting port 164 has a tube 166 with sufficient length to reach the deepest point of cavity 108 . The tube 166 is placed in cavity 108 so that its tip barely touches surface 114 of cavity 108 thereby creating a minute gap between surface 114 of cavity 108 and the tip of tube 166 . The purpose of this port 164 is to prevent air entrapment and ensure that cavity 108 is completely filled with filler 134 as indicated by filler 134 oozing out of this port 166 (as indicated by the egress pointing arrow at the egress port 150 b ). When the cavity 108 is totally filled, both of the ports 150 a /b are closed and filler 134 is left to cure.
[0075] With respect to FIG. 8B in particular, in this non-limiting, exemplary instance, a hole 160 is drilled into structure 104 so as to connect cavity 108 (spalled side) to opposite side surface 162 of structure 104 . Hole 160 is drilled either from inside cavity 108 or into surface 162 of structure 104 opposite to cavity 108 opening. Filler 134 is then introduced into cavity 108 via this hole 160 by either gravity feeding or pressure injection by hole 160 from surface 162 .
[0076] FIGS. 9A to 9C are non-limiting, exemplary illustrations of a method and system for full rehabilitation of reinforced concrete structures that exhibit extensive spalling in accordance with one or more embodiments of the present invention. The method and system illustrated in FIGS. 9A to 9C includes similar corresponding or equivalent components, interconnections, functional, operational, and or cooperative relationships as the method and system that is shown in FIGS. 1 to 8B , and described above. Therefore, for the sake of brevity, clarity, convenience, and to avoid duplication, the general description of FIGS. 9A to 9C will not repeat every corresponding or equivalent component, interconnections, functional, operational, and or cooperative relationships that has already been described above in relation to method and system that is shown in FIGS. 1 to 8B .
[0077] As illustrated in FIGS. 9A and 9B , there are instances where the reinforced concrete structure 104 is so severely damaged that the structure 104 does not have a sufficient surface area where it may be constituted as the face area 116 for secure connection of the FRP laminate form as described above. In fact, reinforcements 106 and any confinement rebars (or hoops, stirrups, etc.) 168 are generally exposed. Accordingly, a platform is created that serve the function of the above mentioned face area 116 to connect and secure an FRP laminate form 130 to such severely damaged structures. In this non-limiting, exemplary instance, the FRP laminate form 130 is a bidirectional FRP to supplement or replace bidirectional reinforcement (i.e., reinforcement 106 and confinement bars 168 ). Therefore, as illustrated in FIG. 9C , a system and a method for rehabilitation and enhancement of structural integrity of a reinforced concrete structure is provided that includes studs 202 (that function support to form a platform to hold FRP laminate 130 ) with a first end 204 associated with surface 114 of cavity 108 . The studs 202 have sufficient height 206 wherein their second end 208 extends out of cavity 108 , providing an elevated surface (e.g., platform) that is generally in continuity (or aligned) with original substrate 222 (non-deteriorated, non-spalled) areas at the exterior of cavity 108 to enable connection of a FRP laminate form 130 to second end 208 of studs 202 . Finally, the FRP laminate forms 130 are fastened to second end 208 of stud 202 with the remaining processes the same as above. In this non-limiting, exemplary embodiment, the studs 202 are comprised of spacers (or bushings, sleeves, etc.) 210 within which are inserted fasteners (e.g., bolts, FRP anchors, etc.) 212 with a first end 214 of fasteners are secured into surface 114 of cavity 108 . FRP laminate form 130 includes connection holes that receive the free ends 216 of the fasteners, with a washer and nut 218 connecting or fixing the FRP laminate form 130 to the spacers 202 via the free ends 216 of the fasteners 212 (if fastener used is a bolt). It should be noted that the first end 214 of the fasteners are secured to surface 114 of cavity 108 by first providing an opening in the surface 114 , and doweling the fastener (placing the fastener in hole, and further securing it in the hole with use of adhesive material). Non-limiting example of FRP anchoring is disclosed in U.S. Pat. No. 8,479,468 to Abbasi.
[0078] Although the invention has been described in considerable detail in language specific to structural features and or method acts, it is to be understood that the invention defined in the appended claims is not necessarily limited to the specific features or acts described. Rather, the specific features and acts are disclosed as exemplary preferred forms of implementing the claimed invention. Stated otherwise, it is to be understood that the phraseology and terminology employed herein, as well as the abstract, are for the purpose of description and should not be regarded as limiting. Further, the specification is not confined to the disclosed embodiments. Therefore, while exemplary illustrative embodiments of the invention have been described, numerous variations and alternative embodiments will occur to those skilled in the art. For example, different types of polymers may be used depending on engineering and design specifications. The thickness, length, width, types, and physical characteristics of FRP laminate 130 may vary according to engineering and design criteria. Non-limiting, non-exhaustive exemplary list of physical characteristics for filler 134 that may vary may include additive fiber type, polymer component, ratios of mix, manufacturer, etc. Filler 134 may be varied in accordance with engineering and designed to meet all specifications. Non-limiting, non-exhaustive exemplary list of physical characteristics for filler 134 that may vary may include the required compressive strength, required tensile strength, modulus of elasticity, use of fiber in the mix. Further, for horizontal applications ( FIG. 3B ), FRP laminate form 130 is first applied as described for the vertical and overhead applications, thereafter, an opening is made through the FRP laminate form 130 at intersection 313 , and filler 134 is filled via the opening until cavity 108 is completely filled in its entirety. Finally, if needed, FRP laminate form 130 or parts thereof may further be patched (e.g., due to uneven surfaces, voids, etc.) with compatible patching material, and apply finish as required. Such variations and alternate embodiments are contemplated, and can be made without departing from the spirit and scope of the invention.
[0079] It should further be noted that throughout the entire disclosure, the labels such as left, right, front, back, top, bottom, forward, reverse, clockwise, counter clockwise, up, down, or other similar terms such as upper, lower, aft, fore, vertical, horizontal, oblique, proximal, distal, parallel, perpendicular, transverse, longitudinal, etc. have been used for convenience purposes only and are not intended to imply any particular fixed direction or orientation. Instead, they are used to reflect relative locations and/or directions/orientations between various portions of an object.
[0080] In addition, reference to “first,” “second,” “third,” and etc. members throughout the disclosure (and in particular, claims) is not used to show a serial or numerical limitation but instead is used to distinguish or identify the various members of the group.
[0081] In addition, any element in a claim that does not explicitly state “means for” performing a specified function, or “step for” performing a specific function, is not to be interpreted as a “means” or “step” clause as specified in 35 U.S.C. Section 112, Paragraph 6. In particular, the use of “step of,” “act of,” “operation of,” or “operational act of” in the claims herein is not intended to invoke the provisions of 35 U.S.C. 112, Paragraph 6.
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The present invention discloses system and method for rehabilitation and enhancement of structural integrity of a reinforced concrete structures, comprising exposing beyond a deteriorated portion of a reinforcement where a non-deteriorated portion is visible, covering a surround of the exposed reinforcement by a tensile member that is coupled with an exterior surface of the reinforced concrete structure, and encapsulating the exposed reinforcement, with the encapsulation formed by the tensile member.
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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 divisional application. The related application is currently pending under Ser. No. 09/179,227, dated Oct. 26, 1998. Such application, as amended, is hereby incorporated herein by reference.
BACKGROUND OF THE INVENTION
It is a common production practice to release various dissolvable materials into oil and gas wells. These materials are often stick shaped.
For example, an oil and gas well's production of hydrocarbons is often terminated by the presence of produced formation water in the well. This occurs when a column of such water has a hydrostatic pressure higher than the pressure of the producing formation. To prevent this from occurring, it is common to periodically release "soap" sticks into the well which, when dissolved, will decrease the hydrostatic pressure of the fluid column to an extent which allows the formation to continue to flow.
The actual release of such sticks is typically done by hand, although mechanical stick release devices are now in use. One such stick release mechanism is found in U.S. Pat. No. 5,188,178, which teaches a device and related methods, involving an enclosed magazine holding several sticks. It has the ability to rotate each stick into a position to be dropped into the well. A disadvantage present in this device is that the entire top of the magazine enclosure must be removed for loading the sticks into the magazine. Furthermore, the top of the device is flat which is not an optimum design for handling high pressure in an enclosure.
An electric motor is suggested for rotating the magazine in this device, which fails to take advantage of the available well gas pressure for this purpose.
Other disadvantages of this device is a lack of total isolation from well pressure during the typical reloading process, and the absence of an emergency shut down feature for events of unusually high well pressure. The device is isolated from well liquids only, using a check valve which is not pressure sensitive. The check valve also introduces a reduction of internal diameter in the path followed by the stick.
Another known device, that of J & J Oilfield & Electric Service, utilizes well gas pressure to automatically open a number of valves positioned in series between each pipe nipple section in a vertically oriented single line. The valves are opened from the bottom up, and pipe nipple holds two sticks of material, with the higher section dropping sticks through the previously emptied lower section. A disadvantage is that the number of releases is limited to approximately two, because of the undesirable height associated with additional sections. Similarly, the person reloading the device must climb a significant height to load the device.
What is needed is an automatic stick launcher for releasing such sticks, which has a simple method of loading, total isolation of the magazine from well pressure and liquids during reloading, optimum housing structural integrity, adequate provisions for higher pressure wells, an ability to operate almost entirely from available well pressure, and an emergency shut down system in the event the well over pressures.
SUMMARY OF THE INVENTION
My device is an automatic stick launcher for an oil and gas well, that provides a simple method for loading the sticks, optimized housing structural integrity, provisions for higher pressure wells, the ability to operate from available well pressure, and an emergency shut down system in the event the well over pressures.
My invention includes an apparatus for periodically inserting sticks of various materials into an oil or gas well, with a magazine being enclosed by a housing, where the magazine has two or more stick chambers which are shaped to receive the sticks and also orient the sticks in a substantially vertical position. The magazine is rotatable within the housing which, in some preferred embodiments, has a generally dome-shaped top and bottom. The housing top has a closable entry port, which is aligned with only one of the stick chambers and is sized to allow one of the sticks to move into the stick chamber through the housing top entry port. The housing also has a bottom exit port which is in communication and alignment with the well, such that a stick may pass from one of the stick chambers into the well through the housing bottom exit port. A shaft is attached to the magazine which rotates with the magazine, with the shaft extending through the top or bottom of the housing in various preferred embodiments. Periodic rotation means are provided for rotating the shaft such that the stick chambers are sequentially positioned in stationary alignment with the housing bottom exit port. Both automatic and manual periodic rotation means are provided in various preferred embodiments. In one preferred embodiment the periodic rotation means are initiated in response to timer means. My invention contemplates a battery for powering the timer and a solar panel for charging the battery.
My invention includes a preferred embodiment wherein the periodic rotation means is powered by an electric motor.
My invention contemplates a magazine having stick chambers shaped to receive more than one stick per stick chamber and to position the same in a stacked, substantially in line configuration.
In one preferred embodiment of my invention, the shaft is rotated by pneumatic ratchet means which automatically rotates the shaft such that the stick chambers are sequentially positioned in stationary alignment with the housing bottom exit port. The pneumatic ratchet means, in one preferred embodiment, includes a shaft rotation gear attached to the shaft, a double acting cylinder actuator in which alternating pressure in the cylinder causes a rod to move between an extended position and a retracted position with respect to the cylinder. A rod connecting arm is pivotally attached to the shaft and the rod's exposed end, and a ratchet pawl is attached to the rod connecting arm and is positioned to engage and rotate the shaft rotation gear upon return of the rod from its extended position to its retracted position. The rod is moved between positions by actuator pressure means which alternately pressurizes and depressurizes the cylinder causing the rod to move between its extended and retracted positions. My invention contemplates using either gas well pressure or an independent source of pressure to power the actuator pressure means.
In one preferred embodiment of my invention, well pressure reduction means is provided to reduce the pressure of the well gas prior to pressurization of the actuator.
In another preferred embodiment, released gas recovery means are provided to contain gas released by the actuator during depressurization.
In various preferred embodiments of my invention, the initiation of shaft rotation by various means is in response to low differential pressure in the well, low static pressure in the well, a predetermined decrease in well production rate, remote signals, automatic dialing codes enabling control by telephone from a remote location, and other variable processes.
My invention includes preferred embodiments wherein housing seal means such that well gas is contained within the housing during intervals between stick releases.
In another preferred embodiment of my invention, well isolation means are provided for isolating the housing top entry port from well gas pressure. In one preferred embodiment, this apparatus is a bottom valve between the housing bottom port and the well. Various preferred embodiments include pressure sensitive check valves, liquid sensitive check valves, and ball valves for use in this regard. A preferred embodiment of my invention includes pressure equalization means, such that pressure communication can be alternately established and broken between the well and the housing while the bottom valve is closed.
Emergency isolation means are provided in one preferred embodiment which automatically isolates the housing from well gas pressure when the well gas pressure exceeds a predetermined level.
Another preferred embodiment of my invention includes housing pressure relief means for venting pressure from within the housing when such pressure exceeds a predetermined level.
My invention includes a process for periodically inserting one or more sticks of various materials into an oil or gas well, including the steps of (1) providing an apparatus having a magazine with individual stick chambers, with one or more of the magazine stick chambers containing one or more sticks, the apparatus being attached to the well, (2) rotating the magazine until one of the sticks is released into the well, and (3) repeating the foregoing step, if desired, for one or more additional sticks until a predetermined number of sticks have been released into the well.
My invention includes an apparatus for periodically inserting one or more sticks of various materials into an oil or gas well having stick positioning means for receiving and holding the sticks and positioning the sticks in a substantially vertical orientation, well entry means providing a path for the stick to exit the apparatus and enter the well, and periodic rotation means for moving each stick into position for insertion into the well.
My invention includes a process for loading sticks of various materials into an automatic stick launcher of the type having a magazine rotatably mounted within a housing, the magazine having a plurality of stick chambers for holding the sticks prior to periodic release into an oil and gas well, the process including the steps of providing the stick launcher with a permanently enclosed housing top having an entry port aligned with only one stick chamber, isolating the magazine from well pressure, if necessary, by opening the entry port, inserting one or more sticks into the aligned stick chamber, by rotating the stick chamber until one of the additional stick chambers becomes aligned with the entry port, by repeating, as necessary, until the desired number of stick chambers are loaded, closing the entry port, and reestablishing well pressure to the magazine, if necessary.
Another preferred embodiment of my invention includes an apparatus for loading sticks of various materials into an automatic stick launcher of the type having a magazine rotatably mounted within a housing, the magazine having plurality of stick chambers for holding the sticks prior to periodic release into an oil and gas well, having isolated stick chamber loading means such that access through the housing top is limited to only one stick chamber at a time.
My invention includes a preferred embodiment including an apparatus for loading sticks of various materials into an automatic stick launcher of the type having a magazine rotatably mounted within a housing the magazine having a plurality of stick chambers for holding the sticks prior to periodic release into an oil and gas well, this preferred embodiment having a housing top, the housing top being permanently attached to the housing, the housing top having an entry port, the housing top entry port being positioned for sequential alignment with each of the stick chambers as the magazine is rotated, the housing top entry port being of sufficient width to allow the passage of one of the sticks, and housing top entry port access means for opening and closing the housing top entry port. In one preferred embodiment, the top port access means is a ball valve and a nipple, the nipple connecting to the housing top entry port and the ball valve.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an oblique view of the device installed on an oil and gas well.
FIG. 2 is an oblique view of the device installed on an oil and gas well from a second angle.
FIG. 3 is a cutaway exposing the top portion of the magazine.
FIG. 4 is a cutaway exposing a side view of the magazine, and a stick positioned within a stick chamber.
FIG. 5 is a cutaway exposing the lower portion of the magazine.
FIG. 6 is an oblique view of a portion of the ratchet mechanism with the rod extended.
FIG. 7 is an oblique view of a portion of the ratchet mechanism with the rod retracted.
FIG. 8 is an oblique view of a portion of the ratchet mechanism which includes the solenoid attachments to the double acting cylinder actuator.
DESCRIPTION
A preferred embodiment of the device 10 is shown in position on a typical gas well in FIGS. 1-2. The housing 12 has a generally domed shaped housing top 14 and a generally domed shaped housing bottom 16. The housing top 14 is accessible through a housing top port nipple 18 which, in this preferred embodiment, is a 2 inch I.D. nipple made from Schedule 80 steel. A top ball valve 20 is attached to the housing top port nipple 18 for alternately opening or closing the housing top port nipple 18. A full port 2 inch I.D. ball valve is utilized for the top ball valve 20, in this preferred embodiment. Sticks are loaded through the top ball valve 20, through the housing top port 18, and into the housing 12.
The housing bottom 16 is accessible through a housing bottom port swage 22, which, in this preferred embodiment, is a 21/2 inch I.D. to 2 inch I.D. swage made of Schedule 80 steel. For servicing convenience a hammer union 24 is attached to the housing bottom port swage 22. A 2 inch I.D. nipple 26, made from Schedule 80 steel, extends downwardly from the hammer union 24 to a bottom ball valve 28 for alternately opening and closing the housing bottom port nipple 22 for passage of a stick. A full port 2 inch I.D. ball valve is utilized for the bottom ball valve 28 in this preferred embodiment, although pressure sensitive or liquid sensitive check valves can be used in other preferred embodiments. Both the top ball valve 20 and the bottom valve 28 are rated at 2000 psi in this preferred embodiment.
An equalizer line 30 is provided in this preferred embodiment, with a first equalizer valve 32 and a second equalizer valve 33, positioned on the equalizer line 30. The equalizer line 30 is attached to an equalizer port 34 on the housing bottom 16, establishing fluid communication between the housing 12 and the well 36 at a well swage 38 which is attached to the bottom ball valve 28. In this preferred embodiment, the equalizer line 30 is 3/8 inch stainless steel tubing rated at 3000 psi, and the equalizer valves 32,33 are needle valves rated at 6000 psi.
FIGS. 3-5 depict the housing 12 portion of the device 10, with various portions of the housing 12 removed to allow a view of the magazine 50, the magazine 50 being formed from the joinder of the 11 stick chamber sections 52 to a magazine top plate 54 and a magazine bottom plate 56, with a shaft 58 attached to the magazine 50 and extending upwardly through a housing top shaft port 60, the housing top shaft port being sealed by a shaft packing assembly 62. The magazine 50 is supported by a spindle and bearing assembly 64 for rotation within the housing 12. In this preferred embodiment the housing 12 is constructed from Schedule 80 steel. The magazine top and bottom plates 54,56 are constructed from 3/16 inch mild steel plate. The stick chamber sections 52 are 13/4 inch I.D., gauge 10 stainless steel. The shaft 58 is formed from a cold roll steel axle spindle rated at 2000 pounds. The shaft packing assembly 62 is a pinion gear head assembly, and the spindle and bearing assembly 64 is rated for 2000 pounds. These materials, although chosen for this preferred embodiment, could be replaced by numerous other combinations of various grades of steel, aluminum, fiberglass and other materials well known to persons skilled in the art.
A representative stick 66 is shown in a partial cutaway view of a stick chamber 52 in FIG. 4. The housing bottom port 68 is also depicted in relation to the housing bottom port nipple 22.
FIGS. 6-8 depict the ratchet mechanism by which the shaft 58 is rotated in this preferred embodiment. A double acting cylinder actuator 80 is mounted on a hinge 81 and is positioned such that a rod 82 is extendable across the housing top 14. Pivotally attached to the rod 82 is a rod connecting arm 84. The rod connecting arm 84 also connects to the shaft 58, although the shaft 58 rotates independently of the rod connecting arm 84. Attached to the shaft 58 is a sprocket 86. Rotatably attached to the rod connecting arm 84 is a ratchet pawl 88 which is urged against the sprocket 86 by the tension of the spring 90. A nut 92 is attached to the shaft 58 for rotation of the shaft 58 by a wrench, ratchet and socket, or other hand tools. Manual rotation allows each stick chamber 52 to be positioned beneath the housing top port nipple 18 for stick 66 insertion during the loading procedure. By manually lifting the ratchet pawl 88 from the sprocket 86, the shaft 58 can be rotated in a reverse direction, allowing for partial reloads where only some of the stick chambers 52 need reloading.
In this preferred embodiment, the rod 82 extends from, or retracts into, the double acting cylinder actuator 80 in response to pressure alterations within the double acting cylinder actuator 80. Well gas provides the pressure to operate the double acting cylinder actuator 80. The ends of the double acting cylinder actuator 80 are alternately pressurized and depressurized with a solenoid 94 regulating the changes. The alternating pressure causes the rod 82 to move from its normally extended position (FIG. 6) to its retracted position (FIG. 7). This movement causes the ratchet pawl 88 to engage and rotate the sprocket 86, which in turn rotates the magazine 50 which places a stick chamber 52 above the housing bottom port 22, causing the stick to be released into the well 36. In this preferred embodiment, the solenoid 94 then alternates the pressure after about 10 seconds, causing the rod 82 to return to its extended position. FIG. 8 depicts the double acting actuator cylinder 80, and the solenoid 94.
The housing top 14 has a pressure regulator port 100, by which pressurized well gas is passed through a pressure regulator port needle valve 101, then provided to and reduced by a first pressure regulator 102. The pressurized well gas is again reduced in a second pressure regulator 104. Pressure monitoring gauges 106,108 and a pressure relief valve 110 are also provided. In this preferred embodiment, the first pressure regulator 102 reduces the well gas pressure to within 50-150 psig, while the second pressure regulator 104 reduces the pressure to within 5-35 psig. The optimum operating pressure in this preferred embodiment is expected to be 30 psig. In this preferred embodiment the pressure regulator port needle valve 101 is a 1/4 inch needle valve rated at 6000 psi, the first pressure regulator is a 1/4 inch regulator (model 1301-F-2) rated at 6000 psi, the second pressure regulator 104 is a 1/4 inch low pressure regulator rated at 255 psi. The pressure relief valve 110 is a 1/2 inch orifice, TEFLON seat relief valve set at 1440 psi. Persons skilled in the art will be familiar with other well known components by which the well gas pressure may be similarly regulated.
The well gas, having its pressure reduced, is routed through a stainless steel line 111 to a solenoid 94 which alternately pressures either end of the double acting cylinder actuator 80 causing the rod 82 to either extend or retract. When the rod 82 is extended, the ratchet pawl 88 engages the sprocket 86 such that when the rod 82 retracts, the sprocket 86 is rotated. Rotation of the sprocket 86 causes the magazine 50 to rotate, which in turn causes a stick chamber 52 to be positioned over the housing bottom port 68, allowing the stick 66 within such stick chamber 52, to be released through the housing bottom port 68.
In this preferred embodiment, the solenoid 94 alternates the pressure in response to a signal from a timer 114 and then automatically reverses after a predetermined amount of time, although it is contemplated within my invention that any variable process may be monitored and utilized to signal the solenoid 94, including other preferred embodiments where the solenoid 94 responds to an automatic telephone dialing code, remote signals, a low differential pressure, a low static pressure, or changes in flow rate.
In this preferred embodiment, the timer 114 is powered by a battery 116, the same being charged by a solar battery charger 118. This battery and charging mechanism can be used for various power requirements which may arise in other preferred embodiments, as well.
Other preferred embodiments of my invention include additional means for powering the timer 114, e.g. AC electrical supply or ordinary batteries.
In an alternative preferred embodiment (not shown) an emergency isolation valve is positioned between the bottom ball valve 28 and the well 36. The emergency valve is also positioned in fluid communication with the well gas, and closes upon sensing pressure in the well gas which is higher than a predetermined level.
In another alternative preferred embodiment (not shown) the magazine is rotated by rotation means such as an electric motor, instead of the ratchet mechanism discussed above. This would involve a coupling to the magazine shaft at the top or bottom.
In another alternative preferred embodiment (not shown) the pneumatic ratchet mechanism is powered by an independent source of air or gas (hydrocarbon gas or otherwise), other than the well gas.
In another alternative preferred embodiment each stick chamber 52 is sized to hold two or more sticks 66 in a substantially stacked, in-line position within the stick chamber 52.
Although the present invention has been described in considerable detail with reference to certain preferred and alternate embodiments thereof, other embodiments are possible. Accordingly, the spirit and scope of the claims should not be limited to the description of the embodiments contained herein.
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An apparatus, and related methods, for automatically releasing sticks of various materials into oil and gas wells. The apparatus has an enclosed magazine which has several chambers for the sticks. The magazine rotates on a shaft when a sprocket on the shaft is engaged by a rod moving from an extended to a retracted position. The rod movement is actuated by a double acting cylinder which is powered by well gas. When rotated the magazine positions the next chamber above a bottom exit port which is aligned with the well, causing the stick to be released into the well. During the stick loading process, only a single valve need be opened to enable the sticks to be loaded into the stick chambers. The magazine is rotated by hand after each stick is loaded.
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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 pertains to retaining a screen frame assembly in a window, more particularly to a corner bracket used in constructing a standard screen frame, in which the bracket is designed for retaining the screen frame assembly in a window by latching it in the window frame.
It is common in the manufacture of a window screen frame assembly, to insert two legs of a 90 degree angle corner bracket, into adjacent ends of hollow frame bars which comprise the four sides of the frame.
One example of the manufacture is described in U.S. Pat. No. 4,506,478, patented by Anderson, Mar. 26, 1985. The description may be found at column 14 line 43 through column 15, line 9, as it applies to FIGS. 29-34 of that patent.
In the present invention, the corner bracket has a pair of crossed tracks and a track-engaging, sliding, frame retainer latch bolt, and the window frame which is to receive the screen is adapted for receiving the front end of the latch bolt.
2. Description of the Prior Art
U.S. Pat. No. 410,217 patented Sep. 3, 1889 by D. Stone describes a screen frame having a corner-piece with a tubular opening in one of its arms. The tubular opening is provided with a bolt that is thrown out by a coiled spring behind the bolt within the tube. A stem projecting up through a slot in the corner-piece is topped off by a finger piece for drawing the bolt back into the tubular opening against the spring tension. The window frame molding includes sockets for receiving the front end of the bolt at various heights along the window frame.
U.S. Pat. No. 1,238,854 patented by W. Watson, Sep. 4, 1917, describes a screen frame corner-piece having a tubular barrel in one of its two legs. The tubular barrel is provided with a bolt that is thrown out by a coiled spring behind it, within the tube. The rear end of the bolt has a rod extension that passes through the center of the spring and extends through an opening in the tube behind the spring. The portion of the rod beyond the tube is pivotally attached to a finger lever that is pivotally attached to, and passes through, the frame rail in which the first leg is located. Pulling on the lever draws the bolt back into the barrel against the spring tension.
SUMMARY OF THE INVENTION
It is one object of the invention to provide a screen frame assembly corner bracket which has a frame retainer bolt.
It is another object of the invention to provide a screen frame corner bracket with retainer bolt in which the bolt may be installed in one of two possible directions within the bracket.
It is another object that the retainer bolt can be installed in the bracket in one of two possible directions in a track which the bolt body engages directly in either an extended or retracted position of the bolt with respect to the bracket.
It is yet another object that the bolt body engages the track with a bifurcated spring molded as one piece with the bolt.
It is still another object that the corner bracket with springly track engaging bolt, installable within the track in one of two directions consist of only two elements which can be shipped as separate items, and assembled in the bracket in the direction desired just before insertion of the bracket leg containing the bolt into the hollow frame bar, and that the bolt may not be removed after insertion of the leg into the hollow frame bar.
It is another object that the limit of extension of the bolt be controlled by the track, and the limit of withdrawal of the bolt back into the bracket be limited by the hollow frame bar.
Other objects and advantages of the invention will become apparent from the ensuing description of the invention.
The bracket of the present invention has first and second legs. Each leg has a track that is adapted for receiving a bolt, the front end of which can be extended from the bracket. The tracks intersect one another and each track traverses the bracket and terminates at an opening in a respective wall of the bracket.
The intersection of the tracks is spaced from the two termination walls.
The bolt has spring means adapted for bearing radially on the track which receives the bolt. Preferably, the spring means comprises bifurcated legs at the back of the bolt. A finger on one of the legs may be received in a detent on each of the tracks.
The corner bracket and legs with tracks are molded in a single element, and the bolt and spring means are also molded in a single element.
A first stop means on each of the tracks limits the forward travel of the bolt by direct engagement with the bolt.
A second stop means on each of the first and second legs limits forward travel of a frame bar on the leg by direct engagement with the leg.
Means on the bolt is adapted for limiting the rearward travel of the bolt by direct engagement with a frame bar engaging the second stop means on the leg receiving the bolt.
One of the tracks is open to the front side of the bracket sufficiently to receive the bolt through the front side. The frame bar prevents removal of the bolt by way of the front side opening when the frame bar is engaging the second stop means.
BRIEF DESCRIPTION OF THE DRAWINGS
In order that the invention be more fully comprehended, it will now be described, by way of example, with reference to the accompanying drawings, in which:
FIG. 1 is an elevated front view of a right front corner portion of a screen frame assembly, including screen, with a screen frame corner bracket according to the present invention, installed in adjacent hollow frame bars.
FIG. 2 is a front view of a screen frame corner bracket according to the invention.
FIG. 3 is a front view of a track-engaging sliding latch body according to the invention.
FIG. 4 is an exploded view of a screen frame assembly of two hollow frame bars, the corner bracket shown in FIG. 2, and the track-engaging, sliding latch bolt shown in FIG. 3.
FIG. 5 is an elevated rear view of an assembled set of the hollow frame bars, corner bracket and sliding latch bolt shown in FIG. 4.
FIG. 6 is an exploded view of the assembly shown in FIG. 5.
FIG. 7 is a side view in vertical cross section of a screen assembly having the present invention, being inserted in a window frame.
FIG. 8 is a side view in vertical cross section of the screen assembly of FIG. 7, with the bolt of the present invention retaining the screen frame assembly in a window frame.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Before explaining the invention in detail, it is to be understood that the invention is not limited in its application to the detail of construction and arrangement of parts illustrated in the drawings, since the invention is capable of other embodiments and of being practiced or carried out in various ways. It is also to be understood that the phraseology or terminology employed is for the purpose of description only and not of limitation.
Referring to FIG. 1, screen frame assembly 20 includes corner bracket 24, top hollow frame bar 26, and right side hollow frame bar 28, and insect screen cloth 30. Frame retainer bolt 36 is shown with the front 40 of the bolt extended forward, beyond face 46 of outside corner 52 of corner bracket 24. The frame retainer bolt can be moved forward or back as indicated by double ended arrow 38 between the extended position shown, and a retracted position in which front face 44 is approximately coplanar with top face 46 of corner bracket 24.
Referring to FIGS. 2 and 3, screen frame corner bracket 24 shown in FIG. 2, has two tracks, track 50 and 54, crossing through one another at 90 degrees. When bracket 24 is located at the upper right hand corner of a screen frame as shown in FIG. 1, track 50 receives the frame retainer bolt shown in FIG. 3, in horizontal reciprocally sliding motion in which front face 44 of bolt 36 extends from the bracket beyond face 48 of outside corner 52, similarly to the above description with regard to face 46, or track 54 receives the bolt in vertical reciprocally sliding motion. The bolt may be gripped by cross-bar stop 56, or by finger ring 58 for drawing it forward or back in the track. Corner 52 comprising surfaces 46 and 48 preferably has a shape to fit the inside corner of the window in which the present invention system will be installed. Outside corner 52, therefore, will usually be a right angle corner as shown, but may be rounder or otherwise angled as desired.
Left and right forward stop shoulders 62 and 64 on bifurcated left and right legs 66 and 68 of frame retainer bolt 36 engage shoulders 72 and 74 of track 54, limiting the forward most travel of bolt 36 in track 54. In like manner shoulders 62 and 64 engage shoulders 76 and 78 on track 50 when the bolt is moving in track 50.
Divergent left and right fingers 82 and 84 on legs 66 and 68 bearing on the track generally normally to the length of the track engage left and right detents respectively 86 and 88 of track 54 to hold the bolt in the forward most position until it is drawn back by cross-bar stop 56 or finger ring 58.
In like manner, left and right detents 92 and 94 of track 50 hold the bolt in the forward most position when it is in track 50.
The bolt is held in the rearward most position in track 54 by engagement of fingers 82 and 84 in track 54 left and right detents 102 and 104.
In like manner, left and right detents 106 and 108 of track 50 hold the bolt in the rearward most position when it is in track 50. Detent 106 falls at the end of shortened wall 114, as the end of leg 116 is angled to ease insertion of the leg into a hollow frame bar.
Leg 118 is squared off at the end, but may also be angled if desired.
Turning now to FIG. 4, assembly comprises the steps of sliding retainer bolt 36 into track 50 of leg 116 at the distal end of the track, or pressing it into the track at the front side 112 of the bracket. Similarly, it is slid or pressed in to track 54 of leg 118. In FIG. 4, the bolt is aligned for locating slidingly in track 54.
Once the bolt is in place in track 54, leg 118 is inserted into opening 122 of hollow frame bar 28 until the end 126 of right side hollow frame bar 28 comes to a stop at shoulder plane 128. The inner surface of front wall 132 of bar 28 covers front face 134 of bolt 36 behind cross-bar stop 56, preventing the bolt from leaving track 54.
When bolt 36 is drawn back, it is stopped at the rearmost position by engagement of rear face 136 of cross bar stop 56 with end 126 of hollow bar 28. In like manner, end 138 of hollow bar 26 limits the rear most movement of bolt 36 by engagement of face 136 when the bolt is in track 50.
In the assembly as seen from the rear, in FIG. 5, front 40 of frame retainer bolt 36 is extended forward, beyond top face 46 of corner bracket 24. Right side hollow frame bar 28 and left side hollow frame bar 26 butt up fully respectively against shoulder planes 128 and 130 of legs 118 and 116 which are not shown in this figure.
Rolled seams 142 and 144, and pin 148 form continuous right angle channel 152 for a rubber bead strip that is usually used to hold insect screen cloth in a screen frame assembly. Position pin 154 on back side 160 of the bracket keeps the screen frame assembly from sliding about during installation or removal of the screen frame assembly from a window frame, as will be later described with respect to FIG. 7.
Referring to FIG. 6, ridges 156 and 158 accommodate grooves 164 and 166 respectively.
Screen assembly 172, FIG. 7, includes top and bottom hollow frame bars 174 and 176, right side frame bar 178, and insect screen cloth 182, held in surrounding channel 184 by rubber bead strip 186. The frame retainer bolt is drawn back by cross-bar stop 56, and is not in sight. The screen assembly is about to be installed in window frame 192. Upper and lower position pins 194 and 196 will closely fit into openings 198 and 200 respectively, preventing excessive movement of the screen assembly when urging force is applied by fingers to cross-bar stop 56.
In FIG. 8, screen assembly 172 is installed in window frame 192 with pins 194 and 196 received in openings 198 and 200. Cross-bar stop 56 has moved front 40 of frame retainer bolt 36 up into recess 204 to retain the top of screen assembly 172 in the frame. The lower part of screen assembly 172 being retained in the window frame by recess 206. In a screen assembly which has the present invention at the corners, one corner bracket and one frame retainer bolt may be assembled at any corner for bolt extension in one of two different directions, preferably 90 degrees apart.
As may be seen from the above drawings and description, the present invention provides for a screen frame corner assembly of as few as two elements, a latching screen corner comprising a universal corner bracket having a bolt that can be installed for extending in two different directions and which engages the track in which it moves with bifurcated spring legs molded as one with the bolt including track engaging fingers on the legs, and which is assembled integrally with the frame bars at any corner of the frame without change in design of the bracket or bolt bodies.
Although the present invention has been described with respect to details of certain embodiments thereof, it is not intended that such details be limitations upon the scope of the invention. It will be obvious to those skilled in the art that various modifications and substitutions may be made without departing from the spirit and scope of the invention as set forth in the following claims.
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A bracket for a screen frame corner has a bolt for latching the frame in a window frame, and intersecting tracks for the bolt, one track in each leg, from which the bolt may be extended from the bracket. Bifurcated radial spring legs on the bolt grip the track. The bolt may be inserted in a track by a front opening in bracket, and a frame bar mounted on the leg prevents removal of the bolt from the track. The corner bracket and the bolt with spring are each, molded single elements.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to well tools and more particularly to ported sliding sleeve devices for controlling fluid communication between flow conductors in wells.
2. Description of the Prior Art
Well tools having lateral ports through their walls to provide fluid communication between their interiors and the regions exterior thereof and controlled by sliding sleeve valves slidable therein between port-opening and port-closing positions have been used for many years to provide a fluid communication path between, for instance, the tubing and the surrounding annulus so that treating or loading fluids could be circulated through the well for such purposes as treating or killing the well, or the like.
Examples of such sliding devices and related tools are found in the following U.S. patents.
______________________________________2,947,363 3,115,188 3,292,7062,999,546 3,211,232 3,871,4503,051,243 3,244,234______________________________________
U.S. Pat. No. 2,947,363 issued Aug. 2, 1960 to T. H. Sackett et al. and discloses a ported sliding sleeve device in which the sliding sleeve valve is initially in port-open position to provide a passage through the wall of the device for the transfer of fluids between the interior of the pipe string to the exterior thereof. The sleeve valve is moved to closed position by dropping a ball or the like into the conduit and allowing it to come to rest on the sliding sleeve, after which the conduit is pressurized to force the ball and sliding sleeve down to closed position where it is held thereafter by a deformed washer engaging serrations on the sleeve's exterior surface. The bore of the sliding sleeve is necessarily restricted.
U.S. Pat. No. 2,999,546 issued Sept. 12, 1961 to G. G. Grimmer et al. and discloses a sliding sleeve device connected in a main flwo conductor and having a lateral opening connected to a smaller conductor or barrel extending alongside it. Its sliding sleeve is connected to a sliding valve in the smaller conduit. When the sliding sleeve is shifted, the sliding valve in the outer conduit is shifted. In this manner, flow through the lateral ports of both conduits is controlled. The sliding sleeve is shiftable by a tool lowered through the main flow conductor.
U.S. Pat. No. 3,051,243 issued Aug. 28, 1962 to G. G. Grimmer et al. and discloses a ported sliding sleeve device connectable in a well flow conductor. A sliding sleeve valve inside is shiftable between positions in which it either closes or opens the lateral ports in the wall of the body to either allow or prohibit the passage of fluids through the lateral ports as for circulation between the tubing and the casing. The sliding sleeve is shifted by use of a shifting tool lowered into the tubing, as on a wire line, in the manner shown and described in the patent and well known in the industry.
The device of the present invention is an improvement over the device of U.S. Pat. No. 3,051,243, and this patent, together with U.S. Pat. No. 3,211,232 next to be discussed, is believed by applicant to be the most pertinent prior art with which he is familiar.
U.S. Pat. No. 3,211,232 issued Oct. 12, 1965 to G. G. Grimmer and discloses a device like that covered by U.S. Pat. No. 3,051,243 just discussed but with added features. This sliding sleeve initially has its lateral ports closed by pump-out plugs 43 which can be expelled by applying a predetermined high pressure thereto through the tubing. The sliding sleeve is initially in open position, and a shifting device 130, 140 is locked therein. During completion of the well, the pump-out plugs prevent communication through the lateral ports so long as the pressure in the tubing does not exceed that exterior thereof by an appreciable amount. The pressure exterior of the tubing can be much higher than that inside without consequence since the pump-out plugs are supported against inward movement. When it is desired to circulate fluids through the lateral ports, the pressure in the tubing is increased until one or more of the pump-out plugs move outwardly, breaking the band or wire 48 which surrounds the device to retain these plugs in place. There are usually four of these plugs, but it has been common experience for less than the total number to be expelled because once one, or two, or three of them are expelled, the differential pressure may be so reduced that the remaining plug(s) cannot be expelled. Further, one or two of the pump-out plugs could be so close to the inner wall of the casing that they cannot be expelled. This could easily happen in crooked or deviated well bores where the tubing may lean against the wall of the surrounding casing. When it is desired to shift the sliding sleeve closed, a ball or plug is dropped down the tubing bore and allowed to settle atop the shifting device, thus plugging the bore through the shifting device. Pressure is then increased above the ball or plug, and the sleeve valve is forced down to closed position. The plug and shifting device are in this manner expelled and dropped to the bottom of the well. The pump-out plugs withstand considerable pressures from exterior of the tubing, but are responsive to and are expelled only by pressure within the tubing.
U.S. Pat. No. 3,244,234 issued to D. H. Flickinger on Apr. 5, 1966 and discloses a sliding sleeve device having a ported body and a sleeve controlling flow through the ports. In each of the two forms shown and described, the sleeve valve is moved to open position responsive to high exterior pressure. In one form the sleeve valve is inside the body and is spring biased toward closed position. In the other form, the sleeve valve surrounds the body. Both of these embodiments permit inward flow but prevent outward flow.
U.S. Pat. No. 3,292,706 issued to G. G. Grimmer et al. on Dec. 20, 1966 and discloses a well safety device utilizing a sliding sleeve device which admits annulus pressure to a safety valve mounted within the tubing. When the annulus pressure becomes excessive, the safety valve closes. The differential pressure which then develops across the closed safety valve in the tubing and moves the sliding sleeve valve to closed position to shut off communication from the annulus to the safety valve.
U.S. Pat. No. 3,871,450 issued to Marion B. Jett et al. on Mar. 18, 1975 and discloses a sliding sleeve device in which the sliding sleeve means surrounds dual side-by-side mandrels connectable to dual parallel tubing strings. A port in each mandrel communicates with a different variable-volume pressure chamber formed between the exterior of the mandrels and the interior of the sliding sleeve means. Pressuring one mandrel causes the sleeve to open the lateral flow ports and pressuring the other mandrel causes the sleeve to move to its closed position.
U.S. Pat. No. 3,115,188 issued Dec. 24, 1963 to C. B. Cochran et al. and discloses a sliding sleeve device and shifting tool therefor similar to that disclosed in U.S. Pat. No. 3,051,243 to Grimmer et al. discussed previously.
None of the prior art known to applicant shows a sliding sleeve device which can be installed in a well with its main sleeve valve in open position and has its lateral flow ports initially closed by means responsive to casing pressure but not to tubing pressure, and after the ports are opened by a predetermined high casing pressure, the closure is held in port-opening position.
The present invention overcomes at least some of the problems and shortcomings associated with ported well tools in which the ports are controlled by sliding sleeve valves which are shifted for the most part by shifting tools lowered thereto through the tubing. By providing a port closure responsive to casing pressure, high tubing pressures can be utilized in completing the well. Such a closure saves a trip into the well with a shifting tool and thus saves rig time and money. And, since the closure, once it is opened, is held in open position, it cannot at a later time interfere with flow through the flow ports. Further, since the port closure is inside the body, the casing wall cannot interfere with its operation. Additionally, the closure is protected during its trip into the well because it is completely enclosed within the body.
SUMMARY OF THE INVENTION
The present invention is directed to a well tool for controlling fluid communication through the wall of a flow conductor in a well, this well tool having an elongate body with lateral ports through its wall and connecting means on its ends for attachment to a well flow conductor to become a part thereof, a first sleeve valve mounted for limited sliding movement in the body and movable between positions opening and closing the lateral ports, this first sleeve valve having means thereon engageable by a shifting tool for movement between open and closed positions, and a second sleeve valve between the body and the first sleeve valve initially closing the lateral ports but movable to a position openin such ports in response to a predetermined high pressure at the lateral ports, that is, exterior of the well tool.
It is an object of this invention to provide a well tool having one or more lateral communication ports through the wall thereof to allow circulation of fluids between flow conductors in a well.
Another object of this invention is to provide a well tool of the character described having a first sleeve valve movable therein between positions opening and closing the lateral ports.
A further object is to provide such a well tool wherein the first sleeve valve has means thereon adapted to be engaged by a shifting tool for movement of the first sleeve valve between its open and closed positions.
Another object is to provide a device of the character set forth having a second sleeve valve, which second valve is placed between the body and the first sleeve valve and is initially releasably secured in a position closing the lateral ports and movable to a position opening the lateral ports.
Another object of this invention is to provide such a well tool in which the second sleeve valve is movable from its initially closed position to its open position in response to the pressure of the fluid in the lateral ports and acting on the exterior surface of the second sleeve valve reaching a predetermined high value.
A further object is to provide such a well tool in which the second sleeve valve upon being moved to open position is thereafter held in such position so that flow through the lateral ports is thereafter controllable by the first sleeve valve without interference from the second sleeve valve.
Other objects and advantages will become apparent from reading the description which follows and from studying the accompanying drawing wherein:
BRIEF DESCRIPTION OF THE DRAWING
FIGS. 1A, 1B, and 1C, taken together, form a longitudinal view partly in section and partly in elevation showing the upper, intermediate, and lower portions, respectively, of a well tool constructed in accordance with the present invention with its first sleeve valve open and its second sleeve valve closed;
FIG. 2 is a cross-sectional view taken along line 2--2 of FIG. 1B;
FIG. 3 is a cross-sectional view taken along line 3--3 of FIG. 1B;
FIG. 4 is a longitudinal sectional view showing an intermediate portion of the device of FIGS. 1A, 1B, 1C with both its first and second sleeve valves open; and
FIG. 5 is a view similar to FIG. 4 showing the device of FIG. 4 with its first sleeve valve shifted to closed position and its second sleeve valve held in its open position.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIGS. 1A-3, it will be seen that the device of this invention is indicated generally by the numeral 10. It comprises a housing 11 which includes upper sub 12, intermediate sub 13, ported sub 14, and lower sub 15 threadedly connected together as shown. The upper and lower ends of the housing 11 are provided with threads 17 and 18 for attachment to upper and lower portions 19 and 20 of a well flow conductor such as a well tubing string. The ported sleeve 14 is provided with a plurality of lateral ports 22 which communicate the interior of the sleeve with the exterior thereof and thus provide a path for transfer or circulation of fluids between the interior of the well tubing and the exterior thereof.
A sliding sleeve valve 24 is slidably disposed within the housing 11 and is movable longitudinally therein between upper, intermediate, and lower positions. Through slots 26 near the upper end of the sliding sleeve valve 24 are alignable with the ports 22 of the housing when the sliding sleeve valve is in its lower position shown in FIGS. 1B and 1C. When the sliding sleeve valve is in its upper position shown in FIG. 5, the slots 26 thereof are not aligned with the ports 22 of the housing. Suitable packing sets are disposed between the sliding sleeve valve and the housing to direct flow through the ports of the housing and to prevent flow between the exterior of the sleeve and the interior of the housing. The upper set of packing 28 seals between the sliding sleeve valve and the housing at a location spaced above the lateral ports 22 of the housing while a similar packing set 29 seals between the sliding sleeve valve and the housing at a point spaced considerably below the lateral ports 22 of the housing.
The sliding sleeve valve is provided with an internal annular downwardly facing shoulder 32 near its upper end and with a similar upwardly facing shoulder 33 near its lower end for engagement by a suitable shifting tool by which the sleeve valve is positioned within the housing to control flow through the lateral ports 22 of the housing. Just above the upwardly facing shoulder 33 near the lower end of the sliding sleeve valve, a plurality of longitudinal slots 35 provides fingers therebetween forming a closed collet. These collet fingers 36 each have a boss 37 extended outwardly therefrom as shown, and these bosses have outwardly convergent upper and lower sides or cam surfaces. The bosses 37 are engageable in internal annular recesses formed in the lower sub 15 for the purpose of retaining the sliding sleeve valve in its proper position. For instance, the bosses 37 of the collet fingers 36 are engaged in the internal annular recess 40 of the lower sub 15 when the sliding sleeve valve 24 is in its lower position as shown in FIGS. 1B and 1C. In a similar manner, the bosses 37 of the collet fingers 36 will be engaged in the internal annular recess 42 of the lower sub when the sliding sleeve valve is in its upper position as shown in FIG. 5. In moving the sliding sleeve valve from its closed position, shown in FIG. 5, to its open position, shown in FIGS. 1B and 1C, the sliding sleeve valve should be stopped with the bosses 37 of the collet fingers 36 in engagement with the intermediate internal recess 44 in which position the equalizing port 46 of the sliding sleeve valve will be aligned with the lateral ports 22 of the housing allowing pressures internally and externally of the device to equalize. After such pressures have been equalized, the sliding sleeve valve 24 is then moved to its full open position shown in FIGS. 1B and 1C.
The features just described with respect to the drawings are well known and are shown in U.S. Pat. No. 3,051,243 to Grimmer et al. Such devices have been in use for many years. In addition, the upper sub 12 of FIG. 1A is provided with suitably prepared bore surfaces at 50 and 51 and with suitable internal annular lock recesses at 52 and 53, and at the same time the lower sub 15 is provided with a suitably prepared bore surface as at 54 for the purpose of receiving a suitable peak-off device or other tool in locking and sealing relationship with ported well tool 10 in order to control or prevent flow through the lateral ports 22 of the housing. Ported sliding sleeve devices having such bore surfaces and lock recesses are well known and have been used for many years. Such devices are shown in the Composite Catalog of Oil Field Equipment and Services-1970-71 Edition at page 3838, the devices shown on that page being available from Otis Engineering Corporation, Dallas, Texas.
Insofar as this present application is concerned, the sliding sleeve of the device illustrated and described herein operates in a manner similar to that of the device illustrated and described in the U.S. Pat. No. 3,051,243 to Grimmer et al. and the device illustrated in the aforementioned catalog, and the sliding sleeve is shifted between its longitudinal positions by a shifting tool like or similar to that illustrated and described in the Grimmer U.S. Pat. No. 3,051,243. A very similar shifting tool is illustrated on page 3839 of the catalog mentioned above.
In U.S. Pat. No. 3,211,232 Grimmer teaches the use of pump-out plugs for closing the lateral ports of the housing and also teaches the shifting of the sliding sleeve valve by dropping a plug into the tubing at the surface and then using fluid pressure thereabove to move the sliding sleeve to closed position. The present invention is similar to but is an improvement over the devices of Grimmer and Grimmer et al., just mentioned, with respect to U.S. Pat. Nos. 3,051,243 and 3,211,232 which are incorporated herein, together with the other patents mentioned hereinabove, for all purposes.
The well tool or sliding sleeve device 10 illustrated in the drawing embodies the present invention as will now be described.
The ported sleeve 14 which makes up a portion of the housing 11 of sliding sleeve device 10 is provided with a stepped bore immediately above the lateral ports 22, and a suitable annular resilient seal ring 60 fits closely in bore 61, as shown, and this seal ring 60 is held in the position shown by a plurality of screws 62 threaded through the wall of the ported sleeve 14 with their inner ends projecting inside to support the seal ring 60 against displacement from its proper position (shown). A port closure sleeve 63 surrounds the sliding sleeve valve 24 and has its upper reduced end portion 65 engaged within the seal ring 60 as shown in FIG. 1B. The port closure sleeve 63 carries a suitable annular seal ring such as the o-ring 66 in a suitable external annular recess, and this o-ring sealingly engages the bore wall 67 of the ported sleeve 14, as shown, so that the port closure sleeve 63 effectively seals the ports 22 of the ported sleeve. Fluid pressure entering through the ports 22 cannot pass around either end of the sleeve because of the seal rings 62 and 66 which are sealingly engaged between the port closure sleeve and the inner wall of the ported sleeve. It should be noticed, however, that the area within the circle of sealing contact between the upper end of the port closure sleeve 63 and the inner surface of the seal ring 60 is somewhat smaller than that area within the sealing circle defined by the bore wall 67 of the ported sleeve which is engaged by the seal ring 66. This area difference is exposed to tubing pressure from the inside and pressure exterior of the tubing from the outside. Thus when the pressure exterior of the well tool 10 exceeds the pressure within the tubing bore, there will be a tendency for this differential pressure to move the port closure sleeve downwardly to its open position.
The port closure sleeve 63 is provided with an external annular recess or a dimple, as desired, in which is engaged the inner end of one or more frangible shear screw 70 which is threaded through the wall of the ported sleeve 14 to lock the port closure sleeve 63 in the closed position as shown in in FIG. 1B. When the port closure sleeve 63 is thus closed, fluids may not pass or be transferred through the lateral ports 22 of the ported sleeve 14 regardless of the position of the sliding sleeve valve 24 therewithin. It will be noted in FIG. 1B that the sliding sleeve valve 24 is in its lower open position with its ports 26 aligned with the lateral ports 22 of the ported sleeve, but fluids cannot pass through the lateral ports 22 because the port closure sleeve 63 is, as yet, in its closed position.
The lower end of the port closure sleeve is threaded as at 72, and a sleeve 73 having an external flange 74 thereon is threadedly attached to the port closure sleeve as shown. The ported sleeve 14 has an internal annular flange 76 therein, and a ring or split-ring 77 surrounds the sleeve 73 and is lodged against the lower side of internal flange 76 while a coiled compression spring 78 surrounds the sleeve 73 and is confined between the ring 77 and the flange 74 just mentioned. The spring 78 thus applies a constant bias to the sleeve 73 and the port closure sleeve 63 attached thereto, tending to bias the port closure sleeve downwardly to its open position, but this sleeve is, as yet, still securely held in its closed position by the screws 70 described earlier.
After the sliding sleeve device 10 has been installed in a well and it is desired to circulate or transfer fluids therethrough, as by pumping fluids from the tubing into the casing or vice versa, the pressure in the tubing-casing annulus is increased above the well packer (not shown). When this pressure reaches a predetermined value, which value is higher than the value of the pressure within the tubing by a predetermined amount, this differential pressure acting on the difference between the areas sealed by the seal rings 60 and 66 applies sufficient downward force to the port closure sleeve 63 to shear the screws 70 and move the port closure sleeve downwardly, thus opening or uncovering the ports 22 in the ported sleeve 14. As soon as the screws 70 are sheared, the spring 78 expands, and the energy stored in the spring is sufficient to move the port closure sleeve 63 downwardly to its fully open position wherein the lower end of sleeve 73 comes to rest against the upper side of the split-ring 80 which forms a stop for the upper side of the packing set 29. The open position of the port closure sleeve is clearly shown in FIG. 4.
It will be seen in FIG. 4 that the port closure sleeve 63 is in its lowermost position, that its upper end is clear of the lateral ports 22 of the ported sleeve 14, that the sliding sleeve valve 24 therewithin is still in its lower open position, that the ports of the sliding sleeve valve are aligned with the lateral ports 22, and that circulation between the tubing and the exterior thereof, that is, the tubing-casing annulus can take place freely.
The spring 78 will maintain a downward bias on the sleeve 73 and will hold the port closure sleeve 63 in its lower position, shown in FIG. 4, and will not allow it to move upwardly where it might interfere with the circulation of fluids through the ports 22.
Thus, the port closure sleeve 63 which initially closed the lateral ports 22 of the device has been moved to its open position by the application of fluid pressure to the tubing-casing annulus, and it was not necessary to run any sort of tool into the well either by wireline, cable, or by pumpdown methods, and that once the ports 22 have been opened, they will remain open until the main sliding sleeve valve 24 is shifted to closed position.
To close the ports 22 of the ported sleeve 14 again in order to isolate the tubing-casing annulus from the tubing bore, a suitable shifting tool such as that illustrated in U.S. Pat. No. 3,051,243 to Grimmer et al. is run into the well by some suitable means such as by wireline, and the keys thereon are engaged with the downwardly facing shoulder 32 near the upper end of the sliding sleeve valve, and an upward force is applied thereto to slide the sliding sleeve valve from the lower position shown in FIGS. 1B and 1C to the closed position shown in FIG. 5.
In FIG. 5 it will be readily seen that an imperforate section of the sliding sleeve valve 24 now bridges the lateral ports 22 of the ported sleeve 14, and that this imperforate portion of the sliding sleeve valve is engaged within the upper and lower packing sets 28 and 29 so that fluid pressure entering through the lateral ports 22 cannot get into the tubing because such fluid pressure is confined between the two packing sets just mentioned.
If it is desired to again open the lateral ports 22, the same shifting tool that was used to shift the sleeve upwardly can be inverted as taught in the aforementioned U.S. Pat. No. 3,051,243 and run into the tubing string again until the keys thereof engage upward facing shoulder 33 at the lower end of the sliding sleeve valve 24 and a downward force is applied thereto to slide the sliding sleeve valve downwardly from its upper position shown in FIGS. 1B and 1C to its closed position shown in FIG. 4, in which position its slots 26 are aligned with the lateral ports 22. Since the port closure sleeve 63 remains held down out of the way by spring 78, as shown in FIG. 4, circulation of fluids between the tubing and its exterior may take place freely through the slots 26 and the ports 22.
In operation, when it comes time to complete a well which has just been drilled, and a string of casing has been placed in the well bore to extend from the surface downwardly to or past the production formation, the well is further equipped by running a string of tubing thereinto, the string of tubing having a packer near its lower end, to lock the tubing to the casing and seal therebetween at a location immediately above the producing formation. The casing may be perforated at the producing formation either before or after the tubing is run into the well. A sliding sleeve device such as that illustrated in FIGS. 1A-5 may be included in the tubing string a short distance above the packer. At the time that the packer is set, the tubing and casing both will be full of weighted fluid such as mud in order to maintain the producing formation under control. After the packer is set, the pressure of the mud in the tubing-casing annulus is increased to test the packer, then the annulus pressure is further increased to open the sliding sleeve device by applying a downward pressure to the port closure sleeve 63 to shear the screws 70 so that the port closure sleeve 63 can be moved to its fully open position by the spring 78. This opens the lateral ports 22 of the well tool so that a lighter medium such as water or oil may be used to displace the mud from the tubing by pumping it down the tubing and forcing the mud outwardly through the lateral ports 22 into the annulus where it rises to the surface. In many cases it is desirable to close the sliding sleeve valve 24 as soon as the mud is displaced from the tubing so that the mud will remain in the tubing-casing annulus and the water will remain in the tubing string. Now, if the producing formation is of abnormal bottom hole pressure, it is only then necessary to open the well up and let it come in or flow. However, if the bottom hole pressure is not sufficient to lift the water, then it may be necessary to swab the well or use other means to unload the well of the water and permit the well products to flow.
It is readily understood that one advantage of the device just described is that the ports 22 are initially closed but can be opened by application of mud pressure to the annulus, thus making it unnecessary to run tools or drop plugs into the tubing at this time when the tubing is full of mud. Tools do not fall through the mud readily, nor do they operate as efficiently in mud as compared to water or oil. It is further understood that after the mud pressure has caused the ports 22 to open and the mud is displaced from the tubing through the ports 22, the shifting tool may be run into the well, the tubing now filled with water, and its work easily accomplished since these tools work much better in water than they do in mud. In this manner, much time and expense is saved, and this could be considerable in view of the fact that many wells are now being drilled offshore from expensive platforms or expensive drill ships or semi-submersible structures where operations run into the thousands of dollars per hour. Also, most such wells have deviated bores making it even more desirable to have water or oil in the tubing when carrying on tool operations therein.
Thus it has been shown that the device of this invention accomplishes all of the objects set forth in the beginning of this application and that changes in the sizes and the shapes of the parts and the arrangements thereof may be had by those skilled in the art without deparing from the true spirit of this invention.
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A ported sliding sleeve valve for use in a well tubing to provide a lateral flow path for transfer of fluids between the tubing and the annulus exterior thereof, the lateral ports of the device being initially closed by a port closure sleeve which is movable to port-opening position by increasing the annulus pressure to a level exceeding tubing pressure by a predetermined value, the port closure sleeve moving to fully open position upon being released and afterwards remaining in this position while the lateral ports of the device are thereafter opened and closed by shifting a built-in sliding sleeve valve through use of a shifting tool run and operated via wireline or pumpdown tools in a manner well known in the industry.
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RELATED APPLICATION
This application is based upon and claims the benefit of Provisional Application 61/135,070, filed Jul. 15, 2008.
BACKGROUND OF THE INVENTION
1. Technical Field
The present invention relates to a dual anchor assembly for embedment in concrete slabs and to a lifting shackle adapted to simultaneously engage the multiple anchors of the assembly. In its more particular aspects, the invention is concerned with a void former which provides for positioning and placement of the anchors and forms an arcuate recess in the slab in intersecting relationship with the anchors. It is also concerned with an anchor assembly and hoisting shackle of increased load capacity, as compared to existing assemblies and shackles which employ single anchors.
2. Description of the Prior Art
The prior art relating to the present invention is typified by U.S. Pat. Nos. 3,883,170 and 4,367,892. These patents show single anchor assemblies for embedment in concrete slabs and associated releasable lifting shackles for engagement with the anchors. They also teach the provision of an arcuate recess around the end of the anchor engaged by the shackle. The '892 patent, in particular, teaches a void former for forming the recess and placing the anchor.
It is also known in the prior art to provide anchor assemblies for embedment in concrete slabs, wherein the anchors have divergent portions to spread the load and resist pullout. Such a device, for use with a releasable lifting shackle, may be since in U.S. Pat. No. 4,173,856. In the device of that patent, however, each shackle engages only a single anchor.
SUMMARY OF THE INVENTION
The hoisting shackle of the invention comprises a ring-shaped body having a hollow toroidal portion with slots extending thereacross at spaced locations and an arcuate locking bolt slidably received within the toroidal portion for select extension across the slots and through anchors received within the slots.
The invention also provides an anchor assembly for embedment within a concrete slab to place a pair of anchors within the slab and form a void therearound.
The anchor assembly comprises a void former having a generally arcuate lower surface. At least two grooves are formed in and opening through the arcuate surface in annually spaced relationship to one another. Anchors are received within the grooves and extend laterally from the void former. Internally of the void former, the anchors provide annually aligned openings.
The concrete structure and lifting mechanism of the invention provide an arcuate recess within the concrete structure, a pair of anchors embedded within the structure and extending into the recess, and a releasable shackle complimentally received within the recess and engaged with the anchors.
The invention also provides a method for lifting a concrete structure wherein two or more anchors are embedded within the structure in divergent relationship and a ring-shaped lifting shackle is simultaneously engaged with the anchors.
A principal object of the invention is to provide an increased load capacity hoisting shackle having a quick release mechanism engagable with two or more anchoring elements embedded within a concrete structure.
Another and related object is to provide such a hoisting shackle which is not larger than existing shackles used with single anchoring elements.
Still another object of the invention is to provide a hoisting shackle and anchor combination for use in lifting concrete structures, wherein the load is divided into two parts to reduce the stress level within the shackle.
Yet another object of the invention is to provide an improved lifting anchor system for use in a relatively shallow concrete structure, which provides a wider spread of lifting forces within the structure.
A further object of the invention is to provide an anchor system for use in relatively a narrow concrete wall, which provides a wider spread of forces when pulled in the plane of the wall.
Another object of the invention is to provide the anchor system for use in narrow walls, wherein lifting forces are perpendicular to the plane of the wall and a wider lifting force sheer plate is provided within the wall.
Another object is to provide an anchoring system and lifting shackle for use in a deep mass concrete structure, which spreads the overall stresses within the structure and reduces the stresses within the shackle.
These and other objects will become more apparent from the following detailed description and accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevational view of the prior art lifting shackle of U.S. Pat. No. 3,883,170, showing the single anchor with which the shackle is used embedded within a concrete structure;
FIG. 2 is an elevational view of the lifting shackle of the present invention and the associated dual anchor embedded within a concrete structure;
FIG. 3 is a cross-sectional elevational view of the lifting shackle shown in FIG. 2 ;
FIG. 4 is a perspective view of the void former of the invention, with bar anchors shown in place within the void former;
FIG. 5 is an elevational view of one of the bar anchors shown in FIG. 3 ;
FIG. 6 is a perspective view of the void former, without anchors in place;
FIG. 7 is a plan view of a pair of wire anchors positioned relative to one another, as they would appear in practice of the present invention;
FIG. 8 is a side elevational view of the anchor shown in FIG. 7 ; and
FIG. 9 is a front elevational view of one of the anchors shown in FIG. 7 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates the prior art releasable lifting shackle of U.S. Pat. No. 3,883,170. The shackle comprises a cast steel shackle body 10 having a hollow toroidal cavity formed therein which carries an arcuate locking bolt 12 . The bottom of the shackle body 10 is formed with a slot 14 for receipt of an apertured anchor 16 embedded in a concrete structure 18 . A generally arcuate recess 20 is formed in the concrete structure around the anchor 16 .
In operation, the anchor 16 is received within the slot 14 , with the bolt 12 removed from the slot, and the bolt is then extended across the slot and through an aperture 22 formed in the anchor 16 . In this condition, the shackle is securely engaged with the anchor 16 and lifting force may be imparted to the concrete structure through the shackle.
The shackle of the present invention in seen in FIGS. 2 and 3 wherein the steel shackle body is designated, in its entirety, by the numeral 24 . The body 24 has an annular cavity 26 which is open to the outside in the upper half of the body. The upper half of the body is thus an open U-shaped cross-section. The bottom of the body is of a closed U-shaped configuration and formed with a pair of generally trapezoidal slots 28 and 30 extending thereacross. Slot 28 has a vertical wall 32 and an outwardly divergent wall 34 . Slot 30 , similarly has a vertical wall 36 and an outwardly divergent wall 38 . This arrangement enables the shackle to move vertically into engagement with a pair of anchors 40 , 42 cast in place within an arcuate recess 44 formed in the concrete structure 46 to be lifted. Such movement can be appreciated from a comparison of FIGS. 2 and 3 wherein, in FIG. 2 , the shackle is above the recess and in FIG. 3 is received within the recess. A support section 33 , forming an integral part of the shackle body, is disposed between the slots 28 . A throughbore 35 extends fully through and across the section 33 .
The angle of the divergent walls 34 , 38 is chosen to compliment the angle at which the anchors 40 , 42 are set. The preferred range of angles, as measured from vertical, is between 10 and 35 degrees. When the anchors are received within the slots, the outer surfaces of the anchors engage the divergent surfaces. Complimental engagement of the anchors with the shackle also occurs through means of sockets 48 formed in the shackle body at the ends of the slots 28 , 30 . These sockets are of a generally trapezoidal configuration corresponding to that of the ends of the anchors 40 , 42 .
The anchors 40 , 42 are of identical configuration and are of each “bar” type. Their configuration can best be appreciated from FIG. 5 where it will be seen that each anchor comprises:
an elongate body 50 ; a convergent/divergent proximal portion 52 ; a foot 54 ; and a distal portion 56 having an elongate aperture 58 formed there through.
The top of the distal portion 56 has a flat upper surface 60 and tapered side surfaces 62 . The upper surface 60 and side surfaces 62 form a generally trapezoidal configuration generally complimental to the sockets 48 formed in the shackle body 24 .
The basic structure of the inventive shackle is completed by an arcuate locking bolt 64 slidably received within the shackle body 24 for movement between the open condition shown in FIG. 2 and the closed condition shown in FIG. 3 . The bolt extends through approximately 180° of the circumference of the shackle body and, when unloaded, is freely movable therein. The throughbore 35 is of an arcuate configuration complimental to that of the bolt 64 and so proportioned and positioned as to enable the bolt to extend freely therethrough, when unloaded. When loaded, lifting forces imparted to the bolt by anchors 40 , 42 are transmitted to and carried by the lower interior surface of the throughbore 35 and the lower interior surfaces of annular cavity 26 . A handle 66 extends through the open slotted top of the shackle body to enable the bolt to be manually moved between the open and closed conditions.
As shown in FIG. 2 , a closed link 68 extends through a generally centrally disposed opening 70 formed through the shackled body 24 . The link would be secured to a lifting hoist (not illustrated).
The operation of the lifting shackle can be appreciated from a comparison of FIGS. 2 and 3 . In FIG. 2 , the shackle is about to be lowered into receiving engagement with a pair of anchors embedded within the concrete structure. During this lowering process, the vertical walls 32 , 36 of the shackle body pass between the anchors 40 , 42 . Ultimately, the ends of the anchors complimentally nest within the sockets 48 and the outer surfaces of the anchors complimentally engage the divergent walls 34 , 38 of the shackle body. The later condition is shown in FIG. 3 .
Once the shackle body is fully engaged over the anchors, the locking bolt 64 is moved annularly within the body and extended through the throughbore 35 of the section 33 and the apertures 58 of the anchors, as shown in FIG. 3 . This serves to both secure the shackle to the anchors and to maintain the outer surface of the shackle in complimental engagement with the inner surface of the arcuate recess 44 .
FIG. 4 shows a void former 72 for positioning the anchors 40 , 42 within a concrete structure, as the structure is being formed, and creating an arcuate recess within the surface of the structure. The void former 72 is fabricated from a relatively strong resilient material, such as rubber or polymer. The lower surface 74 of the void former is of arcuate configuration corresponding to that of the recess 44 to be formed within the concrete structure. The upper surface 76 is generally flat and may have a recess formed therein for the attachment of placement hardware. Grooves 78 extend the cross and open through the lower surface 74 of the void former, for receipt of the anchors 40 , 42 . These grooves are proportioned for snug receipt of the anchors and are disposed to position the anchors at the desired inclination within the body of the concrete structure being formed. Protrusions 80 within the grooves 78 are provided for engagement with the apertures 58 of the anchors.
In use, the void former is positioned within the form for the concrete structure and concrete is then poured around the void former and anchors, to the level of the upper surface 76 of the void former. Removable pedestals (not illustrated) may be secured to the feet 54 to support the anchors. Once the concrete has sufficiently cured, the void former is removed, thus leaving an annular 44 recess formed in the surface of the concrete structure, with the anchors 40 , 42 extending into the recess.
FIGS. 7 to 9 illustrate an alternative pair of anchors which may be used in place of the anchors 40 , 42 . These alternative anchors are made of bar or wire stock and are particularly well adapted for use in relatively thin concrete slabs to better spread lifting loads through the mass of the concrete. Each anchor, designated 82 , is of a generally v-shaped configuration having a pair of divergent legs 84 defining a clevis 86 at their joinder. The legs terminate in inwardly bent distal ends 88 .
The preferred dimensions and angles of divergence for the anchors 82 , when placed within a concrete slab, are shown in FIGS. 8 and 9 . These dimensions and angles, together with the provision of the inwardly extending distal ends 88 , provide for optimum resistance to pull out by maintaining a large body of concrete under compression, as lifting forces are applied to the anchors.
In use, the anchors 82 are positioned relative to the lifting shackle in essentially the same relationship shown in FIGS. 2 and 3 , with regard to the anchors 40 , 42 . The principal difference is the inward surfaces of the devises 86 provide the apertures through which the locking bolt 64 is extended. Void formers, similar to that of FIGS. 4 and 6 , may be provided for initial placement of the anchors 82 .
CONCLUSION
From the foregoing description, it should be apparent that the present invention provides for the attainment of the objects initially set forth herein. In particular, it provides a dual anchor lifting shackle and an improved apparatus and method for placing multiple anchors within a concrete structure and lifting the structure through a common shackle simultaneously engagable with the anchors. It should be understood, however, that the invention is not limited to the specifics which have been described and illustrated, but rather is defined by the accompanying claims.
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A lifting mechanism for a concrete structure is provided through means of a void former and anchor assembly which it cast in place to provide an accurate recess in the structure having two or more spaced divergent anchors therein. The anchors define annularly aligned apertures within the recess. A lifting shackle of an arcuate configuration complimental with that of the recess is received within the recess and carries an arcuate locking bolt extendable through the aligned apertures.
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FIELD OF THE INVENTION
[0001] The invention relates to a flexible modular habitat where the number of modules, assembled into the habitat, depends on the space available and facility to be covered. The flexible modular habitat is installed on-site, to safeguard welding in wells and/or high fire risk rated facilities. The habitat is used or catching slag, sparks, and the like. More particularly, the present invention is related to a module-based habitat for an assembly, which expands the safety of workers and provides greater security to infrastructures where this habitat will be used. The habitat provides outstanding and innovative features relative to the state of the art preceding the present invention; and further it utilizes individual modules that are sealed together to form the flexible modular habitat. The habitat can be modified or sized to reflect the different works within the habitat.
BACKGROUND OF THE INVENTION
[0002] Subsequent to the drilling of an underground oil or gas well, if such a well is located within or on a platform, a drilling ship or the like, the well is completed by the introduction of a tubular pipe, which is referred often to as the “casing”. The casing is welded in place as part of the finishing operation.
[0003] Before or after the introduction of one or more sections of pipes that form the casing in the underground well, or the like, it may be required to perform several welding operations in one or more ends of the casing for the connection, for example, a leak preventer, heads, valves or other desirable components. It may be desired to fasten sections of each pipe of the casing. In many cases, such a component is fixed to the pipe members of the casing through welding operations by means well known in the industry.
[0004] As a result of the discharge of the flame from a welding plant, during the welding operation, sparks, slag and other inconveniences can be expected to be expelled in the air around the welding operation resulting in a serious risk during the welding operation. Slag and sparks could cause a fire or even worse, an explosion, as the casing is inserted often onto “live” wells, which sometimes could become uncontrollable at any time as a result of a breakdown or boiling of flammable liquids, such as natural gas or the like.
[0005] To address this danger, there is desired an enclosure that prevents or treats this problem by providing a habitat for welding in underground wells, which not only captures the slag and sparks during the welding procedure in an area which is isolated from the wellbore fluids, but the environment provides for controlled dissemination of slag and spark through habitat and away from the welding operation in a safe and controllable manner.
[0006] In the state of the art relative to that described above, there exists the following published documents: U.S. Pat. No. 2,872,933; U.S. Pat. No. 3,837,171; U.S. Pat. No. 3,946,571, U.S. Pat. No. 4,257,720; U.S. Pat. No. 5,018,321, Mexican Utility Model No. 1624 and Mexican Patent Application No. MX 308,953.
[0007] However, all these published documents have certain disadvantages and deficiencies that are accentuated when performing the welding process. As a result, it is desirable to make structural changes to these existing structures in order to provide greater benefits to workers and higher security to facilities where these activities are performed.
[0008] U.S. Pat. No. 2,872,933 relates to the construction of an air inflated ring cover which is used to cover drilling sites in oil wells, regardless of weather conditions. The cover is hanged by its top over the drilling site.
[0009] U.S. Pat. No. 3,837,171 relates to an underwater inflatable structure, which provides an artificial environment around a work area, for example, in a submarine base of an offshore oil platform, allowing for welding and the like to be performed. The structure comprises an integral sheet of material for a custom work or a number of selected sheets attached to the structural support elements. The material includes rack sections so that the material can be placed over and around the structural members in order to ensure a substantially airtight system. Neck sealing means are included on the structural members at their intersection with the sheet material and sealing means within the rack sections although the system could be used on land, it is particularly applicable to subsea situations.
[0010] U.S. Pat. No. 3,946,571 relates to an insulated module for use in environments with hostile temperatures that are uncomfortable for humans. This service module is lowered and put into service by the top of the module.
[0011] U.S. Pat. No. 4,257,720 relates to a capsule for works in the deep sea, allowing personnel access for maintenance work.
[0012] U.S. Pat. No. 5,018,321 discloses a flexible habitat for welding in underground wells to trap slag, sparks and the like. The habitat generally includes an air hanged external arched dome, which is mountable on an entry point of an underground well. The entry point of the underground well receives a pipe member which is extensible in the well and on which a process is carried out by welding. A fire resistant protective element is disposed about at least a bottom of the dome. Means are provided for selectively introducing air to hang the dome on the entry point. The means includes an air inductor motor, a fan, or the like. Means extend through the upper portion of the dome and away from the entry point to communicate with the inside of the dome to allow discharge of smoke including particulate matter, a result of welding procedure that is discharged from inside the dome. The means for introducing air and the means extending through an upper portion of the dome are aligned whereby the air supply forms a carrier stream for transmitting the smoke and particulate matter at least to the means extending through an upper portion of the dome, and preferably to transmit to and through the outside of the dome without the aid of any other means. The habitat also includes a fire resistant skirt which is available around the highest outermost portion of the pipe member. The guard is extended to ensure that the slag and the spark are not discharged downward around the outside of the casing or pipe member of transmission of fluid through the well. However, it has seen that in overworked hours, smoke and particulate waste is relatively excessive, tending to occlude the expulsion means of the habitat. This causes the worker to suffer significant health risks, and in the other hand, considerable costs are generated by the excessive change of filters which are arranged in the discharge means of the habitat.
[0013] Mexican Utility Model No. 1624 discloses a flexible habitat for welding in underground wells to trap slag, sparks and the like. The habitat generally includes an air hanged external arched dome which is mountable on an entry point of the underground well, which includes a ventilation system which is comprised basically of a structure porous sublayer arranged throughout the area comprising the dome of the habitat. The sublayer is releasably secured by conventional means, which serves as a filter.
[0014] However, upon conditions of use; particularly for U.S. Pat. No. 5,018,321 and Mexican Utility Model No. 1624, are not very favorable, as the degree of difficulty of assembling the structure in a work area is considerably high and dangerous, so the habitat of these two references are not suitable under the habitat occurs in one piece and resulting inconvenient to carry various habitat elements of different sizes. This causes the work schedules to be extended while the cost per hour/man rises considerably.
[0015] Mexican Patent No. 308953 and the state of the art cited, display wide shortcomings in their modularity to form the modular habitat and therefore reflect these deficiencies in the safety management to users and infrastructure where the modular habitat is used for working. These shortcomings are reflected in the management of tasks performed as the welding of tube. That is, in this reference, certain disadvantages are identified when performing the assembly process and adaptation in the workplace of the device for welding work, so the present invention overcomes these shortcomings by introducing structural changes in this habitat's modularity in order to provide greater benefits to the worker and the best development of the activities for which Flexible modular habitat was designed, while increasing the safety of workers and therefore infrastructure where the flexible modular habitat is installed.
[0016] In Mexican Patent No. 308,953, there is disclosed a flexible and inflatable habitat for welding in underground wells to trap slag, sparks and the like, by a module based structure and/or assembly. The structure allows different applications to fit different hot work applications without having to stop production. However, it has shortcomings by not hermetically sealing the contact of modular habitat with the element to be developed in works, so that security to the users and facilities is poor, and wherein it does not have security elements such as the emergency door.
[0017] A further advantage of the present invention over the art cited is the non-use of racks, stanchions or mechanical closures raised from “hard” devices or continuous use. Such lack of racks, stanchions or mechanical closures makes the current invention less susceptible to malfunction in assembly and disassembly of each the modules that form the flexible modular habitat. Thereby, the current invention increases the security provided within the modular habitat, by preventing the modules from separating or opening.
SUMMARY OF THE INVENTION
[0018] It is one of the objects of the present invention to provide structural improvements to existing habitats that enable a user to perform various jobs such as welding wells, pipes and/or other devices in high fire risk rated facilities, offshore and onshore. It is desirable to increase the versatility and modularity of flexible modular habitat, which allows, among other features, a user to adjust the size of flexible modular habitat to the conditions of required space, where the flexible modular habitat will be installed. This ability to select the number of modules allow for size adjustment for the resulting habitat. This feature is in addition to an individual module that allows for sealing with another module to form the flexible modular habitat. This sealing of the modules together is accomplished with the panel element provided. The flexible modular habitat allows for the catching of slag, sparks and the like, by the structure and/or module-based assembly (see FIGS. 1 and 2 ). This allows the habitat to adapt to different applications of hot work applications without having to stop the production, and reducing assembly times by simplifying the attachment devices of the modules that in turn provide escape routes from inside Modular Flexible Habitat to the crew. Also, there is provided at least one escape route provided in the facility. If desired, escape routes can be provided on opposite sides of the habitat.
[0019] It is an object of the present invention to enable the formation of the floor of the habitat with a plurality of individual modules. Each module forming the floor is preferably sized “0.50 cm×0.50 cm”, thereby enabling the size of the floor to vary based upon the number of individual tiles assembled together. This makes the habitat adjustable to any type, size or amount of crossings of piping. The smaller size of the flooring modules also reduces the time of the floor assembly, avoiding stumbles and/or damage to tubular pipe crossings in the work area to be covered. The union of these individual modules is accomplished by a Velcro® type hook and loop type fastener closure mechanism. The individual modules are attached to one another at their edges using seams and in turn, the flaps are arranged in an opposing manner. This overlapping mechanism of the flaps is used in order have the Velcro® type hook and loop type fastener strips allow for assembly of the individual modules together. The overlapping structure obviates the needs for stanchions or racks, thereby achieving a faster assembly.
[0020] It is another object of the present invention to provide an adjustable composite module to accommodate cylindrical shaped pipes of different sizes ranging from a cylindrical shaped pipe having an OD (outside diameter) ranging from 10 cm to 76 cm, which fit through the opening or closing of the Velcro® type hook and loop type fastener closure and flap, thus eliminating the need to move the modular structure as a whole so that the center pipe is surrounded allowing for greater versatility for the suitability of the invention in any type of space in which the works are required to perform.
[0021] It is another object of the present invention to have an emergency exit module consisting of a module comprising about 2 meters high and about 1 meter wide that has in its middle, a removable device quickly arranged vertically, for allowing the user to make a quick exit.
[0022] Another object of the present invention is to provide a removable door, consisting of an aluminum structure attached to the structure through Velcro® type hook and loop type fastener closure, eliminating the use of racks or stanchions. This provides the ability of a user to easily release the entire structure of the door for a quick escape action from inside of the structure, if required by crew, for any incident that triggers an emergency protocol.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] A more complete appreciation of the improvements to the art that is embodied by the invention and many of the intended features and advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in conjunction with the accompanying drawings, wherein:
[0024] FIG. 1 illustrates a front perspective view of a flexible modular habitat for welding in wells and/or high fire risk rated facilities, offshore and onshore, according to the present invention, showing the modularity of the walls and roof, where for illustrative purposes but not limiting, the invention may have at least one flexible hose as air supply for inside the flexible modular habitat and at least one hose for air extraction.
[0025] FIG. 2 illustrates a perspective view of the rear of the flexible modular habitat for welding in wells and/or high fire risk rated facilities, offshore and onshore, according to the present invention, showing another view of modularity the walls and roof, plus emergency exit module.
[0026] FIG. 3 a illustrates a flat view of one of the plurality of modules forming the floor.
[0027] FIG. 3 b illustrates the face of Velcro and flap.
[0028] FIG. 3 c illustrates the connection between the modules and the way the floor is made up.
[0029] FIG. 3 d illustrates the top view of the formation of the floor.
[0030] FIG. 4 illustrates a flat view of a module with a window for the habitat assembly according to the present invention.
[0031] FIG. 5 illustrates a flat view of a module with a sleeve for the habitat assembly according to the present invention.
[0032] FIG. 6 illustrates a flat view of the connection between modules for habitat assembly according to the present invention.
[0033] FIGS. 7 a , 7 b , 7 c and 7 d illustrate a flat view of the assembly of parts making up an adjustable module to smooth pipe for habitat assembly according to the present invention. FIG. 7 a is an external view of the main module of adjustable composite module, FIG. 7 b shows the setting insert, FIG. 7 c shows the Velcro and the sealing flap, and FIG. 7 d shows the interior view by placing the setting insert and the sealing flap of adjustable composite module.
[0034] FIGS. 8 a and 8 b illustrate an external and internal flat view respectively of Emergency Exit module for habitat assembly according to the present invention.
[0035] FIGS. 9 a , 9 b and 9 c illustrate an exterior flat view of the door module, an interior view of the removable door module and the door for habitat assembly respectively according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0036] According to FIGS. 1 and 2 , a flexible modular habitat 10 is shown which is already assembled, expanded and inflated. The flexible modular habitat 10 is composed of a plurality of individual modules 11 , 11 ′, 11 ″, 11 ′″, 11 ″″, 11 v , and 11 vv that are attached by a Velcro® type hook and loop type fastener closures 12 . The flexible modular habitat 10 can also be supported via external supports (not shown) as an optional means using cables 22 to give greater stability when the working area is considerably large. The cables 22 are attached to the flexible modular habitat through attachment points or handles 3 . Assembly of the flexible modular habitat 10 is performed in ascending order. In addition, the habitat 10 is preferably assembled using a second special module 11 ′ with a window contained therein (see FIG. 4 ). The window comprises a gap 14 that has a transparent acrylic part 15 for monitoring and enabling control of the work performed from the outside or for other visual purposes and communication. Also, at least one third special individual module may be provided 11 ″ that is provided with a sleeve 16 (See FIG. 5 ), which is attached to a flexible hose 18 . This flexible hose 18 is attached to a fan (not shown) which is driven by a pneumatic motor through the flexible hose 18 for supplying air into the modular habitat 10 .
[0037] At the periphery or edge of each individual module, there is provided one or more strips of Velcro® type hook and loop type fastener closures ( FIG. 3 b ) which is attached to each individual module via stitching and in turn, has one or more flaps 19 (See FIGS. 3 a , 3 b , 3 c and 3 d ) arranged oppositely, in order to cover the Velcro® type hook and loop type fastener closure strip 12 for each more enabling two or more modules to be assembled together. (See FIG. 3 c ). The flaps 19 are important because they serve as a mechanism of secondary sealing securing to prevent any leakage of slag or sparks out of modular habitat 10 . The flaps 19 operate as a secondary emergency sealing reinforcement as a result of them having a pair of strips of the Velcro® hook and loop type fastener closures 12 .
[0038] The plurality of individual modules 11 , 11 ′, 11 ″, 11 ′″, 11 ″, 11 v , and 11 vv (See FIG. 1 ), assembled together, comprise the modular habitat 10 which can be made of a silicon fiber cloth material which may withstand temperatures upwards of 315° C.
[0039] The compound individual module 11 ′″ for attachment to a pipe (See FIGS. 7 a , 7 b , 7 c and FIG. 7 d ) is composed of four pieces that are assembled to achieve an accurate fit at the required location as the need arises in places in which the work will be done using the flexible modular habitat, as it allows for attachment together by a Velcro® type hook and loop type fastener closure 12 . The module body is formed around the outer diameter of a pipe within the Outer diameter range of 10 cm to 76 cm, thereby allowing sealing of this joint.
[0040] The plurality of individual modules that form the floor 11 ″ (See FIG. 3 d ) allow for greater versatility for its modularity to suit the characteristics and conditions that present the places where the work will be performed, namely where the flexible modular habitat is used, because the floor modules have a smaller size that is preferably 0.5 m×0.5 m in square. Assembly of a number of individual modules is required to cover the entire work area. On the floor inside the modular habitat 10 , a fire resistant protector (not shown) is provided, which can be made from flexible refractory material. The fire resistant protector should be placed inside of habitat 10 to completely weld around the interior at a height of about 91 cm above the highest end of the casing to help control the slag and sparks in the welding operation. The welder will perform a welding operation using a conventional arc process that fixes the element to be secured to the casing.
[0041] A door module 11 vv or emergency exit (See FIGS. 8 a and 8 b ) is assembled in the flexible modular habitat by a Velcro® type hook and loop type fastener closures 12 , sealing the joints of the door with flaps 19 . Such a door module is included to provide a quick exit or entrance into the flexible modular habitat if required by any unexpected incident unwanted because it has a joint closed by a Velcro® type hook and loop type fastener type closures 12 arranged and easy sealing flap 19 to help control the slag and sparks in the welding operation. The welder will perform a welding operation using a conventional arc process that fixes the element to be secured to the casing.
[0042] The flexible modular habitat has a joint with Velcro® type hook and loop type fastener closures 12 and a sealing flap 19 for easy separation, that is vertically provided and spanning 2 meters high off the ground for the emergency door module.
[0043] A variation of the module 11 v for a removable door 21 (See FIGS. 9 a , 9 b and 9 c ) with inlet and outlet pressure gauges (not shown) is provided, so that the crew can enter into the modular habitat 10 . The door 21 is affixed to the module 11 v with Velcro® type hook and loop type fastener closures 12 , allowing quick and easy removal if required due to a sudden situation occurring inside the habitat, as the result of an emergency. In this embodiment, the removable door may or may not include a space for insertion of an acrylic window 15 .
[0044] The modular habitat 10 may be conveniently stored in the separate condition. That is the modules are kept in an unassembled form. When it is desired to be used, each piece or module is carried to the area immediately adjacent to the well. Each module 11 , 11 ′, 11 ″, 11 ′″, 11 ″″, 11 v , and 11 vv is then attached, and placed over the pipe or piping.
[0045] Subsequently, a blower fan (not shown) is affixed to the sleeve 16 of special module 11 ″ through a flexible hose 18 for introducing the air supply into flexible modular habitat 10 . A second special module 11 ″ with a sleeve 16 is attached to the other side of the modular habitat 10 with an exhaust fan (not shown) driven by a pneumatic motor (not shown) in order to release the air circulating inside the same habitat.
[0046] While the blower fan forces the air into the modular habitat 10 , it expands to the desired suspension over the well and with the help of cables 22 , which are pulled in an ascending fashion. At this time, the habitat proceeds to externally seal over the casing or piping by use of the assembled flexible modular habitat 10 .
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The present invention relates to a new inflatable and flexible modular habitat for welding in wells and/or high fire risk rated facilities, offshore and onshore to trap slag, sparks and the like, by a structure and/or module-based assembly. The structure can be resized and assembled on site to allow it to adapt to different applications of hot work without having to stop the production.
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CROSS-REFERENCE TO OTHER APPLICATION
This application claims priority from provisional 60/316,439 filed Aug. 31, 2001, which is hereby incorporated by reference.
BACKGROUND AND SUMMARY OF THE INVENTION
The present invention relates to earth-penetrating drill bits, and particularly to pressure compensation systems in so-called roller-cone bits.
1. Background
Rotary Drilling
Oil wells and gas wells are drilled by a process of rotary drilling, using a drill rig such as is shown in FIG. 3 . In conventional vertical drilling, a drill bit 110 is mounted on the end of a drill string 112 (drill pipe plus drill collars), which may be several miles long, while at the surface a rotary drive (not shown) turns the drill string, including the bit at the bottom of the hole.
Two main types of drill bits are in use, one being the roller cone bit, an example of which is seen in FIG. 2 . In this bit a set of cones 116 (two are visible) having teeth or cutting inserts 118 are arranged on rugged bearings. As the drill bit rotates, the roller cones roll on the bottom of the hole. The weight-on-bit forces the downward pointing teeth of the rotating cones into the formation being drilled, applying a compressive stress which exceeds the yield stress of the formation, and thus inducing fractures. The resulting fragments are flushed away from the cutting face by a high flow of drilling fluid.
The drill string typically rotates at 150 rpm or so, and sometimes as high as 1000 rpm if a downhole motor is used, while the roller cones themselves typically rotate at a slightly higher rate. At this speed the roller cone bearings must each carry a very bumpy load which averages a few tens of thousands of pounds, with the instantaneous peak forces on the bearings several times larger than the average forces. This is a demanding task.
2. Background
Bearing Seals
In most applications where bearings are used, some type of seal, such as an elastomeric seal, is interposed between the bearings and the outside environment to keep lubricant around the bearings and to keep contamination out. In a rotary seal, where one surface rotates around another, some special considerations are important in the design of both the seal itself and the gland into which it is seated.
The special demands of sealing the bearings of roller cone bits are particularly difficult. The drill bit is operating in an environment where the turbulent flow of drilling fluid, which is loaded with particulates of crushed rock, is being driven by hundreds of pump horsepower. The flow of mud from the drill string may also carry entrained abrasive fines. The mechanical structure around the seal is normally designed to limit direct impingement of high-velocity fluid flows on the seal itself, but some abrasive particulates will inevitably migrate into the seal location. Moreover, the fluctuating pressures near the bottomhole surface mean that the seal in use will see forces from pressure variations which tend to move it back and forth along the sealing surfaces. Such longitudinal “working” of the seal can be disastrous in this context, since abrasive particles can thereby migrate into close contact with the seal, where they will rapidly destroy it.
Commonly-owned U.S. application Ser. No. 09/259,851, filed Mar. 1, 1999 and now issued as Ser. No. 6,279,671 (Roller Cone Bit With Improved Seal Gland Design, Panigrahi et al.), copending (through continuing application Ser. No. 09/942,270 filed Aug. 27, 2001 and hereby incorporated by reference) with the present application, described a rock bit sealing system in which the gland cross-section includes chamfers which increase the pressure on the seal whenever it moves in response to pressure differentials. This helps to keep the seal from losing its “grip” on the static surface, i.e. from beginning circumferential motion with respect to the static surface. FIG. 4 shows a sectional view of a cone according to this application; cone 116 is mounted, through rotary bearings 12 , to a spindle 117 which extends from the arm 46 seen in FIG. 1. A seal 20 , housed in a gland 22 which is milled out of the cone, glides along the smooth surface of spindle 117 to exclude the ambient mud 21 from the bearings 12 . (Also visible in this Figure is the borehole; as the cones 116 rotate under load, they erode the rock at the cutting face 25 , to thereby extend the generally-cylindrical walls 25 of the borehole being drilled.) The present application discloses a different sealing structure, in place of the seal 20 and gland 22 , but FIG. 4 gives a view of the different conventional structures which the seal protects and works with.
A critical part of the design of a “roller cone” drill bit is the sealing system. The roller cone bit, unlike any fixed-cutter bit, requires its “cones” to rotate under heavy load on their bearings; when the bearings fail, the bit has failed. The drilling fluid which surrounds the operating bit is loaded with fragments of crushed rock, and will rapidly destroy the bearings if it reaches them. Thus it is essential to exclude the drilling fluid from the bearings.
Rock bit seals are exposed to a tremendously challenging fluid environment, in which large amounts of abrasive rock particles and fines are entrained in the fluid near one side of the seal. Moreover, the very high-velocity turbulent flows cause fluctuating pressures near the seals.
Fluid seals are therefore an essential part of the design of most roller-cone bits. However, an important aspect of seal functioning is control of differential pressures; if the pressure inside the seal becomes substantially less than the pressure outside the seal, particulates from the drilling fluid can be pushed into or past the dynamic face. (This can lead to rapid destruction of the seal.) A pressure compensation arrangement is therefore normally used to equalize these pressures.
The life of a rotary-cone drill bit is usually limited by bearing failure, and that in turn is heavily dependent on proper sealing and lubrication. Such bits usually include a grease reservoir in each arm, connected to supply grease to that arm's bearings. Since the bearing will operate at low speeds, high load, and fairly high temperature (possibly 250° F. or higher), the grease used is typically quite stiff at room temperature. However, to provide pressure equalization between the reservoir and the bearings, it is desirable to avoid air pockets in the grease.
When the grease reservoir is filled at the factory, a vacuum is usually applied to remove trapped air, and then the grease is injected under some pressure (e.g. 2000 psi or so). The reservoir's pressure-relief valve operates to limit the pressure inside the reservoir to an acceptable level, but this still implies a positive pressure which slightly distends the reservoir's elastomeric diaphragm.
With the old hydrodynamic seals, where some grease leakage past the seal was intentionally designed in, depletion of the reservoir during the service lifetime was a major concern. However, this is not much of a concern anymore. Thus the main purposes of the reservoir now are to assist in complete filling of the bearing and passageways, and to provide pressure compensation in-service.
The normal pressure compensation arrangement uses a tough concave diaphragm to transmit the pressure variations from the neighborhood of the cones to the bearings. The diaphragm is typically filled with grease, and is fluidly connected (on its concave side) through a grease-filled passageway to the grease volume inside the seal. The exterior of the diaphragm is fluidly connected, through a weep hole, to the volume of drilling fluid below the bit body.
One current production system uses a pierced rubber plug (which is separate from the diaphragm) for pressure relief. However, since the phase of pressure transient waves at this plug will not precisely match with those at the diaphragm, this can result in underprotection or overprotection by the plug (i.e. insufficient OR excessive extrusion of grease). Moreover, it was found that the frequent transients seen at the plug would fatigue it.
Pressure Relief System
The present application discloses roller-cone-type bits and methods where a modified pressure compensation structure is used to keep the pressure differential across the dynamic rotary seal within a predetermined operating range. In various embodiments, the pressure relief valve is either made integral with (or very closely coupled to) the lubricant reservoir's diaphragm. Thus there is little or no phase shift between the diaphragm and the pressure relief valve, and overpressures are accurately limited. Preferably this is achieved by using a hydrostatically-asymmetric seal, which is integrated with or in proximity to the diaphragm, as the pressure relief valve.
In one class of embodiments, the lip of the concave diaphragm is turned back to make a seal which faces in the desired direction. (That is, the direction of lubricant flow into the concavity is the same as the “easy” direction of lubricant flow past the seal.) This choice is somewhat surprising, since it requires some care in the assembly operation (and appropriate chamfering to not tear the seal edge during assembly); but this turned-back lip provides several advantages. First, the overpressure bypass path is very close to the interior of the diaphragm. Second, the overpressure bypass path is short. Third, when vacuum is applied before grease is injected, the preferred lip seal will hold vacuum for the necessary time. Fourth, this orientation permits an overall reservoir design which is very compatible with existing bit designs. Fifth, the overall piece count is not increased.
Thus one advantage of the hydrostatically-asymmetric-seal pressure relief is its close proximity to the diaphragm.
Another advantage is the relatively low fluid impedance of the seal once fluid bypass flow begins.
Another advantage is simple manufacturing.
BRIEF DESCRIPTION OF THE DRAWING
The disclosed inventions will be described with reference to the accompanying drawings, which show important sample embodiments of the invention and which are incorporated in the specification hereof by reference, wherein:
FIGS. 1A-1C show a first embodiment, in which a hydrostatically-asymmetric seal is integrated with the bladder (concave diaphragm) of the pressure compensator. FIG. 1A shows the bladder, with a hydrostatically-asymmetric seal as its lip, in place in the pressure compensator. FIG. 1B shows how the hydrostatically-asymmetric seal of this embodiment allows free flow in one direction, and FIG. 1C shows how this seal blocks reverse flow.
FIGS. 1D-1E show a second embodiment, in which a hydrostatically-asymmetric seal is still integrated with the bladder (concave diaphragm) of the pressure compensator, but is turned in the opposite direction to the embodiment of FIG. 1 A. FIG. 1D provides an sectional view of the bladder, with a hydrostatically-asymmetric seal as its turned-down lip, in place in the pressure compensator, and FIG. 1E shows the path of bypass (free) flow in this embodiment.
FIG. 1F shows a third embodiment, in which the hydrostatically-asymmetric seal is not integrated with the bladder, but is merely in close proximity to it.
FIG. 2 shows a roller-cone-type bit.
FIG. 3 shows a conventional drill rig.
FIG. 4 shows a sectional view of a cone mounted on a spindle which extends from a bit's arm.
FIG. 5 shows a sectional view of a larger extent of a roller-cone-type bit's arm, including the pressure compensation system.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The numerous innovative teachings of the present application will be described with particular reference to the presently preferred embodiment (by way of example, and not of limitation).
The present application discloses roller-cone-type bits and methods where a modified pressure compensation structure is used to keep the pressure differential across the dynamic rotary seal within a predetermined operating range. In various embodiments, the pressure relief valve is either made integral with (or very closely coupled to) the lubricant reservoir's diaphragm. Thus there is little or no phase shift between the diaphragm and the pressure relief valve, and overpressures are accurately limited. Preferably this is achieved by using a hydrostatically-asymmetric seal, which is integrated with or in proximity to the diaphragm, as the pressure relief valve.
In one class of embodiments, the lip of the concave diaphragm is turned back to make a seal which faces in the desired direction. (That is, the direction of lubricant flow into the concavity is the same as the “easy” direction of lubricant flow past the seal.) This choice is somewhat surprising, since it requires some care in the assembly operation (and appropriate chamfering to not tear the seal edge during assembly); but this turned-back lip provides several advantages. First, the overpressure bypass path is very close to the interior of the diaphragm. Second, the overpressure bypass path is short. Third, when vacuum is applied before grease is injected, the preferred lip seal will hold vacuum for the necessary time. Fourth, this orientation permits an overall reservoir design which is very compatible with existing bit designs. Fifth, the overall piece count is not increased.
The term “hydrostatically-asymmetric seal” is used, in the present application, to refer to seals which allow fluid passage easily in only one direction. A simple example (and the presently preferred embodiment) is the vee-lip seal. However, many other seal designs are possible, as detailed in the Seals and Sealing Handbook (4.ed. M. Brown 1995).
Embodiments with Pass-Through Pressure Relief
FIGS. 1A-1C show a first sample embodiment, in which a hydrostatically-asymmetric seal 130 is integrated with the bladder (concave diaphragm) 100 A of the pressure compensator 100 . FIG. 1A shows the bladder 100 A, with a hydrostatically-asymmetric seal 130 as its lip, in place in the pressure compensator. FIG. 1B shows how the hydrostatically-asymmetric seal 130 of this embodiment allows free flow in one direction, and FIG. 1C shows how this seal 130 blocks reverse flow.
Note that in these embodiments the lubricant first passes into the concavity 102 , and only from there escapes past the seal (pressure relief valve) to relieve overpressure.
Embodiments with Paralleled Pressure Relief
FIGS. 1D-1E show a second embodiment, in which a hydrostatically-asymmetric seal 130 D is still integrated with the bladder (concave diaphragm) 100 D of the pressure compensator, but is turned in the opposite direction to the embodiment of FIG. 1 A.
FIG. 1D provides an sectional view of the bladder 100 D, with a hydrostatically-asymmetric seal 130 D as its turned-down lip, in place in the pressure compensator, and FIG. 1E shows the path of bypass (free) flow in this embodiment. Note that in this embodiment bypass flows of lubricant do not have to pass through the cavity 102 . This is advantageous in that the pressure relief valve is more closely coupled to the bearings and seal, and this embodiment is presently preferred.
Alternative Embodiment with Separated Lip
FIG. 1F shows a third embodiment, in which the hydrostatically-asymmetric seal 130 F is not integrated with the bladder 100 F, but is merely in close proximity to it.
In this class of alternative embodiments the seal preferably has a diameter which is at least half of the width of the opening of diaphragm 130 F (to provide low-impedance bypass), and is axially separated from the bladder (along its central axis) by no more than half of the diaphragm diameter (to provide close coupling).
Note also that this FIG. explicitly illustrates the stand-off bumps 104 , which keep the bladder separate from the surrounding metal surface, and allow reverse pressure surges to be communicated to the pressure relief valve.
This class of embodiments is generally less preferred, but is considered to be a possible adaptation of the ideas described above.
Note also that, in this embodiment, while the diaphragm needs to be an elastomer, the hydrostatically-asymmetric lip seal DOES NOT have to be.
Modifications and Variations
As will be recognized by those skilled in the art, the innovative concepts described in the present application can be modified and varied over a tremendous range of applications, and accordingly the scope of patented subject matter is not limited by any of the specific exemplary teachings given. Some contemplated modifications and variations are listed below, but this brief list does not imply that any other embodiments or modifications are or are not foreseen or foreseeable.
In alternative embodiments, TWO pressure relief valves can be used (possibly operating at different pressures), of which (e.g.) only one is a hydrostatically-asymmetric seal as described.
Most roller-cone bits today use journal bearings. However, the disclosed inventions are also applicable to rock bits which use rolling bearings (e.g. roller bearings or roller and ball).
In alternative embodiments the bit can have two or more compensator reservoirs per arm, or could have a central reservoir which feeds multiple arms.
In one class of alternative embodiments the grease (and/or the drill bit) can be heated during the filling operation, to reduce the viscosity of the grease.
A variety of materials can be used in implementing the disclosed inventions. The elastomeric diaphragm is nitrile rubber in the presently preferred embodiment, but can alternatively be made of neoprene or other suitably strong elastomer. The hydrostatically-asymmetric seal is preferably an integral part of a homogeneous diaphragm, but alternatively and less preferably the diaphragm can be inhomogeneous.
The “cones” of the roller-cone bit do not have to be (and typically are not) strictly conical nor frustro-conical. Typically the sides of a “cone” are slightly swelled beyond a conical shape, but the exact geometry is not very relevant to the operation of the disclosed inventions. The disclosed inventions are applicable to any sealed roller-cone bit.
While drill bits are the primary application, the disclosed inventions can also be applied, in some cases, to other rock-penetrating tools, such as reamers, coring tools, etc.
In various embodiments, various ones of the disclosed inventions can be applied not only to bits for drilling oil and gas wells, but can also be adapted to other rotary drilling applications (especially deep drilling applications, such as geothermal, geomethane, or geophysical research).
Additional general background on seals, which helps to show the knowledge of those skilled in the art regarding implementation options and the predictability of variations, can be found in the following publications, all of which are hereby incorporated by reference: SEALS AND SEALING HANDBOOK (4.ed. M. Brown 1995); Leslie Horve, SHAFT SEALS FOR DYNAMIC APPLICATIONS (1996); ISSUES IN SEAL AND BEARING DESIGN FOR FARM, CONSTRUCTION, AND INDUSTRIAL MACHINERY (SAE 1995); MECHANICAL SEAL PRACTICE FOR IMPROVED PERFORMANCE (ed. J. D. Summers-Smith 1992); THE SEALS BOOK (Cleveland, Penton Pub. Co. 1961); SEALS HANDBOOK (West Wickham, Morgan-Grampian, 1969); Frank L. Bouquet, INTRODUCTION TO SEALS AND GASKETS ENGINEERING (1988); Raymond J. Donachie, BEARINGS AND SEALS (1970); Leonard J. Martini, PRACTICAL SEAL DESIGN (1984); Ehrhard Mayer, MECHANICAL SEALS (trans. Motor Industry Research Association, ed. B. S. Nau 1977); and Heinz K. Muller and Bernard S. Nau, FLUID SEALING TECHNOLOGY: PRINCIPLES AND APPLICATIONS (1998).
Additional general background on drilling, which helps to show the knowledge of those skilled in the art regarding implementation options and the predictability of variations, may be found in the following publications, all of which are hereby incorporated by reference: Baker, A PRIMER OF OILWELL DRILLING (5.ed. 1996); Bourgoyne et al., APPLIED DRILLING ENGINEERING (1991); Davenport, HANDBOOK OF DRILLING PRACTICES (1984); DRILLING (Australian Drilling Industry Training Committee 1997); FUNDAMENTALS OF ROTARY DRILLING (ed. W. W. Moore 1981); Harris, DEEPWATER FLOATING DRILLING OPERATIONS (1972); Maurer, ADVANCED DRILLING TECHNIQUES (1980); Nguyen, OIL AND GAS FIELD DEVELOPMENT TECHNIQUES: DRILLING (1996 translation of 1993 French original); Rabia, OILWELL DRILLING ENGINEERING/PRINCIPLES AND PRACTICE (1985); Short, INTRODUCTION TO DIRECTIONAL AND HORIZONTAL DRILLING (1993); Short, PREVENTION, FISHING & REPAIR (1995); UNDERBALANCED DRILLING MANUAL (Gas Research Institute 1997); the entire PetEx Rotary Drilling Series edited by Charles Kirkley, especially the volumes entitled MAKING HOLE (1983), DRILLING MUD (1984), and THE BIT (by Kate Van Dyke, 4.ed. 1995); the SPE reprint volumes entitled “Drilling,” “Horizontal Drilling,” and “Coiled-Tubing Technology”; and the Proceedings of the annual IADC/SPE Drilling Conferences from 1990 to date; all of which are hereby incorporated by reference.
None of the description in the present application should be read as implying that any particular element, step, or function is an essential element which must be included in the claim scope: THE SCOPE OF PATENTED SUBJECT MATTER IS DEFINED ONLY BY THE ALLOWED CLAIMS. Moreover, none of these claims are intended to invoke paragraph six of 35 USC section 112 unless the exact words “means for” are followed by a participle.
The claims as filed are intended to be as comprehensive as possible, and NO subject matter is intentionally relinquished, dedicated, or abandoned.
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A roller-cone rock bit in which the compensation reservoir is integrated with a hydrostatically-asymmetric seal, such as a V-seal, which provides pressure relief. This seal not only relieves overpressure during filling, and when the grease thermally expands as the bit first goes downhole, but also compensates transient overpressures during operation.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
1. Technical Field
This invention is related to devices which are adapted to be attached to ladders to provide auxiliary support for equipment, tools and supplies to be used while on the ladder.
2. Description of Prior Art
Prior art devices of this type have been directed to attachments for ladders that utilize the hollow rung of an extension ladder for support such as access trays and brackets used to hold work related items, see for example U.S. Pat. Nos. 3,160,383, 4,660,794, 5,031,723, 5,135,193, 5,181,682, 5,191,954, 5,293,957, 5,649,682 and 5,934,632.
In U.S. Pat. No. 3,160,383 a hanging device is disclosed that extends through the ladder's hollow rung with a paint can hook and support arms extending therefrom.
U.S. Pat. Nos. 4,660,794, 5,031,722, 5,135,193 and 5,191,954 are all directed to trays and platforms that are secured to the ladder using a support rod that extends through the hollow ladder rung.
In U.S. Pat. Nos. 5,191,954 and 5,135,193 secondary support elements engage the ladder's adjacent rungs.
U.S. Pat. No. 5,031,722 discloses a device that extends through the ladder rung providing for a secondary can holding notch on its opposite end.
U.S. Pat. No. 5,181,682 is directed to a tool holder having a bifurcated ladder rung insert that is compressed and inserted into the rung expanding within to hold the tool engagement ring extending therefrom.
U.S. Pat. No. 5,293,957 discloses a container holding attachment which is insertable into a ladder rung having a U-shaped wire insert portion with a sleeve so as to angularly offset within to engage the inner surface of the rung.
U.S. Pat. Nos. 5,649,682 and 5,934,632 claim paint can holders for ladders in which a support arm is inserted into the hollow ladder rung with a can engagement ring extending from its free end. U.S. Pat. No. 5,934,632 has a locking unit that extends from a rung engaging the opposite ladder rail.
SUMMARY OF THE INVENTION
A tool and accessory holder device for ladders with hollow rungs having a universal engagement and support shaft insertable partially into the rung. Multiple tool and utility holders are adjustably secured anywhere along the support shaft's extended portion with a safety ladder engagement locking bracket and registration insert adjustable fittings for interior rung engagement.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view of the ladder tool holder of the invention;
FIG. 2 is a top plan view of the ladder tool holder of the invention as shown in FIG. 1;
FIG. 3 is an elevational view of the ladder tool holder device of the invention mounted within a ladder with portions broken away for illustration purposes:
FIG. 4 is an end elevational view of the holder device in use with the ladder and tool accessories for holding a paint can and brush in broken lines;
FIG. 5 is an end view of the ladder tool holder's main support and extrusion member within a ladder rung illustrated in broken lines;
FIG. 6 is a side elevational view of an access hook and insert of the invention;
FIG. 7 is a side elevational view of an alternate size insert portion for the ladder tool holder device with a ladder and ladder rung shown in broken lines;
FIG. 8 is a perspective exploded assembly view of a paint can holder accessory and mounting insert;
FIG. 9 is a cross-sectional view of the ladder tool holder extrusion member with a size adapter mounted thereon;
FIG. 10 is a partial top plan view of the ladder tool holder slidably secured within a rung portion of the ladder with the safety retaining bracket engaged thereon;
FIG. 11 is a partial top plan view of a ladder stabilizing accessory slidably secured within a portion of the insert member; and
FIG. 12 is an enlarged cross-sectional view of the ladder stabilization extension adapter on the ladder of FIG. 11 .
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIGS. 1, 2 and 5 of the drawings, a tool holder 10 for a ladder can be seen having an elongated extrusion member 11 with multiple engagement side channels 12 and 13 and a top channel 14 within and a closure end cap 11 A. The extrusion member 11 is configured to fit within a hollow rung 15 of an extension ladder 16 , best seen in FIGS. 3 and 5 of the drawings. The extrusion member 11 has an arcuate lower wall portion 17 which extends to form the respective oppositely disposed side engagement channels 12 and 13 . Each of the channels 12 and 13 have a back engagement wall 18 with spaced upper and lower contoured lip portions 19 and 20 with respective access openings at 23 formed therebetween. The top channel 14 is formed within the upper surface 24 of the extrusion member 11 with a bottom wall 25 , and integrally upstanding oppositely disposed sidewalls 26 and 27 . A channel opening at 28 is formed within the upper surface 24 defining retaining flanges 24 A and 24 B. It will be noted that the lower wall portion 17 and the upper surface 24 have a plurality of engagement beads 29 extending longitudinally therealong so as to provide multiple points of contact within an interior surface 30 of the hollow ladder rung 15 .
A safety retaining clip 31 can be seen as being pivotally secured to the upper surface 24 of the extrusion member 11 by an adjustable threaded fastener assembly 32 . The retaining clip 31 has a pair of ladder engagement portions 33 A and 33 B that are of a generally U-shaped configuration interconnected by a mounting portion 34 having an apertured flange 34 A through which the fastener assembly 32 is engaged. The threaded fastener assembly 32 comprises a threaded lock nut knob 32 A that extends through the apertured flange 34 A and registers with an apertured retaining fitting 32 C slidably positioned within the top channel 14 as hereinbefore described.
An engagement stud 35 is threadably secured within the channel 14 by a retaining fitting 35 A. The stud 35 will act as a stop for the extrusion 11 during the insertion of same into the hollow rung 15 as best seen in FIGS. 2 and 7 of the drawings.
In use, the extension member 11 is inserted into the selected hollow ladder rung 15 up to the stud 35 . The retaining clip 31 is rotatably adjusted about the fastener assembly 32 and is positioned around an adjacent ladder rail 36 . The retaining clip 31 acts as a safety retaining device for the extension member 11 which is held by frictional engagement within the ladder rung 15 .
Multiple tool engagement fixtures are selectively and adjustably positioned within the extension member 11 by insertion into the respective access mounting slots 12 , 13 and 14 as will be described in greater detail hereinafter.
Referring now to FIGS. 1, 2 , 4 and 8 of the drawings, an accessory holder 37 for a paint can can be seen having a support plate 38 with a separate mounting insert plate 39 slidably disposed within a selected channel 12 . The support plate 38 defines an engagement surface with oppositely disposed angularly extending edge portions 40 A and 40 B. An angular offset apertured mounting and engagement tab 41 extends integrally from an upper edge surface 42 of the support plate 38 . The engagement tab 41 has a contoured handle insert portion 44 that will engage and support a typical handle 45 of a paint can C (as illustrated in broken lines) in FIG. 6 of the drawings. The mounting plate 39 is registerable within the side channel 12 and receives a pair of threaded fasteners F locking the accessory holder 37 in place.
Referring now to FIGS. 4 and 6 of the drawings, a utility tool hook holder 46 can be seen having a hook portion 46 A, a threaded shaft 46 B and a retainer 46 C portion. A mounting fitting 47 is slidably positioned within one of said selective channels 12 or 13 and threadably receives a hook holder 46 locking it into position with a paint brush B thereon shown in broken lines in FIG. 4 of the drawings.
Referring to FIGS. 7 and 9 of the drawings, a dimensional adjustment plate 48 can be seen removably positioned by fasteners F within the top channel 14 effectively increasing the overall engagement dimension of the extrusion member 11 so as to be engageable within an alternate ladder rung 49 which is of a larger interior diameter than that of the preferred ladder rung 15 as best seen in FIG. 11 of the drawings.
It will be seen that a variety of tool holder accessories can be added to and supported by the unique multiple channeled configuration of the extrusion member 11 and adjustably positioned thereon.
An example of such holder accessories is illustrated in FIGS. 11 and 12 of the drawings wherein a ladder stabilization standoff bracket assembly 50 can be seen having an elongated mounting extrusion 51 that is registerable within the side channel 13 in this example chosen for illustration. A spring urged locking pin 52 extends through aligned apertures at 53 and selectively engages selective apertures 54 in the extrusion member 11 . An L-shaped extension member 55 extends from the end of the mounting extrusion 51 having a resilient structure engagement pad insert 56 in its free end as will be well understood by those skilled in the art.
The above description will illustrate that by using a pair of tool holders 10 with attached ladder standoff bracket assemblies 50 the ladder L in use will be held in spaced stabilized engagement against a structure (not shown) as is typical of a ladder standoff device.
It will thus be seen that a new and novel ladder tool holder device has been illustrated and described and it will be apparent to those skilled in the art that various changes and modifications may be made therein without departing from the spirit of the invention.
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A ladder tool holder for holding hand tools and paint cans on an extension ladder having hollow rungs. The holder comprises a custom metal extrusion member that is registerable within a selected ladder rung. Multiple tool engagement and holding attachments are adjustably keyed into the portion of the extrusion extending from the registration ladder rung.
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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 generally to multi-function dispensers and, more specifically, to a device for diffusing an air-treatment concentrate to the ambient air surrounding a toilet and for dispersing a water-treatment concentrate to the tank of the toilet.
2. Description of the Related Art
Assemblies for diffusing air-treatment concentrates are well known. Such air-treatment assemblies were used to provide an air-diffused fragrance in the living areas of a house or the work and service areas of commercial environments. Diffusion of masking fragrances was especially useful in bathrooms and kitchen areas that were subject to a higher incidence of offensive odors. Assemblies were also used to diffuse an air-treatment concentrate capable of otherwise treating ambient air. Various means were developed to improve the diffusion of fragrances or treatment concentrates from the assemblies of the prior art. For example, fan assists were included in the assemblies to increase airflow across the air-treatment concentrate and thus the diffusion of the concentrate in ambient air. Heating elements were also included in some prior art assemblies to increase the temperature of the air-treatment concentrate to aid in volatilization of the concentrate and thus the diffusion of the concentrate.
Assemblies for discharging a water-treatment concentrate to the flush water contained in the tank or bowl of a toilet are also well known in the art. Such water-treatment assemblies were used to clean, color, or otherwise treat the water used to flush the toilet.
One type of such prior art water-treatment assembly, sometimes referred to as a “tank-hanger” assembly, pretreated the flush water by placement of a water-treatment concentrate directly in the toilet tank, or by placement of a water-treatment concentrate in a housing or reservoir. One type of tank-hanger assembly was the “active” assembly, which pumped or siphoned a solution of dissolved water-treatment concentrate into the toilet tank, usually at the flush cycle (See, for example, U.S. Pat. No. 4,357,718 by Corsette). With an active assembly, the housing containing the water-treatment concentrate could be located inside the toilet tank above the fill-level of the toilet tank or could be located completely or partially below the fill-level. Another type of tank-hanger assembly was the “passive” assembly, in which the water-treatment concentrate was placed inside the toilet tank in a housing at least partially submerged below the toilet tank fill-level. The water-treatment concentrate then passively dispersed in the tank water during the quiescent period between toilet flushes (See, for example, U.S. Pat. No. 4,216,027 by Wages).
Another type of prior art water-treatment assembly, sometimes referred to as a “rim-hanger” assembly, treated the flush water flowing from the rim of the toilet bowl only during the flush cycle. Since a rim-hanger assembly treated the flush water only during the short time of the flush cycle, it was generally ineffective in providing the treatment level provided by a tank-hanger assembly. As noted earlier, in a tank-hanger assembly a dispersible water-treatment concentrate, such as a hypochlorite tablet or puck, could be placed in continuous contact with the flush water stored in the toilet tank. No rim-hangers can currently claim sanitization or superior cleaning to tank-hanger dispersed hypochlorite tablets.
Further, attempts were made in the prior art to include air-treatment concentrates with the water-treatment concentrates contained in both tank-hanger and rim-hanger prior art assemblies. However, the approach of including air-treatment concentrates within the water-treatment concentrates proved an ineffective means to achieve air freshening of the ambient bathroom air surrounding a toilet fixture. In the case of tank-hangers, air-treatment concentrate, which diffused into the headspace above the toilet tank fill-level, did not have an effective exit point from the enclosed toilet tank to enter the ambient air. In the case of rim-hangers, the periodic dosing of the ambient air only during the flush cycle of the toilet proved ineffective in providing continuous air freshening of the general bathroom air. Rim-hangers had the additional disadvantage of being unsightly and, after the recommended four to six weeks of continuous use, becoming germ laden.
Accordingly, what is needed is a simple, easy-to-use device that provides, in combination, effective toilet flush water-treatment and that further provides effective continuous treatment of the ambient bathroom air surrounding the toilet fixture.
SUMMARY OF THE INVENTION
In accordance with the principles of the present invention, in one embodiment, a device comprises a water treatment part for mounting inside a toilet tank; an air moving part for mounting inside a toilet tank; an air treatment part in communication with the air moving part; and a bellows formed from an interior of the air moving part, wherein air displaced from the bellows moves through the air treatment part; and wherein the bellows has a differential cross-sectional area along its depth.
According to another embodiment of the present invention, a multi-function toilet device comprises a water treatment part for mounting inside a toilet tank; an air moving part for mounting inside a toilet tank; an air treatment part in communication with the air moving part; and a bellows formed from an interior of the air moving part, wherein an amount of air displaced from the bellows and delivered to the air treatment part varies through a flush cycle.
According to a further embodiment of the present invention, a multi-function toilet device comprises an air moving part; a water treatment part nested within the air moving part; an air treatment part in communication with the air moving part; and a bellows formed from an interior of the air moving part, wherein air displaced from the bellows moves through the air treatment part; and wherein the bellows has a differential cross-sectional area along its depth.
To use the multi-function toilet device of the present invention, the tank lid of the toilet is removed, the connector may be placed over the lip of the toilet tank to position the air-treatment concentrate adjacent the exterior surface of the toilet tank and to position the water-treatment concentrate adjacent the interior surface of the toilet tank. In one embodiment, the air-treatment concentrate may be located adjacent the interior surface of the toilet tank, above the fill-level of the toilet tank, with a vent communicating the air-treatment concentrate to the exterior of the toilet tank. In one embodiment, the water-treatment concentrate may be positioned at least partially below the fill-level of the toilet tank. After placement of the connector and positioning of the air-treatment and water-treatment concentrates, the tank lid is replaced on the toilet tank over the connector. The bellows may be located inside the toilet tank so that the water level inside the toilet tank immediately after flush is below the bellows and the water level inside the toilet tank at the filled level covers at least a portion of the bellows.
In one embodiment, the multi-function toilet device of the present invention further includes an air-treatment housing coupled to the air-treatment end portion of the connector and a water-treatment housing coupled to the water-treatment end portion of the connector, opposite the air-treatment end portion of the connector. As described in the various embodiments below, the water-treatment housing may form the bellows, may be a separate entity from the bellows, may be nested in the bellows or may be formed integrally with the bellows. Disposed within the air-treatment housing is the air-treatment concentrate and disposed within the water-treatment housing is the water-treatment concentrate.
The air-treatment housing can include a heating element or a fan coupled to the multi-function toilet device to enhance diffusion of the air-treatment concentrate. The water-treatment housing can be an active device, which provides pumping or siphoning of an aliquot of water-treatment concentrate pre-mixed with toilet tank water. Alternatively, the water-treatment housing can be a passive device, which merely contains and positions the water-treatment concentrate at least partially below the toilet tank fill-level to passively disperse into the tank water.
The air and water-treatment housings can be adjustably coupled to the connector to allow suitable positioning of the housings upon installation of the multi-function toilet device of the present invention. In one embodiment, the air and water-treatment housings are slideably adjustable along a connector.
The connector can take alternate shapes. In one embodiment, the connector is a planer ribbon configured generally as a rigid inverted “J” shaped bracket. The inverted “J” has a “top” intermediate the two unequal length “legs” that makeup the air-treatment and water-treatment end portions of the connector such that the top contacts the lip of the toilet tank and the legs hang adjacent the interior and exterior of the toilet tank to suitably position the air-treatment concentrate and water-treatment concentrate, respectively. In another embodiment, there may be two hanging parts with a water-treatment end portion nested inside the air-treatment portion. In another embodiment, the connector is generally shaped in the form of an inverted “U”, having the air-treatment end portion and the water-treatment end portion of equal length. Various other configurations of the connector are possible and would be apparent to those of ordinary skill in the art. For example, the connector may be simply shaped as an inverted “L” having only one end portion.
In yet another embodiment, the connector is a planar ribbon having living hinges, well known to those of ordinary skill in the art, and adapted to allow folding of the connector into, for example, the inverted “J”, “U”, or “L” configurations described and to allow adjustment of the air-treatment and water-treatment housings for suitable positioning at installation of the multi-function toilet device. In one embodiment, the connector is a bendable wire, band, ribbon, or tube configurable as described above to accommodate placement on the toilet tank and positioning of the air-treatment and water-treatment housings adjacent the toilet tank interior surface and exterior surface, respectively. For these embodiments, the multi-function toilet device may be conveniently packaged in a flat folded configuration and bent to a suitable configuration before use.
In yet another embodiment, the connector is not placed over the tank lip but is rather attached to the removable toilet tank lid such that the air-treatment concentrate is positioned adjacent the exterior surface of the tank and the water-treatment concentrate is positioned adjacent the interior surface of the tank when the toilet tank lid is replaced.
The connector, air-treatment and water-treatment housings of the multi-function toilet device of the present invention can be made of any suitable material. Exemplary materials include but are not limited to metal, and metal composites, ceramics, polypropylene (PP), polyethylene (PE), high density polyethylene (HDPE), polyethylene terephthalate (PET), polystyrene (PS), acrylonitrile-butadiene-styrene (ABS), polymer composites, and other engineered plastics that may be formed with a variety of fabrication technologies, such as, for example, thermoforming or blowmolding.
The multi-function toilet device of the present invention can be disposed after depletion of the water-treatment and air-treatment concentrates or can be refillable with the concentrates. Further, the device of the present invention can include one or more indicia that alert the user that the air or water-treatment concentrates are depleted.
Further features and advantages of the present invention will become apparent to those of ordinary skill in the art in view of the detailed description of embodiments below, when considered together with the attached drawings and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing aspects and others will be readily appreciated by the skilled artisan from the following description of illustrative embodiments when read in conjunction with the accompanying drawings, in which:
FIG. 1A shows a right side perspective view of a toilet containing a multi-function toilet device in accordance with the principles of the present invention;
FIG. 1B shows a left side perspective view of the toilet containing the multi-function toilet device of FIG. 1A ;
FIG. 2A shows a front side view of a multi-function toilet device of the present invention;
FIG. 2B shows a left side view of the multi-function toilet device of FIG. 2A ;
FIG. 2C shows a right side view of the multi-function toilet device of FIG. 2A ;
FIG. 2D shows a perspective view of the air-treatment portion of the multi-function toilet device of FIG. 2A ;
FIG. 2E shows a cross-sectional view of the bottom of the air-treatment portion of the multi-function toilet device of FIG. 2A ;
FIG. 3 shows a front side view of another embodiment of the multi-function toilet device of the present invention;
FIG. 4 is a graph showing the relative mass flux of fragrance release over time for the multi-function toilet device of the present invention, such as the multi-function toilet device of FIG. 3 , as compared to a conventional toilet device;
FIG. 5 is a graph showing the cumulative amount of fragrant air dispense over time for the multi-function toilet device of the present invention, such as the multi-function toilet device of FIG. 3 , as compared to a conventional toilet device;
FIG. 6A shows a front side view of another embodiment of the multi-function toilet device according to the present invention;
FIG. 6B shows a side view of the multi-function toilet device of FIG. 6A ;
FIG. 6C shows a perspective view of the air-treatment portion of the multi-function toilet device of FIG. 6A ;
FIG. 6D shows a front side view of another embodiment of the multi-function toilet device according to the present invention;
FIG. 6E shows a side view of the multi-function toilet device of FIG. 6D ;
FIG. 7 is a front side, cross-sectional view of the multi-function toilet device of the present invention having a fan disposed therein;
FIG. 8 is a front side, cross-sectional view of the multi-function toilet device of the present invention having a delay valve disposed therein;
FIG. 9 is a front side, cross-sectional view of the multi-function toilet device of the present invention having a collapsible bellows; and
FIG. 10 is a front side, cross-sectional view of the multi-function toilet device of the present invention having a paddle disposed therein.
DETAILED DESCRIPTION
Reference will now be made to the drawings wherein like numerals refer to like parts throughout. Exemplary embodiments of the present invention are illustrated in the context of a multi-function toilet tank device placed on a toilet fixture having a toilet tank, a removable tank lid covering the toilet tank, and a toilet bowl having a bowl rim. The skilled artisan will readily appreciate, however, that the materials and methods disclosed herein will have application in a number of other contexts where diffusion of an air-treatment concentrate to the ambient air and dissolution or dispersal of a water-treatment concentrate into a liquid storage tank is desirable, particularly where ease of use is important.
The aforementioned needs may be satisfied by the multi-function toilet device of the present invention which includes a connector with an air-treatment end portion and a water-treatment end portion opposite the air-treatment end portion; an air-treatment concentrate coupled to the air-treatment end portion of the connector; and a water-treatment concentrate coupled to the water-treatment end portion of the connector. The connector may be configured to position the air-treatment concentrate adjacent an exterior surface of the toilet tank and to position the water-treatment concentrate adjacent an interior surface of the toilet tank at least partially below the fill-level of the toilet tank. As discussed in greater detail below, the connector may form an air passage between the air-treatment portion and a bellows section of the water treatment portion.
In use, the tank lid of the toilet may be removed, and the connector may be placed over the lip of the tank to position the air-treatment concentrate adjacent the exterior surface of the tank and to position the water-treatment concentrate adjacent the interior surface of the tank below the fill-level of the tank.
More particularly, FIG. 1A shows a right side perspective view of a toilet 10 containing a multi-function toilet device 12 in accordance with the principles of the present invention. FIG. 1B shows a left side perspective view of the toilet 10 containing the multi-function toilet device 12 of FIG. 1A . Referring to FIGS. 1A and 1B together, toilet 10 includes a toilet tank 14 having a toilet tank lip 16 at the top of the toilet tank 14 , a toilet tank lid 18 which may fit on the toilet tank lip 16 , and a toilet bowl 20 having a toilet bowl rim 22 . While FIGS. 1A and 1B show the multi-function toilet device 12 mounted on the right side of the toilet tank 14 , the multi-function toilet device 12 may be mounted on other portions of the toilet tank lip 16 . As shown in FIG. 1A , an air treatment portion 24 of the multi-function toilet device 12 may be mounted on an exterior portion 26 of the toilet tank 14 . As shown specifically in FIG. 1B , a water treatment portion 28 of the multi-function toilet device 12 may be mounted on an interior portion 30 of the toilet tank 14 . As will be discussed in more detail below, the water treatment portion 28 may be mounted below a water line 32 inside the toilet tank 14 . When the toilet 10 is flushed, the water line 32 may move below the water treatment portion 28 .
Referring now to FIG. 2A , there is shown a front side view of the multi-function toilet device 12 according to one embodiment of the present invention. The multi-function toilet device 12 may include a water treatment side 34 and an air moving side 36 . The water treatment side 34 and the air moving side 36 may have flat sides 34 a , 36 a that allow the water treatment side 34 and the air moving side 36 to be pushed together as to appear as a single unit. Alternatively, the water treatment side 34 may be formed integrally with the air moving side 36 . In a further alternate embodiment, the water treatment side 34 may be separately located on the toilet tank 14 from the air moving side 36 .
The water treatment side 34 may contain a water treatment concentrate 38 . In one embodiment of the present invention, the water treatment concentrate 38 may be disposed at a lower end 40 of the water treatment side 34 such that the water treatment concentrate 38 is below the water line 32 (see FIGS. 1A and 1B ) during at least a portion of a flush cycle. Hereinafter, a “flush cycle” may be defined as the action of the water level in the toilet tank, going from a full level (as indicated, for example, by the water line 32 of FIGS. 1A and 1B ), to a flushed level (not shown), and returning to a full level. Alternatively, the water treatment concentrate 38 may be located above the water line 32 with a means, as is known in the art, such as with an active pumping or a dosing type of water treatment concentrate dispenser, for delivering the water treatment concentrate 38 into the toilet tank 14 at the appropriate times (e.g., during a flush cycle or after a flush cycle).
The water treatment concentrate 38 may be any water-dispersible compound formulated to treat toilet flush water. Examples of suitable compounds include, but are not limited to, bleaches, surfactants, disinfectants, inorganic compounds, chelators, optical brighteners, and mixtures thereof. Furthermore, the water treatment concentrate 38 may be formulated to include components, such as polymers, that protect or modify toilet bowl interior surfaces, or components that protect or treat toilet valve parts. The water treatment concentrate 38 may be in the form of a liquid, solid, semi-solid, impregnated non-woven substrate, impregnated cellulosic substrate, impregnated solid or in other forms suitable for use in water treatment applications.
Referring to FIG. 2E , there is shown a cross-sectional view from a bottom end 42 of the air moving side 36 of the multi-function toilet device 12 of FIG. 2A . The air moving side 36 may include a housing 44 having an opening 46 at the bottom end 42 thereof. In one embodiment of the present invention, a cross-sectional area of the lower end 42 of the air moving side 36 may be less than a cross-sectional area of an upper end 48 of the air moving side 36 . This differential cross-sectional area along a depth D of the air moving side 36 may be realized, for example, by forming the lower end 42 with a first length L 1 that is less than a second length L 2 . This differential cross-sectional area may also be realized (either separately or in combination with the different lengths L 1 , L 2 ) by forming the lower end 42 with a first width W 1 (see FIG. 2C ) that is greater than a second width W 2 formed at the upper end 48 . Alternatively, as shown in FIG. 3 , the lower end 42 may be formed with the first length L 1 that is greater than the second length L 2 .
Referring to FIG. 2B , there is shown a left side view of the multi-function toilet device 12 of FIG. 2A . The water treatment side 34 may be attached to the toilet tank 14 by a bracket 50 . Alternatively, any conventional means may be used to affix the multi-function toilet device 12 to the toilet tank 14 . For example, water-proof adhesive may be used to attach the multi-function toilet device 12 to the toilet tank 14 . As discussed above, the water treatment side 34 may include the water treatment concentrate 38 at the lower end 40 of the water treatment side 34 .
Referring to FIG. 2C , there is shown a right side view of the multi-function toilet device 12 of FIG. 2A . The air moving side 36 may be attached to the toilet tank 14 by a bracket 50 a . The bracket 50 a may include an air passage 52 for communicating an interior 54 of the air treatment portion 24 with an interior 56 of the air moving side 36 . This interior 56 of the air moving side 36 may also be referred to as a bellows 56 , as when water fills the toilet tank, the volume of air inside the bellows 56 may be expelled through the air passage 52 as the air inside the bellows 56 is replaced by water. The air expelled through the air passage 52 may pass through the air treatment portion 24 and be delivered to freshen the air in the room containing the toilet 10 .
Referring to FIG. 2D , there is shown a perspective view of the air-treatment portion 24 of the multi-function toilet device 12 of FIG. 2A . The air treatment portion 24 may receive air through the air passage 52 . The air may pass through an air treatment concentrate (not shown) located within the interior 54 of the air treatment portion 24 . Holes 58 may be formed in the air treatment portion to allow the air from the air passage 52 to flow over the air treatment concentrate, through the holes 58 and into the room containing the toilet 10 . In one embodiment, as shown in FIG. 2D , the holes 58 may be formed opposite from where the air passage 52 joins with the air treatment portion 24 . Such a configuration may allow for the air in the air passage 52 to pass over the air treatment concentrate before being expelled to the ambient surroundings (such as the room containing the toilet 10 ).
The present invention may include a bellows 56 that has a differential cross-sectional area when comparing the upper end 48 with the lower end 42 . As shown in FIG. 2A , this differential cross-sectional area may be realized, for example, by forming the lower end 42 with the first length L 1 that is less than the second length L 2 . Such a configuration may provide an initially lower amount of air moving through the air treatment portion 24 , as water in the toilet tank 14 begins to cover the lower end 42 of the air moving side 36 and fill the bellows 56 . As the water continues to rise in the toilet tank 14 , the water may continue to fill the bellows 56 , expelling a greater volume of air through the air treatment portion 24 . Depending on the consumer needs and market research, such a design may be beneficial in providing a greater amount of fragrant air dispensed at the end of the flush cycle. This design may also be particularly useful when a delay valve (not shown, discussed below with reference to FIG. 8 ) is used to increase the rate of air flow over the air treatment concentrate to deliver a more intense fragrance release/burst. In this case, as discussed in more detail below, the smaller length L 1 at the lower end 42 may allow for a slow buildup of pressure before releasing the air through the air passage 52 .
Alternatively, referring to FIG. 3 , the differential cross-sectional area may be realized, for example, by forming the lower end 42 of the air moving side 36 with the first length L 1 that is greater than the second length L 2 . The air moving side 36 may be formed with an exterior shape, as shown be the dotted line 60 , substantially symmetrical to the water treatment side 34 . This design may impart a greater initial release of fragrance compared to conventional uniform cross-sectional area designs. As the toilet tank 14 fills during the flush cycle, a greater volume of air and fragrance is displaced earlier in time, when the consumer may be more likely to desire such a fragrance concentration.
An additional benefit to the design of FIG. 3 may be realized due to the smaller length L 2 at an upper end 48 of the air moving side 36 . In this embodiment of the present invention, the amount of potential dead space 62 may be minimized. Dead space 62 may refer to the amount of space occupied by air in the air moving side 36 when the water line 32 in the toilet tank 14 is at a maximum position. Fill levels inside various consumer toilet tanks 14 may be variable and any volume above the fill level (e.g., dead space 62 ) will not be dispensed. Therefore, it may be beneficial to minimize dead space 62 by having the upper end 48 of the air moving side 36 having a relatively small cross-sectional area (i.e., by a smaller length L 2 ).
Referring now to FIG. 4 , there is shown a graph describing the exemplary rate of fragrance release over time for the multi-function toilet device 12 of FIG. 3 as compared to conventional, uniform cross-sectional area designs. The relative mass flux for fragrance release for the design of FIG. 3 may be shown by line 64 and the conventional, uniform cross-sectional area design may be shown by line 66 . As can be seen from the graph, the present invention may afford a greater mass flux of fragrance early in the flush cycle.
Referring to FIG. 5 , there is shown a graph describing the exemplary cumulative amount of fragrant air dispensed over time for the multi-function toilet device 12 of FIG. 3 as compared to conventional, uniform cross-sectional area designs. The fragrant air dispensed for the design of FIG. 3 may be shown by line 68 and the conventional, uniform cross-sectional area design may be shown by line 70 . As can be seen from the graph, the present invention may afford a greater amount of fragrant air dispensed early in the flush cycle. For example, during the first third of the flush cycle, the design of the present invention may dispense at least about 50%, and typically about 60% more fragrance as compared to the conventional design.
Referring to FIG. 6A , there is shown a front side view of another embodiment of the multi-function toilet device 72 according to the present invention. Similar to the embodiment of FIGS. 2A-2E , the multi-function toilet device 72 may include a water treatment part 74 and an air moving part 76 . The water treatment part 74 may be nested in the air moving part 76 . The water treatment part 74 may have a bracket 78 and the air moving part 76 may have a separate bracket 78 a . Brackets 78 , 78 a may permit the parts 74 , 76 to be mounted on the toilet tank 14 as described above with reference to FIGS. 2A-2E .
A lower end 80 of the air moving part 76 may have a length L 1 that is longer than a length L 2 of an upper end 82 of the air moving part. This design may result in a differential cross-sectional area between the lower end 80 and the upper end 82 . Such a differential cross-sectional area may impart benefits similar to those discussed above with respect to the graphs of FIGS. 4 and 5 .
While FIG. 6A shows the water treatment part 74 behind the air moving part 76 , in an alternate embodiment of the present invention, the water treatment part 74 may be disposed in front of the air moving part 76 in order to allow for easy replacement of the water treatment part 74 . Alternatively, a channel (not shown) may be formed in the air moving part 76 for the placement of a connector 90 of the water treatment part 74 .
Referring now to FIGS. 6B and 6C , the interior of the air moving part 76 may form a bellows 84 which may be in communication with an air treatment portion 86 via an air passage 88 . As the water level in the toilet tank 14 increases, the air displaced by water in the bellows 84 may flow through the air passage 88 and through the air treatment portion 86 to release fragrance contained therein.
Referring to FIG. 6D (side view shown in FIG. 6E ), the bellows 84 (i.e., the interior of the air moving part 76 ) may be a collapsible bellows, which may have a fixed end 130 and a floating end 132 . The floating end 132 may be designed to float at the water line in the toilet tank. The length L 1 of the lower end 80 of the bellows 84 may be different from the length L 2 of the upper end 82 of the bellows 84 . This difference between L 1 and L 2 may provide a differential cross-sectional area of the bellows from the lower end 42 to the upper end 48 , thereby providing a variable flow of fragrance from the air treatment part 86 .
While the above embodiments described particular embodiments of the present invention, the embodiments should not be taken in a limited sense. Modifications within the skill of those in the art are included in the scope of the present invention. Furthermore, certain other features and designs may be included in the present invention, including those shown in FIGS. 7-10 below.
Referring to FIG. 7 , there is shown a front side, cross-sectional view of a multi-function toilet device 92 of the present invention having a fan 94 disposed therein. The fan 94 may be located in a dead space 96 (that is, the portion of the air moving side 100 that is above the water line 32 when the toilet tank 14 is full) of the air moving side 100 . In this configuration, the fan 94 may be designed to run continuously or, alternatively, a sensor 98 may be employed to determine when the toilet 10 is in a flush cycle by, for example, detecting the water level 32 in the toilet tank 14 . In an alternate configuration (not shown), the fan 94 may be located below the dead space 96 and may be turned on only when the water line moves below the fan 94 . Regardless of the particular configuration, the fan 94 may provide an increased air flow through the air treatment portion (See FIGS. 2D and 6C ).
The fan 94 may be powered by a power supply (not shown), such as a battery, or the fan 94 may be driven by the air flow caused by water displacing air in the air moving part 100 during the flush cycle. In either case, the fan may provide improved fragrance delivery as well as a cue for the consumer of the operation of the multi-function toilet device 92 .
Referring to FIG. 8 , there is shown a front side, cross-sectional view of a multi-function toilet device 102 of the present invention having a delay valve 104 disposed therein. The delay valve 104 may be positioned at any location within an air moving side 110 of the multi-function toilet device 102 . For example, the delay valve 104 may be located above the water line 32 when the toilet tank 14 is full or the delay valve 104 may be located below the water line 32 . Alternatively, the delay valve 104 may be disposed within the air passage (e.g., air passage 52 of FIG. 2C ) communicating the air moving part 110 to the air treatment part. The delay valve 104 may be of a design, such as a burp valve, that will open once a predetermined pressure is achieved below the delay valve 104 . In one example, the delay valve 104 may include a hinged flap 106 designed to open to release air through an air passage to the air treatment part as previously described. The delay valve 104 may increase the rate of air flow over the air treatment concentrate to deliver a more intense fragrance release/burst. The delay valve 104 may include a check valve 108 to allow air to flow into the lower end 42 of the air moving side 110 , thereby allowing the water to exit from the air moving side 110 during the flush cycle.
Referring to FIG. 9 , there is shown a front side, cross-sectional view of a multi-function toilet device 112 of the present invention having a collapsible bellows 114 disposed therein to act as the air moving part as described in the embodiments above. The collapsible bellows 114 may have a fixed end 116 and a floating end 118 . The fixed end 116 may be attached to either the toilet tank 14 or the toilet lid 18 . The floating end 118 may be designed to float at the water line 32 . A bellows 120 may be formed between the fixed end 116 and the floating end 118 . The length L 1 of the lower end 42 of the bellows 120 may be different from the length L 2 of the upper end 48 of the bellows 120 . This difference between L 1 and L 2 may provide a differential cross-sectional area of the bellows from the lower end 42 to the upper end 48 , thereby providing a variable flow of fragrance from the air treatment part (not shown).
Referring to FIG. 10 , there is shown a front side, cross-sectional view of a multi-function toilet device 122 of the present invention having a paddle 124 disposed therein. The paddle 124 may be driven by a flow 126 from a secondary chamber, such as a cup 128 , when the water level 32 moves below the cup 128 . The cup 128 may fill when the water level is above the cup 128 (e.g., prior to a flush cycle). The paddle 124 may spin to provide an increased air flow through the air treatment portion (See FIGS. 2D and 6C ).
This invention has been described herein in detail to provide those skilled in the art with information relevant to apply the novel principles and to construct and use such specialized components as are required. However, it is to be understood that the invention can be carried out by different equipment, materials and devices, and that various modifications, both as to the equipment and operating procedures, can be accomplished without departing from the scope of the invention itself.
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Described is a multi-function device for attachment to the tank of a toilet fixture. The multi-function device provides a diffusible air-treatment concentrate for deodorizing or otherwise treating the ambient air surrounding the toilet. At the same time, the multi-function device provides a water-soluble water-treatment concentrate for treating the flush water stored in the toilet tank. The multi-function device has a bellows with a varying cross-sectional area to provide, during a flush cycle, a variable flow of air over the air treatment concentrate and into the air.
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BACKGROUND OF THE INVENTION
This invention relates to devices for digging and cutting in the ground, and more particularly to a trailer assembly for preparing and refurbishing trenches that are used to improve irrigation in citrus groves and other agricultural landscapes.
Many different devices have been used to dig trenches for agriculture irrigation, examples of which are disclosed in U.S. Pat. Nos. 4,535,555 and 4,887,372. These devices include rotating cutting blades connected to a frame that is pulled behind a tractor. The cutting blade when pulled is rotated about an axis perpendicular to the wall of the trench to dig new trenches and repair existing trenches.
The trees and shrubs for citrus groves are typically located in rows. Trenches are then dug between the rows to provide proper drainage for the soil. However, in some groves trees are placed further apart than other groves. Thus the width of the trench must be changed to accommodate the tree placement. A drawback to the prior trenching devices is that they do not provide adjustments for changing the trench width.
In closely spaced groves, conventional trenching devices discharge debris and earth in large particles and in a random direction. Many of the prior trenching devices cannot redirect this discharge resulting in damage to the leaves on the trees.
SUMMARY OF THE INVENTION
It is an object of this invention to provide an improved apparatus for digging and repairing trenches.
It is another object of this invention to prepare trenches with a left and right rotating cutting blade with a position that can be remotely moved to change the width and volume of the trench.
It is a further object of this invention to place a remotely adjustable cover over the discharge of a trencher's cutting blade to redirect the discharge to prevent crop damage when preparing trenches.
An additional object of this invention is to dig trenches with a blade that breaks down the earth being dug into small particles to prevent large particle from damaging the foliage.
These and other objects are provided with an apparatus for preparing trenches comprising an elongated frame, a left and right support pivotally carried by the frame and a left and right rotatable cutter respectively connected to a left and right shaft. An axis of rotation extends through the shafts which is inclined with respect to horizontal. A left motor is connected to the left support and the left shaft. The left shaft extends from the left motor through the left support to connect to the left cutter. A right motor connected to the right support and the right shaft. The right shaft extends from the right motor through the left support to connect to the left cutter. The motors are operative to rotate the cutters about the axis. A device is connected between the support and the frame that pivots the support to change the angle of inclination of the cutter. Preferably, a device is connected between the support and the frame for remotely varying the distance between the left and right support to change the width of the trench.
In another aspect of the invention, an apparatus for preparing trenches in by removing earth in the ground is provided. The apparatus comprises an elongated frame, and a left and right support pivotally carried by the frame. A left and right rotatable cutter having a plurality of blades is used to cut the trenches. Each cutter has an axis of rotation which is inclined with respect to horizontal. The plurality of blades extend radially outward from the axis of rotation. At least one motor operative is connected to the other to rotate the blades about the axis to cut a trench out of the ground. A cover is pivotally connected to each support at a preselected orientation and radially aligned with the blades. The cover's orientation is selected to direct the angle of earth being projected over the side of the trench when the cutter rotates to prepare the trench. A hydraulic cylinder in combination with a controller is included for remotely varying the orientation of the cover on the support to change the angle the earth being projected.
BRIEF DESCRIPTION OF THE DRAWINGS
Further features and advantages of the invention will be apparent from the following description which is given solely by way of example with reference to the accompanying drawings, in which:
FIG. 1 is a right side perspective view of the apparatus for preparing trenches according to the invention;
FIG. 2 is a front side perspective view of the apparatus shown in FIG. 1 with the cutter supports in a separated position;
FIG. 3 is a partially sectioned top view of the apparatus along 3--3 of FIG. 1;
FIG. 4 is a partially cutaway perspective view of the apparatus illustrating the movement of the supports;
FIG. 5 is a rear partially sectioned view of the apparatus shown in FIG. 1;
FIG. 6 is a front side perspective view of the apparatus shown in FIG. 1;
FIG. 7 is a bottom right side partially sectioned view shown in FIG. 1 illustrating the cutter blades and support;
FIG. 9 is a section view of the cutter in FIG. 7 along line 8--8; and
FIG. 9 is a simplified schematic diagram of a device for controlling the apparatus for preparing trenches.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 1 and 2, there is shown the apparatus for preparing trenches generally referred to as trencher 10, having a frame 12 connected to support 14 (L and R) on a respective left and right side of trencher 10. Frame 12 includes a longitudinal bar 16 integrally connected at its rearward end to vertical rear frame 18 and connected at its forward end to vertical fame 20.
Referring to FIG. 1 and 6 vertical frame 20 is pivotally attached at its lower end tow bar 22 which is connected with pin 24 to a tow arm of a tractor. Referring to FIGS. 1-4, vertical frame 20 of trencher 10 is connected through a link assembly 15 which includes brs 26 (R and L) rectangular branch 62 (R and L), and bars 28 (R and L) to support 14 (R and L). Frame 20 is connected through bars 26R, branch 62R and bar 28R. Supports 14 (L and R) are disposed symmetrically on the left and right sides of trencher 10 and hold motor 30 (R and L) and cutter 32 (R and L) respectively.
Referring to FIGS. 1, 2 and 5, disposed at the rear end of trencher 10 and pivotally interlocked with the lower portion of frame 18 is fork 36. Hydraulic jack 38 is connected at one end to bar 18 and at its other end to fork 36. Jack 38 expands and contracts piston 39 to pivot fork on frame 18 to raise and lower supports 14 and cutter 32 into the ground during operation. Disposed at opposite ends of fork 36 are wheels 40 and 42 which are laterally spaced in a line longitudinally with tractor wheels (not shown). Conventionally, trencher 10 is pulled by a tractor to prepare, refurbish or excavate a trench. However, the invention is not limited to being pulled and trencher 10 may be adapted to be pushed in a forward direction as well.
The left side of link assembly 15 and frame 20 are identical and are symmetrical about the longitudinal axis of tractor 10. Thus only the right side will hereafter be described.
Referring to FIGS. 1-4, bars 26 are connected at one end with pin 44 to vertical frame 20. Bars 26 are pivotally connected at their other end to the outer portion of branch 62 with pin 45. An inner portion of branch 62 pivotally engages with wing bars 28 using pin 47. Bars 28 are pivotally connected at one end with pivot 45 to vertical frame 20. Attached to the mid-portion of the upper surface of the top parallel bar 28 is bar 48 which extends laterally outward from bar 26. A cylindrical coupling 49 integrally connects at its lower end to bar 48 and extends vertically upward therefrom. Horizontal strut 51 is attached at one end with pin 55 to coupling 49 and is attached at its other end with pin 52 to piston 65 of jack 54. Center pin 52 has a collar 55 that slides laterally along track 53 attached to a bottom surface of bar 16.
The rearward end of jack 54 is connected to the rear portion of bar 16 with coupling 57. Jack 54 is fed hydraulic fluid from control panel 110 (FIG. 9) which by conventional mean expands piston 71 outward to push pin 52 forward thereby forcing bars 28 (L and R) to pivot outward. In FIG. 3 there is shown in phantom the position of assembly 15 when piston 71 expands to its extended position.
Referring to FIG. 4, there is shown a blade 59 which is optionally attached with adjustable bracket 61, that changes the height of blade 59, to a plate 63, engaging the mid-portion of frame 20. Blade 59 extends with bar 65 below frame 20 and has flat left and right blades 67 and 69 which plows through the center of a trench being refurbished when blade 59 is used.
Support 14 is pivotally attached along its side to branch 62 with pin 63 extending through support 14. Vertically oriented jack 74 is connected at its top end to branch 62 and connected at its bottom end to a top surface of frame 70 of support 14. Jack 74 includes a piston 77 which expands and contracts to vary the angle of support 14 and cutter 32 with respect to horizontal. Support 14 includes a rearward deflection portion 66 which has a vertical plated to prevent cutter 32 discharging debris behind trencher 10.
Support 14R and cutter 32R are placed on the right side of trencher 10, and cutter 32L and support 14R are positioned symmetrical about an axis of symmetry of trencher 10. Support 14 holds a motor 30 in housing 68.
Referring to FIGS. 7 and 8, a shaft 76 extends downward from motor 30 and is attached on the bottom side of frame 70 to blades 90 and 92. Referring to FIGS. 2-8, shield 80 is pivotally connected to lateral edge of frame 70 with elongated pin 81. The angle of shield 80 is controlled by expanding and contracting piston 83 of jack 82. It is recognized by changing the angle of shield 80 with respect to top surface of plate 70, the angle at which earth is projected out of trencher 10 during operation, is directed and controlled.
Hydraulic motor 30 is constructed using conventional techniques and is powered with fluid originating from hydraulic supply 86. Referring to FIGS. 7 and 8, motor 30 rotates elongated shaft 76 about a longitudinal axis 111. Shaft 76 extends through an aperture 71 in support 14. Each left and right hydraulic motor 30 independently controls the rotation of it3 s own respective blades 90 (L and R) and 92 (L and R) to increase precision during the trenching operation.
Referring to FIG. 6, disposed behind vertical frame 20 is a tow bar 22 pivotally connected to vertical frame 20. A jack 89 is oriented at an approximately 45° angle between vertical frame 20 and tow bar 22. Jack 89 is connected to the mid-portion of support 20 above tow bar 22, and extends to the mid-portion at tow bar 22. Piston 91 extends inward and outward from jack 89 to pivot tow bar 22 about frame 20. Pivoting tow bar 22 frame 20, raises and lowers frame 20 to change the angle of attack of cutters 32.
Referring to FIGS. 7 and 8, cutter 32 is shown having a first level of blades 90 and a second level of blades 92. Blades 90 and 92 rotate about axis 111 to excavate the ground and refurbish trenches. It has bee recognized by the inventor that when more than four blades are used and preferably at least 20 blades are used, smaller particles are dispersed when trench is refurbished thereby reducing damage to foliage. These blades 90 and 92 extend radially outward with struts 93 from shaft 76. Disposed at the end of shaft 76 is annular disk 94 which rotates in a horizontal plane normal to axis 111 of shaft 76.
Each of blades 90 and 92 have a flat lower surface 96 and 98 respectively. Further the front surface 104 and 108 is also flat. Disk 94 also has a flat front surface 102 in the vertical plane. Preferably the lower surface 98 are at a lower level than the upper surface 100. Blades 90 and 92 alternate between the first level and the second level while extending outward from shaft 76. Extending through shaft 76 is an axis 111 by which blades 90 and 92 rotates.
Referring to FIG. 9, there is shown a panel 110 that is preferably mounted in the cabin of a tractor that pulls trencher 10. On panel 110 are switches 112-124 which respectively control jacks 54, 82 (R and L), 74 (L and R), 89, and 38. Switches 112-124 operate by being pulled or pushed to inject hydraulic fluid into their respective jacks by conventional means. Each one of these jacks are operated individually and may be used to change angles of cutters 32 as well as the angle of attack of trencher 10. Moving switch 112 changes the position of pin 52 to vary the span between support 14 and cutters 32 (L and R).
It is recognized by the inventor that by placing pin 52 within a track 53 in bar, and using jack 54 to move pin 52 laterally, support 14 and cutter 32 on the left side and the right side of trencher 10 move inward and outward while maintaining the same distance from the axis of symmetry of trencher 10. This distance between the cutters 32 is critical to maintain the walls of the trench at identical distances from the center point of the trench when preparing a trench with walls of uniform construction. It is also recognized by the inventor that by using the various controls and hydraulics described, any angle of attack and dispersal of debris can be provided.
This concludes the description of the preferred embodiments. A reading by those skilled in the art will bring to mind various changes without departing from the spirit and scope of the invention. It is intended, however, that the invention only be limited by the following appended claims.
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An apparatus for preparing and refurbishing trenches having two cutters supported on a frame. During operation of the apparatus, the cutters rotate about an axis to prepare the trench. The distance between the cutters as well as the angle of the cutters are adjustable to change the size and shape of the trench. A cover is placed over the cutters and has a remotely adjustable orientation which can be varied to select the direction of earth being projected over the side of the trench during operation. The cutters are preferably powered by dedicated motors, and include a multiplicity of blades mounted on dual levels to increase efficiency of cutting the trench.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
This is a continuation, of application Ser. No. 892,765, filed Apr. 3, 1978 now abandoned.
BACKGROUND OF THE INVENTION
The present invention has as its object a three-dimensional componental module at "T" modified for the industrial preformation of buildings.
In present-day research in the field of industrial building, the attention of planners and producers is directed to prefabricated systems which permit the maximum constructive rationalization, united to a productivity of contained costs.
To obtain high industrial results in practice it is necessary to prepare the various prefabricated elements in a special workshop and thereafter to assemble them at the building site, obtaining building structures whose property, given the constitutive scheme and method of construction, provide notably advantageous costs in comparison to other prefabricated techniques and traditional methods.
The problems are therefore various and complex which are presented in the research of an optimum solution which at the same time is particularly economic, versatile and simple.
Among these problems it will be sufficient to mention a few which seem today to be of the most difficult to resolve.
The first problem concerns the choice and shape of a minimum number of standardized elements with which it is possible to realize variously composed buildings in a variety of both internal and external sizes.
A second problem, closely tied to the first, is that of producing these elements in specially-fitted workshops utilizing industrial techniques of mass production; and also to this last problem an another is directly connected: given the conformation of production workshops, they are constituted by fixed machinery and from this is born the problem of transporting the ready prefabricated elements to the building site by road vehicles which have load and size limitations.
In this operational phase of transportation the stresses due to the condition of the roads and to the mechanical means cannot be overlooked.
The technical aim of the present invention proposes to resolve the preparation of a modular prefabricated structure which can by itself or with the aid of complementary elements, permit the construction of buildings of one or more floors, and which allows such freedom of design as to permit plans sufficiently free to allow freedom to creative expression by the designer.
The solution of this technical aim must be seen in the context of an industrial production and therefore repetitive at low cost of various prefabricated elements.
From that which is proposed the primary object for the present invention is to reduce to a minimum the number of base elements, and to produce a basic module which will be called "base" from which other elements can be easily and directly derived for the composition of buildings of one or more floors with the maximum flexibility of design.
And not the last aim coming from the technical plan proposed is that of realizing all of these elements with a mould installation, bringing into use the economy and industrialism of the product.
SUMMARY OF THE INVENTION
The technical purpose and its consequent scopes are possible by means of a three-dimensional componental module in the shape of a "T" modified for industrial preformation of buildings characterized by the fact of comprehending a fundamental module in the shape of a dissymetrical "T" composed of a vertical reinforced concrete slab (principal ribbing) sustaining with a fixed joint a horizontal slab presenting on the upper surface some secondary ribs in its partial or complete extension; this fundamental module developing in a longitudinal sense still being characterized by the fact that both the horizontal and vertical slabs derived from it by subtraction of the parts contain all the necessary and sufficient elements for the realization of the most varied buildings of distributive physionomy, means being foreseen for the realization on the aforesaid horizontal slab and on the heads of other elements of areas of casting in loco --ortbeton-- conveniently reinforced, enough so as to realize a connection-beam between the various elements, realizing in such a way the necessary static function of the module.
BRIEF DESCRIPTION OF THE DRAWINGS
More characteristics and advantages of the invention come into play by the detailed description of the module which for its characteristic form we shall call "module base Γ" (gamma-capital letter), of some other elements derived from it, of some complementary elements and of typical composite forms.
The description and illustrations are given indicatively and must not be considered limitative of the inventive concept.
For that which regards the tables of design included:
FIG. 1 represents a base module derived from dissymetrical T that in this description we shall call "base module Γ";
FIG. 2 represents in light line the base module Γ from which a second element Γ a is derived with a jutting out vertical slab on one side in respect to the horizontal slab;
FIG. 3 is a detail section on a horizontal plane, and looking upward, of an assembly of the elements of FIGS. 1 and 2;
FIG. 4 represents by a light line the base element Γ from which a third element Γ b is derived with a jutting out vertical slab on both sides in respect to the horizontal slab;
FIG. 5 represents the Γ b element;
FIG. 6 represents an example of compositeness of two Γ b elements with two Γ elements;
FIG. 7 represents in light line the base element Γ from which the fourth element Γ c is derived with the horizontal slab partially interrupted.
FIG. 8 represents element Γ c ;
FIG. 9 represents in light line the base element Γ from which an element Γ d is derived with the function of a wall;
FIGS. 10-11 represent a Γ d element alone and in union with the horizontal slab of another element;
FIGS. 12-13-14-15 represent other elements derived from the base element Γ by subtraction of the parts in the vertical slab;
FIG. 16 represents the formation of an angle obtained with an element Γ b and an element Γ a ;
FIG. 17 represents the formation of an angle obtained with a base element Γ and an element Γ d ;
FIG. 18 represents a typical assembly obtained with the use of various elements;
(The figures from 19 to 40 which now follow represent other elements derived as well as means of joining; and in the description, the numeration is taken from a base 100).
FIGS. 19-20-21 represent further variants of base element Γ;
FIG. 22 represents the association of a base element Γ with an element which we shall call "wall-beam" with an uneven-edged head duct (groove);
FIG. 23 represents an intermediate section of that which represents FIG. 22;
FIG. 24 represents in section a wall-beam with an even-edged duct united to a base module Γ;
FIG. 25 represents a front view of a variant of the said wall-beam;
FIG. 26 represents a front view of a form of execution of a connection-beam;
FIGS. 27-28-29-30 represent front views of the union of Γ elements and of wall-beams;
FIG. 31 represents a further Γ element;
FIGS. 32-33 represent two views, one frontal and one lateral, of the composition of Γ elements, of wall-beams and flat slabs;
FIG. 34 represents the front view of a Γ element and a wall-beam showing the openings of localized or continuous casting;
FIG. 35 represents the front view of another example of compositeness of the said prefabricated elements;
FIG. 36 represents another element derived from element Γ;
FIG. 37 represents the lateral view of the overlaying of two Γ base elements for the realization of multi-storeyed buildings;
FIGS. 38-39-40 and 41 represent some views of a first method of the joining of the head of the horizontal slab of the said elements Γ;
FIG. 42 and 43 represent a second method of joining of the horizontal slab of the Γ elements;
FIG. 44 represents the realization of more diverse elements by means of a single mould of great length.
DETAILED DESCRIPTION OF THE INVENTION
With reference to the cited figures with 1 is indicated the module Γ from which by subtraction of the parts both in the horizontal and vertical slabs, all the necessary and sufficient elements are taken for the realization of one-storeyed and multi-storeyed buildings, some of which will now be described.
It was necessary to give importance to this element calling it "base element Γ", as it ideally unifies every other element and for this reason it will be possible, as will be seen from the succeeding, to carry out production with only one mould of casting in a longitudinal line, with an industrial technique analogous to that utilized for the production of beams in general.
From this base element Γ indicated by 1 a second element is derived Γ a indicated by 2 and obtained by subtracting a part of the horizontal slab and therefore composed by a vertical slab 3 and by a horizontal slab 4 constituted by two dissymmetrical wings 5 and 6. Of these, wing 5 of minor transverse dimensions presents a perimetrical ribbing 7 whose height will be conveniently equal to the final thickness obtained with a casting in loco.
The fundamental characteristics of this element Γ a is that the vertical slab 3 juts out beyond the horizontal slab 4 for a length that has been indicated by "b" FIG. 2.
On this jutting element 8 the wing of another element will rest; for instance the horizontal wing of base element 1 may rest upon the extended end portion 8 of vertical slab 3 and therefore the "b" dimension will be conveniently equal or less then the length of the wing jutting out.
In FIG. 3 the example of this way of composing a structure is shown: the view on the plan shows two base elements Γ indicated by 9, composed by two Γ a elements indicated by 10.
In FIG. 4 with a light line the base element Γ 1 is still indicated from which by subtraction of two portions of the horizontal slab a new element Γ b 11 is formed.
The characteristic of this element Γ b indicated by 11 is that of having the vertical slab 12 which juts out at both ends in respect to the horizontal slab 13, thereby providing two appendices of support of opportune length on which the wing of the base element 1 of FIG. 1 will rest. An example of such an arrangement is seen in FIG. 6--of other elements 14 as example of base type Γ.
In FIG. 7, always based on the base element Γ 1 , by subtraction of a portion of the horizontal slab another element is obtained Γ c 15 with the following characteristics: for a certain length the horizontal slab has two adjoining wings 16 and 17 which for the remaining length indicated by "b 1 ", a portion of the wing 17 is omitted, entirely to an intermediate point of the vertical slab obtaining a step 18 on which the horizontal slab of another element will rest.
If, instead of omitting only the length "b 1 " of the horizontal wing 17, the entire length of the horizontal slab is omitted, as seen in FIG. 9, a new element called Γ d is obtained and indicated by 19.
As clearly as is seen in FIGS. 10 and 11 the upright slab of element 19 may define a true self-carrying closing wall presenting in the upper part a continuous step 20 which extends for the entire length of the element and on which the horizontal slab 21 of another element will rest.
Up to now elements have been obtained by the subtraction of parts in the horizontal slab of the base element Γ 1 while the FIGS. 12-13-14-15 show four examples of elements obtained by subtraction of parts in the vertical slab.
In such a way openings 22 at the ends of the element can be formed; window-openings 23 intermediate to the vertical slab, openings at full height 24 or at reduced height as at 25 which will constitute internal spaces necessary to access throughout the premises.
In FIG. 16 instead the formation of an angle of a building is illustrated utilizing an element Γ b 26 and an element Γ a 27.
The projecting ends 28 and 29 of the vertical slabs that further extend from elements 26 and 27 that form the angle, constitute the rests for the continuation of the structure without limitations of development.
In FIG. 17 the angle is formed instead utilizing a base element F 30 united to a Γ d 31 element (of FIGS. 9-10) which acts as a closing wall.
In FIG. 18 as an example a structure is illustrated which is composed utilizing two elements Γ a 32 and 33 (of FIG. 2) arranged parallelly and with horizontal slab in contraposition in order to create a larger room, further supported parallely to a first base element Γ 34 (of FIG. 1). The three elements are closed by a second base element Γ 35 arranged transversely, to the other direction and the structure is closed by an element Γ d 36 or by a wall.
From this view, one notes the extreme versatility of the elements and the possibility to compose free plans, given that the dimensions both in length of the vertical slabs and of the width of the horizontal slabs can be chosen, with the only exception of the limits of transport.
Further amplifying the gamma of the elements that can be derived from base element Γ, in FIG. 19 an element substantially constituted by a vertical slab 101 and two horizontal wings 102 and 103 of different width. More in particular the wing 102 is of transverse dimensions reduced and presents a longitudinal secondary upright rib 104 along the free edge.
A second longitudinal secondary upright rib 105 parallel to the first and practically localized in vertical alignment with the said vertical slab 101, the ribs 104, 105 define a perimetrical duct or channel 106 that will preferably confine a continuous reinforcement, of eventual precompressed cables and of a casted beam which will later be described.
In FIG. 20 an element is shown that presents a few variants in respect to that already described.
In fact the two wings 102 a and 103 a , do not present any projection-rib on the upper surface: in this case the projection-rib can conveniently be realized in loco according to the necessity, or they can be constituted, for example, by elements in the shape of a U upside down with the double advantage of realizing moulds at a loss for the seating of reinforcement, and internally roomducts for the passage of various services.
The base of the principal vertical slab 101 a , presents in this case two parallel rests or ribs 107, separated by a duct or recess 108. This can be convenient for the superimposition of the Γ elements centralizing and positioning them.
In FIG. 21 one sees a further variant of base module Γ. The wings of this element present a plurality of upstanding ribbing-projections 109 that can extend partially or through the complete length of the wings.
These ribbing-projections 109 give origin to an analogous plurality of ducts recesses 110, which can constitute both the seating place of reinforcement, and seatings of passage of service installations.
FIG. 22 represents an example of assemblage of a Γ element with a first execution form of wall-beam.
The latter is composed by a vertical slab-form 111, that at its height presents two projection-ribs 112 and 113, rib 112 being lowered with respect to rib 113 that form between them a longitudinal seat or recess 114.
The wing 103 b , of element Γ surmounts the lowered projection-rib 112 and there rests as can more clearly be seen in FIG. 23.
The longitudinal seating or recess 114 will include a reinforcement steel cage and a joining casting (beam) of the structure.
In the case of not wanting to surmount wing 103 c (FIG. 24), the wall-beam 111 c will have two projection-ribs 112 c and 113 c of equal dimensions still presenting a longitudinal seat or recess 114 c .
In FIG. 25 a further variant of the wall-beam is represented. In this case the zone presenting the seating or recess 114 d is prolonged in relief for an interval 115 of length equal to the lesser wing of the element Γ to which it will be put side by side. In this way foreseeing a lateral opening 116, it is possible to carry the beam perimetrically in respect to the element Γ.
In FIG. 26 the preparation of a connection-casting is represented with a wall-beam of the type illustrated in Fig. 24.
The wall-beam, here indicated by 117, is put beside an element Γ 118, presenting a head duct 119 with lateral opening 120; therefore a metalic cage reinforcement 121 is situated which will be successively sunk in a casting in loco--ortbeton--of joining.
In FIGS. 27 and 28 another two methods of association of two fundamental elements are illustrated, realized in the intention of obtaining passages indicated by 122 and 123.
In the first case then the wing 124 completely surmounts the wall 125 and in order to realize the joning-casting are foreseen openings of type 126 localized in correspondence of the duct 127 of the wall 125. The same dispositions are still illustrated in FIGS. 29 and 30.
FIG. 31 shows instead an element Γ where the principal ribbing or vertical slab is subdivided into two parts 127 and 128 which leave two passages free 129 and 130.
FIG. 32 exemplifies the joining of two elements Γ 131 and 132, of two walls 133 and 134 and of a flat plate 135.
In this case the two walls 133 and 134 alternately jut out in respect to elements Γ functioning as rests for plate 135, likewise obtaining openings of type 136. In the case that there might not be openings, the structure will be of the type indicated in FIG. 33.
The wall-beam 137 --FIG. 34-- can function also as divider in respect to an element Γ 138, and then localized openings 139 will be foreseen, or continue to permit the joining castings.
In FIG. 35 the composition of two base elements Γ 141 and 142 is shown, completed by two wall-beams 143 and 144 disposed to sustain said elements at Γ.
Other than these base elements another one is present comprehending an upper horizontal wing --145-- associated to a vertical ribbing or slab --146-- partially jutting out beyond the development of the same wing to provide a rest for other structures.
FIG. 37 exemplifies the superimposition of two elements Γ: the two principal ribbings or vertical slabs --147-- of the lower element and --148-- the upper one are aligned between each other; between the base of said ribbing 148 and the perimetrical projection-rib --149-- a longitudinal duct or channel --150-- is formed where a joining casting is created at --151-- and reinforced to constitute a beam.
The vertical ribbing or slab --148-- finds rest for the alignment on a longitudinal projection --152-- present on the horizontal wing 153 of the lower Γ element.
This is one of the possible methods of superimposition which can therefore be different according to the conformation of the surfaces of the wings and the ribbings.
To join by the head the horizontal wings of two put side by side elements Γ, indicated by figures 38-39-40--41 with numbers 154-155, there are foreseen in a first form of execution more open seatings of casting 156 provided in the same body of the wings, presenting on a lower level a septum of base 157.
Putting beside the two elements 154-155 moulds at loss are formed with a bottom already predisposed in which steel reinforcement 158 is present coming out from the elements Γ.
A casting followed in the work will solidly connect the heads realizing the necessary static continuity of the structure.
In a second exemplifying form of connection FIGS. 42, 43, the elements Γ 159 and 160 present along the edge a lowered step 148 which at the moment of putting beside will realize a continuous seating 162 in which steel reinforcement 163 will come out. To augment the stability of connection two precompressed cables 164 are foreseen inserted with sheath connected between them in the zone of casting by means of a screw-sleeve 165 with a dual effect.
The casting being executed, after the desired time the putting under tension of the cables 164 will be accomplished from sleeves 165 where elements 159 and 160 come out.
All these elements illustrated are provided in concrete with the possibility of good characteristics of thermic and acoustic insulation.
Other than these elements there is another not indicated which is consequently evident and that is a flat floor plate that can be interplaced between two elements Γ to amplify the free internal length of the rooms.
Retracing the concept of base element Γ and its derivitives one notes how all these elements can be produced in one only mould (see the plan indicated in FIG. 44) developed longitudinally of great length with industrial techniques analogous to those used for the realization of beams. The parts to "take away" from base element Γ will be obtained with septa or conveniently separated only to obtain complementary elements.
Such an example in FIG. 44 which shows an element Γ a 37, where the part to take away is only separated to obtain a portion of floor plate (slab) 38; there follows a base element Γ 39 and an element Γ d 40.
Obviously these examples of disposition which have been given with development of the plan can be repeated for multi-storeyed buildings, where the disposition of the elements on various floors can be homotetic or not, according to the plans and the premises that are desired.
The reconductability of all these elements necessary and sufficient for the construction of buildings to an one-based element Γ gives the possibility of maximum industrialization in the production of the same elements reaching the primary scope that the inventor has prefixed.
The dimensional limits and the materials, not being binding theoretically, will grow out of the problems of an economic transport both for that which regards dimensions and weights.
With the tree-dimensional elements of the present invention which have been described hereinabove, not only multi-storeyed structures of any predetermined configuration are realized, but also, for each floor, a rigid box-like structure is obtained in which the two fundamental parts (i.e. floor plates and walls) of the structure anhance the resistance when external actions, such as static loads, wind pressure and seismic actions, are exerted onto the structure itself.
This advantageous behaviour of the structure, which renders it particularly suitable to be utilized in seismic zones and for multi-storeyed buildings, derives from the fact that the form and structure of the various elements are such as to allow a connection between them by which the floor plates result in being rigidly jointed with the carrying walls, so that spatial structures are originated which are substantially monolithic and whose parts are able to efficiently interact with each other; in other words, even if the structure is formed by a plurality of elements, each of these is, statically and constructionally, so intimately integrated in the structure that it loses its individuality as a single element of the structure whose behaviour can only be evaluated as a whole.
The rigid and efficient connection between the structure elements which is realized in correspondence of each joint derives not only from the form of the base module, but also from the particular shape which has been contrived for each element obtained by subtraction of parts of the module itself. In fact, in connecting two elements in each joint, not only a junction of the two adjacent vertical edges of the respective vertical plates is realized, but a true superimposition of a portion of a wing of one element upon a corresponding portion of vertical plate of the adjacent element is obtained. With regard to this, see the connections obtained in this way in the joints shown in FIGS. 3, 6, 11, 16, 17, 22; in each of these joints the rigidity of the connection derives mostly from the superimposition relationship of one of the wings 5 and 6 with the vertical plate 3 of another element. A connection having the same characteristics of rigidity and monolithicality is obtained also when an element Γ is associated with a wall-beam 111 (FIG. 22) of the type of those described with reference to Figures from 22 to 35; in fact, also in this case there is still a superimposition relationship of a wing of one element with the uper edge of the vertical plate of the element associated with it.
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A three-dimensional componental module at "T" modified for industrial preformation of buildings, comprising a fundamental dissymmetrical module at "T" with a vertical slab substaining a horizontal slab presenting two flanges and on its upper surface projection-ribbings, said fundamental module developing prevalently in a longitudinal sense, is described. From said module are derived, by subtraction of the parts both of the horizontal and the vertical slabs, all the elements necessary and sufficient for the realization of buildings of the most varied distributive physionomy, means being foreseen for realizing, on said horizontal slab and on the heads of the adjacent elements, zones of casting in loco conveniently reinforced.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND
[0001] This application is a Continuation-In-Part of U.S. application Ser. No. 09/986,414, having been filed on Nov. 8, 2001, herein incorporated by reference in its entirety.
[0002] 1. Field of the Invention
[0003] The invention is a joint cover assembly that includes a molding similar to a T-Molding, for covering a gap that may be formed adjacent a panel in a generally planar surface, such as between two adjacent flooring materials, a floor and a wall, or a riser and a runner in a step (or a series of steps).
[0004] 2. Background of the Invention
[0005] Wood or laminate flooring has become increasingly popular. As such, many different types of this flooring have been developed. Generally, this type of flooring is assembled by providing a plurality of similar panels. The differing types of panels that have developed, of course, may have differing depths and thicknesses. Thus, when panels having different thicknesses are placed adjacent to each other, transition moldings are often used to create a smooth joint.
[0006] Additionally, one may desire to install floor panels adjacent to an area with different types of material. For example, one may desire to have one type of flooring in a kitchen (e.g., laminate flooring or ceramic tile), and a different appearance in an adjacent living room (e.g., linoleum or carpeting), and an entirely different look in an adjacent bath. Therefore, it has become necessary to develop a type of molding or seal that could be used as a transition from one type of flooring to another.
[0007] A problem is encountered, however, flooring materials that are dissimilar in shape or texture are used. For example, when a hard floor is placed adjacent a carpet, problems are encountered with conventional edge moldings placed there between. Such problems include difficulty in covering the gap that may be formed between the floorings having different height or thickness.
[0008] Moreover, for purposes of reducing cost, it is important to be able to have a molding that is versatile, having the ability to cover gaps between relatively coplanar surfaces, as well as surfaces of differing thicknesses.
[0009] It would also be of benefit to reduce the number of molding profiles that need to be kept in inventory by a seller or installer of laminate flooring. Thus, the invention also provides a method by which the number of moldings can be reduced while still providing all the functions necessary of transition moldings.
SUMMARY OF THE INVENTION
[0010] The invention is a joint cover assembly for covering a gap between edges of adjacent floor elements, such as panels. The assembly includes a body having a foot positioned along a longitudinal axis, and a first arm extending generally perpendicularly from the foot. The assembly may include a second arm also extending generally perpendicular to the foot. A tab may additionally be provided on either the first or second arms, displaced from the foot, extending perpendicularly from the arm.
[0011] The assembly is preferably provided with a securing means to prevent the assembly from moving once assembled. In one embodiment, the securing means is a clamp, designed to grab the foot. Preferably, the clamp includes a groove into which the foot is inserted. In a preferred embodiment, the rail may joined directly to a subsurface below the floor element, such as a subfloor, by any conventional means, such as, a nail, screw or adhesive.
[0012] The outward-facing surface of the assembly may be formed as a single, unitary, monolithic surface that covers both the first and second arms. This outward-facing surface may be treated, for example, with a laminate or a paper, such as a decor, impregnated with a resin, in order to increase its aesthetic value, or blend, to match or contrast with the panels.
[0013] A shim may also be placed between the foot and the subfloor. In one embodiment, the shim may be positioned on the underside of the clamp; however, if a clamp is not used, the shim may be positioned between the foot and the subfloor. The shim may be adhered to either the foot or subfloor using an adhesive or a conventional fastener, e.g., nail or screw.
[0014] The assembly may also include a leveling block positioned between the first arm and the adjacent panel. The leveling block generally has an upper surface that engages the arm, and a bottom that abuts against the adjacent panel. In a preferred embodiment, the leveling block has a channel formed in upper surface, configured to receive the tab on the arm. The particular size of leveling block is chosen, conforming essentially to the difference in thicknesses between the first and second panels. The exposed surfaces of the leveling block is typically formed from a variety of materials, such as a carpet, laminate flooring, ceramic or wood tile, linoleum, turf, paper, natural wood or veneer, vinyl, wood, ceramic or composite finish, or any type of covering, while the interior of the leveling block is generally formed from a wood or other structural material. The leveling block additionally facilitates the use of floor coverings having varying thicknesses when covering a subfloor. The leveling block helps the molding not only cover the gap, but provide a smoother transition from one surface to another.
[0015] Alternatively, the tab may be positioned to slidingly engage the edge of a panel when no leveling block is used. A lip may additionally be positioned on the tab in order to slidingly engage a protuberance, adjacent an upper edge of the clamp in order to retain the assembly in its installed position.
[0016] The tab is preferably shaped as to provide forces to maintain the assembly in the installed position. Thus, typically the tab may be frustum-shaped, with its narrow edge closest to the arm and the wider edge furthest from the arm. Additionally, the tab may be lobe shaped, having a bulbous end furthest from the arm. Of course any suitable shape is sufficient, as long as the tab can provide enough resistive forces to hinder removal of the installed assembly. By forming a corresponding channel in the leveling block (or in the upper surface of the flooring element) the tab can help to secure the assembly in place.
[0017] The assembly may additionally be used to cover gaps between tongue-and-groove type panels, such as glueless laminate floor panels. In addition to the uses mentioned above, the tab may also be designed to mate with a corresponding channel in the panel the edge of one of the flooring elements, or may actually fit within a grooved edge. In order to better accommodate this type of gap, a second tab may be positioned to depend from the second panel engaging surface.
[0018] An adhesive, such as a glue, a microballoon adhesive, contact adhesive, or chemically activated adhesive including a water-activated adhesive, may be positioned on the tab, the foot, and the arms. Of course, such an adhesive is not necessary, but may enhance or supplement the snap-type fit of the assembly into the gap between the floor elements. Additionally, the adhesive may assist in creating a more air-tight or moisture-tight joint.
[0019] The assembly may be used in other non-coplanar areas, such as the edge between a wall and a floor, or even on stairs. For example, the assembly may include, the first and second arms, and foot as described above, but instead of transitioning between two floor elements placed in the same plane, may form the joint between the horizontal and vertical surfaces of a single stair element.
[0020] The inventive assembly may be used for positioning between adjacent tongue-and-groove panels; in this regard, the assembly functions as a transition molding, which provides a cover for edges of dissimilar surfaces. For example, when installing floors into a home, the assembly could be used to provide an edge between a hallway and a bedroom, between a kitchen and living or bathroom, or any areas where distinct flooring is desired. Additionally, the assembly may be incorporated into differing types of flooring, such as wood, tile, linoleum, carpet, or turf.
[0021] The invention also is drawn to an inventive method for covering a gap between adjacent panels of a generally planar surface. The method includes multiple steps, including, inter alia, placing the foot in the gap, pressing the respective arms contact with the respective floor elements, and configuring at least one of the tab and the foot to cooperate to retain the assembly in the gap after the assembly has been installed.
[0022] Other objects, features and advantages of the present invention will become apparent from the following detailed description. It should be understood, however, that the detailed description and the specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] FIG. 1 is an exploded view of an embodiment of the joint cover assembly in accordance with the invention;
[0024] FIGS. 1A and 1B are alternate embodiments for the molding of the invention;
[0025] FIG. 2 is a perspective view of a second embodiment of the joint cover assembly in accordance with the invention;
[0026] FIGS. 3 and 3 A are a comparative perspective views of embodiments of the leveling block;
[0027] FIG. 4 is perspective view of an additional embodiment of the joint cover assembly in accordance with the invention;
[0028] FIGS. 5 and 5 A are a comparative perspective views of embodiments of the leveling block;
[0029] FIGS. 6-16 show comparative cross-sectional views of various embodiments of the molding portion of the joint cover assembly;
[0030] FIG. 17 depicts an embodiment of the assembly of the invention for use with stairs;
[0031] FIG. 18 shows a second embodiment of the assembly for use with stairs; and
[0032] FIG. 19 is a side view of a generic element, which may be broken in the components of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0033] FIG. 1 shows an exploded view of the various parts of the inventive joint cover assembly 10 . The assembly 10 includes a T-shaped molding 11 , having an foot 16 formed so that it can fit in a gap 20 between adjacent floor elements 24 , 25 . FIG. 1 demonstrates a typical use, in which the gap 20 is formed adjacent an edge 27 of a floor element 24 . Although FIG. 1 , depicts all of the floor elements 24 to be conventional tongue-and-groove type floor panels (having a groove 27 positioned adjacent to the gap 20 ), this is merely one of any number of embodiments. For example, floor elements 24 , 25 need not be the same type of floor element. Specifically, the floor elements 24 can be any type of flooring designed to used as a floor or placed over a subfloor 22 , e.g., tile, linoleum, laminate flooring, concrete slab, parquet, vinyl, turf, composite or hardwood. As is known, laminate floors are not attached to the subfloor 22 , but are considered “floating floors”.
[0034] The molding 11 is provided with a first arm 12 and a second arm 14 extending in a single plane generally perpendicular to the foot 16 . Preferably, the foot 16 , first arm 12 , and the second arm 14 from a general T-shape, with the arms 12 and 14 forming the upper structure and the foot 16 forming the lower structure.
[0035] The molding 11 , as well as any of the other components used in the invention, may be formed of any suitable, sturdy material, such as wood, polymer, or even a wood/polymer composite. Due to the growing popularity of wood and laminate flooring and wood wall paneling, however, a natural or simulated wood-grain appearance may be provided an the outward facing surface 34 of the molding 11 . The outward facing surface 34 may be a conventional laminate, such as a high pressure laminate (HPL), direct laminate (DL) or a post-formed laminate (as described in U.S. application Ser. No. 08/817,391, herein incorporated by reference in its entirety); a foil; a print, such as a photograph or a digitally generated image; or a liquid coating including, for example, aluminum oxide. Thus, in the event natural wood or wood veneer is not selected as the material, the appearance of wood may be simulated by coating the outer surface 34 with a laminate having a decor sheet that simulates wood. Alternatively, the decor can simulate stone, brick, inlays, or even fantasy patterns. Preferably, the outward facing surface 34 extends completely across the upper face of the molding, and optionally over under surface 36 and 38 of arms 12 and 14 , respectively.
[0036] The core structure of components of the invention, including the center of the molding 11 , that is in contact with the outward facing surface 34 is formed from a core material. Typical core materials include wood based products, such as high density fiberboard (HDF), medium density fiberboard (MDF), particleboard, strandboard, and solid wood; plastic-based products, such as polyvinyl chloride (PVC), thermal plastics or mixtures of plastic and other products; and metals, such as aluminum, stainless steel, or copper. The various components of the invention are preferably constructed in accordance with the methods disclosed by U.S. application Ser. No. 08/817,391, as well as U.S. application Ser. No. 10/319,820, filed Dec. 16, 2002, Attorney Docket No. TPP30422CIP, each of which is herein incorporated by reference in its entirety.
[0037] A securing means, such as a metal clamp 26 , may be coupled to the subfloor 22 within the gap 20 formed between the two floor elements 24 . The clamp may be coupled to the subfloor 22 by fasteners, such as screws or any conventional coupling method, such as nails or glue. The clamp 26 and the foot 16 are preferably cooperatively formed so that the foot 16 can slide within the clamp 26 without being removed. For example, the clamp 26 may be provided with in-turned ends 30 designed to grab the outer surface of the foot 16 . Typically, the foot 16 has a dove-tail shape, having the shorter parallel edge joined to the arms 12 and 14 ; and the clamp 26 is a wire element having a corresponding shape as to mate with the foot 16 and hold it in place. Additionally, the securing element may take the form of an inverted T-element 50 ( FIG. 1A ), configured to mate with a corresponding groove 52 in an end of foot 16 , such that friction between the T-element 50 and the groove 52 secures the molding 11 in place, or, in the alternative, the end of the foot 16 may be provided with a narrowed section, designed to mate with a groove in the securing element. Finally, each of the T-element 50 , mating section of the foot 16 and/or various grooves, may be provided with notched or barbed edges 55 to simultaneously assist in mating and resist disassembly ( FIG. 1B ). However, in an alternative embodiment, the securing element can be eliminated because the molding 11 can be affixed to one of the floor elements 24 , 25 , by, for example, an adhesive. Preferably however, the molding 11 is not secured to both floor elements 24 , 25 , as to permit a degree of relative movement, or floating, between the floor elements 24 , 25 .
[0038] The clamp 26 may additionally be formed of a sturdy, yet pliable material that will outwardly deform as the foot 16 is inserted, but will retain the foot 16 therein. Such materials include, but are not limited to, plastic, wood/polymer composites, wood, and polymers.
[0039] A tab 18 is shown as extending downwardly from the first arm 12 . As shown in FIG. 1 , the tab 18 extends downward, or away from an outward facing surface 34 of the molding, and runs generally parallel to the foot 16 . As shown in FIG. 1 , the tab 18 may also be in the shape of a dove-tail with a shorter edge adjacent to the first arm 12 ; however, other suitable shapes are possible. The shape of the outwardly facing surface 34 of the molding 11 is shown as being convex in some of the Figures (e.g., FIGS. 1A, 1 b and 7 ), and substantially planar in others (e.g., FIGS. 1, 2 , 4 , and 6 ). When the outwardly facing surface 34 is substantially planar, the edges of the molding 11 may either be upright or at an angle, typically angling away from the foot 16 .
[0040] The assembly may further include a leveling block 40 . When flooring elements 24 and 25 are of differing heights, the leveling block 40 is positioned between either the first arm 12 or the second arm 14 and the subfloor 22 . Preferably, the size of the leveling block 40 is selected to correspond essentially to the difference in heights of the two flooring elements 24 and 25 . For example, if one flooring element 24 is a ceramic tile, having a thickness of 2″ and the second flooring element 25 is linoleum, having a thickness of ¼″, the leveling block 40 would typically have a thickness of 1¾″ to bridge the difference and be placed between arm 12 and the other flooring element 25 . Without the leveling block 40 , a significant space would exist between the second flooring element 25 and the molding 11 , allowing for moisture and dirt to accumulate. While the difference in heights of the flooring elements 24 , 25 is generally caused by a difference in thickness between the two flooring elements 24 , 25 , the present invention may also be used to “flatten out” an uneven subfloor 22 . In a preferred embodiment, the leveling block is provided with a channel 42 designed to receive the tab 18 .
[0041] Even though the assembly 10 may function without any type of glue or adhesive, an alternate embodiment includes the placement of adhesive 31 on the molding 11 . The adhesive may be placed on molding 11 at the factory (for example, pre-glued). Alternatively, the glue may be applied while the floor elements 24 , 25 are being assembled. As shown in FIG. 6 , the adhesive 31 may be provided as a strip-type adhesive, but any type of adhesive, such as glue, chemical or chemically-activated adhesive, water-activated adhesive, contact cements, microballoon adhesive may be used. Additionally, while the embodiment in FIG. 6 shows a single adhesive strip 31 attached to the arm 12 , the adhesive 31 may be attached to the tab 18 , foot 16 , and/or any location where two pieces of the assembly are joined. Preferably, adhesive 31 is only applied to one of the arms 12 , 14 in order to allow accommodate some slight relative movement that may occur during changes of temperature, for example. This relative movement is known in the flooring art as “float”. Allowing float may also eliminate unneeded material stresses as well, thereby reducing warping or deterioration of the material surface. Typical adhesives used in the invention include a fresh adhesive, such as PERGO GLUE (available from Perstorp AB of Perstorp, Sweden), water activated dry glue, dry glue (needing no activation) or an adhesive strip with a peel off protector of paper.
[0042] FIG. 2 shows a typical embodiment of the assembly 10 in an installed condition, wherein the floor elements 24 and 25 are of differing thicknesses (H and H′ respectively). Of course, the element 24 may be of any type of covering, such as carpet, turf, tile, linoleum or the like. As shown in FIG. 3 , the leveling block 40 typically includes a substantially flat bottom 46 , and a top 45 having a channel 42 , and an inner surface 44 . The top 45 of the leveling block 40 is designed to firmly abut the under surface 36 of the first arm 12 , while the bottom 46 abuts floor element 25 . Typically, the channel 42 is shaped as to firmly hold the tab 18 . The inner surface 44 of the leveling block 40 need not abut the foot, as generally, a small amount of clearance is provided between the clamp 26 or foot 16 and the inner surface 44 of the leveling block. However, the inner surface 44 may configured to contact either of the clamp 26 or foot 16 .
[0043] The leveling block 40 may be made of a composite, pliable material that is also resilient. For example, the tab 18 may be formed to be slightly larger than the opening of the channel 42 , thereby forcing the channel 42 to outwardly deform in order to accommodate the tab 18 , and therefore snap-fit together.
[0044] As shown in FIG. 3 , the outer surface 47 of the leveling block 40 is generally treated to match or blend with the outer surface 34 of the molding or the floor element 24 , 25 in order to improve aesthetics.
[0045] FIG. 3A shows an alternate embodiment of a leveling block 40 ′. An outer surface 47 ′ of this embodiment is configured generally perpendicular to an upper surface 44 ′ and a lower surface 46 ′ of the leveling block 40 ′. This alternate configuration of the outer surface 47 ′ not only provides a different appearance, it also has been shown to be preferred when softer surfaces, such as carpet or turf, are positioned beneath the lower surface 46 ′ of the leveling block 40 ′.
[0046] FIG. 4 shows yet another alternate embodiment of the leveling block 140 . The leveling block 140 includes a bottom 146 , and a top 145 and an inner surface 144 . The top 145 of the leveling block 140 is designed to firmly abut the under surface 36 of the first arm 12 , while the bottom 146 abuts floor element 25 . This leveling block 140 is positioned between a first arm 112 of the molding 111 and the flooring element 125 . In this embodiment of the assembly 110 , the tab 118 engages the inner surface 144 of the leveling block 140 .
[0047] FIG. 5 shows an embodiment of a leveling block 140 that may be used in the assembly shown in FIG. 4 . Specifically, the leveling block 140 in FIG. 5 has a solid, uninterrupted upper surface 145 , without the need for a channel because the tab ( 118 , as in FIG. 4 ) will engage the inner surface 144 of the leveling block of instead of the top surface 145 .
[0048] FIG. 5A shows an additional shape of a leveling block 140 ′ that can be incorporated into the assembly shown in FIG. 4 . Leveling block 140 ′ has a front surface 146 ′ that will be generally perpendicular to a floor 122 (as shown in FIG. 4 ) when the leveling block 140 ′ is installed. This perpendicular configuration of the front surface 147 ′ not only provides a different appearance, it has also been found to be preferred with softer surfaces, such as carpet or turf.
[0049] FIG. 6 shows an underside view of the molding 11 . In particular the first under surface 36 of the first arm 12 , and the second under surface 38 of the second arm 14 are shown. In one embodiment, under surface 36 is provided with the adhesive 31 positioned to adhere to a surface of a floor element 24 , 25 or leveling block 40 , 40 ′, 140 , 140 ′.
[0050] FIGS. 7-15 show various cross-sectional views of the molding 11 . These figures show comparative configurations for the arms 12 , 14 , the tab 18 , and the shape of molding 11 .
[0051] In FIG. 7 , the tab 18 is selected to be an outward-facing hook having a barb facing away from the foot 16 , while the upper surface of the molding has a convex curvature. This particular selection for the tab 18 may be used to engage an edge or groove of an adjacent floor element 24 , 25 , or in the alternative, an adjacent leveling block 40 . Additionally, a shim 48 may be positioned between the foot 16 and the subfloor 22 . The shim 48 is generally a pliable and flexible, yet durable material. The shim 48 may be used in place of, or in combination with, clamp 26 .
[0052] FIGS. 8-15 show cross-sections of other shapes for the molding 11 . The configurations of the moldings are very similar, except for the shape of the tab 18 . The differing tabs have been assigned decimal numbers beginning with 18, for clarity purposes. A tab 18 . 1 ( FIG. 8 ) is a bulbous shape, having its rounded end furthest from the arm 12 . A tab 18 . 2 of FIG. 9 is provided with a hook-shape with a point facing the foot 16 . In the embodiment shown in FIG. 10 , a tab 18 . 3 is in the shape of a dove-tail, similar to the shape of the tab 18 shown in FIG. 2 .
[0053] The purpose of the various-shaped tabs ( 18 - 18 . 8 ) is multi-fold. Primarily the tab 18 serves to engage the channel 42 of the leveling block 40 , which is used when covering of differing thickness is used. Alternatively, the respective tab ( 18 - 18 . 8 ) may engage an edge of a panel, carpet, turf, or other type of floor covering. As shown herein, the respective tab ( 18 - 18 . 8 ) may even be configured to engage a leveling block.
[0054] It is additionally considered within the scope of the invention to eliminate the tab. In such an embodiment, preferably, the molding 11 includes an adhesive on the under surface 36 , 38 of one of the arms 12 , 14 .
[0055] With respect to FIG. 16 , the invention may also be used when the floor elements are not co-planar. For example, one embodiment includes a stair nose attachment 210 that can be attached to the same molding 11 , as described above. As used herein, a stair nose attachment is a component capable of mating with the molding 11 as to conceal, protect or otherwise cover a joint forming a single stair. Typically, the molding 11 is provided atop the first floor element 24 on the horizontal, or run 220 of the stair, such that the stair nose attachment 210 bridges the joint between the first floor element 24 and the second floor element 25 , forming the vertical, section of the stair, or rise 230 . As a result, the invention can be used to cover and protect joints between flooring elements on stairs. While in a preferred embodiment, the floor elements covering the rise 220 and run 230 are the same type of flooring material, the flooring elements need not be of the same construction.
[0056] The stair nose attachment 210 may include a tab receiving groove 212 , permitting connection of the stair nose attachment 210 to the molding 11 . Because the tab receiving groove 212 in the stair nose attachment 210 is preferably shaped according to the shape of the tab 18 of the molding 11 , the stair nose attachment 210 may be attached to the molding 11 by, for example, snapping or sliding.
[0057] However, in other embodiments, the tab on the under surface 36 of first is eliminated. While the tabs and corresponding grooves may be eliminated, it is nevertheless considered within the scope of the invention to utilize an adhesive, as described herein. Alternatively, the stair nose attachment 210 may include a tab 218 to mate with a corresponding groove 219 on the foot 16 of the molding 11 ( FIG. 17 ), or vice-versa.
[0058] Additionally, an adhesive, as described herein, may be applied to any component in order to secure the connection between the molding 11 and the stair nose attachment 210 . Although FIG. 16 shows tab 18 (and accordingly the tab receiving groove 212 ) as having a dove-tail shape, it is considered within the scope of the invention to vary the particular shape of the tab 18 and tab receiving groove 212 . For example, the shapes may be bulbous, or slide tongue to matching groove, or any other configuration described herein.
[0059] It is also possible to form the molding 11 , leveling block 40 and stair nose attachment 210 from the same element, as shown in FIG. 18 . Specifically, a generic element, indicated at 300 can be milled, sawed or otherwise constructed with a variety of “break away” sections 300 A, 300 B, and 300 C. When one or more break away sections 300 A, 300 B, 300 C are removed, by for example, scoring and snapping, cutting, sawing or simply bending, the individual pieces can result. Preferably, the generic element 300 is formed as a unitary structure which is then scored as to provide stress-points to allow the removal of the break-away sections. While not required by the present invention, typically, the removal of the break away sections 300 A, 300 B, 300 C requires a significant amount of physical force or labor, as the remaining structure must maintain its structural integrity. Alternatively, removal of the break-away sections 300 A, 300 B, 300 C may require the use of a specialized tool.
[0060] By designing the generic element 300 in accordance with the invention. An installer can manipulate the generic element 300 to produce any needed component. For example, removing sections 300 B and 300 C would produce a typical stair nose attachment 210 , while removing sections 300 A and 300 C would produce a typical molding II. Due to this construction, it is possible to manufacture the generic elements to be purchased and appropriately broken down by the installer. Similarly, when removing sections 300 A and 300 C to form the molding 11 , section 300 A can be used as a leveling block as described herein.
[0061] By allowing an end user to purchase the generic element 300 instead of separate components, the retailers and/or distributors may accordingly reduce their inventory requirements. For example, typically over one-hundred different design patterns for the outwardly facing surface 34 of the molding 11 (as well as for the leveling block 40 and stair nose attachment 210 ) are produced. By allowing for the inventory to include only the generic elements of the invention, the total number of components retained can be reduced from three per design to one per design. Similarly, the installer only need purchase the generic elements 300 , rather than three individual components.
[0062] It should be apparent that embodiments other than those specifically described above may come within the spirit and scope of the present invention. Hence, the present invention is not limited by the above description.
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The invention is a joint cover assembly for covering a gap adjacent an edge of a panel that covers a sub-surface, and a method of covering such a gap. The assembly includes a molding having a foot, a first arm, and a second arm. The foot is positioned along a longitudinal axis, and the first arm extends generally perpendicularly from the foot. The second arm extends generally perpendicularly from the foot. A tab depends generally perpendicularly from the first panel engaging surface. At least one of the tab and the foot engage the edge in order to tightly fit within the gap. The method includes the steps of placing the foot in the gap, pressing the respective panel engaging surfaces into contact with respective panels, and configuring at least one of the tab and the foot to cooperate to retain the molding in the gap when the assembly is in an installed condition.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] The present invention is related to my co-pending U.S. patent application entitled “Leveling Rail Joints With Plane Support For Different Profiles”, filed of even date herewith, U.S. patent application Ser. No. ______, Attorney Docket No. 070867.000010, and “Leveling Rail Joints With Plane Support For Different Height Rails”, filed of even date herewith, U.S. patent application Ser. No. ______, Attorney Docket No. 070867.000011.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to rail joints for railroad track.
[0004] 2. Description of the Related Art
[0005] A railroad way is formed by joining two sets of parallel rails together, each set of rails formed of a number of rails connected lengthwise at their adjoining aligned ends. When one of the installed rails required replacement due to breakage, damage or completion of useful service life, the old installed rail has been replaced with a replacement or substitute rail, which could be a new or a used rail. In such cases, the replacement or substitute rail has often been a different height than that of the connecting rail to which connection was made.
[0006] So far as is known, it has been the practice to maintain the base portions of the replacement rail and the remaining rail of the original joint at a common level in the new joint being formed. This resulted in the upper surfaces of the head portions of the joined rails being at a different height. In these situations, however, there were impacts and shocks caused when the wheels of the engines and the rolling stock passed over the joint with the rail heads of different height. The repeated application of the resulting impacts so caused resulted in damage to the rails with resulting damage and loss of service life for the rails. There were also possible safety concerns.
SUMMARY OF THE INVENTION
[0007] Briefly, the present invention provides new and improved rail track structure formed at adjoining end portions of rails which have differing characteristics. The present invention provides a new and improved leveling joint connector bar for connecting adjoining end portions of rails of different height in a track structure. The adjoining end portions of the rails have an oblique surface formed below a head portion extending inwardly towards a web portion and an oblique surface on a foot portion extending inwardly towards the web portion. The leveling joint connector bar includes an elongate joint body spanning the adjoining end portions of the rails to be joined, and having a number of connector holes formed therein aligned with connector holes in the web portions of the adjoining end portions of the rails to be joined.
[0008] The elongate joint body member has an oblique upper surface formed with and extending along the length of the joint body, and the oblique upper surface is machined to conform to and engage with the oblique surface formed below the head portions of the adjoining end portions of the rails to be joined.
[0009] The elongate joint body member has an oblique lower surface formed with and extending along the length of a first segment of and conforming to and engaging with the oblique surface formed on the base portion of a first of the two rails to be joined. The elongate joint body member also an oblique lower surface formed with and extending along the length of a second segment of and conforming to and engaging with the oblique surface formed on the base portion of a second of the two rails to be joined.
[0010] The oblique upper surface of the elongate joint body member and the oblique lower surface of the first segment of the elongate joint body member are spaced from each a distance corresponding to the height of the first of the two rails to be joined, and the oblique upper surface of the elongate joint body member and the oblique lower surface of the second segment of the elongate joint body member are spaced from each a distance corresponding to the height of the second of the two rails to be joined.
[0011] The rail track structure includes a first track and a second segment having a web portion, a base portion and a head portion, the web portions of the first and second track segments having a number of connector holes formed therein for the passage of connectors at their end portions. The head portions of the first and second track segments each have an oblique surface formed below a head portion extending inwardly towards their web portions. The base portions of the first and second track segments also an oblique surface formed on a foot portion extending inwardly towards their web portions
[0012] An elongate connector bar is connected to span and join the adjoining end portions of the first and second track segments being joined, with a number of connector holes formed in the connector bar aligned with the connector holes in web portions of the adjoining end portions of the first and second track segments.
[0013] The elongate joint body member has an oblique upper surface formed with and extending along the length of the joint body. The oblique upper surface conforms to and engages with the oblique surface formed below the head portions of the adjoining end portions of the rails. The elongate joint body member has an oblique lower surface formed with and extending along the length of a first segment of and conforming to and engaging with the oblique surface formed on the base portion of a first of the two rails.
[0014] The elongate joint body member has an oblique lower surface formed with and extending along the length of a second segment of and conforming to and engaging with the oblique surface formed on the base portion of a second of the two rails to be joined. The oblique upper surface of the elongate joint body member and the oblique lower surface of the first segment of the elongate joint body member are spaced from each a distance corresponding to the height of the first of the two rails. The oblique upper surface of the elongate joint body member and the oblique lower surface of the second of the elongate joint body member are spaced from each a distance corresponding to the height of the second of the two rails.
[0015] The present invention provides new and improved leveling rail joints where the fitting, engagement and engagement with the rails being connected at their end portions is made by a set of joint or connector bodies that provide increased strength to the assembly.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The characteristic details of the present invention are clearly shown in the following description and accompany figures, which illustrate this and provide points of reference to indicate the same parts in the figures shown.
[0017] FIG. 1 is a side view of a leveling rail joint according to the present invention for joining rails of different height characteristics.
[0018] FIG. 2 is a cross-sectional view taken along the lines 2 - 2 of the leveling rail joint of FIG. 1 .
[0019] FIG. 3 is a cross-sectional view taken along the lines 3 - 3 of the leveling rail joint of FIG. 1 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0020] In the drawings, the letter S designates generally a railroad track structure formed by a leveling rail joint L between a pair of adjacent track components, such as rail sections or segments R whose end portions E are to be joined. As will be set forth below, the adjoining end portions E of rails R which are joined by the leveling rail joint L have differing height characteristics.
[0021] Turning first to the rails R, the adjoining end portions E of the rails R to be joined have differing characteristics, in this case a different height. Each of the rails R has a web portion below a head portion 10 downwardly to a foot or base portion 12 . The end portions E are brought into engagement along their respective end surfaces 14 in forming the leveling rail joint L, as will be set forth.
[0022] As is evident in FIGS. 2 and 3 , a first rail 20 ( FIG. 2 ) of the rails R is of a greater height than a second rail 22 ( FIG. 3 ), due for example to the rails 22 having been in service for a period of time and rail 20 being newer. In some cases, the height difference is also in part due the result of a greater vertical of a web portion 24 of first rail 20 in comparison with web portion 26 of the second rail 22 . Typically, the rails 20 and 22 are of like or comparable profile. In other cases, the height of the head portion or the base portion, or both, of the rails R may differ and contribute to the different height characteristics of the rails R to be joined.
[0023] Each of the rails R is what is termed a standard rail and includes an oblique or slanting planar surface 30 formed on a lower surface 31 extending inwardly in a downward direction from a side surface 32 on each side of the head portion 10 of the rails R. The oblique surface 30 extends at a slanting or transverse angle with respect to the vertical axis of the rails R. The slope and the angle of surface 31 , as well as their extent in the rails R is in accord with appropriate rail industry standards for the particular rails being used based on the services conditions and the like.
[0024] Each of the rails R also includes an oblique or slanting planar upper surface 34 formed extending upwardly and inwardly from a side surface 35 of the foot or base portion 12 . The oblique surface 30 also extends at a slanting or transverse angle with respect to the vertical axis of the rails R. The slope and the angle of surface 34 and their extent in the rails R is also in accord with appropriate rail industry standards for the particular rails being used based on the services conditions and the like.
[0025] The leveling rail joint L according to the present invention is in the form of an elongate joint body 40 of sufficient length to span the adjoining end portions E of the rails R to be joined and provide requisite strength and support in the structure so formed. The length of the joint body 40 and its extent along the adjoining end portions E with which it is mounted are determined by the intended service or usage nature of the rails R and load bearing considerations.
[0026] The joint body 40 is formed of suitable strength alloy steel, depending upon the intended load and service usages of the rail structure S. Alloy steel bars are machined with flat planar surfaces to conform and engage corresponding planar surfaces of the rails R, as will be described, to form the joint body 40 . The joint body is elongate in the context of being of adequate extent along the rail joint between the rails R to provide adequate strength, support and durability during service life usage. This is determined by rail dimensions, and also intended service or usage nature of the rails, load bearing considerations and other rail design factors.
[0027] The joint body 40 has a suitable number of connector holes or ports 42 formed through it along its longitudinal extent. The connector holes 42 are spaced from each other along the joint body 40 at locations aligned with the connector holes 44 in web portions 24 and 26 of the adjoining end portions E of the rails R to be joined. It is preferable that the connector holes 42 be located on center points spaced no more than about four inches from each other along the extent of the joint body 40 for increased strength. If necessary, new connector holes may be formed in the web portions of the rails R according to the location of connector holes 42 in the joint body 40 .
[0028] The elongate joint body member 40 has an oblique upper surface 48 formed with and extending along the length of the joint body, and the oblique upper surface 48 is machined to conform to and engage with the oblique surface 30 formed below the head portions of the adjoining end portions E of the rails R to be joined.
[0029] The elongate joint body member 40 further has an oblique lower surface 50 ( FIG. 2 ) formed with and extending along the length of a first segment 54 to conform to and engage across its surface area with the oblique surface 34 formed on the base portion 12 of the rail 20 to be joined. The elongate joint body member 40 also has an oblique lower surface 56 ( FIG. 3 ) formed with and extending along the length of a second segment 58 to conform to and engage across its surface area with the oblique surface 30 formed on the base portion of the rail 22 to be joined.
[0030] Each of the oblique lower surfaces 50 and 56 of the joint body member 40 is also machined to conform to and engage the surfaces 30 on the rails 20 and 22 in forming the leveling rail joint L. Thus, each of the oblique planar surfaces of the joint body member 40 is in contact with a corresponding oblique planar surface on the corresponding rail end portion E to be engaged in forming the leveling rail joint L.
[0031] The oblique upper surface 48 of body member 40 and the oblique lower surface 50 of the segment 54 of the elongate joint body member 40 are spaced from each a distance indicated as D 1 ( FIG. 2 ) in the drawings, corresponding to the height of the web portion of the rail 20 to be joined. The oblique upper surface 48 of the joint body member 40 and the oblique lower surface 56 of the second segment 58 of body member 40 are spaced from each a distance D 2 ( FIG. 3 ) corresponding to the height of the web portion of rail 22 to be joined.
[0032] Thus with the rail joint L according to the present invention, the end portions E of the rails R are aligned as a common plane along upper surfaces 60 of the head portions 10 . Accordingly, as the wheels of traffic from engines and rolling stock pass over the joined rails, a level surface is present for the wheels to contact. In this way damage to the rails due to wheel impact on the rail joint with different height is substantially reduced with the present invention. In a number of cases, it is desirable to insert a shim or chuck or other support below the base portion of the shorter height rail and on the rail cross-tie as load bearing support for the joint L beneath the shorter height rail.
[0033] The joint body 40 takes the form of an inner portion 62 located between the head portion 10 and base 12 of the adjoining end portions E of the rail R inwardly of the side surface 32 of the head 10 . The joint body 40 also has a support segment 64 extending outwardly from the side surface 32 of the head portions 10 of the rails R to be joined to provide additional strength to the assembled leveling joint and rail end portions E. The support segment 64 includes a surface 66 extending downwardly away from the juncture of the planar surface 30 and side surface 32 of the head portion of the rail R. The support segment 64 has a vertical outer surface 68 extending downwardly to the outer edge of oblique lower surfaces 50 and 56 . The support segment 64 is at least as thick as the inner portion 62 of the joint body member 40 located below the head portion 10 of the rail R, and can be, if desired, as much as 150% thicker is cross-section than the inner portion 62 .
[0034] The joint body 40 shown in the drawings is configured to be installed on the outer side of rails R at end portions E to form a composite joint for what is known as a left hand joint, where the first rail 20 of greater height than the second rail 22 is to the left of rail 22 when one is facing the centerline of the track. For a right-hand joint, the joint body 40 is located on the inner side of the rails being joined. The joint body 40 between rails 20 and 22 could thus be on either of the parallel rails of a section of track.
[0035] In assembling the leveling joint L, the head portions 10 of the rail ends E are brought into contact with each other along their vertical end surfaces 14 . Further, the end portions E are aligned so that the upper surfaces 60 of the head portions 10 are aligned in a common horizontal plane as the leveling joint L is being assembled.
[0036] In an installed leveling joint L, a second joint body 140 is provided to be installed opposite the joint body 40 on right hand joints, such as an inner side of the rails 20 and 22 where the two such rails are of different height. The joint body 140 has like structural components to the joint body 40 , but the relative location of the upper surface 48 and the lower surfaces 50 and 56 of segments 54 and 58 on joint body 140 are reversed from those of joint body 40 . Accordingly, the joint body 140 is used on the inner side of a left hand joint and on the outer side of a right hand joint.
[0037] The leveling joint bodies 40 and 140 which are installed on opposite sides of end sections E of a rail joint according to the present invention are manufactured so that dimensions D 1 and D 2 correspond to the height difference between the taller or newer rail 20 and the shorter or worn rail 22 . The leveling joint bodies 40 and 140 thus have corresponding height dimensions to the difference in height between rails being joined, and the rails R have the same level at their joined end portions E along a level upper surface 60 at their juncture.
[0038] The leveling rail joints according to the present invention achieve increased strength in the assembled structure. The assembled joint bodies in place on the rail ends form a solid unitary structure. This structure functions is achieved as an assembly of several engaged pieces with their aligned contacting surfaces. However, should the need arise one of the structural components of the leveling rail joint can be readily changed in a short time for maintenance or replacement.
[0039] The leveling rail joints in accordance with the present invention enhance the strength of the rail and joint since the matching and engagement of the joint bodies with the corresponding surfaces on the rail ends cause the joint bodies to function in effect as two additional webs to the rail.
[0040] The leveling rail joints of the present invention provide accuracy in the vertical dimensions so that the heads of both rails have the same level at the upper part of the rail heads, making passage of the train wheels relatively noise free and without impact due to a change in height at the rail joint. The leveling rail joints also provide accuracy in the horizontal dimensions so that the connector bolts when installed compress the structural components of the joint with increased strength comparable to that of a solid, unitary piece. The leveling joints according to the present invention in effect provide an additional two web portions in the track structure S in the area of joined rail end portions.
[0041] With the leveling rail joints of the present invention, dips or gaps are not formed between the adjoined end portions of the rails R, so that impact on or movement of rails on passage of wheels is significantly diminished. This in turn affords fewer maintenance needs, safer operation and cost savings.
[0042] Having described the invention above, various modifications of the techniques, procedures, material and equipment will be apparent to those in the art. It is intended that all such variations within the scope and spirit of the appended be embraced thereby.
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A joint between connected ends of two rails of different height is provided with a connector/juncture bar member which is configured to fit with and engage corresponding surfaces formed on the rails when the rails are connected together. The joint so formed is one with increased strength, with ease and accuracy of alignment during assembly.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
The invention relates to foldable ladders of the type which are folded for storage in the event of an emergency at which time they can be unfolded and used to escape from an elevated structure. These ladders are often used as emergency fire escape means and may be secured in a container outside a window, for immediate use. Similar, though shorter ladders, are often used in boats to permit ease of returning into the boat from, for example, the water.
Foldable ladders are well known and have been in use for many years. An extremely old and very common type of foldable ladder is a so-called rope ladder. These usually comprise a series of elongated rigid steps maintained approximately parallel to each other by two ropes, one secured to each end of the steps. The rope permits rolling the ladders into a cylindrical bundle.
The main disadvantage of the known foldable ladders resides in their lack of apparent stability. As these ladders may find utilization as emergency exits, persons not used to climbing ladders may find themselves in a position when they must use a folding ladder in an emergency. If the ladder feels insecure, one often encounters difficulty in using a ladder for the first time. If the person is at all acrophobic, the use of prior art type foldable ladders can be devastating, if not fatal.
In an endeavor to avoid the deficiencies of the prior art type ladders, the instant invention teaches a ladder which, when in use, provides a relatively rigid structure, while still permitting the ladder to be folded or collapsed into a small space.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary large scale perspective view of a ladder according to an embodiment of the instant invention:
FIG. 2 is a perspecitve view of a modification of a partially open ladder of FIG. 1, showing the top step of the ladder mounted on the inside of a storage container;
FIG. 3 is a perspective view similar to FIG. 2 in the fully open position;
FIG. 4 is a perspective view similar to FIG. 2 showing a modification that includes a stacking rod;
FIG. 5 is an enlarged fragmentary view, partially in section of the modification of FIG. 4, of the upper end of the stacking rod secured in place with a quick disconnect retaining ring; and
FIG. 6 is an enlarged fragmentary side elevational view of a modified embodiment that includes an adjustment linkage for the window rods.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In carrying the invention into effect in the embodiment which have been selected for illustration in the accompanying drawings and for description in this specification, and referring now particularly to FIG. 1, a plurality of steps 11 are supported, one below the other to form a ladder, by a plurality of rigid links 12. The links 12 are pivotally secured together and to the steps 11 by pivot pins 13.
The pivot pins 13 are supported, in the links 12, by pivot pin bearing means such as bearings 14, 16 and 17, respectively. These bearing means 14, 16, are so formed and disposed as to permit pivotal securing together of adjacent links 12 using a single pivot pin 13. Thus, in the preferred embodiment shown in FIG. 1, the bearing 16 comprises a single arm 18 with a bore 19 therethrough. The bearing 14 comprises two arms 21, 22 spaced apart for a distance to permit the arm 18 of the bearing 16 to fit therebetween. Each arm 21, 22 of the bearing 14 has a bore 23' therethrough wherein a pivot pin 13 can be inserted through the bore 19 of the arm 18 to journal the arms 18 and 21, 22 pivotably together.
The desired direction of fold of adjoining links 12 is shown in FIG. 1 by arrows A and B. To help restrain folding in an undesirable outward direction, stop means may be provided such as a projection 15 that is formed on the bearing 16, as shown in FIG. 1.
To provide for the pivotal securing of a step 11 to the links 12, in the preferred embodiment shown in FIG. 1, the bearings 17 are provided in the step 11. As shown, these may take the form of arms 23, 24 that extend on opposite sides of the step 11, and are spaced apart for a distance sufficient to permit the arms 18, 21, 22 of the links 12 to fit therebetween. By providing bores 26 in these arms, which bores line up with the bores 19 and 23' in the arms 18, 21, 22 provided in the links 12, a single pivot pin 13 can be received by the bearings 14, 16 and 17 simultaneously. For reasons of safety, the pivot pins 13 can be trimmed to a length that will not protrude beyond the outermost arms.
In order to secure the ladder to a window, hand rails or window rods 27 may be provided. As shown in FIG. 1, the hand rails 27 also form the top pivot pin and are therefore pivotally secured to the ladder.
The ladder may also be provided with apertures such as hand holds 28 in the steps 11, and with hand holds 29 in the links 12, for the convenience of a person using the ladder. The hand holds may, of course, take other forms, for example the links 12 can be made in the form of an "I" wherein one can easily grab the narrow center or web portion of the "I" shape linkage (this embodiment is not shown). The steps 11 may also be formed with ridges 30, molded or otherwise formed therein. These ridges 30 act to provide a relatively non-slip surface on the steps 11. Other non-slip surfaces may be provided instead, as would be evident to a person skilled in the art.
When the ladder is intended for use as a fire escape means, the ladder may be too long to fold conveniently without additional aid. Therefore, apertures 20 may be formed in the steps 11, essentially aligned with each other and a rope or similar means (not shown) can be passed through these apertures 20 and be attached to the bottom step. One need only pull up on the rope, by hand or with a simple winch device (not shown), to fold the ladder for storage.
Other uses for a foldable ladder as herein described, would be obvious to persons using foldable ladders. An example of such a use would be in marine applications wherein a ladder is often used to board a boat from the water.
The material from which the ladder should be manufactured will depend on its final use. Thus, for fire escape purposes, a flame-retarding polymer or similar material (Lexan - S.E., A.B.S., glass-filled material, fiber-filled material) may be used. These materials for the most part, may be conveniently molded into appropriate parts for both the steps and the linkages. The pivot pins may also be of a synthetic polymer or of a metal such as steel.
If used for marine purposes, the possibility of corrosion or other deterioration associated with such applications, must be taken into account when deciding the material to be used.
The ladder may also be provided with a plurality of stand-offs 25 extending from the ladder. These act to keep the ladder apart from a wall or side of a boat or other downwardly extending part of the structure to which the ladder is secured.
In the embodiment shown in FIG. 2, the ladder is shown secured to a storage container such as a box 31, mounted outside of a window. The ladder is pivotally secured to the inside of the box 31. A hand rail or window rod 32 (similar to the hand rail 27 of FIG. 1) is shown secured to the box 31. Although much of the detail of the ladder has been omitted from FIG. 2, for the sake of clarity, the manner of folding the ladder can be seen and is similar to that of FIG. 1. FIG. 2 shows the ladder in a partially folded position.
Adjacent links 12, pivot or fold towards each other on each side of the ladder. This results in the steps 11 moving towards each other to form a small, folded, structure. For the embodiments shown in FIG. 2, the ladder is pulled up into the box 31 and a cover (not shown) is placed over the box 31 to protect and hold the ladder.
When the ladder is to be used, its links will be extended to unfold the ladder, and the window rod 32 will engage the window sill, all as shown in FIG. 3.
Referring to FIGS. 4 and 5, the ladder may also be provided with a stacking rod 33 which simultaneously passes through apertures 20 to aid in maintaining the steps 11 in an aligned relation to each other when the ladder is folded. The stacking rod 33 has an enlarged portion 34 at one end to prevent that end from passing through apertures 20. The other end of the rod 33 is provided with a releasable enlarged portion such as a quick disconnect retaining ring 36, shown in detail in FIG. 5. A reinforcing collar 37, shown in FIG. 5, may be molded into the steps 11 to provide reinforcement around the apertures 20.
A further modification, which aids in providing a more rigid feeling ladder for the person using it, provides for a length adjustment means such as adjustment linkage 35, for the hand rail 27a, as shown in FIG. 6. The hand rail 27a of FIG. 6 is similar to hand rail 27 of FIG. 1 except that it has an adjustment means such as adjustment link 35 for securing it to the link 12. The end of the hand rail 27a is provided with a threaded rod 38 and means for adjusting the position of the link 12 with respect to the threaded rod 38, for example adjustment nuts 39. By turning the nuts 39 on the threaded bar 38, the effective length of hand rail 27a can be adjusted to the width of the window sill or other structure to which the the ladder is to be secured.
In a preferred embodiment means for shielding the threaded bar 38, such as guard 41, and for preventing accidental removal of the threaded bar 38, such as stop 42, are also provided on the ladder.
Operation
The operation of the above described embodiments of the invention is as follows:
When used as an emergency escape means, the ladder may be removed from storage and secured to a window or other convenient escape path, and permitted to unfold. The embodiment of FIG. 2 shows a ladder already secured outside of a window, and one need only release the cover of the box 31 to drop the ladder. Once the ladder is secured, for example to the window sill, as shown in FIG. 3, one need only step onto the ladder gripping the hand rail 32, and climb down. The weight of the person will act to hold the ladder relatively rigid and the stop means 15, when provided on the ladder, acts to aid in maintaining the ladder extended. Hand holds 28 and 29 may be provided for easy grasping by hand.
The ladder is folded simply by moving the steps 11 together with the links 12 folding towards each other in the direction A, B, respectively, as shown in FIG. 1. A stacking rod 33 may be inserted through apertures 20, and a quick disconnect retaining ring 36 inserted on the end passing through the apertures 20. This will aid in handling the ladder in its folded condition. If the retaining ring 36 is inserted over the end of the rod 33 protruding from the top step 11, it can be easily slipped off and the rod 33 allowed to fall out, thus releasing the ladder, as shown in FIG. 4.
The adjustment linkage 35 permits adjusting the position of the hand rail 27a relative to the ladder, whereby a firmer grip on the window sill or other wall support can be attained. This linkage 35 permits adjustment to various widths of window sills or other supports, for example the gunwalls of a boat when the ladder is used for marine purposes.
I wish it to be understood that I do not desire to be limited to the exact details of construction shown and described, for obvious modifications will occur to a person skilled in the art.
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A foldable ladder having a plurality of rigid steps and of rigid links which steps and links are pivotally secured together with pivot pins to result in a rigid ladder in use, but capable of being folded for storage.
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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 an apparatus for unlocking a door lock for a vehicle, in which collision direction detecting means detects a side of a vehicle on which a collision has occurred, and an unlocking mechanism unlocks a door located on a side opposite to the detected collision side.
2. Description of the Prior Art
In a conventional door unlocking apparatus (Japanese Patent Application Laid-Open No. (kokai) 58-11275) shown in FIG. 16, when a vehicle undergoes a collision, an inertia lever L swings in the clockwise direction due to inertial force of a weight W disposed at the lower end of the inertia lever L. As a result, a bell crank B is swung in the clockwise direction so that all the doors are unlocked via an intermediate rod R, thereby allowing vehicle occupants to be rescued.
In the conventional door unlocking apparatus, even a door close to a position where a collision has occurred is unlocked. Therefore, there is a possibility that a door close to a position where a collision has occurred cannot be unlocked smoothly due to the impact of the collision, or the door cannot be unlocked at all. Accordingly, the conventional door unlocking apparatus has a drawback that it carries out considerably useless operations.
SUMMARY OF THE INVENTION
It is a primary object to smoothly and securely unlock a door lock located on a side opposite to a collision side of a vehicle.
It is another object to rescue vehicle occupants when a collision of a vehicle occurs.
It is a further object to provide a door unlocking apparatus based on a technical idea of unlocking a door lock located on a side opposite to a collision side of a vehicle.
It is a still further object to provide an apparatus for unlocking a door lock for a vehicle, comprising: a plurality of door locks for being mounted on doors of the vehicle; collision direction detecting means for detecting a direction of an impact applied to the vehicle; and an unlocking mechanism for unlocking a door lock mounted on a side opposite to a collision side based on the direction detected by the collision direction detecting means.
It is a still further object to provide an apparatus for unlocking a door lock for a vehicle wherein the collision direction detecting means detects an impact on the front side or rear side of the vehicle.
It is a yet further object to provide an apparatus for unlocking a door lock for a vehicle wherein the collision direction detecting means detects an impact on the left side or right side of the vehicle.
It is a yet further object to provide an apparatus for unlocking a door lock for a vehicle wherein the collision direction detecting means comprises a collision detecting mechanism including a plurality of movable members which correspond to sides at each of which a collision will occur and which moves due to an impact caused by a collision of the vehicle, and that the movement of the movable member is transmitted to the unlocking mechanism located at a side opposite to a collision side.
It is another object to provide an apparatus for unlocking a door lock for a vehicle wherein the moving member comprises a swing member which has a weight functioning as an inertia mass at the time of a collision of the vehicle, and which swings about a single supporting point in the direction of an inertial force opposite to the direction of the impact of the collision.
It is a still further object to provide an apparatus for unlocking a door lock for a vehicle the collision direction detecting means comprises an acceleration sensor for detecting the direction of an impact acceleration when a collision of the vehicle occurs.
It is a yet further object to provide an apparatus for unlocking a door lock for a vehicle wherein the unlocking mechanism comprises a controller which outputs, in accordance with the direction of the impact acceleration detected by the acceleration sensor, an unlocking signal for unlocking a lock condition of a door lock located on a side opposite to a collision side, and a door control motor which responds to the unlocking signal from the controller so as to unlock the door lock located on the side opposite to the collision side.
In the apparatus for unlocking a door lock for a vehicle according to the present invention and having the above-described structure, when the vehicle encounters a collision, the collision direction detecting means detects the direction of an impact applied to the vehicle, and the unlocking mechanism unlocks the door lock located on the side opposite to the detected collision side based on the direction detected by the collision direction detecting means.
In the apparatus for unlocking a door lock for a vehicle according to the present invention and having the above-described structure, when the vehicle encounters a collision, the direction detecting means detects the impact on the front side or rear side of the vehicle.
In the apparatus for unlocking a door lock for a vehicle according to the present invention and having the above-described structure, when the vehicle encounters a collision, the direction detecting means detects the impact on the left side or right side of the vehicle.
In the apparatus for unlocking a door lock for a vehicle according to the present invention and having the above-described structure, when the vehicle encounters a collision, among the plurality of movable members constituting the collision direction detecting means, one movable member moves in accordance with the direction of the impact of the collision, and the movement of the movable member is transmitted to the unlocking mechanism located on the side opposite to the collision side, so that the door located on the side opposite to the collision side is unlocked.
In the apparatus for unlocking a door lock for a vehicle according to the present invention and having the above-described structure, when the vehicle encounters a collision, the swing member, which constitutes the movable member and which has the weight functioning as the inertia mass at the time of the collision of the vehicle, swings about the single supporting point in the direction of an inertial force opposite to the direction of the impact of the collision. As a result, the movement of the swing member is transmitted to the unlocking mechanism of the door lock located on the side opposite to the collision side, so that the door located on the side opposite to the collision side is unlocked.
In the apparatus for unlocking a door lock for a vehicle according to the present invention and having the above-described structure, the acceleration sensor constituting the collision direction detecting means detects the direction of an impact acceleration when a collision of the vehicle occurs, and the controller constituting the unlocking mechanism outputs, in accordance with the direction of the impact acceleration detected by the acceleration sensor, an unlocking signal for unlocking the lock condition of the door lock located on the side opposite to the collision side. The door control motor responds to the unlocking signal from the controller so as to unlock the door lock located on the side opposite to the collision side.
In the apparatus for unlocking a door lock for a vehicle according to the present invention and performing the above-described action, a door lock located on the side opposite to the collision side detected by the collision direction detecting means is unlocked by the unlocking mechanism. Accordingly, the apparatus according to the first aspect has an effect of making it possible to smoothly and securely unlock a door lock located on the side opposite to the collision side and thus making it possible to rescue vehicle occupants.
In the apparatus for unlocking a door lock for a vehicle according to the present invention and performing the above-described action, the rear-side or front-side door lock located on the side opposite to the collision side detected by the front/rear direction detecting means is unlocked by the front/rear unlocking mechanism. Accordingly, the apparatus according to the second aspect has an effect of making it possible to smoothly and securely unlock the rear-side or front-side door lock located on the side opposite to the collision side and thus making it possible to rescue vehicle occupants.
In the apparatus for unlocking a door lock for a vehicle according to the present invention and performing the above-described action, the right-side or left-side door lock located on the side opposite to the collision side detected by the right/left direction detecting means is unlocked by the right/left unlocking mechanism. Accordingly, the apparatus according to the third aspect of the present invention has an effect of making it possible to smoothly and securely unlock the right-side or left-side door lock located on the side opposite to the collision side and thus making it possible to rescue vehicle occupants.
In the apparatus for unlocking a door lock for a vehicle according to the present invention and performing the above-described action, one movable member moves in accordance with the direction of the impact of the collision, and the movement of the movable member is transmitted to the unlocking mechanism of a door lock located on the side opposite to the collision side, so that the door lock located on the side opposite to the collision side is unlocked. Accordingly, in addition to the effect of the first aspect, the apparatus according to the fourth aspect has an effect of making it possible to unlock the door lock located on the side opposite to the collision side by a simple structure.
In the apparatus for unlocking a door lock for a vehicle according to the present invention and performing the above-described action, the swing member, which has the weight functioning as an inertia mass at the time of a collision of the vehicle, swings about the single supporting point in the direction of the inertial force opposite to the direction of the impact of the collision, and unlocks the door lock located on the side opposite to the collision side via the connection member. Accordingly, in addition to the effect of the fourth aspect, the apparatus according to the fifth aspect has an effect of securely performing the detection of the collision side of the vehicle, and the cancellation of the locked state, because the swing member has the weight.
In the apparatus for unlocking a door lock for a vehicle according to the present invention and performing the above-described action, only when the inertial force of the weight functioning as the inertia mass becomes greater than the urging force in the opposite to direction produced by the spring member, the swing member swings so as to unlock the door lock located on the side opposite to the collision side. This prevents the door lock from being unlocked due to quick acceleration, quick stop, quick turn, very light hit, or the like, and allows the door to be unlocked only when the vehicle receives the impact equal to or greater than the predetermined level produced by the collision of the vehicle. Accordingly, in addition to the effect of the fifth aspect, the apparatus according to the sixth aspect has an effect of preventing erroneous operations.
In the apparatus for unlocking a door lock for a vehicle according to the present invention and performing the above-described action, the controller outputs, in accordance with the direction of the impact acceleration detected by the acceleration sensor, an unlocking signal for unlocking the door lock located on the side opposite to the collision side, and the door control motor responds to the unlocking signal from the controller so as to unlock the door lock located on the side opposite to the collision side. Accordingly, the apparatus according to the seventh aspect has an effect of making it possible to unlock a door lock located on the side opposite to the collision side, only by adding the acceleration sensor and by partially modifying the control program.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view showing a main portion of an apparatus according to a first embodiment of the present invention;
FIG. 2 is a side view showing the entire apparatus according to the first embodiment;
FIG. 3 is a partial plan view of a collision direction detecting mechanism according to the first embodiment showing its locked state;
FIG. 4 is a partial plan view of the collision direction detecting mechanism according to the first embodiment showing its unlocked state;
FIG. 5 is a side view of an apparatus according to a second embodiment of the present invention showing a state in which a front door is in the unlocked state;
FIG. 6 is a partial side view of the apparatus according to the second embodiment showing a state in which the front door is in the locked state;
FIG. 7 is a partial side view of an apparatus according to the second embodiment of the present invention showing a state in which a rear door is in the locked state;
FIG. 8 is a partial side view of the apparatus according to the second embodiment showing a state in which the rear door is in the unlocked state;
FIG. 9 is a partial side view of an apparatus according to a third embodiment of the present invention showing a state in which a front door in the locked state;
FIG. 10 is a partial plan view of the apparatus according to the third embodiment showing a state in which the front door in the unlocked state;
FIG. 11 is a block diagram of the overall structure of an apparatus according to a fourth embodiment of the present invention;
FIG. 12 is a flowchart showing the auto-locking control in the apparatus according to the fourth embodiment;
FIG. 13 is a flowchart showing the locking control in the apparatus according to the fourth embodiment;
FIG. 14 is a flowchart showing the unlocking control in the apparatus according to the fourth embodiment;
FIG. 15 is a time chart showing signals at various portions in the apparatus according to the fourth embodiment; and
FIG. 16 is a partial side view showing a conventional apparatus.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Embodiments of the present invention will now be described with reference to the drawings.
(First Embodiment)
As shown in FIGS. 1-4, an apparatus for unlocking a door lock for a vehicle according to a first embodiment comprises a collision direction detecting mechanism 1 and a door unlocking mechanism 2, which are provided in each of doors of a vehicle, which are disposed at four openings of the vehicle located at the front-left, front-right, rear-left and rear-right of the vehicle such that they can be opened and closed. The collision direction detecting mechanism 1 comprises a door lock knob 10 which has a weight 11 functioning as an inertia mass and which is swingably supported so as to serve as a swing member. The door unlocking mechanism 2 comprises a bell crank 22 and adapted to transmit movement of the door lock knob 10 to a door lock 3 when a collision occurs.
As shown in FIGS. 1 and 2, the door lock knob 10 constituting the collision direction detecting mechanism 1 is disposed within an inside handle bezel 100 together with a door handle 12 to be parallel thereto. The door lock knob 10 comprises a generally semicircular head portion 101 and a stem portion 102 and has a mushroom-like cross section.
As shown in FIGS. 1 and 2, the door lock knob 10 is swingably supported, at the connecting portion between the head portion 101 and the stem portion 102, by a vertically disposed pin 103. Both ends of the pin 103 are supported by flanges 1041, which are integrally provided on a door inside handle base plate 104 such that the flanges 1041 are located at the upper and lower positions in the inside handle bezel 100. A locked position and an unlocked positions are set at both ends of swing movement of the door lock knob 10.
A cylindrical weight 11 made of a metal and having an adjusted weight is disposed at one side of the head portion 101 of the door lock knob 10 such that the weight 11 can act as an inertia mass. When another vehicle or the like hits against the left side of the vehicle, the door lock knob 10 is swung in the counterclockwise direction in FIGS. 1 and 3 due to the inertial force of the weight 11 so as to unlock the right-side door.
In contrast, when another vehicle or the like hits against the right side of the vehicle, the door lock knob 10 in the locked state is swung in its locking direction, i.e., in the clockwise direction in FIG. 3 due to the inertial force of the weight 11. Therefore, the door lock knob 10 does not move.
The door unlocking mechanism 2 comprises a link 21 whose one end is connected to the door lock knob 10, a V-shaped bell crank 22 whose one end is connected to the other end of the link 21 and which is swingably supported by the door, and a link 23 which is connected to the other end of the bell crank 22 and whose other end is connected to a lock lever 31 of the door lock 3.
In the apparatus for unlocking a door lock for a vehicle according to the first embodiment having the above-described structure, when another vehicle or the like hits against the left side of the vehicle, the door lock knob 10 of a right-side door of the vehicle is swung due to the inertia of the weight 11, so that the door lock knob 10 swings in the counterclockwise direction from the locked position to the unlocked position, i.e., the door lock knob 10 is brought from the state of being swung toward the front of the vehicle (state shown in FIG. 3) into the state of being swung toward the back of the vehicle (state shown in FIG. 4).
When the door lock knob 10 swings in the counterclockwise direction in FIG. 3, the link 21, which constitutes the door unlocking mechanism 2 and whose one end is connected to the door lock knob 10, is moved leftward in FIG. 3. As a result, the V-shaped bell crank 22, whose one end is connected to the other end of the link 21 and which is swingably supported by the door, swings in the counterclockwise direction.
When the bell crank 22 swings in the counterclockwise direction, the link 23, which is connected to the other end of the bell crank 22 and whose other end is connected to the door lock 3 is obliquely moved downward in FIG. 2, so that the door lock 3 of the right-side door of the vehicle is brought from the locked state into the unlocked state (i.e., the locked state is canceled).
When another vehicle or the like hits against the right side of the vehicle, the door lock knob 10 of a left-side door of the vehicle is swung due to the inertia of the weight 11, as in the above-described case, so that the door lock 3 of the left-side door of the vehicle is brought from the locked state into the unlocked state (i.e., the locked state is canceled) via the link 21, the bell crank 22, the link 23, and the lock lever 31.
When another vehicle or the like hits against the right side of the vehicle, the door lock knob 10 in the locked state is swung in the locking direction, i.e., in the clockwise direction in FIG. 3 due to the inertial force of the weight 11. Therefore, the door lock knob 10 does not move, so that the door lock knob 10 is prevented from affecting the door lock 3 via the door unlocking mechanism 2.
In the apparatus for unlocking a door lock for a vehicle according to the first embodiment, which performs the above-described action, the door lock 3 of a right-side or left-side door located on a side opposite to the collision side detected by the collision direction detecting means 1 for detecting left-side and right-side collisions is unlocked by the door unlocking mechanism. Accordingly, the apparatus according to the first embodiment has an effect of making it possible to smoothly and securely unlock a right-side or left-side door located on a side opposite to the collision side and thus making it possible to rescue vehicle occupants.
In the apparatus for unlocking a door lock for a vehicle according to the first embodiment, the door lock knob 10, which has a T-shaped cross section and functions as a swing member, swings in the direction opposite to the direction of the impact of a collision of the vehicle, and cancels the locked state of the door lock 3 of a door located on the side opposite to the collision side, via the link 21, the bell crank 22, and the link 23. Accordingly, the apparatus according to the present embodiment has an effect of making it possible to unlock a door lock located on the side opposite to the collision side by a simple structure.
In the apparatus for unlocking a door lock for a vehicle according to the present embodiment, the door lock knob 10, which has the weight 11 functioning as an inertia mass at the time of a collision of the vehicle and which serves as the swing member, swings about the single supporting point in the direction of an inertial force opposite to the direction of the impact of the collision, and unlocks a door located on the side opposite to the collision side via the bell crank 22. Accordingly, the apparatus according to the present embodiment has an effect of securely performing the detection of a collision side of the vehicle, and the cancellation of a locked state, because the door lock knob 10 is provided with the weight 11.
In the present embodiment, the door lock knob 10 is indirectly urged, in the direction opposite to the direction of the inertial force of the weight 11 at the time of a collision of the vehicle, by the spring (not illustrated) which urges the locking lever 31 in the locking direction. However, it is possible to interpose a spring between the door lock knob 10 and the door so as to directly urge the door lock knob 10.
As described above, since the door lock knob 10 is urged by the spring in the direction opposite to the direction of the inertial force, the door is prevented from being unlocked due to quick acceleration, quick stop, quick turn, very light hit, or the like, and is unlocked only when the vehicle receives an impact equal to or greater than a predetermined level produced by a collision of the vehicle, Accordingly, the apparatus according to the present embodiment has an effect of preventing erroneous operations.
(Second Embodiment)
As shown in FIGS. 5-8, an apparatus for unlocking a door lock for a vehicle according to a second embodiment differs from the first embodiment in that a weight 11 is disposed on the lock lever 31, which serves as a swing member in the door lock 3 of each of front and rear doors of the vehicle, so as to constitute the collision direction detecting mechanism 1, thereby unlocking a lock condition of a door upon a front or rear collision of the vehicle. This difference will be mainly described hereinafter.
In each front door, as shown in FIGS. 5 and 6, the link 23 is engaged with the central portion of the lock lever 31, which swings about its upper end serving as a supporting point, and the weight 11 is attached to the lower end of the lock lever 31. One end of the bell crank 22 is connected to the rink 21 connected to the-above mentioned door lock knob (non-illustrated), and the link 23 is connected to the other end of the bell crank 22.
In each rear door, as shown in FIGS. 7 and 8, the link 23 connected to the door lock knob is engaged with the central portion of the lock lever 31, which swings about its lower end serving as a supporting point, and the weight 11 is attached to the upper end of the lock lever 31.
In the apparatus for unlocking a door lock for a vehicle according to the second embodiment having the above-described structure, when another vehicle or the like hits against the back of the vehicle, the lock lever 31 having the weight 11 at its lower end swings counterclockwise about the upper end of the front door serving as a supporting point due to the inertia of the weight 11, so that the lock lever 31 is brought from the state shown in FIG. 6 to the state shown in FIG. 5. As a result, the front door is unlocked.
On the contrary, when another vehicle or the like hits against the front of the vehicle, the lock lever 31 having the weight 11 at its upper end swings counterclockwise about the lower end of the front door serving as a supporting point due to the inertia of the weight 11, so that the lock lever 31 is brought from the state shown in FIG. 7 to the state shown in FIG. 8. As a result, the rear door is unlocked.
In the apparatus for unlocking a door lock for a vehicle according to the second embodiment, which performs the above-described action, a front-side or rear-side door located on a side opposite to the collision side detected by the collision direction detecting means 1 for detecting front-side and rear-side crushes is unlocked. Accordingly, the apparatus according to the second embodiment has an effect of making it possible to smoothly and securely unlock a rear-side or front-side door located on a side opposite to the collision side and thus making it possible to rescue vehicle occupants.
In the apparatus for unlocking a door lock for a vehicle according to the second embodiment, the door lock lever 31, which is an element of the door lock, is directly swung by the weight 11 disposed at the tip end of the lock lever 31, due to the impact at the time of a collision of the vehicle, so as to cancel the locked state of the door lock 3. Accordingly, the apparatus according to the present embodiment has an effect of making it possible to unlock a door lock located on the side opposite to the collision side by a simple structure.
In the apparatus for unlocking a door lock for a vehicle according to the second embodiment, the lock lever 31, which has the weight 11 functioning as an inertia mass at the time of a collision of the vehicle, swings about the single supporting point in the direction of an inertial force opposite to the direction of the impact of the collision, and unlocks a door lock located on the side opposite to the collision side. Accordingly, the apparatus according to the present embodiment has an effect of securely performing the detection of a collision side of the vehicle, and the cancellation of a locked state, because the lock lever 31 has the weight 11.
(Third Embodiment)
As shown in FIGS. 9 and 10, an apparatus for unlocking a door lock for a vehicle according to a third embodiment uses a bell crank 22, whose one end is connected to one end of the link 23 connected to the lock lever and which has a weight 224 at its other end, instead of the lock lever of the door lock provided with the weight, which is used in the second embodiment as a swing member for unlocking a front door. The bell crank 22 constitutes the swing member of the collision direction detecting mechanism 1.
In the apparatus for unlocking a door lock for a vehicle according to the third embodiment having the above-described structure, when another vehicle or the like hits against the back of the vehicle, the bell crank 22 is swung counterclockwise due to the inertia of the weight 224 at the time of the collision, so that the bell crank 22 is brought from the state shown in FIG. 9 to the state shown in FIG. 10. As a result, the door lock of the door is unlocked via the link 23.
As in the second embodiment, in the apparatus for unlocking a door lock for a vehicle according to the third embodiment, which performs the above-described action, a front-side or rear-side door located on a side opposite to the collision side detected by the collision direction detecting means 1 for detecting front-side and rear-side crushes is unlocked. Accordingly, the apparatus according to the present embodiment has an effect of making it possible to smoothly and securely unlock a rear-side or front-side door lock located on a side opposite to the collision side and thus making it possible to rescue vehicle occupants.
In the apparatus for unlocking a door lock for a vehicle according to the third embodiment, the locked state of the door lock is canceled by the weight 224 added to the lower end of the bell crank 22 due to the impact at the time of a collision of the vehicle. Accordingly, the apparatus according to the present embodiment has an effect of making it possible to unlock a door lock located on the side opposite to the collision side by a simple structure and through a slight modification.
In the apparatus for unlocking a door lock for a vehicle according to the third embodiment, the bell crank 22, which has the weight 224 functioning as an inertia mass at the time of a collision of the vehicle, swings about the single supporting point in the direction of an inertial force of the weight 224 opposite to the direction of the impact of the collision, and unlocks a door lock located on the side opposite to the collision side. Accordingly, the apparatus according to the present embodiment has an effect of securely performing the detection of a collision side of the vehicle, and the cancellation of a locked state.
(Fourth Embodiment)
As shown in FIG. 11, in an apparatus for unlocking a door lock for a vehicle according to a fourth embodiment, the above-described collision direction detecting means 1 comprises an acceleration sensor 15 for detecting the direction of an impact acceleration when a collision of the vehicle occurs, and the above-described unlocking mechanism comprises a controller 251 which judges the direction of the impact acceleration detected by the acceleration sensor 15 and outputs an unlocking signal for unlocking a lock condition of a door located on a side opposite to the detected collision side, and a door control motor 252 which responds to the unlocking signal from the controller 251 so as to unlock the door lock located on the side opposite to the detected collision side.
As shown in FIG. 11, the acceleration sensor 15 comprises an acceleration sensor serving as a collision sensor for detecting a side on which a collision has occurred. Based on the direction of acceleration at the time of a collision, the following signals are output. When another vehicle or the like hits against the front of the vehicle, a front collision signal is output. When another vehicle or the like hits against the back of the vehicle, a back collision signal is output. When another vehicle or the like hits against the right side of the vehicle, a right-side collision signal is output. When another vehicle or the like hits against the left side of the vehicle, a left-side collision signal is output.
As shown in FIG. 11, the controller 251 includes a control section 2514 consisting of an auto-locking control section 2511, a locking control section 2512 and an unlocking control section 2513, a switch section 2515, and a relay section 2516. A vehicle speed sensor 2517, a parking brake switch 2518, a door control switch 2519, and the like are connected to the controller 251.
As shown in FIG. 11, the control motor 252 is each of a motor 2521 for the door lock of the front right door, a motor 2522 for the door lock of the front left door, a motor 2523 for the door lock of the rear right door, and a motor 2524 for the door lock of the rear left door, which are connected to the respective relays of the relay section 2516. Each of the motors locks and unlocks the corresponding door lock.
The controller 251 is controlled in accordance with the auto-locking control flow shown in FIG. 12, the locking control flow shown in FIG. 13, and the unlocking control flow shown in FIG. 14.
In the apparatus for unlocking a door lock for a vehicle according to the fourth embodiment, which has the above-described structure, the auto-locking control is performed as follows. As shown in FIGS. 12 and 15, an auto-locking signal is output when the ignition switch is turned on, each door is in the closed state, no collision has occurred, the vehicle speed has exceeded, for example, 25 km/h, and the door is in the unlocked state.
When the vehicle encounters a collision when the doors are in the locked state, the acceleration sensor 15 detects the direction of the impact acceleration of the collision, as shown in FIGS. 14 and 15. In accordance with the direction of the impact acceleration detected by the acceleration sensor 15, the controller 251 constituting the unlocking mechanism outputs an unlocking signal for unlocking a lock condition of a door located at a side opposite to the detected collision side. The door control motor 252 of that door responds to the unlocking signal from the controller 251 so as to unlock the door.
Specifically, as shown in FIGS. 14 and 15, in accordance with the output from the acceleration sensor which indicates the location of a collision, a relay of the relay section 2516 corresponding to the location of the collision outputs a signal so as to unlock a door lock located at a side opposite to the collision side.
In the apparatus for unlocking a door lock for a vehicle according to the fourth embodiment, which performs the above-described action, a door which is located at the front right, front left, rear right or rear left of the vehicle opposite to the collision side is unlocked electrically, based on the detection signal from the collision direction detecting means 1 for detecting front and back collisions as well as right-side and left-side collisions. Accordingly, the apparatus of the present embodiment has an effect of preventing a door from being opened due to the impact of a collision, and making it possible to smoothly and securely unlock a door lock located on a side opposite to the collision side, thereby making it possible to rescue vehicle occupants.
In the apparatus for unlocking a door lock for a vehicle according to the fourth embodiment, the controller 251 outputs an unlocking signal in accordance with the impact acceleration signal output from the acceleration sensor 15, and the door control motor 252 responds to the unlocking signal from the controller 251 so as to unlock the door lock located on the side opposite to the detected collision side. Accordingly, the apparatus according to the present embodiment has an effect of making it possible to unlock a door lock located on the side opposite to the collision side, only by adding the acceleration sensor to the electric door lock apparatus and by partially modifying the control program.
In the above-described fourth embodiment, a description is given of an example in which the acceleration sensor outputs a signal indicating the location of the vehicle at which a collision has occurred. However, the present invention is not limited to that example, and it is possible to employ an embodiment in which the controller obtains vector components based on acceleration signals from the acceleration sensor, and determines the location of a collision on the vehicle based on the vector components.
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An apparatus for unlocking a door lock for a vehicle, comprising a plurality of door locks for being mounted on doors of the vehicle, a collision direction detecting device for detecting a direction of an impact applied to a vehicle; and an unlocking mechanism for unlocking a door lock located on a side opposite to a collision side based on the direction detected by the collision direction detecting device.
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RELATED APPLICATIONS
This application claims priority to Provisional Application No. 60/209,102, filed on Jun. 2, 2000.
FIELD OF THE INVENTION
This invention relates to a restraint device that works in conjunction with conventional handcuffs. More specifically, this invention relates to a restraint strap that is used in conjunction with conventional handcuffs to provide a handle for restraining a handcuffed individual.
BACKGROUND
When a police officer or other security personal attempts to detain a suspect, the officer normally handcuffs the suspect. This process is one of the most dangerous procedures for a police officer largely due to the possibility of a prisoner attempting to escape. If the suspect attempts to escape as they are being handcuffed, the police officer can be hurt by trying to restrain the suspect by grabbing the handcuff or handcuff chain, or the suspect may escape if the officer fails to hold onto the handcuff. Thus, what is needed in the art is a mechanism for safely restraining a suspect during the handcuff process.
SUMMARY
One embodiment of the invention is a restraint device that mounts a chain disposed between two handcuffs. The restraint device includes: a loop of material adapted to be gripped by a human hand; and a securing device associated with the loop of material, wherein the securing device separates the loop of material into a first gripping loop and a second mounting loop, and wherein the second mounting loop is adapted to securely mount to said chain.
Another embodiment of the invention is a pair of handcuffs and a restraint device that mounts a chain disposed between the handcuffs, wherein the restraint device includes: a loop of material adapted to be gripped by a human hand; and a securing device associated with the loop of material, wherein the securing device separates the loop of material into a first gripping loop and a second mounting loop, and wherein the second mounting loop is adapted to securely mount to said chain.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view illustrating a pair of handcuffs and one embodiment of a restraining strap.
FIG. 2 is a cross-sectional view along the line 2 — 2 of FIG. 1 .
DETAILED DESCRIPTION
Embodiments of the invention relate to restraining straps that mount between a pair of handcuffs to provide a means for a law enforcement officer to restrain a suspect. In one embodiment, a restraining strap is slid over one handcuff and reversibly, yet securely mounts between each handcuff. The restraining strap thus provides a secure and comfortable grip for the officer to control and restrain a handcuffed suspect.
One embodiment of the restraining strap includes a flexible outer shell made of nylon, leather, neoprene, Kevlar or other flexible, yet durable, material. For example, one-inch wide tubular nylon webbing has been found to be suitable due to its tensile strength and smooth texture. As discussed below, the handcuff-mounting portion of the restraining strap can include a loop of material that fits over a handcuff chain and is secured to the chain by a securing band. The securing band prevents the handcuff strap from inadvertently sliding off the handcuff chain. In addition, in one embodiment, the handgrip portion of the restraining strap includes a cushioned hand-grip area that provides a soft surface for gripping with a hand.
In another embodiment of a restraining strap, the hand-grip portion is in the shape of a loop that is connected to a single strap. The single strap is then attached between the handcuffs by, for example, tying a knot, using a snap or any other means for connecting the single strap to the handcuffs.
It should be realized that the hand-grip portion is not limited to only comprising a loop shaped piece of material. For example, the hand-grip portion can be in the shape of a “T” or any other shape that is easily gripped by a human hand.
In use, the police officer mounts the restraining strap to the chain that links the handcuffs. The restraining strap is preferably in the shape of a flexible loop and is adapted to fit inside the palm, or over the hand, of the officer. An officer may hold the handle of the restraining strap in the palm of their hand, or they may place the gripping loop of the strap over their hand. With the restraining strap mounted on the handcuffs and securely held, the officer may place the handcuffs on a suspect while maintaining a secure grip on the handcuffs. Thus if the suspect attempts to fight or escape with one or both handcuffs secured, the officer has a controlling grip on the strap attached to the handcuffs by which to restrain the suspect.
FIG. 1 shows a typical pair of handcuffs 10 , including a left handcuff 12 and right handcuff 14 . Disposed between the right and left handcuffs is a chain 16 that prevents the right and left handcuffs 12 , 14 from being separated. The particular design and materials of handcuffs are well known, and beyond the scope of the present description, thus they will not be discussed herein. For example, some handcuffs incorporate a hinge between each handcuff in place of the chain 16 . Embodiments of the invention include restraining straps that mount to the such a hinge in addition to restraining straps that mount to the chain 16 .
One embodiment of a handcuff restraining strap 20 is shown in FIG. 1 . The handcuff restraining strap 20 is generally characterized by a mounting loop 24 and a gripping loop 28 separated by a retaining band 30 , both of which are preferably adjustable in size. It should be noted that in this embodiment, the mounting loop 24 and gripping loop 28 are formed from a single loop of material.
The restraint strap 20 has a front portion 32 and a rear portion 34 integrally formed with at least the mounting loop 24 as shown. Preferably, the retaining band 30 fits snugly about the front and rear 32 , 34 portions so that it is secured around the chain 16 .
The handcuff restraining strap 20 is preferably made from a substantially flexible, but substantially strong material such that the restraining strap is comfortable to hold, yet has sufficient tensile strength so that it will not break under expected loads. The mounting loop 24 is preferably made of a material which will resist abrasion from contact with the chain 16 .
The retaining band 30 may be made from any suitable material such that it will perform the functions described herein without abrading the material of the mounting loop 24 . For example, the retaining band 30 may be made from a substantially flexible nylon, Kevlar®, or a substantially rigid metal. In one embodiment, the retaining band 30 is fixed to the front portion 32 , leaving the rear portion 34 free to slide relative to the retaining band 30 and the front portion 32 . Thus the size of the mounting loop may be increased or decreased by sliding the free, rear portion 34 in the appropriate direction relative to the retaining band 30 .
For example, the size of the mounting loop 24 can be increased by sliding the rear portion 34 toward the mounting loop 24 , thus decreasing the size of the gripping loop 28 . This embodiment has the particular advantage that when the restraining strap 20 is disposed on a handcuff chain 16 as shown, and the handle 36 is pulled, the mounting loop 24 will tighten around the chain 16 . Alternatively, the retaining band 30 may be disposed such that both front and rear portions 32 , 34 may be free to slide relative to the retaining band 30 .
It should also be realized that the means for mounting the restraining strap to the chain does not necessarily need to be a loop of material. For example, a strong snap or latch mechanism can be positioned within the restraining strap so that once the strap is slid over the chain, the latch or snap can be closed to secure the restraining strap to the handcuff chain. Any similar securing device for reversibly mounting the restraining strap to the handcuff chain is within the scope of the invention.
The gripping loop 28 preferably comprises a handle section 36 . The handle section 36 is preferably sufficiently large to allow a user to comfortably and controllably grip the handcuff restraint strap 20 . The material of the gripping loop 28 is preferably comfortable to hold and substantially flexible. The gripping loop 28 preferably comprises a larger diameter than the mounting loop 24 . The gripping loop 28 may be gripped such that the user's fingers wrap around the handle section 36 , or the user may slide their hand through the gripping loop 28 , thus retaining the restraint strap 20 on the user's wrist.
FIG. 2 is a cross-sectional view of the restraining strap 20 taken across line 2 — 2 (FIG. 1 ). As indicated, the handle section 36 of the restraining strap includes, in one embodiment, an outer shell 50 made of a flexible material, such as neoprene, woven cloth, nylon, Kevlar, cotton, or other similar material. Placed within the interior of the outer shell 50 is, in one embodiment, a strong, thick material 55 , such as rope, rubber, or polystyrene. The combination of the outer shell 50 and inner material 55 provides a gripable area due to its relatively large circumference. The handle section 36 may comprise a variety of materials such that it provides a comfortable handle for the user.
The use and assembly of a restraining strap 20 will now be described with reference to FIG. 1 . In order to put the restraining strap 20 on the handcuff chain 16 , the size of the mounting loop 24 of the restraining strap 20 is increased as much as possible, as discussed above. The mounting loop 24 is then slid over an open end of one of the handcuffs 12 or 14 . Once the mounting loop 24 has been slid over the handcuff 12 or 14 , the mounting loop is tightened across the chain 16 by sliding the rear portion 34 toward the gripping loop 28 through the retaining band 30 . As can be imagined, the retaining band 30 provides a means for securing the restraining strap 20 to the chain 16 and thus the handcuffs 12 and 14 .
In one embodiment, a handcuff restraint strap 20 may be made by taking a section of tubular nylon webbing, inserting a segment of rope into the space within the webbing and sliding it to a position substantially within the webbing. The material is then formed into a loop by securing the ends of the webbing together using any method known to those skilled in the art. For example, the ends may be glued, welded, bar-tacked, sewn, or stapled. A retaining band 30 is then preferably placed about the front and back portions 32 , 34 as described above, and fixed to the front portion 32 if desired. The retaining band 30 is preferably placed about the restraining strap 20 at a position such that it covers and may reinforce the joint of the two ends of the restraining strap material 38 .
In another embodiment, a handcuff restraint strap 20 may be made by taking a section of suitable material as described above, inserting it into a tubular handle material such as a section of rubber or latex tubing, then attaching the ends of the strap material by a method suitable for that material. A retaining band 30 is then preferably placed about the front and back portions 32 , 34 of the restraining strap 20 as described above, and fixed to the front portion 32 if desired. The retaining band 30 is preferably placed about the restraining strap at a position such that it covers and may reinforce the joint of the two ends of the restraining strap material 38 .
Although this invention has been disclosed in the context of certain preferred embodiments and examples, it will be understood by those skilled in the art that the present invention extends beyond the specifically disclosed embodiments to other alternative embodiments and/or uses of the invention and obvious modifications and equivalents thereof. Thus, it is intended that the scope of the present invention herein disclosed should not be limited by the particular disclosed embodiments described above, but should be determined only by a fair reading of the claims that follow.
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A handcuff restraint strap is disclosed herein. The strap is made of a substantially soft, flexible, and strong material, such that it is comfortable to hold, and will withstand the forces applied while an officer holds and controls a suspect. The strap mounts to the center chain on the handcuffs and provides a handle for an officer to easily manage a handcuffed individual.
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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 a method of treating subterranean reservoirs particularly hydrocarbon reservoirs. More specifically, the invention pertains to methods of increasing the exposed surface of such reservoirs, particularly for the purpose of enhancing recovery of hydrocarbon.
BACKGROUND
[0002] It has long been recognized that in order to increase recovery from a hydrocarbon reservoir, it is beneficial to increase the exposure of the reservoir to the well or wells drilled through it. This recognition led to methods such as perforating, fracturing and acidizing.
[0003] Whilst many of those methods are not considered to be relevant for the present invention, it is worth noting that propellants have been used as a substitute for hydraulic fracturing. In conventional hydraulic fracturing a fluid is pressurized from the surface to generate a pressure sufficiently high to generate fractures in the subterranean formation below. In some instances, particularly where the economics were not favorable for the deployment of heavy pumping equipment, propellants have been used. Lowered into the borehole, the propellants when ignited with the correct pressure built-up create the conditions for fracturing the reservoir rock surrounding the well. Likewise propellants have been used to assist as secondary means other explosives or fluids in the fracturing process.
[0004] Such known use of propellants is described for example in the co-owned U.S. Pat. No. 5,355,802 issued to Petitjean, the U.S. Pat. No. 5,295,545 to Passamaneck and the more recent U.S. Pat. No. 7,073,589 to Tiernan and Passamaneck, as well as the patents referenced in these patents.
[0005] As hydrocarbon fields are growing more mature, it has also been found that these established methods are no longer sufficient to exploit a reservoir to the extent theoretically possible. In response to this challenge a plethora of new methods have been proposed to increase recovery beyond that afforded by established methods. These methods are generally referred to as “Enhanced Oil Recovery” or EOR methods.
[0006] It is therefore an object of the present invention to provide novel EOR methods. Ideally the new methods are suitable for all reservoirs but in particular for carbonate rocks.
SUMMARY OF INVENTION
[0007] According to a first aspect of the invention, a method of fracturing a rock formation is provided including placing through a wellbore penetrating said rock formation propellants into a cavity located at a radial distance from said wellbore and igniting the propellants to cause a pressure sufficient to fracture said formation.
[0008] According to a second aspect of the invention, a method of enhancing access to a subterranean rock formation is provided including placing through a wellbore penetrating said rock formation propellants into a cavity located at a radial distance from said wellbore and igniting the propellants to cause a pressure sufficient to fracture said formation, thereby creating more cavities for an iterative placement and ignition of further propellant or other fracturing methods.
[0009] Yet another aspect of the invention relates to the beneficial effects gained by applying the above methods to hydrocarbon bearing reservoirs. With the increased access afforded by these methods many known EOR methods can be applied with higher efficiency leading to improved recovery of hydrocarbons from reservoirs. In a preferred embodiment, such improved EOR methods include the use of heated fluids such as steam pumped through the network of natural fractures as found in many, mostly carbonate, rocks. Access and range of such network increases by making use of the fractures created by the propellants in accordance with the methods of this invention.
[0010] According to these aspects of the invention, the rock formation which is preferably a carbonate rock with a recoverable hydrocarbon fluid content is fractured or even rubblized at locations away from the main well. As result of applying methods in accordance with the invention, the rock surface accessible through macroscopic flow channels such as fractures is increased. The increase in accessible formation can be exploited to increase the amount of fluids drained or produced from or alternatively, expose more rock surface to treatment fluids.
[0011] A well in accordance with the present invention is defined as a drilled hole designed to allow access of standard well tools such as tubing or wireline conveyed instruments or completion and production equipment. The cavities as defined herein are not wide enough to allow for such access. Instead, the creation and/or access to the cavities requires specialized tools of comparatively small diameter, such as a wireline or tubing conveyed lateral drilling tools. Alternatively the cavities may be generated on the force or flow of pressurized fluids or prior ignition of propellants.
[0012] Hence the cavities in accordance with the present invention have a maximum effective diameter of 13 cm [4 inches] or even only 7 cm [2 inches] or less. The effective diameter is defined as a cross-section of a however irregularly shaped opening which is sufficiently wide to allow passage of a cylindrical object of such diameter.
[0013] The cavity or cavities for the propellant can be any opening at a radial distance from the well. The cavity can be either naturally occurring or artificially created. Cavities comprise fissures, fractures, channels or boreholes. To increase the precision of placement and the overall control of the process, it is a preferred variant of the invention to use microboreholes as cavity.
[0014] Such microboreholes are known per se for the purpose of extracting core samples from or positioning sensors into a reservoir. Apparatus for drilling microboreholes and known applications of microboreholes are described for example in the U.S. Pat. No. 4,226,288 to Collins, the co-owned U.S. Pat. No. 5,692,565 to MacDougall et al., U.S. Pat. No. 6,896,074 to Cook et al. and U.S. Pat. No. 7,191,831 to Reid et al.
[0015] A propellant is a source of both energy and working fluid. Typically it can be further distinguished from explosives by the rise time of the pressure build-up after ignition. This rise time is in the order of 0 to 0.4 ms for explosives and in the order of 0.4 ms to 1 ms or even 5 ms for propellants. The pressure rise time for hydraulic fracturing is at least an order of magnitude longer.
[0016] Preferred propellants for the present application are solid propellants mixed with oxidizers such as ammonium perchlorate. The commercially available series of Arcite® propellants widely used as fuel to inflate airbags and in some of the known downhole applications of propellants is seen as a particularly safe and suitable products for use in the present invention.
[0017] These and other aspects of the invention are described in greater detail below making reference to the following drawings.
BRIEF DESCRIPTION OF THE FIGURES
[0018] FIG. 1 is a flow diagram illustrating steps in accordance with an example of the present invention;
[0019] FIG. 2 shows the preparation of a microborehole for use in accordance with an example of the present invention;
[0020] FIG. 3A shows a microborehole loaded with propellants in accordance with an example of the present invention;
[0021] FIG. 3B illustrates the effect of igniting the propellant on the formation; and
[0022] FIG. 4 illustrates an improved EOR operation in accordance with an example of the invention.
DETAILED DESCRIPTION
[0023] The following example of a method in accordance with the present invention is illustrated using the block diagram of FIG. 1 and the drawings of FIGS. 2-4 .
[0024] In the example it is assumed that propellants are to be deposited into a newly drilled microborehole (Step 11 of FIG. 1 ). This step is illustrated in FIG. 2 . This figure shows a main well 21 in a carbonate rock formation 20 . The main well 21 is used to access the desired depth in the reservoir 20 with a wireline suspended drilling unit 22 . The drilling unit is suspended from a wireline surface unit 23 through a well head 24 located at the top end of the well 21 .
[0025] At the desired depth, the wireline suspended drilling unit 22 is deflected by means of a temporary packer 25 and a deflection vane 26 into the formation to drill a microborehole 27 .
[0026] This microborehole 27 is drilled to the target location within the formation 20 , at which stage the drilling unit 22 is withdrawn and a propellant depositing unit 31 is lowered into the drilled microborehole. This step 12 of FIG. 1 is illustrated in FIG. 3A . The depositing step leaves a propellant cartridge 32 unit in the microborehole 27 . A detonator line 33 connects the propellant cartridge 32 with the depositing unit and hence with the surface. As an alternative to the detonator line 33 , the propellant may be ignited using delayed ignition energy release mechanism co-placed with the propellant.
[0027] A suitable propellant is a mixture of ammonium perchlorate as the oxidizer and Actite 386 M as the fuel. Alternatively, a combination of potassium perchlorate and Arcite 497 L can be used. However it should be understood that numerous other oxidizer/fuel combination are also applicable.
[0028] The cartridge with the propellant is then ignited (Step 13 of FIG. 1 ). The ignition releases a pressure pulse with a rise time of more than 0.4 ms. The pressure pulse fractures the surrounding formation as shown in FIG. 3B . This figures shows the elements of FIG. 3A after the ignition of the propellant cartridge 32 .
[0029] The steps of FIG. 1 as described above can be repeated re-using for example the drilled microborehole, drilling further microboreholes or using a cascading set of microboreholes.
[0030] In FIG. 4 , the treatment of the reservoir as described above is shown to have created a network 40 of partly connected or intersecting fractures. This network can be exploited to improve EOR methods as shown. The example of FIG. 4 illustrates a Thermally Assisted Gas-Oil Gravity Drainage (TA-GOGD) similar to the recovery process as implemented by Shell/PDO in Oman Qarn Alam field. A steam injector well 41 is drilled to the depth of the network 40 of fractures.
[0031] To produce from the reservoir 20 , steam is injected via the injector well 41 through the network 40 of fractures into the reservoir 20 . The heat increases the temperature and hence decreases the viscosity of the oil trapped in the reservoir rock. As the steam is distributed through the network 40 of fractures, a greater volume of the reservoir 20 is exposed compared to conventional applications of TA-GOGD. Thus a greater volume of oil can be drained and pumped to the surface.
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A method of fracturing a rock formation is provided including placing through a wellbore penetrating the rock formation propellants in a cavity located at a radial distance from the wellbore and igniting the propellants to cause a pressure sufficient to fracture the formation.
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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 present invention relates generally to an apparatus and method for use in construction of a press box. Press boxes are typically employed at football, soccer, track or racing stadiums. More particularly, though not exclusively, the present invention relates to an apparatus and method for constructing such press boxes in modular fashion.
[0003] 2. Problems in the Art
[0004] As is noted in U.S. Pat. No. 6,457,281 to Teron, the construction industry has been relatively slow in adopting new and developing technology. Generally, the construction industry has remained very labor intensive and of a handicraft nature. The end result is that construction projects are still expensive endeavors in terms of both money and time.
[0005] The Teron patent, mentioned above, attempts to overcome the labor and time intensive nature of the construction industry through the use of pre-cast concrete monolithic units. While such units can be cast in a variety of shapes and sizes, each casting forms a solid structural wall that is not easily prone to adaptation. For example, the use of windows or doors requires separate in-fill panels as such cannot be readily integrated into a pre-cast structure of concrete. Therefore, it is desirable to have a modular building system in which various wall structures, including doors and windows, can be easily added.
[0006] In the world of spectator events, press boxes are ideally located above the area of action. For example, in a high school football field setting, the press box is usually situated to one side of the field above all of the bleachers. Many press boxes also have more than one level from which to view the activity of interest. For these and other reasons, it is desirable to have modular units which are stackable without the need for additional supporting structures.
[0007] Whether a press box is used for a football, soccer, track, or other sporting event, several common features are desirable. For example, every press box will need some sort of viewing area as well as a plurality of counters, tables, chairs and other features typically used by the occupants thereof. Because the features of the press box do not tend to vary greatly whether the press box is used for football, soccer, or in conjunction with any other sporting arena, it is desirable to have a modular unit for constructing press boxes that easily incorporates many of the standard and desirable features of press boxes in use today.
[0008] Many arenas in use today are built with the assistance of public funds. Public funding is typically only awarded after a bidding process. During the bidding process, price, efficiency, and quality of the end product are of prime concern. It is therefore desirable to be able to offer a press box and method of constructing the same that minimizes production costs, increases production efficiency, and can be easily adapted to accommodate all of the customers demands. There is therefore a need for an apparatus and method of constructing a press box which avoids these and other problems.
[0009] Features of the Invention
[0010] A general feature of the present invention is the provision of an apparatus and method for constructing a press box which overcomes the problems found in the prior art.
[0011] A further feature of the present invention is the provision of an apparatus and method for constructing a press box which is easily adaptable for use in many different arenas.
[0012] Another feature of the present invention is the provision of an apparatus and method for constructing a press box which allows the press box to be easily customized for any particular customers desires.
[0013] A still further feature of the present invention is the provision of an apparatus and method for constructing a press box, which allows the press box to include windows, doors, balconies, benches, seats and other features at a variety of locations.
[0014] A further feature of the present invention is the provision of an apparatus and method for constructing a press box, which uses modular units.
[0015] Another feature of the present invention is the provision of an apparatus and method for constructing a press box which incorporates modular units that are stackable.
[0016] A still further feature of the present invention is the provision of an apparatus and method for constructing a press box which simplifies the on-site construction process.
[0017] Another feature of the present invention is the provision of an apparatus and method for constructing a press box which minimizes assembly time.
[0018] A still further feature of the present invention is the provision of an apparatus and method for constructing a press box which minimizes construction costs.
[0019] Another feature of the present invention is the provision of an apparatus and method for constructing a press box which allows additions to be made to existing structures easily.
[0020] These, as well as other features and advantages of the present invention, will become apparent from the following specification and claims.
SUMMARY OF THE INVENTION
[0021] The present invention generally comprises an apparatus and method for constructing a press box through the use of a plurality of press box modules. In one embodiment, a plurality of press box modules are formed offsite. Each press box module generally includes a box-like frame having a number of structural supports built therein. Preferably, each press box module is of a standardized size and shape such that one module may be easily stacked upon another module in a block like fashion.
[0022] When assembled, each module preferably includes a plurality of steel columns or steel tubes at its corners. The steel columns are connected to one another by steel beams which may be secured to the columns through welding, screws, or any other well known method. Each column is preferably topped with a connector plate that acts as both a supporting platform and a means for connecting various modules in a vertical arrangement. Each module also includes a plurality of side beams that provides structural support. Each beam is preferably half of an I-beam or generally C-shaped. This presents the outer edge of the module with a flat surface. By keeping the outer surfaces flat, beams in different modules can be easily connected by including a plurality of corresponding holes in each beam and securing the beams there through. Securement can be performed with nuts and bolts, welding or any other known securing means.
[0023] In another embodiment, construction is further simplified by using steel tubing for both the columns and beams. The added strength associated with the use of steel tubing allows construction of the modules to be done with minimal reinforcing materials. This allows for an open cross-section and thereby provides limitless opportunity for walk ways, placement of doors, windows, benches, electrical fittings and other desirable interior appointments. Using a plurality of steel tubing also minimizes the variety of materials needed, allowing for increased efficiency in both ordering and construction. These modules, formed primarily of steel tubing, can be secured to one another using welding, nuts and bolts or any other known securing means.
[0024] Using either of the above mentioned embodiments, the modules can be rapidly assembled and stacked to form a press box of any desirable shape or size. Because easily modifiable framing elements are used instead of pre-cast structures, various elements are easily added to a press box module. For example, door jambs can be created using L-arm structural steel members, aluminum framing, or wood. In a similar fashion, window sills can be arranged to accommodate a variety of window sizes and shapes without the need to alter the pre-existing box frame. Each of these elements may be secured to the box frame through tack welding of the pieces directly or of suitable connector pieces.
[0025] Each box frame also preferably includes flooring at a pre-determined and consistent level in each box frame. The flooring is generally formed from a plurality of flooring joist secured between the flooring beams by plurality of connector tabs. The flooring joist may be made of wood or metal or even adapted to support concrete slabs. In a similar manner, ceiling joist preferably run along the top of the box frame.
[0026] After the flooring construction is completed, a variety of built-in componentry can be added. For example, if the customer desires a countertop underneath the window or viewing area, a counter can be pre-installed. Additionally, electrical conduit including a plurality of electrical boxes and switchboxes at desired locations may be inserted before wall finishing is completed
[0027] On the top of the uppermost press box module, it is typically desirable to include a roof structure. The roof structure or roof module may be formed from either a column and beam or the steel tubing arrangement. In the column and beam arrangement, the roof module preferably includes a plurality of connector plates corresponding to the connector plates on the top of the press box module. This allows for nut and bolt connections to be easily made. Alternatively, in the steel tubing arrangement, the roof module may be easily welded to the tubing of the press box module below. Either arrangement can be secured together and to the corresponding box module below using any known method.
[0028] Pre-assembling the roof module allows it to be easily connected with minimal onsite customization. Each roof module may include a roof that is angled at a pre-determined level and generally includes a plurality of roofing beams or additional tubes having connector tabs secured thereto. Between the roofing beams or tubes are a plurality of roofing struts that support the actual roofing material. By connecting the roof beams or tubes between two roof columns or additional tubes of varying heights, the roof angle can be controlled.
[0029] Additional structures may be added to the outside of the press box modules, including a staircase for upper level access, and balconies if outdoor viewing is desirable. Both the balconies and the staircases may be easily bolted or otherwise connected to each press box module as desired. Balconies may be preinstalled before all of the modules are assembled into the final press box. Once modules are assembled or stacked, a balcony accessible in one module may be supplementally supported through a beam connection to a lower module. Additional structural supports may be used throughout the modules, including gusset plates with corresponding bracing rods. These keep the modules in tension and therefore minimize the amount of structural flex that may be inherent in each box frame.
[0030] Once all of the individual modules are assembled, standard finishing materials such as drywall, carpeting, lighting, etc. may be applied to give the interior of the press box the desired appearance. Further, after module assembly is complete, siding material may be added to give the outside of the press box a finished appearance.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] The various features and advantages of the invention will become more apparent from the following description of the preferred embodiments of the same wherein references made to drawings including:
[0032] [0032]FIG. 1 is a perspective view of one embodiment of the modular press box in assembled form as would be installed at an arena.
[0033] [0033]FIG. 2 is a front view of the press box module assembly of FIG. 1.
[0034] [0034]FIG. 3 is an exploded view of one embodiment of the press box module assembly showing individual modules separated from one another.
[0035] [0035]FIG. 4 is an exploded view of another embodiment of the press box module assembly showing individual modules separated from one another.
[0036] [0036]FIG. 5 is a side view of a typical roof tube, ceiling tube or flooring tube to which connector tabs have been installed.
[0037] [0037]FIG. 6 is a cross-sectional view of the sidewall of one embodiment of a press box module in finished form.
[0038] [0038]FIG. 7 is a cross-sectional view of the connection between one embodiment of the roof module and one embodiment of the press box module.
[0039] [0039]FIG. 8 is a cross-sectional view of one embodiment of the flooring installed in a press box module.
DETAILED DESCRIPTION OF THE INVENTION
[0040] Referring now to FIG. 1, there is illustrated a perspective view of the modular press box 10 installed in conjunction with a series of bleachers 12 at a stadium 14 . The press box 10 is preferably made from a variety of steel structures, including steel tubes, beams, columns, L-arm members, plates, brackets, rods, etc. Alternatively, other materials, such as aluminum, wood, composites, or plastic materials may be substituted as desired so long as the strength and integrity of the press box 10 is not compromised. As is shown in FIG. 1, the press box 10 is built up of a variety of press box modules 16 . The modules 16 may be arranged to provide an elongated structure with one or more floors as shown.
[0041] A typical press box 10 is placed in an elevated position to allow the members of the press, announcers, coaching staff, and other individuals the desired advantage point. Any number of press box modules 16 may be used until the desired height is reached. Alternatively, the press box modules 16 and the press box 10 in its entirety may be elevated on a supporting platform or base structure, so long as the desired advantage point is reached. A preferred supporting platform (not shown) is constructed of steel beams or columns which are reinforced using a plurality of gusset plates and bracing rods. As the typical vantage point is an elevated one, stairs 18 may be secured to one or more press box modules 16 so that access to the press box 10 may be had from ground level. Alternatively, an elevator (not shown) may be assembled and secured as desired.
[0042] Referring now to FIG. 2, each press box module 16 may include a balcony 20 secured thereto. Each press box module 16 may be designed to include its own balcony 20 , to have no balcony 20 , or to have a balcony 20 that connects with the balconies 20 of other modules 16 . Also shown in FIGS. 1 - 4 are a plurality of roof modules 22 . By stacking the individual press box modules 16 in the desired arrangement and securing roof modules 22 on the uppermost press box module 16 , the desired final shape of the press box 10 can be realized.
[0043] As many sporting events have a very limited off-season time period, it is desirable to keep on-site assembly time to a minimum. By using preformed press box modules 16 in conjunction with preformed roof modules 22 , on-site assembly time can be easily managed and minimized. Thus, a module press box 10 can be easily assembled during the off-season time available causing minimal inconvenience to the purchasing customer.
[0044] As is shown in FIGS. 3 and 4, each of the modules 16 may be formed by creating a box-like frame structure. For example, FIG. 3 illustrates that square steel tubing, preferably ¼ inch think, 8 inch by 8 inch steel tubing, is using to form a plurality of columns 24 placed at the corners of the box-like frame structure. Each of the columns 24 are connected to one another through the use of a plurality of beams 26 . The beams 26 are preferably generally C-shaped as shown. A cross-sectional view of one such beam 26 is shown in FIG. 6.
[0045] Additionally, beam support brackets (not shown) may be secured between the beam 26 and the column 24 to provide additional structural strength if needed. The support brackets are preferably steel plates that are simply welded in place once the beam 26 has been secured to the column 24 . The beam 26 may be secured to the column 24 through welding, bracketry, or any other known method. Additionally, when it is known a customer will not desire to passthrough the beam 26 and column 24 arrangement, i.e. that it will be a solid wall, additional bracing materials may be employed. For example, as shown in FIG. 1, a plurality of gusset plates 32 are secured to the corners of the beam 26 and column 24 assembly. A central gusset plate 32 allows a plurality of bracing rods 30 to be connected to enhance the rigidity of the overall wall formed by the beams 26 and columns 24 .
[0046] In another embodiment of the present invention, the press box module 16 using steel tubing 25 in place of the columns 24 and beams 26 as shown in FIG. 4. Using 8 inch by 8 inch {fraction (1/4)} inch thick steel tubing allows for construction of press box modules 16 without the need for additional bracing materials. This arrangement maximizes the interior space of the press box module 16 while minimizing construction time and cost.
[0047] A wall formed by either the beams 26 and columns 24 , as shown in FIG. 3, or the tubing 25 , as shown in FIG. 4, may also be fitted to include a variety of additional elements. For example, as shown in FIG. 4, a doorjamb 34 has been installed. The door jamb 34 generally includes a plurality of L-arm or other bracketry 40 arranged to accommodate the desired door size. The doorjamb 34 is generally made by using a header 36 and retaining member 38 which can be spot welded into place or alternatively screwed into the tubes 25 or beam 26 and post 24 . Alternatively, the bracketry 40 can be arranged merely to accommodate the desired opening between rooms in the press box 10 .
[0048] Typically one module will become one room in the press box 10 . However, the open wall provided by the beam 26 and column 24 arrangement or the tube 25 arrangement, allows multiple modules 16 to be assembled to form one room. Alternatively, rooms may be broken up in any desired fashion.
[0049] Additionally, other features may be added to the press box module 16 . A counter 42 , shown in FIGS. 3 and 6 may be installed in any desired location. As is shown in FIG. 6, it is usually desirable in a press box 10 to have a counter 42 close to a window 52 . The counter 42 can be secured directly to the flooring 58 such that the countertop 56 abuts against the window wall. As is also shown in FIG. 6, the flooring 58 is generally secured to the beam 26 through the use of an L-arm bracket 40 . The L-arm bracket 40 is preferably a steel member that is supplementally supported through one or more support tabs 66 , generally shown in FIG. 5.
[0050] Referring again to FIG. 3, electrical conduit 46 as well as corresponding electrical boxes 48 and switch boxes 50 may be placed as desired throughout the box-frame structure of any press box module 16 . Preferably, the electrical and countertop work is not performed until the floor 58 has been formed.
[0051] The floor 58 is generally secured in the same manner as the deck or balcony 20 . As is shown in FIG. 6, the flooring 58 or balcony 20 is formed by initially welding a plurality of support tabs 66 to the inside of C-shaped beam 26 . Next, an L-arm bracket 40 is welded or otherwise secured to the beam 26 and support tabs 66 . Preferably, an aluminum deck structure or concrete slab 58 is secured to the L-arm brackets 40 through the use of a puddle weld, cement screws or other securing means. When this arrangement is to be used for a flooring section, the aluminum deck or concrete slab 58 provides a solid surface over which carpet, tile, or other desired flooring material may be placed. As is also shown in FIGS. 3 and 4, flooring support joists 80 may be secured in a similar fashion. The flooring beams 82 , also the bottom beams 26 or bottom tubes 25 , may be fitted with a plurality of flooring connector tabs 84 to accommodate a plurality of transversely placed flooring joists 80 . The flooring connector tabs 84 are preferably secured to the flooring beams 82 or bottom beams 26 or tubes 25 through welding, though any other securing method may be used.
[0052] Preferably, the flooring tabs 84 have a plurality of holes therein that correspond to a plurality of holes in the flooring joists 80 . This allows the flooring joists 80 to be rapidly assembled into proper position using nuts and bolts, though any type of securing method may be used. The flooring joists 80 thereby provide additional support to the decking or flooring material 58 previously discussed. Ceiling joists 86 may be similarly installed between ceiling beams 88 , the upper most beams 26 or upper most tubes 25 , using ceiling connector tabs 90 .
[0053] Alternatively, the flooring 58 may be secured on top of I-beam flooring joists 80 and the flooring beams 82 made from bottom tubes 25 as is shown in FIG. 8. The shape of the steel tubing 25 provides for additional support for the flooring 58 eliminating some of the additional supports required for the beam 26 and column 24 arrangement. A C-channel member 83 having a flat outer edge may be place to meet the end of the flooring 58 . This provides a finished outer surface that may be easily adapted for finishing materials.
[0054] Referring again to FIG. 6, a window 52 may be installed into a wall of the press box 10 by employing smaller C-shaped steel bracketry to form a window seal 44 . Wood framing 54 may be used to ensure a weather tight fit of the window 52 . Again, the open area format of the beam 26 and column 24 wall arrangement or the tube 25 wall arrangement allows a wide variety of shapes and sizes for the window 52 . Once the window 52 has been installed, closure plates, typically provided by a siding supplier, can be employed to ensure the wall is weather tight.
[0055] During assembly of the beam 26 and column 24 arrangement of the individual press box modules 16 and referring to FIG. 7, a plurality of connector plates 70 are preferably placed on the upper and lower portions of the columns 24 or at other alternative locations as desired. Preferably, the connector plates are 14 inch square, ¼ inch thick steel plates that have a plurality of holes therein. Each connector plate 70 is identical such that the connector plates 70 from one module 16 may easily align with the connector plates 70 of another module 16 . In order to minimize assembly time and ease installation, the connector plate 70 are substantially larger than the cross-sectional area of the columns 24 . It is in this access area that hangs over the column 24 , that holes may be placed.
[0056] As is also shown in FIG. 7, when the roof module 22 or any other module 16 is formed in the beam 26 and column 24 arrangement, they may be assembled by matching up the holes in the connector plates 70 and securing the upper connector plate 70 to the lower connector plate 70 with a plurality of bolts 64 and nuts 62 . As is also shown in FIG. 7, the column 24 may include an additional bracket or gusset plate 32 to which bracing rods 30 may be installed as previously discussed. This allows the columns 24 to put pressure on the beams 26 , thereby strengthening the overall rigidity of the entire box-frame press box module 16 .
[0057] As the connector plates are used to secure the various press box modules 16 together in a vertical arrangement, so the beams 26 can be used to secure the press box modules 16 in a horizontal arrangement. As is shown in FIG. 7, the beams 26 of the press box module 16 include a plurality of holes through which bolts 64 and nuts 62 can be secured.
[0058] Alternatively, when the tube 25 arrangement of the press box module 16 is used, the modules may be simply stacked on top of one another or side by side and then they are preferably welded together, preferably using a {fraction (1/4)} inch stitch weld every 2 inches. Any other connection means including welding, screws, etc. can be employed to secure one press box module 16 to another press box module 16 in a vertical arrangement. Thus, it can be seen how the various press box modules 16 can be added to form a press box 10 of any shape or size.
[0059] As is shown in FIG. 3, the roof module 22 , consists generally of two pairs of roof columns 76 . One pair of roof columns 76 is at a pre-determined height with the other pair of roof columns 76 being at a slightly greater height. In this manner, the roof module 22 can have a roof of any desired slope. In between the roof columns 76 , roof beams 74 are placed. As is shown, the roof beams 74 are similar to the ceiling beams 88 and flooring beams 82 in that a plurality of connector tabs 78 are welded thereto. The outer ends of the roof beams 74 have been mitered to correspond with the desired slope of the roof. In between the roof beams 74 are a plurality of roofing struts 72 . The roofing struts 72 are secured to the connector tabs 78 through the use of screws, bolts and nuts, welding, or any other connective means.
[0060] Alternatively, the roof module 22 may be formed using steel tubes 25 as is shown in FIG. 4. The roof columns and beams are formed of steel tubes 74 cut to the desired length and angled or mitered to provide the desired roof shape. As is shown in FIG. 5, the connector tabs 78 are placed on the tubes 25 in the same manner as the connector tabs 84 and 90 for the flooring and ceiling respectively.
[0061] After each of the press box modules 16 are completed in the desired fashion and assembled to form the press box 10 , finishing materials, such as carpeting, siding, insulation, drywall, paint, wallpaper, lighting, etc. may be installed according to the customer's specifications. The manner of installing all of these elements over an existing steel frame structure is well known in the art.
[0062] By making the internal framework in modular form, the entire process may be expedited while still providing the customer with a high quality, customizable end product. It is preferred that the individual press box modules 16 are prefabricated as much as possible at the shop or first location. This would include building in almost all of the electrical systems, heating and ventilation systems, flooring systems, doors, benches and countertops as desired. Once assembly of the individual press box modules 16 is completed to the extent possible, the modules are transported to the construction site or second location. Preferably, the modules 16 are loaded onto a semi-truck trailer for transport. By using the box-frame styles mentioned herein, the size of the individual press box modules 16 can be limited to the height and width allowed to travel down interstate highways without the need for special permits or warning vehicles.
[0063] At the construction site, the individual modules 16 are unloaded and placed into the desired position. They are then secured together as previously discussed and staircases 18 , balconies 20 , and other exterior appointments are added. The roof modules 22 are added and the exterior finishing, including roofing and siding may be completed. The final interior appointments and well-known press box components, including lights, sound systems, computers, chairs, wall finishing materials, and any other customer desired appointments can be added on site to produce the press box 14 desired by the customer. In this manner, it can be seen that the modular approach to building a press box 10 saves time, money and minimizes inconvenience for the customer.
[0064] The modular press box 14 also allows for additions to be easily made. After completing a full press box 14 , individual modules 16 , 22 can be added by simply removing the exterior appointments to expose the steel beam, column or tube. Then additional modules can be connected in the usual fashion and exterior appointments reattached to form a new and expanded press box 14 .
[0065] A general description of the present invention as well as a preferred embodiment of the present invention has been set forth above. Those skilled in the art to which the present invention pertains will recognize and be able to practice additional variations in the methods and systems described which fall within the teachings of this invention. Accordingly, all such modifications and additions are deemed to be within the scope of the invention which is to be limited only by the claims appended hereto.
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A press box generally made from a plurality of modules assembled together wherein each module includes a plurality of tubes or beams and columns arranged to form a box-like frame structure. The modules can be connected to one another in a vertical or horizontal arrangement. Roof modules may be secured to the uppermost module and all modules are secured together. Nuts and bolts, welding, or other means can be used to secure connector plates on the box-like frames to corresponding connector plates or to secured adjacent tubes of different press box modules. The box-like modules can include a doorway, electrical wiring, windows, tables, counters, lights, flooring, ceilings, and be accessible by staircase. Balconies may be secured to one side of the modules as desired. The modules may be individually assembled in a first location, transported to a second location and secured to one another to form a press box.
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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 co-pending U.S. patent application Ser. No. 11/529,447 filed Sep. 28, 2006, which in turn is a divisional application of U.S. patent application Ser. No. 10/812,348 filed Mar. 30, 2004.
THE FIELD OF THE INVENTION
The present invention pertains to a wear assembly for an excavating bucket.
THE BACKGROUND OF THE INVENTION
Excavating buckets for earth working equipment are typically subjected to harsh conditions. A series of wear members are usually provided along the lip of the bucket to improve the digging operation and protect against wear. Wear members have in the past been welded or mechanically secured in many different ways. Nevertheless, there is a need for an improved wear assembly in these environments.
SUMMARY OF THE INVENTION
The present invention pertains to an improved wear assembly for protecting an excavating bucket from wear, which is secure, stable, easy to use, readily manufactured, and provides increased safety. The present invention further eliminates any need for holes to be formed in the lip.
In accordance with one aspect of the invention, the wear assembly includes a wear member provided with a connector in the form of a tongue or slot which has rails or grooves, respectively, to couple with a complementary connector on a boss fixed to the bucket. The rails or grooves are formed with a curved and/or narrowing configuration to ease installation and removal of the wear member, permit the use of wings to better protect adjacent parts, and better resist some loads.
In accordance with another aspect of the invention, the wear member includes an interior which wraps about the front edge of the bucket and a boss fixed to the bucket. The interior has a first recess with a first set of opposed sidewalls to receive an upstanding support on a boss, and a second recess with a second set of opposed sidewalls spaced farther apart than the first set of opposed sidewalls to receive the sides of the boss. By using two sets of recesses, the wear member is more stably mounted and better able to resist side loads.
In accordance with another aspect of the invention, the wear member includes laterally extending wings to overlie adjacent parts, e.g., an adapter, attached to the lip to provide additional protection.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a wear member straddling a lip of a bucket in accordance with the present invention.
FIG. 2 is a front perspective view of a wear member of the invention.
FIG. 3 is a front perspective view of an alternative wear member.
FIG. 4 is a partial perspective view from the bottom of a lip with the alternative wear member.
FIG. 5 is a rear perspective view of the wear member of the invention.
FIG. 6 is a side view of the wear member.
FIG. 7 is a rear view of the wear member.
FIG. 8 is a front perspective view of a boss of the present invention.
FIG. 9 is a rear perspective view of the boss.
FIG. 10 is a side view of the boss.
FIG. 11 is a perspective view of a lock of the present invention.
FIG. 12 is an exploded, perspective view of the lock.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention pertains to a wear assembly 10 for an excavating bucket. While wear assembly 10 is particularly suited for securing a wear member 15 in the form of a shroud to a lip of a bucket, it could also be used to secure other kinds of wear members (e.g., wings or adapters) to the bucket. In a typical bucket, lip 16 includes an inner face 17 , an outer face 18 and a front edge 19 . Although the illustrated lip ( FIG. 1 ) shows the inner face 17 with a ramp surface 17 a , the invention can be used with other kinds of lips.
The invention is at times described in relative terms, such as forward, rearward, up, down, vertical, horizontal, etc. to ease understanding of the invention. These terms are generally to be considered relative to the orientation of the components in FIG. 1 (unless otherwise noted), and are not to be considered limitations on the invention. As can be appreciated, the wear member can be used and oriented in a variety of ways.
A boss or base 20 ( FIGS. 8-10 ) has a pair of legs 21 , 22 that straddle the lip 16 about front edge 19 . Although first leg 21 is preferably the outer leg and second leg 22 the inner leg, they could be reversed. In the illustrated embodiment, the first or outer leg 21 has an inner surface 23 that sets against and extends along outer face 18 of lip 16 . In the preferred construction, first leg 21 includes holes 27 to facilitate welding of the boss to the lip. In this embodiment, welding is also provided along brace 30 and grooves 31 at the end of second leg 22 . While boss 20 is preferably welded to the lip, it could be formed (e.g., cast or forged) as an integral part of the lip or secured by mechanical means. In addition, the boss could be formed as a multiple of parts, which are integral or spaced apart, although a one-piece member is preferred for simplicity and strength.
Outer leg 21 includes a connector 28 that couples to a complementary connector 29 on wear member 15 . In the illustrated embodiment, connector 28 is formed as rails 24 extending axially along sidewalls 26 of the boss ( FIGS. 9 and 10 ). The rails project laterally outward from each sidewall 26 to define a generally inverted T-shaped cross-section, though other shapes are possible. Rails 24 include holding surfaces 25 that are offset from inner surface 23 so as to be spaced from the outer face 18 of the bucket which it faces.
A brace 30 preferably extends laterally across the rear end of first leg 21 ( FIGS. 8-10 ). The rear ends 44 of rails 24 are preferably fixed to brace 30 to provide additional support to the rails when under load. Such support at the rear end of the rails is particularly advantageous in resisting vertical loads that tend to rotate or swing the wear member about the front edge of the lip. Brace 30 preferably extends outward of first leg 21 to define a stop surface 32 adapted to abut a rear end 40 of wear member 15 and thereby reduce the stress on the boss, which in turn, reduces the stress along front edge 19 of lip 16 .
A front end 45 of boss 20 wraps around front edge 19 of lip 16 . The interior 46 of boss 20 (i.e., the surface that faces lip 16 ) is shaped to generally conform to the shape of the particular lip to which it is fixed. In the illustrated embodiment, the interior 46 of boss 20 includes a corner surface 47 that sets against front edge 19 , an inner surface 48 of second leg 22 that sets against ramp 17 a , and inner surface 23 of first leg 21 that sets against outer face 18 . The inner or second leg 22 preferably overlies only ramp surface 17 a so that the boss is outside or below the inner face 17 to avoid impeding the gathering or dumping of the excavated material, but could extend along inner 17 rearward of ramp 17 A. Also, other arrangements for attaching the boss are possible. For other kinds of lips, the interior would preferably be changed to generally match the lip profile.
The front face 49 of boss 20 preferably has a uniform curved shape to provide a smooth surface without corners to act as a thrust bearing face for wear member 15 . In this way, the boss is able to provide a better bearing surface than the front of lip 16 with its relatively sharp and thinner front edge 19 . Nevertheless, other shapes for front face 49 are possible. Inner leg 22 preferably includes an upstanding support 50 that forms an abutment for lock 56 ( FIGS. 8-10 ). Support 50 includes a rear wall 52 to abut lock 56 , a pair of sidewalls 94 and an upper inclined wall 54 that extends upward from front face 49 .
Wear member 15 has a front end 66 and a rear end 70 that is bifurcated to define an outer or first leg 71 and an inner or second leg 72 ( FIGS. 1-2 and 5 - 6 ). In use, wear member 15 overlies and straddles lip 16 and boss 20 . As a result, boss 20 is largely shielded from the movement of abrasive earthen material passing over the component. Wear member 15 includes an interior 85 that includes inner face 80 of outer leg 71 , inner face 87 of inner leg 72 , and an inner corner surface 89 at the intersection of legs 71 , 72 ( FIGS. 5 and 6 ). Inner corner surface 89 has a shape that generally matches front face 49 of boss 20 to abut against it. Accordingly, in the preferred embodiment, inner corner surface 89 has a generally uniform curved surface. Outer leg 71 has a generally flat outer face 76 and a rear deflector face 77 that is inclined forwardly away from lip 16 to direct earthen material away from the wear member during reverse movement of the bucket. Wear member 15 a also optionally includes wings 75 that project laterally, preferably from outer leg 71 a , to overlie the adjacent wear parts 78 (e.g., adapters) and provide additional protection to the adjacent wear parts 78 ( FIGS. 3 and 4 ). Wings 75 are offset from inner face 80 a of outer leg 71 a (i.e., spaced further from lip 16 ) to define clearance for the adjacent wear parts 78 when wear member 15 a is fully seated on boss 20 .
Connector 29 of wear member 15 extends along outer leg 21 in the form of a slot 34 ; i.e., dogleg flanges 35 extend along the inner surface 80 of outer leg 71 to define slot 34 (although slot 34 could be formed in other ways). Grooves 37 are preferably defined by inner surface 80 of outer leg 71 and retaining surface 38 on flange 35 . Rails 24 are received into side grooves 37 along flanges 35 such that the distal ends 39 of flanges 35 are received between rails 24 and outer surface 18 with retaining surfaces 38 opposed to holding surfaces 25 . Alternatively, connectors 28 , 29 could be reversed with a tongue having rails formed on the wear member 15 and a slot having side grooves to be formed on the boss 20 .
Holding surfaces 25 of rails 24 are preferably curved to have a convex shape, and retaining surfaces 38 a complementary concave shape. This curve results in a narrowing of the rail as it extends forwardly. This narrowing of rails 24 allows wear member 15 to be fed onto boss 20 more easily; i.e., grooves 37 are wider at the rear end 40 of wear member 15 as compared to the narrow front ends 41 of rails 24 . As a result, the wear member can be tilted at various angles when it is initially fed onto the rails 24 and then directed into the right orientation by the widening of the rails. Moreover, if the wear member is formed with lateral wings, as discussed below, the narrowing rails permit the wear member 15 to be purposefully titled at an angle to permit the wings to clear the adjacent components as wear member 15 is fed onto boss 20 . The narrowing of rails 24 and grooves 37 also enables easier release of wear member 15 as rails and grooves are not slid along each other surfaces after initial release. Further, the corresponding curved portions 42 , 43 on holding surface 25 and retaining surface 38 (surfaces 25 , 38 could be curved their entire length or only at the front ends) resist certain vertical loads at a more perpendicular orientation and provide a stronger and more stable resistance. As alternatives, rails 24 and grooves 37 could narrow without curved surfaces to achieve some of the benefits of the invention. In addition, the entire rail could be curved. Also, the holding surface could have an inclined but linear configuration such that the rail narrows as it extended forward, but is not curved.
Inner face 87 of inner leg 72 includes a first recess 91 into which upstanding support 50 is received, and a second recess 92 into which the width of boss 20 is received. The first recess 91 includes a pair of opposed sidewalls 93 to bracket the sides 94 of support 50 . The second recess 92 includes a pair of opposed sidewalls 95 , spaced farther apart than sidewalls 93 , to receive the entire width of boss 20 . By using this double set of recesses 91 , 92 , the wear member 15 is more stably mounted on boss 20 and better able to resist side loads.
When wear member 15 is installed, it is slid over boss 20 such that inner and outer legs 71 , 72 straddle the lip ( FIGS. 1-4 ). Rails 24 are fit within grooves 37 as shroud 15 is moved rearward. As discussed above, wear member 15 can be tilted at various angles and still fit onto the rails for easier installation. The rearward movement of shroud 15 is continued until inside corner surface 89 abuts front face 49 of boss 20 . At this juncture, rear ends 33 of flanges 35 of outer leg 71 are preferably placed in close proximity to stop surface 32 . With new cast parts, it is not practical for inside corner surface 89 and rear ends 33 to simultaneously abut front face 49 and stop surface 32 , respectively. However, by placing rear ends 33 in close proximity with stop surface 32 , the two surfaces will typically abut after a short amount of time as wear develops in the parts or under heavy loading to provide extra support to the shroud and provide enhanced protection for the lip. Outer leg 71 overlies outer leg 21 of boss 20 and outer face 18 of lip 16 , and inner leg 72 overlies inner leg 22 of boss 20 and ramp surface 17 a of lip 16 . Inner leg 72 , along inner surface 87 , includes two sets of side surfaces 93 , 95 . Support 50 fits within recess 91 and the entire boss 20 fits within recess 92 for enhanced support and stability.
Inner leg 72 includes an aperture 86 adapted to receive lock 56 . In the preferred embodiment, aperture 86 has a main portion 90 having a generally rectangular configuration to match the shape of the preferred lock, though other shapes are possible, and a stem portion 97 that opens in the rear wall 98 of inner leg 72 to provide clearance for plug member 58 . The rear wall 88 of aperture 86 forms a bearing surface to each side of stem portion 92 to abut lock 56 .
In the preferred construction, lock 56 includes a body 101 having a generally parallelepiped configuration that corresponds to the shape of aperture 86 ( FIGS. 8-11 ), though other shapes can be used. The body includes a front wall 103 , a rear wall 104 , and sidewalls 105 , 106 . A threaded bore 109 extends through body 101 and opens in front and rear walls 103 , 104 . Plug member 58 includes a threaded shank 111 to be threaded into bore 109 , and a tool-engaging formation 113 on rear end 115 . While in the preferred construction formation 113 is formed as a hex-shaped socket, the socket could have other shapes or be replaced with other kinds of flats adapted to cooperate with tools to effect turning of the plug. The front end 117 of plug 58 is adapted to project forward and abut rear wall 52 of support 50 . A recess 57 is preferably formed in front wall 53 of aperture 86 to give clearance for the mount of plug 58 . In this way, the assembly has a more compact profile. Plug member 58 can be advanced so as to push against rear wall 52 of support 50 , which in turn, presses rear wall 104 of lock 56 against rear wall 88 of aperture 86 . This movement of plug member 58 , then, causes shroud 15 to be pushed tightly against front face 49 of boss 20 . A tighter fit reduces the shifting of the shroud during use, which will in turn reduce the amount of wearing among the components. Nevertheless, a lock without an adjustment assembly could also be used.
A retainer 121 is also preferably provided to resist unintended loosening of plug member 58 . In the preferred construction, retainer 121 includes a threaded bolt 123 and a retaining ring 125 . Retaining ring 125 has a non-circular internal hole 127 that matches the exterior of head 113 of plug member 58 , which is preferably a hex shape. The bolt 123 has a threaded shank 131 that threads into a second threaded bore 133 and a head 135 that tightens against retaining ring 125 to prevent its rotation. Of course, other retainers could also be used.
When shroud 15 is fit onto lip 16 , the front wall 53 of aperture 86 is generally aligned with rear wall 52 of support 50 , though it could also be spaced rearward thereof, to permit lock 56 to fit within aperture 86 and be rearward of support 50 . In this way, front wall 103 of lock 56 opposes rear wall 52 of support 50 . As plug member 58 is advanced to engage rear wall 52 , it preferably extends underneath leg 72 . In this way, plug member 58 not only functions as a take up member to tighten the fit of the shroud against the boss, it also functions as a latch to hold the lock in aperture 86 . Moreover, since the rear end 115 of plug member 58 sets within stem portion 92 (which can be easily cleared) the plug member can be easily retracted to remove the lock without concern over impacted fines blocking the movement.
In the preferred construction, one sidewall 105 of lock body 101 has an arcuate shape to fit against an arcuate sidewall 127 of aperture 86 so that the lock can be easily swung into aperture 86 ( FIG. 10 ). Of course, other locks could be used to secure wear member 15 to boss 20 .
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A wear assembly to protect the front edge of an excavating bucket, which is secure, stable, easy to use, readily manufactured, and provides increased safety, and which eliminates any need for holes to be formed in the lip. The wear assembly includes a wear member that has a pair of legs to straddle the front edge of the bucket. One of the legs defines an axial slot, which has opposing grooves for receiving rails of a boss fixed to the bucket. The grooves narrow in a forward direction to permit easier installation and removal of the wear member, to permit use of side wings without interference from adjacent wear parts, and to enable enhanced resistance under some loads.
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CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation of International Application PCT/CH98/00565, filed Dec. 30, 1998, the disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
The invention relates to a stench trap for a urinal, having an interchangeable pot for insertion in the urinal and a cover for covering the pot. The cover has an opening for introducing urine into the pot, a baffle projecting into the pot for restraining sewer stench from the outlet connection, and a stench trap floating on the urine intended to accumulate in the pot.
From the prior art urinals are known, which must be flushed with water following each use. Due to the reduction of the amount of flushing water as a consequence of higher water prices and/or smaller amounts of water being available, such urinals require a disproportionate cleansing expenditure. Due to the mixture of urine with water, the formation of urine stones is promoted, and not only parts of the urinal, but also in particular the siphon-bearing discharge pipes leading away from this, are reduced in cross section by formation of urine stones within a few months and must consequently be cleansed. In addition to the high costs for the required flushing water, there arc those for the periodic cleansing/repair of the pipes.
For these reasons, waterless urinals have already been proposed. From German published patent application DE-A1 28 16 597 (Ernst), a pot-shaped insert is known, which is inserted into a recess located at the deepest point of the urinal and is connected with the outlet pipe. In the insert an annular space is formed, in which a cylindrical jacket-shaped tube is inserted from above, which subdivides the annular space into two regions, an inner and an outer, which are connected with each other and form a stench barrier or a siphon. A barrier liquid of lower density than water, for example oil, is present in the outer annular space. The urine entering into the container passes through the barrier liquid due to its higher specific gravity and thus reaches the outlet and from there the sewer system. This device has the disadvantage that the barrier liquid, which can contain additional active disinfecting agents and optionally fragrant substances, is successively flushed away by the strong stream of water passing through the barrier liquid during the periodic cleansing of the urinal with a strong torrent of water and consequently loses its action.
In International Patent Application publication WO 97/15735, an insert for a waterless urinal with a barrier liquid is disclosed which, through the special geometrical construction of the insert container, should prevent the barrier liquid from floating away. Even if the floating away of the barrier liquid is substantially prevented there, it cannot be avoided, however, that its active ingredients, which are necessary to create a flawless protection against stench, are successively degraded, and consequently even with this arrangement, the barrier liquid must frequently be replaced. Also, the substances which are used for the barrier liquid are not completely harmless, and can lead to problems with wastewater processing. Monitoring the momentary condition of the barrier liquid can create additional difficulties, since this is not directly examinable, and in principle, only the nose decides whether enough of it is present, or whether this has already been degraded or indeed flushed away.
SUMMARY OF THE INVENTION
The objective of the present invention is the creation of a stench trap, which manages without barrier liquid. This objective is accomplished by a stench trap of the type described at the outset, wherein the stench trap is constructed as a float designed to seal off the opening in the cover. Advantageous embodiments of the invention are described in the following and in the dependent claims.
The arrangement according to the invention operates completely without barrier liquid and can accordingly, if necessary, be periodically thoroughly cleansed without further ado with a torrent of water. Moreover, a doubled stench trap is present, in which first of all the dammed up liquid, namely the urine, flawlessly blocks the stench from the sewer system and moreover, as a second seal, the linear or strip-shaped contact of the float on the collection surface prevents the exit of odors. A build up of urine stones is completely absent, since the portions of water necessary for their formation are not present. The water optionally used with periodic cleansing is negligible for the formation of urine stones, because this can only react with the urine residue for a short time. The lift of the lifting element is so proportioned, that the amount of urine (liquid column) collecting in the cover suffices to depress or raise the lifting element temporarily to the extent that the urine can flow off downwardly. When using a spherical lifting element, this necessarily always lies on the circular opening. In addition, sealants applied to the opening can be installed to increase tightness. In a special embodiment of the invention, a magnet can be arranged below the first container section, in which the lifting element floats, by which the lifting element can be sporadically pulled down and thus the amount of urine situated above its surface can be completely drained off. In this maimer, at times when the urinal is little used, the dammed up amount of liquid can be sporadically removed. Advantageously, the magnet is activated by a capacitor charged by a light sensitive cell.
In a further embodiment of the invention, the lifting element has a U-shaped cross section and covers the upper end of the outlet connection on the container. With this construction the insertion of an additional baffle holding back the stench is dispensed with.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
The foregoing summary, as well as the following detailed description of the invention, will be better understood when read in conjunction with the appended drawings. For the purpose of illustrating the invention, there arc shown in the drawings embodiments which are presently preferred. It should be understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown. In the drawings:
FIG. 1 is a side view of a urinal with a recess for insertion of an exchangeable pot;
FIG. 2 is a cross section through the urine collection region of the urinal and a pot inserted therein; along line II—II in FIG. 4;
FIG. 3 is a longitudinal section through the container of a further embodiment of a pot; 2
FIG. 4 is a cross section through the pot along line IV—IV in FIG. 2;
FIG. 5 is a longitudinal section through a further embodiment of a pot along line V—V in FIG. 6 with the float lying on the cover;
FIG. 6 is a cross section through the pot in FIG. 5 along line VI—VI;
FIG. 7 is a longitudinal section through a further embodiment of a pot along line VII—VII in FIG. 8 with the float depressed;
FIG. 8 is a cross section through the pot in FIG. 7 along line VIII—VIII;
FIG. 9 is a front view of a urinal with solar cells;
FIG. 10 is a cross section through the pot in a further embodiment of the invention with a slidable magnetic lifting device;
FIG. 11 is a cross section through the pot with a spherical float lying over the cover;
FIG. 12 is a cross section through the cover with a spherical lifting element;
FIG. 13 is a cross section through the cover with an asymmetrical float; and
FIG. 14 is a side view of a further embodiment of a stench trap.
DETAILED DESCRIPTION OF THE INVENTION
In FIG. 1 a urinal is designated schematically with reference numeral 1 , which is fastened on a wall 3 and is connected below via an outlet connection 5 to a wastewater conduit 7 . The urinal I can be made of ceramics, metal or plastic and has a recess 11 at the deepest point of its collection basin 9 , at whose base the outlet connection 5 opens. In the transition between the collection basin 9 and the recess 11 , a surrounding ledge 13 is preferably formed, on which lies the flange 15 of a pot-shaped insertion container (pot 17 for short) inserted into the recess 11 .
In the first embodiment of the pot 17 forming a stench trap, which includes a jacket 19 and whose bottom is penetrated by the upper part 23 of a discharge tube, a container-shaped space, hereinafter called float space 25 , is arranged. At least one part of its jacket can be shared with the jacket 19 of the pot 17 . A chord-form running wall 18 separates the float space 25 from an overflow space 27 and the upper part 23 of the outlet connection 5 , which is connected with the head space 28 of the overflow space 27 . The upper part 23 can be formed by two wall parts 24 or by a pipe (not shown). The upper end 22 of the part 23 lies at a vertical spacing from the ledge 13 .
The upper opening of the pot 17 is covered by a frustum-shaped cover 29 , at whose deepest point a circular opening 31 is situated. The opening 31 lies over the float space 25 . The float space 25 and the at least one overflow space 27 are joined with each other below by a connection opening 37 .
Within the float space 25 lies a freely movable float 33 , in the first example according to FIG. 2 a sphere, whose specific density is less than the density of urine 35 . The diameter D of the sphere is larger than the diameter d of the opening 31 in the cover 29 . Below the flange 15 on the cover 29 an 0 -ring or an otherwise constructed seal can be arranged.
Urine 35 , flowing from above into the collection basin 9 , accumulates on the cover 29 . As soon as the liquid column above the opening 31 in the cover 29 exceeds by weight the buoyancy of the float 33 in the float space 25 , and consequently is greater than the contact pressure of the float 33 on the cover 29 , the float 33 is pressed downwardly and the accumulated urine 35 can flow out downwardly through the opening gap. It then reaches the float space 25 , flows from there through the passage opening 37 to the overflow space 27 , and thereafter flows into the outlet connection 5 . The upper rim of the upper part 23 of the outlet connection 5 lies at a height which assures that the float 33 is pressed against the opening 31 , whereby the contact pressure, that is the lift, suffices to guarantee a faultless scale and at the same time also to enable the discharge already of a small amount (i.e., already a liquid column of, e.g., 10 mm) of urine 35 on the cover 29 .
In the second embodiment of the invention according to FIG. 3, the outlet nozzle 23 lies in the center of the float space 25 , which in this example is identical with the pot 17 . The rotation symmetrically-shaped float 33 has a U-shaped cross section and can be manufactured as a hollow body or from a material which has a lesser density than urine. The upper end 23 of the outlet connection 5 comes from below to lie in the cylindrical recess of the float 33 . The cylindrical wall 34 of the float 33 surrounding the outlet connection serves as a baffle. The surface of the float 33 lying on top can be shaped as a hemisphere, an ellipse or a cone (indicated in broken lines), so that a flawless linear contact at the opening 31 and optimal sealing can be guaranteed.
In the third embodiment of the invention according to FIGS. 5 to 8 , a cylindrical float 33 with a spherical segment or a cone-shaped upper closure 41 replaces a spherical or cap-shaped float 33 . Advantageously, the float 33 comprises two cylinders of unequal size, in order to generate as much lift as possible in the lower region. The upper cylindrical region serves at the same time as a vertical guide, laterally guided by the guide segments 43 mounted on the underside of the cover 29 . As an alternative to the guide segments 43 , ribs 45 can be applied on the jacket of the float 33 , which serve as vertical guides. If the latter run helically, represented in FIG. 5, then the float 33 rotates when liquid flows past in larger amounts. The contact and sealing surfaces between the float 33 and the rim of the opening 31 are thereby always kept clean. In cross section according to FIG. 6, it is apparent that the float space 25 is configured as a space arranged eccentrically to the pot 17 , likewise constructed cylindrically.
In FIGS. 5 through 8 and 10 , a laterally open space 47 is represented below the float space 25 , in which a depression device for depressing the float 33 can be inserted, in case such is desired. The depression device can include an electromagnet or a permanent magnet 49 , wherein the former is activatable by a condenser and/or a battery 55 . The battery 55 can be charged by a solar cell 59 , which is installed at the top of the urinal 1 (FIGS. 9 and 10) and is illuminated by daylight or artificial light. Alternatively, other energy sources or a manual actuation can also be used for depressing and elevating. The opening of the passage for discharging the urine can take place one or more times while using the urinal.
When using a permanent magnet 49 (FIG. 10 ), the latter is periodically driven back and forth by a linear drive 57 in the area below the float 33 . Alternatively, the magnet 49 can also be arranged to be vertically slidable. In order to achieve a certain depression of the float 33 , soft iron or a magnetic element 61 , e.g., a soft iron plate or a permanent magnet, is inserted on its bottom. Preferably, the element 61 lies outside the float 33 and as near as possible to the magnet 49 . When using an electromagnet, this can also be rigidly attached. The float 33 can also be depressable with a manually operable device. In FIG. 10, in addition, an alternative liquid discharge inside the pot 17 is represented. The outlet nozzle 23 extends only over a small height and leaves the pot 17 laterally.
In the embodiment of the invention according to FIG. 14, the stench trap is made from elements with exclusively cylindrical jacket-shaped walls. In the likewise cylindrical jacket-shaped recess 11 , which can be part of the urinal I or the outlet connection 5 , the pot 17 accommodating the stench trap is inserted. This is closed on the bottom and has on its upper edge at least one overflow opening 28 , through which the urine 35 from the container space 25 can reach the recess 11 and from there the outlet connection 5 . A cylindrical wall part 30 is fastened on the underside of the cover 29 , which serves as a baffle and extends into the vicinity of the bottom 21 of the pot 17 and divides the container space 25 . The wall palt 30 can be an independent element or form a part of the cover 29 . The cover 29 and the pot 17 are preferably firmly connected with one another and are insertable as a unit into the recess 11 . The pear-shaped float 33 in this embodiment is loosely secured in the pot. In the space 47 accessible from outside, the depression device, e.g., a permanent or electromagnet 49 (cf. also FIG. 10 ), can be moved in and out from the side or preferably in a vertical direction from below.
In the further embodiment of the invention according to FIG. 11, the float 33 is spherical and lies on the opening 31 of the cover 29 . Along the opening 31 in the cover 29 , a seal 32 can be molded on or secured.
An alternative float 33 is represented in FIG. 12 . This has the configuration of a cone, whose tip is guided through opening 31 into the pot 17 and can at least partially dip into the urine 35 . In both embodiments (FIGS. 11 and 12) the float 33 is elevated from the urine accumulating above the cover 29 , so that the latter can reach the container 25 through the gap thereby arising along the float.
In a further advantageous embodiment of the invention according to FIG. 13, the float 33 is configured frustum-shaped and has on its upper end an asymmetrically arranged plate 34 which, when the urine level rises, causes the float 33 to be elevated on one side, whereby a gap arises not running parallel along opening 31 and thus makes possible a ventilation of the space lying below during the outflow of the urine. On the jacket of the float 33 grooves 65 can be provided in addition, which after the elevation of the float 33 above the opening cross section in the cover 29 project out and facilitate the outflow (illustrated only in FIG. 12 ).
Preferably, in all embodiments a protective screen or lattice 63 can lie over the cover 29 , which bridges over the float 33 and protects the latter from unauthorized access.
The pot 17 can obviously also be inserted in urinals 1 , which are not attached to the wall as individual urinals, but rather stand on the floor or are configured as troughs whose deepest point lies in, above or under the level of the floor (not illustrated).
It will be appreciated by those skilled in the art that changes could be made to the embodiments described above without departing from the broad inventive concept thereof. It is understood, therefore, that this invention is not limited to the particular embodiments disclosed, but it is intended to cover modifications within the spirit and scope of the present invention as defined by the appended claims.
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A waterless urinal ( 1 ) is provided with a pot ( 17 ) in which urine ( 35 ) accumulates. A float ( 33 ) floats on the urine ( 35 ) and is pressed upwardly by the buoyancy thereof against an opening ( 31 ) in the cover ( 29 ) of the pot ( 17 ). As soon as a pre-determinable column of urine rises above the float ( 33 ), the float ( 33 ) is pressed downwardly, and the urine ( 35 ) can flow out. In a preferred embodiment, the float ( 33 ) can be pulled downwardly by an electromagnet, in order to sporadically empty the urine ( 35 ), which has accumulated above the float ( 33 ) and the cover ( 29 ).
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This application claims the benefit of Canadian Patent Application No. 2,725,683 filed on Dec. 21, 2010, the contents of which are herein incorporated by reference.
FIELD OF THE INVENTION
The present invention relates to a method and a system for treating pieces of wood flooring, such as, but not limited to, hardwood floorboards, and particularly for treating peripheral edges thereof.
BACKGROUND OF THE INVENTION
Floorings may be made of hard wood floorboards or laminate panels made from a derived timber product, in particular a highly compressed medium or high-density fiberboard.
Floorings are generally made of elongated floorboards or boards, with a top decorative surface, a bottom opposite surface and peripheral edges In particular; the edges have a connecting profile for the purpose of connecting adjacent boards and form the flooring.
A treatment can be applied to the peripheral edges of each floorboard, for instance in order to prevent the penetration of moisture and bacteria, which can cause the boards to swell up or mould to appear.
Different methods in the field of floorboard treatment have been disclosed in U.S. Pat. No. 2,431,225 (BELK); US patent applications published under Nos. 2002/0023702 A1 (KETTLER), 2002/0152714 A1 (VAN CAPELLEVEEN), US 2006/0037270 A1 (NIESE) or European patent application published under No. EP 2 127 807 (DELLE VEDORE).
Whilst the top and bottom surfaces of boards are generally provided with a very stable and wear-resistant coating which is also largely moisture proof, the unprotected derived timber material is exposed at the edges which are usually cut and profiled. Moisture can therefore penetrate at this point and cause swelling in a floorboard because the derived timber material that is used is relatively hygroscopic.
Floorboards being generally hydroscopic, any change in the relative humidity of the surrounding atmosphere leads to a change in the boards' shape after installation i.e. shrink or swell, and a gap between the boards will appear, rendering these edges permanently visible.
Some board models have profiled tapered edges. Two adjacent boards will then form a groove along two connected edges. This groove is commonly named “micro-V” in the art of flooring.
The flooring will become unsightly when gaps and micro-Vs between the floorboards are particularly visible, in particular when the peripheral edges have a different color or shade than the top surfaces of the boards. This difference may be due to the fact that the edges have not been treated. Furthermore, the top surface may have its color fading with the passing of time, surface wear or both.
Although top surfaces and tapered edges of the boards are manufactured or treated with a same color and shade, a shadow effect will render the shade of the micro-V apparently darker than the shade of the top surface.
A solution to the problems described above would be to have the peripheral edges treated or dyed in a way to obtain a shade of the edges slightly lighter than the shade of the top surfaces. The shades will be selected by the manufacturer in order to have edges and surfaces appearing with a same shade, once the boards are assembled to form the flooring. And despite the shadow effect or the color fading of the top surfaces.
Boards with the above-described properties can be treated manually. However, this method is not economically profitable for a mass-production of boards, except in countries providing cheap labour.
SUMMARY OF THE INVENTION
The present invention allows resolving at least one of the problems mentioned above in that it concerns a new method and system for treating floorboards.
According to a first aspect, the invention concerns a method for treating elongated pieces of flooring. The method comprises the steps of:
a) providing a plurality of panels, each panel comprising a plurality of elongated pieces of flooring, each piece having an upper and a lower surface, two opposite longitudinal edges and two opposite transversal edges, said pieces being assembled together by at least one of their longitudinal and/or transversal edges to form the panel; b) mechanically dismantling the panel in order to expose each edge of each elongated piece; and c) applying a treatment product to the longitudinal and/or transversal edges of the elongated pieces.
As aforesaid, floorings are generally made of hard wood floorboards or laminate panels made from a derived timber product, in particular a highly compressed medium or high-density fiberboard. However, the method of the invention is not limited to the making of floorboards, and can be suitable to any kind of boards or panels made of any sorts of materials known in the art. For example, the method may be suitable for the treatment of any kind of elongated board used in construction, furniture, decorative boards, frames, beams or the like.
The method of the invention is particularly suitable for a mass-production of floorboards on a production-line, in that the panels of boards are firstly dismantled in order to expose the peripheral edges to be secondly treated. The edges can be then treated separately from the top and/or bottom surfaces of the boards, allowing a treatment of the board edges different than the surfaces. For example, after step c), the method may further comprise the step d) of mechanically assembling the elongated pieces to form a reassembled panel for further treatment of the upper and/or lower surfaces of the elongated pieces.
In step c) of the method, the treatment product may be a first dye having a first shade of a color, whereas in step d), the treatment consists of applying to the upper surface of the pieces a second dye having a second shade of said color as in step c). Preferably, the second shade of the second dye applied to the surfaces in step d) is darker than the first shade of the first dye applied to the edges in step c), allowing edges and surfaces of the boards to appear having the same shade once the boards are assembled to form the flooring.
In the particular case of a mass-production line of the boards, the method of the invention may further comprise, before step a), a step of mechanically dismantling a stack comprising a plurality of layered panels, each being made of a plurality of elongated pieces of wood flooring. This step allows providing the plurality of panels that are then dismantled.
In step c), the treatment product may be applied simultaneously to the longitudinal and transversal edges of each elongated piece. This treatment product may include varnishes, paints, dyes, or the like. These products may comprise ant-moisture and anti-fungi compounds allowing a better protection of the flooring.
In step c) of the method, the treatment product may be applied using rolls or sprays. More preferably, the product is applied using several directional sprays or guns, located above the passage of the boards, pointing in the direction of the transversal or longitudinal edges.
According to a second aspect, the invention concerns a system for treating elongated pieces of wood flooring. The system comprises:
a first conveyer for conveying panels, each panel being made of several elongated pieces of wood flooring, each piece having an upper and a lower surface, two opposite longitudinal edges and two opposite transversal edges, said pieces being assembled together by at least one of their longitudinal and/or transversal edges to form the panel;
a dismantling device for dismantling the panels along a longitudinal axis into separated pieces while the pieces are transversally conveyed on the first conveyer; a second conveyer for conveying the separated pieces perpendicularly with respect to the first conveyor, the second conveyer longitudinally conveying the separated pieces and maintaining a separation therebetween; and a treating device for applying a treatment product to the longitudinal and/or transversal edges of said elongated pieces while the pieces are longitudinally conveyed on the second conveyer.
The first conveyer of the system may comprise a plurality of parallel rotating chains in contact with the elongated pieces for transversally conveying the pieces.
Then, the second conveyer of the system may comprise a plurality of rotating cylinders. A first group of these rotating cylinders of the second conveyer is proximate the first conveyor, each cylinder of the first group being then located between two adjacent chains of the first conveyer.
These rotating cylinders are vertically movable between a lower position, wherein the pieces are in contact with the rotating chains of the first conveyer, and an upper position wherein the pieces are in contact with the rotating cylinders of the second conveyer, allowing the pieces to transfer from the first conveyer to the second conveyer.
The system of the invention may further comprise a third conveyer for conveying the pieces perpendicularly with respect to the second conveyer and for transversally conveying the pieces. The third conveyer may further have an assembling device for assembling the pieces conveyed on it, once treated, via their longitudinal edges and form as such a reassembled panel. The entire surface of the reassembled panel may be then treated, e.g. sanded, painted, dyed and/or varnished.
The third conveyer may comprise a plurality of parallel rotating belts, such as for the chains of the first conveyer. The second conveyer then comprises a second group of rotating cylinders in proximity of the third conveyer, each adjacent cylinders of the second group being located between two belts of the third conveyer. The rotating cylinders are also vertically movable between an upper position, wherein the pieces are in contact with the rotating cylinders of the second conveyer, and a lower position wherein the pieces are in contact with the rotating belts of the third conveyer, allowing the pieces to transfer from the second conveyer to the third conveyer.
The system of the invention may further comprise a second dismantling device for dismantling pieces that would have remained connected by at least one of their transversal edge, allowing as such the transversal edges to be also treated when conveyed on the second conveyer. Then, the system preferably further comprises an assembling device for assembling the pieces conveyed on the second conveyor, once treated, along their transversal edges.
Preferably, the treating device of the system comprises a plurality of directional spraying guns. Each gun is adapted to spray an appropriate amount of the treatment product precisely to the longitudinal and/or transversal edges of each piece.
The invention and its advantages will be better understood upon reading the following description made with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top schematic view of the system for treating elongated pieces of wood flooring according to a preferred embodiment of the invention.
FIG. 2A to 2C are side views illustrating the transfer zone between the first and second conveyers of the system illustrated on FIG. 1 .
FIG. 3 is a side view of the treating section of the system illustrated on FIG. 1 .
DETAILED DESCRIPTION
As aforesaid, the present invention concerns a method and a system for treating pieces of wood flooring, such as hardwood floorboards, and particularly for treating peripheral edges thereof.
FIGS. 1 to 3 illustrate one preferred embodiment of the system according to the invention.
Referring to FIG. 1 , there is shown a top schematic view of the system ( 1 ) for treating elongated pieces of wood flooring.
The system ( 1 ) as illustrated, is an automated treatment line including a first conveyer ( 3 ) comprising a plurality of parallel rotating chains or belts ( 5 ) for conveying floorboard panels ( 7 ).
Indeed, each floorboard panel ( 7 ) comprises several elongated pieces of wood flooring, hereafter named floorboards or boards ( 9 ). Each board ( 9 ) has two opposite longitudinal edges ( 911 , FIG. 3 ) and two opposite transversal edges ( 912 , FIG. 3 ). These edges ( 911 , 912 ) are preferably pre-machined or pre-cut in order to be properly assembled to form the flooring.
The rotating chains ( 5 ) of the first conveyer ( 3 ) support and convey by friction the panel ( 7 ) which is first conveyed through a dismantling device ( 11 ), such as a panel breaker or the like. The panel ( 7 ) is thus dismantled into separated boards ( 9 ) along their longitudinal axis while the boards ( 9 ) are transversally conveyed on the first conveyer ( 3 ).
The system ( 1 ) also comprises a second conveyer ( 13 ) for conveying the separated boards ( 9 ) perpendicularly with respect to the first conveyor ( 3 ). As detailed hereinafter, the second conveyer ( 13 ) is adapted to longitudinally convey the boards ( 9 ) and maintain an adequate gap therebetween.
As illustrated on FIGS. 1 and 2 , the second conveyer ( 13 ) comprises a plurality of rotating cylinders ( 15 ). A first group of these rotating cylinders ( 151 , 152 ) of the second conveyer ( 13 ) is proximate the first conveyor ( 3 ), in a zone named hereinafter the “transfer zone” ( 17 ). In the transfer zone ( 17 ), each cylinder ( 15 ) is located between two adjacent chains ( 5 ) of the first conveyer ( 3 ).
As illustrated on FIG. 2A to 2C , these rotating cylinders ( 151 , 152 ) are vertically movable between a lower position ( FIGS. 2A and 2B ), wherein the boards ( 9 ) are in contact with the rotating chains ( 5 ) of the first conveyer ( 3 ), and an upper position ( FIG. 2C ) wherein the boards ( 9 ) are now in contact with the rotating cylinders ( 151 , 152 ) of the second conveyer ( 13 ). This movement between the lower and upper position of the rotating cylinders ( 151 , 152 ) allows the boards ( 9 ) to transfer from the first conveyer ( 3 ) to the second conveyer ( 13 ), and also to change the movement of the boards from a lateral movement when the boards are on the first conveyer ( 3 ), and a longitudinal movement when the boards ( 9 ) are on the second conveyer ( 13 ). As detailed hereinafter, a longitudinal movement of the boards on the second conveyer ( 13 ) allows an easier treatment of the edges according to step c) of the method.
Step b) of the method according to the present invention allows the edges of the boards to be exposed for treatment. For doing so, the boards are separated and maintained in a parallel position in order to form a gap therebetween.
As illustrated on FIGS. 1 and 2A to 2 C, the transfer zone ( 17 ) also comprises a series of vertically movable stoppers ( 19 ). The stoppers in their lower position ( FIG. 2B ) retain the boards in a parallel position before to be transferred on the second conveyer ( 13 ).
As illustrated on FIG. 2A , the stoppers ( 19 ) are programmed to lower and then block the boards ( 9 ) one after the other ( 191 , 192 ), while the boards ( 9 ) are moving into the transfer zone ( 17 ).
In order to have the boards ( 9 ) entering the transfer zone ( 17 ) separately, they are previously settled in a parallel position ( FIG. 1 ) thanks to a plurality of movable blockers ( 21 ) located between the dismantling device ( 11 ) and the transfer zone ( 17 ). The blockers ( 21 ) are movably mounted between the rotating chains ( 5 ) of the first conveyer ( 3 ). As for the stoppers, a first series of blockers ( 211 ) automatically blocks the first board ( 91 ) coming from the dismantling device ( 11 ). After the passage of the first board ( 91 ), a second series of blockers ( 212 ) located between the dismantling device ( 11 ) and the first series of blockers ( 211 ), arise between the rotating chains ( 5 ) in order to block the second board ( 92 ) in a parallel position to the first board ( 91 ). It is understood that the number of stoppers and blockers may vary depending on the number of boards ( 9 ) to be treated by the system ( 1 ).
After that, all the boards ( 9 , 91 , 92 ) having been settled in a parallel position, the first series of blockers ( 211 ) moves in order to release the first board ( 91 ), allowing it to move first into the transfer zone ( 17 ) until it reaches and is blocked by the first stoppers ( 191 ) settled down in their lower position. Meanwhile, the second series of blockers ( 212 ) release the second board ( 92 ), allowing it to move into the transfer zone ( 17 ) after the first board ( 91 ), until it reaches and is blocked by the second stoppers ( 192 ) that have moved down in their lower position right after the passage of the first board ( 91 ). The same sequence occurs for the others boards until all the boards are blocked and settled in a parallel position in the transfer zone ( FIG. 2B ).
The transfer of the boards ( 9 ) from the first ( 3 ) to the second conveyer ( 13 ) in the transfer zone ( 17 ) corresponds to a sequenced upwards movement of the rotating cylinders ( 15 ) and stoppers ( 19 ) from their lower position ( FIG. 2B ) to their upper position ( FIG. 2C ).
Referring to FIGS. 1 and 3 , the boards ( 9 ), after their transfer, move forward into a treating section ( 23 ) of the system ( 1 ), wherein step c) of the method is performed, i.e. a treatment product is applied to the longitudinal ( 911 ) and/or transversal ( 912 ) edges of the boards while the boards ( 9 ) are longitudinally conveyed on the second conveyer ( 13 ).
The longitudinal floorboards ( 9 ) may be formed of a plurality of shorter board pieces assembled by their transversal edges ( 912 ). In that case, these shorter pieces have to be preferably separated before entering the treating section ( 23 ), allowing as such the transversal edges ( 912 ) of each board pieces to be also treated. Therefore, according to another preferred embodiment of the invention, the system ( 1 ) may comprises a second dismantling device for dismantling these board pieces that remain connected by at least one of their transversal edges.
Referring to FIG. 1 , a first manner to transversally dismantle the boards consists in having the rotating cylinders ( 151 ) of the transfer zone ( 17 ) being close to the treating section ( 23 ) and programmed for a higher speed of rotation than the other rotating cylinders ( 152 ) located at the beginning of the second conveyer ( 13 ), i.e. far from the treating section. Consequently, the pieces of the boards ( 9 ) close to the treating section ( 23 ) separate from the rest of each board and move first into the treating section.
The separation of the shorter pieces may also be done by having the rotating cylinders ( 151 ) close to the treating section ( 23 ) programmed for having a higher rotating speed than the other rotating cylinders ( 152 ).
According to another preferred embodiment of the invention illustrated on FIG. 3 , the treating section ( 23 ) comprises a treating device ( 25 ) including several directional spraying guns ( 251 , 252 ). Some guns ( 251 ) are positioned to spray an appropriate amount of at least one treatment product ( 27 ) precisely to the longitudinal edges ( 911 ) of each board ( 9 ), whereas other guns ( 252 ) are positioned to spray another appropriate amount of a treatment product ( 27 ) precisely to the transversal edges ( 912 ). Preferably, the treatment is performed while the boards ( 9 ) are moving forward on the second conveyor ( 13 ).
As also illustrated on FIG. 1 , the boards ( 9 ), after being treated, move into a second transfer zone ( 29 ) between the second conveyer ( 13 ) and a third conveyer ( 31 ).
The third conveyer ( 31 ) allows conveying of the boards ( 9 ) perpendicularly with respect to the second conveyer ( 13 ) and for transversally conveying them. As for the first conveyer ( 3 ), the third conveyer ( 31 ) comprises a plurality of parallel rotating chains or belts ( 33 ).
As for the first transfer zone ( 17 ), the second conveyer ( 13 ) of the second transfer zone ( 29 ) comprises a second group of rotating cylinders ( 35 ) in proximity of the third conveyer ( 31 ), each adjacent cylinder ( 35 ) of the second group being located between two adjacent belts ( 33 ) of the third conveyer ( 31 ). The rotating cylinders ( 35 ) are also vertically movable between an upper position, wherein the boards ( 9 ) are in contact with the rotating cylinders ( 35 ) of the second conveyer ( 13 ), and a lower position wherein the boards are in contact with the rotating belts ( 33 ) of the third conveyer ( 31 ), allowing the boards to transfer from the second conveyer ( 13 ) to the third conveyer ( 31 ).
Before being transferred from the second to third conveyer ( 13 , 31 ), the smaller pieces constituting each board are reassembled in the second transfer zone ( 29 ) by entering into contact with an abutting device ( 37 ) located at the end of the second conveyer ( 13 ), reforming as such each elongated board ( 9 ).
In order to reform a quite perfect elongated board ( 9 ), it is preferable to guide the smaller pieces thanks to a second series of stoppers or guides ( 39 ) that may be identical to the stoppers ( 19 ) of the first transfer zone ( 17 ). The transfer of the boards ( 9 ) from the second to the third conveyer ( 13 , 31 ) within the second transfer zone ( 29 ) corresponds to a sequential downwards movement of firstly the rotating cylinders ( 35 ) and secondly the guides ( 39 ) from their lower position to their upper position. The smaller pieces abutting the abutting device ( 37 ), while being on the second conveyer, allow the transversal edges of the pieces to reconnect and reform each board ( 9 ). Then, the boards ( 9 ) abutting the stoppers or guides ( 39 ), while being on the second conveyer, allow each board ( 9 ) to align and reform an elongated board ( 9 ).
Then, the stoppers or guides ( 39 ) move upwards and the boards are conveyed on the third conveyer ( 31 ) to move out the second transfer zone ( 29 ) in a lateral movement.
The third conveyer ( 31 ) preferably includes an assembling device ( 41 ) for assembling the boards ( 9 ) conveyed on it. The boards moving out of the second transfer zone abut the assembling device ( 41 ), reassemble via their longitudinal edges and reform as such a reassembled panel ( 43 ).
The entire surface of the reassembled panel ( 43 ) may then be further treated, e.g. sanded, painted, dyed and/or varnished. The treatment of the surface may commence after transferring the re-assembled elongated pieces from conveyor ( 31 ) to another perpendicular conveyor.
It is to be understood that the above example is a schematic view of the system invented by the inventors. The materials to make each piece of the system, the pieces themselves and their movement, involve material, assembling and engineering techniques of the art. Each piece of the systems, their speed, movement, amount of treatment product spread, can be controlled using computer, electronic, optic and/or robotic technologies. The treatment products applied on the boards are also those well known in the art.
The system and method of the invention allows a mass production of treated boards, wherein the edges of the boards can receive a different treatment than their surfaces.
Although the present invention has been explained hereinabove by way of a preferred embodiment thereof, it should be pointed out that any modifications to this preferred embodiment within the scope of the appended claims is not deemed to alter or change the nature and scope of the present invention.
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A method and system for treating floorboards. A plurality of panels are provided and comprise a plurality of floorboards, each floorboard having a top and bottom surface, and longitudinal and transversal edges. The floorboards are assembled together by at least one of their edges to form the panel. The panel is mechanically dismantled in order to expose each edge of each floorboard. A treatment product is applied to the peripheral edges of the floorboards. The method and system of the invention are particularly suitable for a mass production of floorboards on a production line. The method and system of the invention allow the edges of the boards to be treated separately, for example with a color or shade different than the top and bottom surfaces.
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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 United Kingdom Patent Application No. 0402415.4, filed on Feb. 4, 2004, which hereby is incorporated by reference in its entirety.
FIELD OF THE INVENTION
This invention concerns an apparatus and a method for facilitating the installation of a component at an underwater facility, such as a hydrocarbon production facility or well.
BACKGROUND OF THE INVENTION
The installation of equipment for subsea fluid extraction wells involves the lowering of heavy assemblies onto the sea bed. It is particularly difficult to lower components such as subsea control modules to locate on structures already on the sea bed, such as a well tree, as considerable positional accuracy is required. The lowering of such components is normally effected from a surface vessel, in conjunction with the use of a subsea remote operated vehicle (ROV). However, the surface vessel is subjected to the conditions of the surface sea state, causing the vessel to move in pitch, yaw and heave. The effects of pitch and heave are minimised by the use of vessels which are purpose designed to allow lowering from a special access in the center of the vessel. However since the availability of such vessels is limited, their use is expensive. It is therefore desirable to use a “vessel of opportunity” i.e. one which is not purpose designed for this work, in conjunction with the ROV, thus increasing the availability of vessels suitable for installation and so substantially reducing costs for the operator.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide installation apparatus which may be deployed from a general surface vessel, i.e. one which is not purpose-built for such work.
In accordance with a first aspect of the present invention there is provided an apparatus for deployment from a base for installing a component at an underwater facility, comprising a carriage lowered from the base in use of the apparatus, the carriage being adapted to releasably retain the component and compensation means located between the carriage and the base in use for compensating for relative motion between the underwater facility and the base.
Preferably, a cable is used for suspending the carriage from the base, and the compensation means is located between the cable and the carriage.
The compensation means may comprise a resiliently deformable member, such as a spring. The resiliently deformable member may be provided within a parallelogram linkage.
Preferably, the carriage is provided with guide cables for engaging with the underwater facility, to provide a guide for locating the component at the underwater facility. In this case, the compensation means would act to keep the guide cables tensioned during installation of the component substantially regardless of said relative motion. Advantageously, the guide cables are manipulable by a remotely operated vehicle to engage with the underwater facility.
The carriage may be provided with a retractable cable for engaging with the component. This retractable cable is preferably manipulable by a remotely operated vehicle to engage with the component.
According to a second aspect of the present invention, there is provided a method of installing a component at an underwater facility comprising the steps of providing a base, lowering installation apparatus from the base, the apparatus comprising a carriage which releasably retains the component, and compensating for relative motion between the base and the underwater facility using compensation means located between the carriage and the base.
The base is preferably a surface vessel.
The underwater facility may be a hydrocarbon extraction facility.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described by way of example with reference to the following figures, in which:
FIG. 1 shows an embodiment of the apparatus of the present invention, arranged for the lowering of a production module to the sea bed;
FIG. 2 shows the apparatus attached to an underwater facility located on the sea bed;
FIG. 3 shows the apparatus after installation of the production module; and
FIG. 4 shows a second embodiment of the invention, with additional heave capacity.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring first to FIG. 1 , a first embodiment of the inventive apparatus comprises a spring-loaded compensation mechanism supporting a carriage comprising a winch and guide cable assembly, the whole constituting a ‘deployment stack’. The compensation mechanism consists of a parallelogram linkage with four arms 1 connected to each other at their ends by four pivot bearings 2 , and held in the relaxed position shown by a compression spring 3 attached in the proximity of two of the pivot bearings 2 . As the parallelogram linkage is in the form of a pantograph, the linked arms are capable of ‘scissor’ movement to change the length of the mechanism within set limits. The mechanism is attached to a carriage comprising a beam 4 , which carries a winch 5 , the cable of which is attached to the module 6 to be installed by a hook 7 . In the example shown, the module is a subsea control module, although any modules or components are suitable. The winch 5 is driven by a gearbox 8 . An input shaft 9 of the gearbox 8 is designed to be easily engaged with and operated by a remote operated vehicle (ROV), i.e. it is ‘ROV-friendly’. Two guide cables 10 and 11 are attached to anchor points 12 and 13 , which in turn are attached to the beam 4 . These guide cables 10 and 11 may be permanently attached to the anchor points 12 and 13 or advantageously may be attached via shackles (not shown) to facilitate easy replacement if required. The other ends of the guide cables 10 and 11 are attached to hooks 14 and 15 which are removably hooked at each end of the beam 4 on short rods 16 and 17 mounted on trunnions 18 and 19 , so that they can be easily detached by an ROV during installation of the module 6 . The module to be installed 6 is fitted with two guide arms 20 , terminated with collars 21 . During the setting up of the apparatus, the guide cables 10 and 11 are passed through the collars 21 . Typically, the two guide arms and collars are an integral feature of the module to be installed, but could be detachable. The weight of the module 6 with the carriage is insufficient to significantly extend the compensation mechanism and compress the spring 3 .
The use of the apparatus is now described with reference to FIGS. 1 to 3 .
FIG. 1 shows the deployment stack attached to the module to be installed, set up for lowering through the sea towards the sea bed. The whole apparatus is attached to a crane on a deployment vessel of opportunity via the cable 22 and hook 23 , hooked onto the pivot between the upper arms of the compensation mechanism.
The next step in installation is illustrated in FIG. 2 , which shows the deployment stack and module lowered close to equipment 24 of a facility, typically a well tree, located on the sea bed. This equipment is shown much simplified and has been restricted in the figure to solely show a location for the module to be installed. The hooks 14 and 15 on the ends of the guide cables 10 and 11 are detached by an ROV from the rods 16 and 17 , and reattached to anchor points 25 and 26 fitted to the subsea equipment 24 .
The final step in installation is shown in FIG. 3 . The deployment stack is hoisted upwards by the crane on the deployment vessel, thus lifting the crane hook 23 and resulting in a vertical extension of the compensation mechanism and tightening of the guide cables 10 and 11 , which are kept tensioned by the compression of the spring 3 . The apparatus is hoisted vertically just sufficiently to provide tension in the guide cables 10 and 11 at both the peaks and troughs of the vessel heave motion. Thus the compensation mechanism provides compensation for the deployment vessel heave during the rest of the installation phase. Because a parallelogram linkage is used rather than merely incorporating a simple spring in the cable, the spring cannot be over-extended and thus damaged, and also the maximum heave compensation amplitude is known, being delimited by the length of the arms 1 . Once the correct condition has been established, the ROV engages with the input shaft 9 of the winch gearbox 8 , and by rotating the shaft 9 lowers the module 6 into the sea bed equipment 24 . Alignment of the module 6 into the sea bed equipment 22 is facilitated by the collars 21 attached to the module 6 via the arms 20 , running down the tensioned guide cables 10 and 11 as the module 6 is lowered into position. After correct location of the module, the crane on the deployment vessel lowers the deployment stack sufficiently for the ROV to detach the hooks 7 , 14 and 15 , thus allowing recovery of the stack for further use.
The amplitude of heave that the compensation mechanism can accommodate is limited by the length of the arms. However, in circumstances where a greater amplitude of heave must be accommodated, then as illustrated in FIG. 4 a second compensation mechanism 27 can be added to the installation apparatus. Indeed, further compensation mechanisms can be added to the apparatus to accommodate even greater amplitudes of heave.
Thus the invention provides compensation for the heave of the deployment vessel so that vessels of opportunity can be used to install subsea well production equipment. In practice, the apparatus will allow deployment from the stem of the vessel where the heave is greater than the vessel center, but the convenience in installation is often greater. It should also be noted that, bearing in mind the substantial depths of subsea wells, the alignment guidance features of the apparatus greatly facilitate the alignment of modules with the subsea well head equipment during the installation process. This greatly reduces the activity required from the ROV and the problems resulting from the various movements of the deployment vessel, thus reducing installation time and cost.
Although the invention has been described with reference to the embodiments above, there are many other modifications and alternatives possible within the scope of the claims. For example, rather than using a horizontally-orientated compression spring 3 within the parallelogram linkage, it is possible to use a vertically-orientated extension spring connected at the other two pivot bearings 2 . The compensation means is shown as being proximate to the carriage, but may be located at any position between the carriage and the vessel. The compensation means is shown as including a parallelogram linkage, but other configurations using arms of differing lengths are possible.
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A running tool for deployment from a base such as a vessel for installing a component at an underwater facility such as a hydrocarbon extraction well includes a carriage which is lowered from the base. The carriage releasably retains the component. A compensator is located between the carriage and the base for compensating for relative motion between the underwater facility and the base.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
(i) Field of the Invention
The present invention relates generally to a movable bridge, and more particularly to a movable built-up bridge structure for use in the road repairing services.
(ii) Description of the Prior Art
Road repair work generally causes traffic jam or even a complete obstacle for traffic and transportation on a road. In an attempt to cope with such undesired conditions, there has been proposed a movable bridge structure of built-up type which is temporarily installed upon a portion of the road, to be repaired, so that the traffic may be maintained without interruption while the road repair work desired is being continued under such bridge structure.
Conventional movable bridges of this type are, as typically shown in FIGS. 22 and 23, of such a general construction which comprises a central bridge portion (a) equipped with a travelling unit having a working space therein, and a ramp portion (b) either of a hinged type or of a sliding type which may be stored somehow into the central portion for the removal and transportation purposes.
According to the conventional constrution of this type bridge structure, there is a physical restriction such that the slope of a ramp cannot be made too large in order for vehicles to pass smoothly thereover. This type of bridge would require a relatively long extension of the entire bridge structure and the bridge structure cannot be designed with a desired short extension. Bridges of the type have a small height, which creates an inconvenience and difficulty in the repair work under the bridge structure.
Accordingly, it is inevitable in the conventional design of such a movable bridge structure that the whole extension of the central bridge portion (a) would exceed, to a considerable extent, the general length allowed for on-road traffic vehicles which would result in an impracticability of use. On the other hand, if the joint section with the ramp portion (b) is designed to be of a hinged type, and when this is adapted in installation on a road having a certain gradient in the transversal direction, it is inevitable in the operation of this bridge structure that there would occur an undesired torsion or twisting load upon the hinged portion which would eventually result in a weak spot in the structural strength.
Also, it is to be noted that construction of a movable bridge of the type stated above is rather complicated resulting in expensive production costs.
SUMMARY OF THE INVENTION
The present invention is therefore materialized to practice in view of such circumstances and inconveniences as noted above and is essentially directed to the provision of an improved movable bridge structure, which can afford an efficient solution to the above noted problems. According to the entity of the present invention, there is provided, as briefly summarized, an improved construction of a movable bridge structure which comprises a plurality of segment block means consisting of at least one self-propelled block means and at least one non-propelled block means adapted to be coupled releasably with the adjacent self-propelled block means, and translating means adapted to have the non-propelled block translated onto and out of the adjacent self-propelled block means.
Also, according to another embodiment of the invention, there is provided an improved movable bridge structure, as may be summarized in brief, which comprises, in combination, a pair of central bridge element means each having an overhung portion formed integrally with and extending from the front end of a road or ground plate member held on a self-propelled carrier and having a front driving cockpit suspended downwardly and shiftably forwardly and rearwardly from the lower surface of the overhung portion; and a pair of ramp block means including a pair of trailing ramp segment means adapted to be coupled releasably with each of the bridge element means and adapted to be coupled releasably with each pair of ramp segment means, and including a translating device incorporated therein for translating the ramp block means onto and out of the ramp segment means, wherein the leading end of each overhung portion on the part of each central bridge element means is operatively coupled with each other in an opposed relationship so that there is provided a central portion of the bridge structure, whereby there is defined a substantial work space under the ground plate members coupled opposedly together.
By virtue of advantageous constructions as noted above by way of preferred embodiments of the invention, such advantageous effects are attainable in practice that there may be a large work space under the ground plate of a movable bridge structure wherein a central bridge section comprises a pair of central bridge elements each having an overhung portion extending from the front end of a ground plate held in position by a self-propelled carrier, the leading ends of the overhung portions from the opposed central bridge elements being adapted to be coupled with each other in such a manner that the large work space may be made available thereunder. Also, by virtue of an integral structure of the overhung portion with the ground plate held by the self-propelled carrier thereupon, there is attained sufficient structural strength enough to support with stability a substantial traffic volume rendered thereupon, thus allowing a reliable overhung structure in the bridge construction. In addition, owing to the provision of a driver's seat under the overhung portion extending integrally from the front end of the ground plate of the central bridge element in such a manner that the driver's seat may adjustably be shifted back and forth, this can be an efficient measure of dissolution of a poor visibility that is otherwise inevitable from the overhung structure.
Moreover, by the provision of such an advantageous construction that a haul-up type ramp segment forming part of the ramp section may be jointed releasably to each central bridge element, it can exhibit a facility in handling such as in a delivery to or from of a repair work site, an installation and evacuation work, or the like.
Furthermore, in virtue of an efficient constrution such that a translating unit for the haul-up type ramp segment stated above is incorporated in a ramp block connected releasably to the ramp segment which form part of the bridge ramp section, it can afford a facility in the loading and unloading work of the ramp block onto and from the ramp segment without the need for any cumbersome or weighty devices.
Still further, thanks to the divisional construction of a bridge structure into a pair of central bridge elements, a pair of haul-up type ramp segments and a pair of tilt blocks, each of such divisional elements may then be ready for the transportation by way of the normal road free from any restrictions under the traffic regulations, accordingly.
Further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.
BRIEF DESCRIPTION OF THE DRAWING
The present invention will become more fully understood from the detailed description given hereinbelow and the accompanying drawings which are given by way of illustration only, and thus are not limitative of the present invention, and wherein:
FIG. 1 is a schematic side elevational view showing, by way of a preferred embodiment of the present invention, the general construction of an improved movable built-up bridge structure for the road repairing services according to the invention;
FIG. 2 is a top planar view showing the bridge structure shown in FIG. 1;
FIGS. 3 and 4 are similar side elevational views to FIG. 1 showing the processes of delivery and installation of the bridge structure;
FIGS. 5 through 10 are side elevational views showing a sequence of translating a ramp block onto a ramp segment of the bridge structure;
FIG. 11 is a side elevational view showing, by way of a second embodiment of the invention the built-up bridge structure;
FIGS. 12 through 21 are schematic views showing translating unit constructions according to further embodiments of the invention for mounting the ramp block onto a self-propelled bridge element, among which FIG. 12 is a side elevational view showing the same, FIG. 13 is a top plan view thereof, FIG. 14 is a cross-sectional view taken along the line III--III in FIG. 13, FIG. 15 is a cross-sectional view taken along the line IV--IV in FIG. 12, FIGS. 16 through 20 are schematic views showing a sequence of translating work, FIG. 21 is a fragmentary enlarged view showing, in cross section, the detail of the part shown by X in FIG. 20; and
FIGS. 22 and 23 are side elevational views showing respectively the general constructions of the conventional movable bridge structures.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention will now be explained by way of a preferred embodiment thereof as adapted in practice to the movable built-up type bridge structure for use in the road repairing work in reference to the drawings attached herewith. Now, the reference is made to FIGS. 1 through 10, side elevational views of the bridge structure according to the invention, wherein there are shown organizational modules designated at the reference characters A 1 , A 2 which comprise a central bridge element of the bridge structure; modules designated at B 1 , B 2 comprising a haul-up type ramp segment; and modules at C 1 , C 2 comprising a ramp segment, respectively.
According to the construction of the modules A 1 , A 2 shown in these drawing figures, a road plate or ground plate 1 is seen held by a pillar or post 9 upon a carrier frame 5, on which there are mounted a prime mover or engine 2, a hydraulic pump 3 and a rear driving seat 6, and there are also provided traveling wheels 4. In the drawings, there is also shown outriggers designated at the reference numeral 8, which are securely mounted on the ground plate 1.
Extending integrally from the front end of the ground plate 1 is an overhung portion 1a, under which there is mounted shiftably downwardly a drive 11, and from this drive there is seen suspended a front driving seat or cockpit 7. Also, there are installed couplers 12, 23 at the front and rear ends of the ground plate 1, respectively.
In these drawings, there is also designated a compressor at 13, a power generator 14, a roller conveyor 15, and a free-action bearing 16, all which are mounted either from the ground plate 1 or the carrier frame 5.
The hydraulic pump 3 noted above is driven from the engine 2, with the generated hydraulic pressure being fed to the hydraulic driving motor mounted from the carrier 5 for driving the traveling wheels 4 so that the modules A 1 , A 2 may be driven for transporting. It is arranged that these wheels 4 may be steered hydraulically according to electric signals from cockpits 6, 7 permiting not only forward and rearward traveling motions but also skewing and turning motions.
While the cockpits 6, 7 for driving the modules A 1 , A 2 are provided as shown in the both front and rear ends of the modules A 1 , A 2 , it is designed that the front cockpit 7 can be shifted towards the leading end of the rails 10 as designated at the reference numeral 7' by the driving unit 11 so that good visibility may be obtained during the locating operation of the bridge structure.
Incidentally, the equipment such as the compressor 13, the power generator 14, the roller conveyor 15 and the free-action bearing 16 is provided for use in the traveling operation or during the road repair work.
The modules B 1 , B 2 are adapted to comprise the haul-up ramp segment, which is comprised of a road plate or ground plate designated at 17, a free-action bearing 18 suspended downwardly from the ground plate 17, a housing box 19 mounted upon the free-action bearing 18, a set of wheels 20, and steering masts 21 and outriggers 22 mounted from the ground plate 17. Also shown is a coupler 23' installed on the front end of the ground plate 17, which is adapted to be coupled releasably with a corresponding coupler 23 on the part of the modules A 1 , A 2 stated above. There is also shown a jack 25 installed upon the ground plate 17, and a water tank 32, both implemented during the road repairing services.
The modules C 1 , C 2 are comprised of a ground plate 26 having side boards 27 and a wheeled table lift 28 which forms a translating unit for the ramp segment mounted downwardly from the ground plate 26.
In the drawings, there is also shown a tractor 29 for moving module B 1 to a portion of the road under repair work 30.
With such construction of the embodiment of the invention shown in these drawings, when it is required to deliver the built-up bridge structure to a working site, it may readily be divided into three blocks as typically shown in FIG. 3.
In connection with the manner of dismantling and collapsing and placing, at the work base, the module C 1 onto the module B 1 of the bridge structure, while there are known adaptable and typical types such as a hinged type, a sliding type, and the like, as these types generally turn out to be complicated in construction and time-taking in explanation, it is preferred for clarity that only a simple construction having steady and stable lift system is therefore taken for example. Referring to FIG. 8, it is seen that the table lift 28 incorporated in the module C 1 (see FIG. 5) is initially extended to the working position so that the bottom surface of the module C 1 may be lifted higher than the top surface of the ground plate 17 of the module B 1 . Next, after removing the detachable ground plate 24 from the module B 1 , the table lift 28 is moved into a space opened after the removal of the ground plate 24 (see FIG. 7), and then the table lift 28 is let closed to a position where an end of the bottom of the module C 1 would rest upon the top surface of the ground plate 17, thereafter having the jack 25 in the ground plate 17 operated so that the bottom of the module C 1 may be supported duly, and then having the table lift 28 retracted into a position in the module C 1 (see FIG. 8). After this procedure, the jack 25 is lowered to a position where the bottom of the module C 1 may rest upon the ground plate 17 (see FIG. 9), and then lifting the module C 1 upwardly onto the ground plate 17 (see FIG. 10) by using a chain block or the like so that the outrigger 22 may be retracted from the working position, which is the completion of the collapsing job to be performed prior to the hauling by the tractor 29 to a working site.
Then, the module A 1 is, upon the retraction of the outrigger 8, driven from the rear cockpit 6 over to a working site.
On the other hand, each of the modules A 2 , B 2 and C 2 is prepared for the delivery service by retracting the outrigger 8 and by having the front cockpit 7 shifted toward the leading end position 7' of the overhung portion 1a by means of the drive 11. The the module C 2 is also mounted onto the module B 2 in the similar manner to the modules B 1 and C 1 , thereafter being coupled with the module A 2 by way of the couplers 23, 23'. Then, the front cockpit 7' operates to drive the module A 2 so that the module B 2 may be hauled over to a working site.
Now referring to the working operation at a repair site, the modules A 1 and B 1 are coupled together by using the coupler 23. This coupling operation is done through the rear cockpit 6 for driving the module A 1 coupled rigidly with the module B 1 so that the module A1 may move relatively with respect to the module B 1 . In connection with this operation, since the module A 1 is designed to be operable in skewing and centered-turning motions in addition to the forward and rearward motions, this approaching operation may be performed with ease. Next, the module A 1 is driven from the front cockpit 7 in such a manner that the coupler 12 may be set at a position immediately upon an area of the road 30 to be repaired and that the modules A 1 and B 1 may be located in the middle of the width of the road, where the tractor 29 is then disengaged from the modules. After the modules A 1 and B 1 are set in the duly position, the module A 2 is then driven from the front cockpit 7 so that it may be coupled to the module A 1 by using the coupler 12. It is like the case of the modules A 1 and B 1 that the modules A 2 and B 2 are adjusted as close as possible to the center of the width of the road to be repaired. Then, the relative location of these modules A 1 and A 2 may be corrected with a further adjustment, thereafter the outriggers 8 and 22 being extended towards the road surface where they rest securely upon, the modules C 1 and C 2 being loweredonto the road surface in the reverse order, then coupled with the modules B 1 and B 2 by coupling means (not shown), respectively. With this sequence of operations, there may duly be located the built-up bridge structure in the right position on the road surface 30 to be repaired, with the due work space 31 under the overhung portions 1a, 1a of the pair of modules A 1 and A 2 , accordingly.
Upon the completion of installation of the bridge structure, a repair work is then started, which will now be described in detail referring to FIGS. 1 and 2. In the case that an expansion joint under the ground is repaired, in order to firstly remove the concrete portion where the joint is located, the concrete portion is cut away by using a concrete cutter (not shown), thereafter it being broken to pieces by way of a concrete breaker (not shown). Thus-broken concrete scraps and the expansion joint are placed into the housing box 19 so as to be delivered onto the free-action bearing 18 on the modules B 1 , and B 2 by using the roller conveyor 15 and the free-action bearing 16.
The opening left upon the removal of concrete is then cleaned so that it may be filled with fresh concrete. The concrete work is then done in such a manner that cement, sand and aggregate which are stored beforehand in the storing box 19 on the free-action bearing 18 are fed into a concrete mixer (not shown) located on a work space by using the free-action bearing 16 and the roller conveyor 15, and then they are kneaded with water supplied from the water tank 32 on the part of the modules B 1 and B 2 . After the concrete is placed and cured, there is set a new expansion joint thereupon, thus completing the reparation work.
While there are not shown in drawings such portable members as a concrete cutter, a concrete breaker, a mixer and the like which are generally used in the reparation work, it is notable that they are stored in suspension from the ground plate 1 in the work space defined between the modules A 1 and A 2 in such a manner that they are serviceable taken out of such a stored condition, and that these members are put to use with the utilities such as compressed-air and the power from the compressor 13 and the power generator 14.
As stated hereinbefore, after the reparation work is over, the modules B 1 , B 2 and the modules C 1 , C 2 are disengaged from each other in the like initial sequence as done in the work base, thereafter the modules C 1 , C 2 being mounted onto the modules B 1 , B 2 , respectively. Also, the joint between the modules A 2 and B 2 , and between the modules A 1 and A 2 are then released, with the front cockpit 7 being shifted toward the position 7' on the part of the module A 1 and with all the outriggers 8 and 22 retracted, and then the module B 2 is ready for the hauling service by the tractor 29, while the module A 2 is driven from the rear cockpit 6 and the module A 1 is driven from the front cockpit in the position 7', together with the module B 1 ready for a return to the work base.
Now, as reviewed fully with reference to the embodiment as shown, it is appreciated that there may be attained the work space 31 under both overhung portions 1a, 1a by coupling the pair of modules A 1 , A 2 , equipped with the ground plate 1 having the overhung portion 1a extending from the leading end thereof, in an opposed relationship with each other, and there is obtainable a due strength of the ground plate 1 by virtue of the employment of such integral construction as noted hereinbefore, thus making such an overhung structure feasible in practice. In addition, possible poor visibility of the cockpit that is otherwise inevitable from the overhung structure may be eliminated by virtue of the advantageous construction that the front cockpit 7 of the modules A 1 , A 2 may be shifted in location along the extension of the overhung portion 1a.
Also, it is advantageous that the modules A 1 , A 2 and the modules B 1 , B 2 are designed in an optimal manner of division so that these modules may readily be delivered to services or removed out of a working site due to the unique coupling features that can provide such a releasable joint between these modules as stated hereinbefore.
Furthermore, the modules C 1 , C 2 can efficiently be loaded onto and unloaded from the modules B 1 , B 2 by virtue of the incorporation of the table lift 28 without the need for a complicated and cumbersome lifting device.
Still further, each of the divisional elements, owing to the unique separation in construction of the modules A 1 , A 2 , B 1 , B 2 and C 1 , C 2 , can travel by way of normal roads without any restrictions under the traffic regulations, accordingly.
Moreover, it is feasible in practice to insert a space module D as shown in FIG. 11 for the attainment of a further work space under the bridge structure. In such an added organization, the space module D may be either of the self-propelled type or of the hauling type.
Now, referring to FIGS. 12 through 21, there will be described by way of preferred embodiments of the invention an improved translating apparatus which is adapted to translate the ramp block onto the movable bridge element.
In the drawings, there is shown the ground 41 upon which the bridge structure rests, a bridge element at A, and a set of wheels 43 carried under ground plate 42 of the element A. Also, there is disposed a set of outriggers 44 under the ground plate 42, and a detachable gound segment 45 which forms part of the ground plate 42 in the middle of a rear edge portion thereof. In addition, there is provided rotatably a plurality of steel balls 46 along the extension of right and left sides of the ground plate 42 in such a manner that their upper halfs are exposed above the side edges.
Also shown is a ramp block B defined in the form of a gate in cross section having leg wall portions 48 extending from both side edges of the ground plate 47 where there is provided no wheels, and which is designed to rest upon the ground by way of these wall portions 48.
There is shown a lift at C in which there is disposed expandably a lift table 51 supported on lift base 50 having a set of wheels 49. Lift table 51 is connected rigidly to the bottom surface of the ground plate 47 in such a manner the wheels 49 do not reach the ground 41, when the lift C is retracted. It is notable that the lower end of the wall portion 48 is thickened so that there may be provided a pair of linear grooves 52 extending in the longitudinal direction, which engage with the steel balls 46 provided on the ground plate 42 during loading of ramp block B onto bridge element A.
With such construction as shown by way of this embodiment, after the bridge assembly A with ground plate 42 and ground plate 47 of the ramp block B are disengaged from each other, and when the lift table 51 of the lift C is extended, the wheels 49 of the lift base 50 will the ground 41. Thereafter, the ground plate 47 is elevated by lift table 51. When the bottom surfaces of the wall portions 48, having linear grooves 52 therein, becomes higher than the tops of the steel balls 46 as provided in the ground plate 42 on the part of the bridge assembly A, elevating the lift table 51 is then stopped (see FIGS. 16 and 17).
Next, after the removal of the detachable ground segment 45 of the ground plate 42 on the part of the bridge assembly A, the lift C is drawn toward the assembly A by using a suitable pulling means (not shown) so that it may be positioned into the opening or space left open after removing the detachable section 45 (see FIG. 18).
When the lift table 51 is retracted slowly there will occur mutual engagement between the linear grooves 52 in the ramp block B and the steel balls 46 on ground plate 42 of the bridge assembly A. Whereupon the ground plate 47 is then held in a loading position on the ground plate 42, accordingly. When the lift table 51 is retracted further from this loading position, the lift base 50 and the wheels 49 are lifted upwardly towards the lift table 51, eventually retracted in position on the ramp block B (see FIG. 19). Then, the ground plate 47 of the ramp block B is moved, by using a suitable pulling means (not shown), so that ground plate 47 may be disposed completely in a proper resting position on the ground plate 42 of the bridge assembly A, accordingly.
During the pulling stage, the steel balls 46 and the linear grooves 52 are put in a close engagement relationship with each other, which will then make it possible to pull ground plate 47 with relatively small pulling effort and which will also ensure proper alignment or orientation of traveling motion of the ground plate to be stored.
Upon the completion of such loading operation, the ground plates 42, 47 are fixed in the resting position by using certain suitable means not shown, and then the outriggers 44 are retracted accordingly in preparation for the following transportation step.
Now, it will be observable that the bridge assembly A and the ramp block B are to be set in working position following the unloading procedures in the reverse order, upon arrival at a next working spot.
It is to be understood by those skilled in the art that a plurality of element blocks of identical type may be adapted for use in field operations.
In summary, it is now seen that it is feasible in practice according to the preferred embodiments of the invention to have the bridge structure constructed and collapsed readily without any further provision than the lift C incorporated in the ramp block B and to have an advantageous low-friction and high-linearity traction performance in the loading and unloading motions of the ramp block B by virtue of the employment of a positive and smooth ball-and-groove engagement between the bridge assembly A with ramp segment 42 and ramp segment 47 of the ramp block B.
The invention being thus described, it will be obvious that the same way be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims.
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An improved construction of a movable bridge structure which comprises a plurality of segment block means consisting of at least one self-propelled block means and at least one non-propelled block means adapted to be coupled releasably with the adjacent self-propelled block means, and translating means adapted to have the non-propelled block translated onto and out of the adjacent self-propelled block means. Also, there is provided an improved movable bridge structure, which comprises, in combination, a pair of central bridge element means each having an overhung portion formed integrally with and extending from the front end of a road or ground plate member held on a self-propelled carrier and having a front driving cockpit suspended downwardly and shiftably forwardly and rearwardly from the lower surface of the overhung portion; and a pair of ramp block means including a pair of trailing ramp segment means adapted to be coupled releasably with each of the bridge element means and adapted to be coupled releasably with each pair of ramp segment means, and including a translating device incorporated therein for translating the ramp block means onto and out of the ramp segment means, wherein the leading end of each overhung portion on the part of each central bridge element means is operatively coupled with each other in an opposed relationship so that there is provided a central portion of the bridge structure, whereby there is defined a substantial work space under the ground plate members coupled opposedly together.
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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 soils percolation testing apparatus and more particularly relates to improvements in the art of determining the liquid absorptive rate of soil sites under investigation or examination.
2. The Prior Art
The prior art is characterized by large clumsy devices four inches or greater in diameter and requiring a power source, timers, recording media and they operate on the concept of recording the drop in water level over a finite period of time.
SUMMARY OF THE INVENTION
The primary objective of this invention is to provide an inexpensive, rugged, easily employed, highly accurate device for determining the liquid absorption rate of soils.
A small cylindrical shaft is secured in a test hole and is adjustably positioned with the use of vertically slidable blades so that it is virtually centered in an upright position. An integral hand operated pump is used to set the top of a float rod to a zero or null position, whereupon a time measurement is taken and after a predetermined time interval correlated with a calibrated scale, a direct reading of the absorption rate is obtained.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a testing apparatus positioned in a typical placement within a test hole;
FIG. 2 is a fragmentary enlarged view showing additional details of the vertical alignment blades and the sliding track provided in accordance with this invention;
FIG. 3 is a bottom plan view of the lower end of the float rod guide tube spacer;
FIG. 4 is a cross-sectional view taken on line IV--IV of FIG. 3;
FIG. 5 is a cross-sectional view similar to the top portion of FIG. 1 , but enlarged to show additional details of the invention; and,
FIG. 6 is a front elevational view of the calibrated percolation rate scales used in the apparatus of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Although details of the present application can be varied dimensionally without departing from the principles of the present invention, a preferred embodiment will be described with the use of actual dimensions as utilized in an exemplification of the inventive subject matter.
Thus, referring to FIG. 1, a soils testing apparatus constructed in accordance with the present invention is shown disposed in a typical placement within a test hole. The apparatus comprises a 2 inch (5.08 cm.) diameter cylindrical shaft 1 which may be made of a suitable rigid plastic material.
The shaft 1 is approximately 36 inches (91.44 cm.) in length and forms a housing in which there is disposed a round buoyant float 5 which may also be made of a suitable plastic material, for example, the float 5 may be a hollow plastic molding. The float 5 is attached to a float rod 6, which may be formed as an extrusion from an acrylic plastic material. In the exemplification of the present embodiment, the float rod 6 is 0.125 inches in diameter (32 mm.) and 34.625 inches long (87.95 cm.). The upper 6 inches (15.24 cm.) is preferably a distinctive contrasting color, for example, a red color.
The float rod 6 is enclosed by a 0.375 inch (95 mm.) outside diameter clear extruded acrylic guide tube 3 which is particularly characterized at its upper end by a tube 15 which is approximately 6.5 inches (16.51 cm.) long and 0.625 inches (1.59 cm.) outside diameter marked with indicia means forming a graduated scale indicating the exact percolation rate calibrated in terms of time measured in minutes for 1 inch (2.54 cm.) of water to be absorbed by the adjacent soil.
Referring to FIG. 6, the calibrated scales are illustrated. It will be noted that the scale on the left of FIG. 6 designates so-called 30 minute readings while the scale on the right hand side of FIG. 6 is calibrated for 10 minute readings.
In order to facilitate the ease of reading the percolation rate, a magnifying lens 16 is provided which is approximately 5 inches (12.7 cm.) long and is juxtaposed to the end of the float rod 6 and through which the end of the float rod 6 may be viewed relative to the graduated scales on the guide tube 15.
Referring to FIGS. 1 and 5, it will be noted that the entire upper assembly is enclosed and protected by a globe-like cap 17 made of an opaque plastic and having a cylindrical body portion which terminates in a rounded spherical dome at its uppermost end. The cylindrical body illustrated is approximately 3 inches in diameter (7.62 cm.) and is approxi-mately 9 inches (22.86 cm.) in longitudinal dimension. The bottom end of the cylindrical body portion of the cap 17 is formed with internal screw threads 17a for effecting screw threaded engagement with external screw threads 14 a formed on the external flange 14b provided on a cover member 14 which fits over the top end of the shaft 1.
At the lower end of the float guide tube 3 there is provided a spacer 4 which is more particularly shown in FIGS. 3 and 4 in conjunction with FIG. 1. Thus, the spacer 4 made of plastic is essentially a flanged disc approximately 2 inches (5.08 cm.) in diameter and through which extends a centrally disposed opening 4a and four radially outwardly circumferentially spaced openings 4b, each being approximately 0.375 inches in diameter (95 mm.). The spacer 4 functions to hold the lower end of the tube 3 in proper position.
In accordance with this invention, the apparatus is also equipped with a hand operated suction pump shown generally at 13 and comprising a rubberized hollow bulb 13 a having the usual air check valve integrated in the end thereof as at 13b. The bulb 13a is connected to a flexible plastic tubing 12 which, in turn, is connected to a rigid suction tube 2 by way of an elbow 11. The tube 2 is disposed to extend generally downwardly on the outside of the shaft 1 and is of sufficient length to reach within 6 inches of the bottom of the shaft 1. Positioned at the lower end of the suction tube 2 is a foot valve 2 a with a strainer 7 which will maintain zero leakage.
In order to align the apparatus in a test hole accurately and quickly, the device of the present invention is particularly characterized by the utilization of three equiangularly spaced blades 9 carried and positioned in complementary shaped T-tracks 10 fastened in firm assembly with the outside surface of the shaft 1. Each blade 9 is a plate-form element having an upper edge 9a disposed at approximate right angles to a longitudinal edge 9b having a T-flange 9c formed thereon or attached thereto, and which has a sliding insert fitting relationship with an adjoining T-track member 10 having a T-shaped recessed track 10a formed therein to receive the corresponding flange 9c. The front edge of the blade 9 is a piloting edge 9d which tapers downwardly and inwardly and terminates in a bottom edge 9e disposed at right angles to the longitudinal edge 9b. Thus, as the device is placed into a test hole, the piloting edges of the blades 9 guide the apparatus into a properly centered upright position.
In order to properly ventilate the apparatus, an air vent hole 18 is formed by drilling and is located at the top of the shaft 1.
In operation, the percolation testing procedure is as follows:
First of all, a test hole 19 is dug in the site under investigation or examination approximately 4 to 12 inches (10.16 cm. to 30.48 cm.) in width and to the depth of the proposed absorption field, which is generally 24 inches (60.96 cm.) The bottom and the side walls of the test hole 19 are carefully scratched with a knife blade or a similar sharp pointed instrument in order to remove any smeared soil surfaces and to provide a natural soil interface into which water may percolate. All loose material is removed from the test hole. To protect the bottom of the hole from scouring and sediment, 2 inches (6.08 cm.) of coarse sand or fine gravel as shown at G is added.
The test hole 19 is then preconditioned or saturated by filling the hole 19 with clear water to a minimum of 12 inches (30.48 cm.) above the protective layer G and is maintained at such level overnight, or for at least a period of 4 hours. After completion of the saturation period, the water level is adjusted in the test hole to approximately seven inches above the gravel G. Thereupon, the apparatus including the shaft 1 is inserted into the test hole 19. The plastic blades 9 are inserted into the T track 10 and are vertically adjusted by engaging the wedging edges 9d against the sides of the test hole 19.
After securing the instrument properly in the test hole 19, the hand-held suction pump 13 is used to accurately set the top of the float rod 6 and the percolation rate scale 15 to 0 by carefully exhausting some remaining water in the test hole to approximately six inches above the gravel G. The time is recorded accurately and after a 30 minute period, the 30 minutes scale 15 is read. The reading is the desired absorption rate needed for design purposes.
In sandy soils or in such soils in which the first 6 inches of water seeps away in less than 30 minutes after the four hour saturation period, the time interval between measurement should be taken at approximately 10 minutes and a test run should be undertaken for one hour. The drop that occurs during the final 10 minutes is read on the 10 minutes scale 15 and is the desired absorption rate to be used for design purposes.
Although minor modifications might be suggested by those versed in the art it should be understood that I wish to embody within the scope of the patent warranted hereon all such modifications as reasonably and properly come within the scope of my contribution to the art.
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A soils testing apparatus has a hollow shaft for insertion into a test hole and includes vertically adjustable wedging blades slidable and T-tracks on the shaft for centering alignment in the test hole. A hand pump evacuates water from the test hole to a predetermined null point whereupon vertical movement of a float and float rod supported and guided within the shaft over a finite period of time will yield a direct percolation absorption rate.
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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 roof cladding, a method of installing roof cladding and a roof structure incorporating the roof cladding or made using the method of the invention. This invention is primarily concerned with roof cladding using elongate profiled metal sheets.
2. Description of the Prior Art
According to international standards roof cladding should have a minimum of six fastenings per square meter. This presents problems for non-conventional long span roofing, e.g. 1.5 to 2 meters between purlins, where good weather sealing is to be maintained. In order to avoid holes in the body of each sheet, each sheet must be relatively narrow so that the required number of fastenings can be obtained when the longtudinal edge portions only of the sheets are secured. This places high demands on the installer to ensure good sealing between adjacent sheets while working rapidly. In addition long span roofing is usually used with very long sheets so that the effects of thermal expansion will also have to be catered for. For example, coefficients of thermal expansion of available roof cladding are 1×10 -5 /° C. for galvanised iron, 3×10 -5 /° C. for TiZn, and Z×10 -5 ° C. for aluminium, so that over a 10 m length with a temperature range of 40° C. movements of between 4 and 12 mm may be experienced. Yet other problems are those of lateral wind action and capilliary forces by which rain water, for example, may be forced through or may seep through the joint between roofing sections.
SUMMARY OF THE INVENTION
According to one object of the invention there is provided an elongate, transversely profiled roof sheet comprising at least one elongate ridge and flanking valleys and first and second edge formations along opposed elongate edges of the sheet, the first edge formation including juxtaposed first edge flanks meeting in a bent over flange that forms a lock flange extending inwardly from the first edge flanks and the second edge formation comprising a second edge flank, a bent over crest extending from the second edge flank outwardly from the second edge flank to a reentrant bend forming a groove underneath the bent over crest.
According to another object of the invention there is provided an elongate transversely profiled roof sheet comprising at least one elongate ridge and flanking valleys and first and second edge formations along opposed elongate edges of the sheet, the first edge formation having a first edge flank and a lock flange extending inwardly from an upper region of the first edge flank and the second edge formation comprising a second edge flank, an edge crest extending from an upper region of the second edge flank outwardly from the second edge flank to a reentrant bend forming a groove underneath the edge crest.
The edge formations of adjacent roof sheets can be locked to each other by engaging the lock flange of one sheet in the groove of the other sheet. Preferably the first edge flanks or flank have an upturned lip on their lower outer edge to provide a water run-off channel in case some water does penetrate the joint.
A further object is to provide cleats for securing the roof sheet to a roof frame structure, each cleat being securable to a roof frame member and having a clamp portion for engaging a part of the first edge formation. The cleats make it possible to hold down the roof sheets with freedom for expansion and contraction in the longitudinal direction of the sheet.
In another embodiment the first edqe flanks have a base portion by means of which that edge can be secured to a purlin and the like, for example, by nailing through the base portion. Preferably in this event, an upwardly extending lip is formed on the free end of the base portion so as to form a run-off trough with the base portion and the adjacent flank.
Where a cleat or bracket is provided to fasten the first edge formation to a purlin and the like, the cleat may comprise a base portion for securing the cleat to a purlin, an upwardly extending portion, and a clamp portion including a returned lip for engaging the cleat with a flange of a first edge formation of a roof sheet. Alternately, the cleat may comprise a base portion for securing the cleat to a purlin and a portion for engaging a suitable formation on a first edge rib such as one of a flange, a tab, an edge of a perforation or slot, and a step or land.
Preferably the lock flange slopes downwardly toward the valley of the roof sheet. With this slope when the lock flange is engaged in the groove spaces or plenums are formed to act as capilliary breaks. Preferably an edge lip portion is formed at the free end of the returned lip portion of the second edge rib formation. This edge lip portion is preferably constructed to interfere with the flank of the first edge rib formation of an adjacent sheet to form a space preventing water passing through a joint under the action of wind forces.
According to another object of the invention there is provided a method of installing roof sheeting as described above including the steps of laying a roof sheet on a roof frame, securing the first edge formation of the sheet to the roof frame, positioning a second sheet inclined with respect to the first sheet and engaging the second edge formation of the second roof sheet with the first edge formation of the already installed first roof sheet, twisting the second roof sheet into position, securing the first edge of the second sheet and proceeding optionally with further sheets as required to roof over an area.
According to yet another object of the invention there is provided a roof structure comprising roof sheeting as described above and laid on supporting structure using the method of the invention described above.
Preferred embodiments of the invention are described below with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an oblique view of a preferred embodiment of roof sheet of the invention,
FIG. 1a shows an oblique view of an alternative embodiment of roof sheet of the invention,
FIG. 2 shows an enlarged scale, an oblique view of the joint area of adjacent roof sheets connected to each other and to a roof frame,
FIG. 3 shows an oblique view of an embodiment of cleat for use with the invention, and
FIG. 4 shows an oblique view of a joint area of adjacent roof sheets in a roof construction according to another embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a roof sheet 10 which is suitable for "long span" roofing in which the spacing between adjacent supports (purlins) may be as much as 1.5 to 2 m. The sheet I0 has two ridges I4 with flanking valleys 12 and first and second edge formations 16 and I8. Between the ridges 14 and edge formations I6 and 18 are minor stiffening ribs 20. Typically the sheet is 330 mm wide having been formed from 600 mm wide strip.
The first edge formation 16 comprises juxtaposed flank portions 22 and 24 which slope upwardly towards each other and the flanks 22 and 24 are bent over to form a lock flange 26 extending inwardly from the first edge flanks 22 and 24. At the base of the flank 24 there is an upturned lip portion 30 forming a water run-off trough.
The second edge formation 18 comprises a flank 32, a bent over crest 34 extending outwardly from the flank 32, and a reentrant portion 36 the free end of which is turned over to form a lip 38. A groove is formed between the crest 34 and reentrant portion 36.
In FIG. 1a, the same reference numerals are used for corresponding parts to those of the sheet shown in FIG. 1, and the sheet is used in analogous manner.
FIG. 2 shows how the roofing sheet of FIG. 1 is installed on a roof frame including a purlin 40 which extends substantially transversely to the elongate ridges of the roof sheet. Roof cladding or sheets 60 and 70 are secured to roof frame purlin, 40, by a cleat 50, (which may be wider, as shown in FIG. 3), and a hook bolt 61. The edge formation of the sheet 60 includes an inclined flank 62, a lock flange 66, and a substantially vertical flank 64, with the lock flange being bent through 105° from the flank 64 to slope downwardly towards the valley of the sheet. An upward lip 68 on the free end of the flank 64 forms a water run-off gutter. The edge formation of the sheet 70 includes an inclined flank 72, a crest 74, a reentrant part 76 and a lip 78.
The crest 74 is substantially parallel to the va11eys of the sheets 60 and 70, at least when installed and the groove between the crest 74 and reenetrant part 76 receives the flange 66 with a resiliently stressed, snug fit. In practice the sheet 70 is installed by holding it inclined with the edge shown sloping downwardly, engaging the flange 66 in the groove, rotating the sheet 70 to be parallel to the sheet 60, and pulling the sheet 70 away from the sheet 60 so that the end of the lip 78 abuts the flank 62. This stresses the flanges 64 and 76 resiliently against each other and inhibits rattling of the roof cladding, a factor which experience has shown promotes withdrawal of fastening members such as nails. This construction also ensures that plenums A and B are formed in the joint which have a relatively large cross-section and which thus act as capilliary breaks, i.e. prevent the ingress of water through the joint under capilliary forces. The use of a cleat in the construction permits the roof sheets to expand or contract with changes in temperature without applying high forces to the fastening members. Cleat 59 shows an alternative which hooks onto the lip 68.
FIG. 3 shows a cleat 50 including a base part 52 formed with two holes 53 so that it may be secured to a roof frame, an upwardly extending body part 54, and a clamp part 56 having a returned lip 58 forming a groove which will receive the lock flange 26 of an edge rib.
FIG. 4 shows an embodiment not using cleats. In this figure an edge formation 116 of one roof sheet is secured to the purlin 40 by means of a nail 42 that passes through a base portion 28. Of course, in appropriate situations the nail 42 and wooden purlin 40 would be replaced by metal section purlins and hook bolts in a known manner. The edge formation 118 of an adjacent roof sheet is locked to the first mentioned roof sheet which has already been secured to the roof frame, by means of engaging the groove of the reentrant part 136 of the edge formation 118 with the lock flange 126 of the edge formation 116. as shown the lip 138 engages with the flank 112 of the edge formation 116 to form a plenum B which is sufficiently large to prevent capilliary action of water which during a storm may be blown up the flank 122. Also as shown the lock flange 126 is sloped downwardly; this creates a second plenum A and is also to prevent water leaking through the joint between adjacent roof sheets. A layer of Mastic (proprietary name) or similar bituminous sealant 46 is provided between the flange 126 and crest portion 134. Base portion 28 has an upturned lip 29 which turns it into a gutter.
When installing a roof using the roof sheets described above, the roof sheets are installed sequentially in a lateral direction. In other words a roof sheet adjacent one edge is first secured in position on the roof frame including securing the edge formation 16. An adjacent roof sheet is then engaged with the already secured edge formation 116 and, in turn, has its edge formation 116 secured to the roof frame. In this way the roof sheets can be rapidly installed using a minimum of securing elements, each of which is concealed and unexposed to the elements.
The invention is not limited to the precise constructional details shown in the drawings and described herein and modifications may be made without departing from the spirit or scope of the invention. For example a cleat may be provided to engage the lip 68 only of a roof sheet. In this event a suitable sealant may be provided to seal the flange 64 in the groove between members 74 and 76 of an adjacent sheet. Also a pop rivet may connect the crest and lock flanges, the rivet preferably not extending right through the overlapping flanges.
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Elongate, profiled roof cladding sheets with formations on opposed edges for interengaging adjacent sheets to facilitate installation and form watertight joints. The interengaged formations form spaces to act as capilliary breaks. Cleats secure one edge only of each sheet to a roof frame and allow thermal contraction and expansion.
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CROSS REFERENCE TO RELATED APPLICATION
The present application claims priority to Great Britain Application No. GB0724594.7, filed Dec. 18, 2007, which is incorporated herein by reference.
FIELD
The present invention relates to flexible pipe of the type suitable for transportation of production fluids. In particular, but not exclusively, the present invention relates to a method of dissipating heat from a region of flexible pipe covered by a bend stiffener.
BACKGROUND
Traditionally flexible pipe is utilized to transport production fluids, such as oil and/or gas and/or water, from one location to another. Flexible pipe is particularly useful in connecting a sub-sea location to a sea level location. Flexible pipe is generally formed as an assembly of a flexible pipe body and one or more end fittings. The pipe body is typically formed as a composite of layered materials that form a fluid and pressure-containing conduit. The pipe structure allows large deflections without causing bending stresses that impair the pipe's functionality over its lifetime. The pipe body is generally, but not necessarily, built up as a composite structure including metallic and polymer layers.
Flexible pipe may be utilized as a flowline over land and/or at a sub-sea location. Flexible pipe may also be used as a jumper or riser.
A flexible riser is a flexible pipe used to connect a compliant top side structural system with a sea bed location. A flexible riser system can be designed for many types of floating production structures and some well known riser configurations are free hanging catenary risers, lazy “S” risers, lazy “wave” risers, steep “wave” risers or the like. Such configurations are selectively suitable for use in shallow, medium, deep or ultra deep water depths.
During use it is appreciated that a flexible pipe is subjected to dynamic loading due to a number of possible conditions, for example due to motion of a vessel or platform on a surface of sea. Surge motion and heave motion of such surface bound vessel can particularly cause curvature changes in a riser configuration. Dynamic loading can also occur due to content density changes in the flexible pipe and current/tidal effects. Over bending can also occur when the flexible pipe is installed. It is generally advantageous to prevent shape changes or control such changes within predetermined limits when loading occurs.
One particular problem which is well known where flexible pipe is forced to bend is that the pipe may be damaged if the pipe is bent through too tight a radius. A recognized solution to this problem is the fitting of a bend stiffener at locations where the flexible pipe body is likely to be subjected to over flexing particularly at the interface between the pipe and an end termination or at the interface with a topside structure. The bend stiffener typically comprises a flexible molded polyurethane body having a generally tapered cross section. The thick end of the bend stiffener which is substantially rigid can be secured to fixed points. A degree of bending allowed for the flexible pipe steadily increases towards a tapered narrow end of the bend stiffener. During operation substantial heating can occur at the interface between the stiffener flexible casing and the flexible pipe body. Also the interface between the flexible pipe and bend stiffener tends to be subject to relatively high temperatures due to the lack of a means to limit the temperature (sea water cools a remainder of the flexible pipe) and the high temperatures of the transported production fluids. The heat can cause a deleterious effect to the working lifetime of the flexible pipe and bend stiffener arrangement.
A partial solution to this problem has been suggested in U.S. Pat. No. 6,009,907. Here a stiffener designed for fitting to a flexible conduit for use in a marine environment is disclosed. The stiffener comprises a flexible case located at least partially over the flexible pipe with structures in the bend stiffener being included to form channels which can be used to dissipate heat at the interface between the stiffener and flexible conduit.
However, the solution posed in the '907 patent requires the use of complex parts for a bend stiffener to be manufactured which can increase costs and installation times. Also, the channels in the bend stiffener proposed do not extend along the full length of the bend stiffener covering the flexible pipe. As a result areas under the stiffener are not irrigated and thus cooling water is not circulated across the full region of flexible pipe body surrounded by the bend stiffener. Heat is thus not effectively removed from areas of the interface which can have a negative effect on the lifespan of the pipeline.
It is an aim of embodiments the present technology to at least partly mitigate the above-mentioned problems.
It is an aim of embodiments of the present technology to provide a method for dissipating heat from a region of flexible pipe covered by a bend stiffener.
It is an aim of embodiments of the present technology to dissipate heat from a whole region of flexible pipe surrounded by a bend stiffener.
It is an aim of embodiments of the present technology to provide a method of dissipating heat from a region of flexible pipe body covered by a bend stiffener utilizing a methodology which is relatively cost effective to manufacture and simple to install.
According to a first aspect of the present technology there is provided a method of dissipating heat from a region of flexible pipe covered by a bend stiffener, comprising the steps of:
via at least one channel in an outer surface around a flexible pipe, providing a flow path for water to flow from a region of the flexible pipe covered by a bend stiffener to an uncovered region of the flexible pipe.
According to a second aspect of the present technology there is provided flexible pipe body for transporting production fluids, comprising:
a plurality of coaxially orientated layers; and
at least one channel in an outer surface around the flexible pipe, each channel providing a flow path for water to flow from a region of the flexible pipe body covered by a bend stiffener to an uncovered region.
According to a third aspect of the present technology, a method of transporting a fluid comprises:
providing a flexible pipe comprising a plurality of coaxially orientated layers, at least one channel in an outer surface around the flexible pipe, each channel providing a flow path for water to flow from a region of the flexible pipe body covered by a bend stiffener to an uncovered region, and at least one end fitting; and
transporting fluid through the flexible pipe.
Embodiments of the present technology provide a practical solution for dissipating heat from a region of flexible pipe covered by a bend stiffener. By forming channels in an outer surface of a flexible pipe or in an outer surface of a sleeve slid over the flexible pipe water can be made to flow along channels to constantly remove heat from the annulus region at the interface between the bend stiffener and flexible pipe body or outer sleeve.
The channels may be either machined or molded into the outer surface of the flexible pipe or the outer sleeve in a very convenient process to provide paths by which seawater can circulate and thus moderate the temperature. As a result time consuming and costly manufacture of a bend stiffener is obviated. Also installation times are reduced. Water flows through the channels by natural convection due to thermal gradients and/or the dynamic motion of the flexible pipe and bend stiffener which causes a pumping action. The interface is thus automatically and repeatedly cooled.
The foregoing and other features and advantages of the technology will become more apparent from the following detailed description, which proceeds with reference to the accompanying figures.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the present technology will now be described hereinafter, by way of example only, with reference to the accompanying drawings in which:
FIG. 1 illustrates flexible pipe body;
FIG. 2 illustrates a riser, flowline and jumper;
FIG. 3 illustrates a bend stiffener;
FIG. 4 illustrates channels running under a tapered end of a bend stiffener;
FIG. 5 illustrates channels in an outer sheath; and
FIG. 6 illustrates channels in a sleeve.
In the drawings like reference numerals refer to like parts.
DETAILED DESCRIPTION
Throughout this specification reference will be made to a flexible pipe. It will be understood that a flexible pipe is an assembly of a portion of pipe body and one or more end fittings in each of which an end of the pipe body is terminated. FIG. 1 illustrates how a pipe body 100 is formed in accordance with one embodiment from a composite of layered materials that form a pressure-containing conduit. Although a number of particular layers are illustrated in FIG. 1 , it is to be understood that the present invention is broadly applicable to composite pipe body structures including two or more layers. It is to be further noted that the layer thicknesses are shown for illustrative purposes only.
As illustrated in FIG. 1 , pipe body typically includes an innermost carcass layer 101 . The carcass provides an interlocked metallic construction that can be used as the innermost layer to prevent, totally or partially, collapse of an internal pressure sheath 102 due to pipe decompression, external pressure, tensile armour pressure and mechanical crushing loads. It will be appreciated that embodiments of the present invention are applicable to ‘smooth bore’ as well as such ‘rough bore’ applications.
The internal pressure sheath 102 acts as a fluid retaining layer and typically comprises a polymer layer that ensures internal-fluid integrity. It is to be understood that this layer may itself comprise a number of sub-layers. It will be appreciated that when the optional carcass layer is utilized the internal pressure sheath is often referred to as a barrier layer. In operation without such a carcass (so-called smooth-bore operation) the internal pressure sheath may be referred to as a liner.
A pressure armour layer 103 is a structural layer with a lay angle close to 90° that increases the resistance of the flexible pipe to internal and external pressure and mechanical crushing loads. The layer also structurally supports the internal-pressure sheath and typically consists of an interlocked metallic construction.
The flexible pipe body may also include one or more layers of tape 104 and a first tensile armour layer 105 and second tensile armour layer 106 . Each tensile armour layer is a structural layer with a lay angle typically between 20° and 55°. Each layer is used to sustain tensile loads and internal pressure. The tensile armour layers are typically counter-wound in pairs.
The flexible pipe body also typically includes an outer sheath 107 which comprises a polymer layer used to protect the pipe against penetration of seawater and other external environments, corrosion, abrasion and mechanical damage. One or more layers 108 of insulation may also be included.
Each flexible pipe comprises at least one portion, sometimes referred to as a segment or section of pipe body 100 together with an end fitting located at least one end of the flexible pipe. An end fitting provides a mechanical device which forms the transition between the flexible pipe body and a connector. The different pipe layers as shown, for example, in FIG. 1 are terminated in the end fitting in such a way as to transfer the load between the flexible pipe and the connector.
FIG. 2 illustrates a riser assembly 200 suitable for transporting production fluid such as oil and/or gas and/or water from a sub-sea location 201 to a floating facility 202 . For example, in FIG. 2 the sub-sea location 201 is a connection to a sub-sea flow line 203 . The flexible flow line comprises a flexible pipe, wholly or in part, resting on the sea floor or buried below the sea floor. The floating facility may be provided by a platform and/or buoy or, as illustrated in FIG. 2 , a ship. The riser 200 is provided as a flexible riser, that is to say a flexible pipe connecting the ship to the sea floor installation. Alternatively the flexible pipe can be used as a jumper 204 .
FIG. 3 illustrates a bend stiffener 300 surrounding a portion of flexible pipe body 100 . The bend stiffener 300 is a substantially tapered structure having a relatively thick cross section at a first end region 301 and a relatively narrow thickness at a tapered end region 302 . Typically the bend stiffener is manufactured from a polymeric material. The thick end of the bend stiffener is substantially rigid and can thus be secured to a solid structure such as a ship, platform or fitting. The thickness and material selected for the bend stiffener means that the bend stiffener provides a substantially rigid support for the flexible pipe. The tapered cross section means that the flexibility offered by the bend stiffener increases towards the narrow tapered end. The support offered by the bend stiffener at the tapered end enables flexing and bending of the flexible pipe.
Elongate channels 303 are formed in an outer surface of the outer sheath of the flexible pipe body. The channels extend along the whole or part of the region of the flexible pipe body surrounded by the bend stiffener. Whilst the channels illustrated in FIG. 3 are shown as being straight elongate channels, it will be appreciated that the channels may be helically formed winding around the flexible pipe body.
As illustrated in FIG. 3 , a gap g exists between the outer surface 304 of the flexible pipe body and an inner surface 305 of the bend stiffener. An annular region is thus formed between the bend stiffener and outer surface of the flexible pipe body. It will be appreciated that whilst in this example the channels 303 are shown formed in an outer surface of an outer sheath of the flexible pipe, it is optionally possible to provide a sleeve which could be slid over the outer sheath of the flexible and in which the channels were formed. In such an alternative embodiment of the present invention the inner dimensions of the bend stiffener and outer dimensions of the sleeve are predetermined so as to provide a suitable gap g between the bend stiffener and sleeve.
FIG. 4 illustrates an end 400 at the tapered end region 302 of the bend stiffener 300 . Elongate channels are formed circumferentially in a parallel spaced apart relationship around the outer surface of the flexible pipe body 100 so that the channels extend a distance D beyond the end 400 of the bend stiffener. Aptly channels extend a similar distance beyond the remaining end of the bend stiffener. The channels in the external sheath thus pass beyond the limits of the bend stiffener to create a flow path for sea water. The cooling water will circulate by either natural convection due to thermal gradients and/or the dynamic motion of the flexible pipe and bend stiffener in service. In fact the clearance between the bend stiffener and flexible pipe body provide a pumping action as the clearance opens and closes during service when flexing occurs.
FIGS. 5 and 6 illustrate how channels can be formed in an outer sheath 107 of the flexible pipe body or alternatively in an abrasion layer added as an outer sleeve. As illustrated in FIG. 5 the outer sheath 107 has a thickness L with channels having a depth x recessed into the outer surface. The depth and shape of the channels are determined prior to manufacture from analysis of the thermal performance of a design. The ends 500 of the channels may be square or aptly fluted to reduce the risk of fatigue fractures of the external polymer sheath.
FIG. 6 illustrates how channels can be recessed into an outer surface of a sleeve 600 slid over the outer sheath 107 of the flexible pipe body. The sleeve is slid over the flexible pipe body during installation to cover the whole or a part of the flexible pipe surrounded by a bend stiffener. The outer sleeve 600 has a thickness Z thick enough to allow channels having a desired depth x to be formed therein.
During use flexing of the flexible pipe within the bend stiffener can generate heating effects. However, generally heat will occur at an interface between flexible pipe body and a bend stiffener due to the relatively high temperatures of production fluids being transported by the flexible pipe. Where a bend stiffener is utilized this has, in the past, precluded cooling effects of seawater at the annular region forming an interface between the flexible pipe and bend stiffener. The present invention overcomes this problem by forming recessed channels which extend either in a straight manner along the outer surface or which wind helically in a spaced apart relationship around the outer surface. Aptly embodiments of the present invention are suitable for high temperature operations which require the use of a bend stiffener. In such high temperature operations the interface between the bend stiffener and flexible pipe can otherwise reach high temperatures which might exceed the operating limits of polymers employed. Embodiments of the present invention can prevent such high temperatures being reached by providing a means by which cooling can continuously and automatically be achieved.
The channels in the outer surface of the outer sheath or outer sleeve can be created in a highly convenient manner and thus embodiments of the present technology can be provided in a cost effective and timely fashion.
Throughout the description and claims of this specification, the words “comprise” and “contain” and variations of the words, for example “comprising” and “comprises”, means “including but not limited to”, and is not intended to (and does not) exclude other moieties, additives, components, integers or steps.
Throughout the description and claims of this specification, the singular encompasses the plural unless the context otherwise requires. In particular, where the indefinite article is used, the specification is to be understood as contemplating plurality as well as singularity, unless the context requires otherwise.
Features, integers, characteristics, compounds, chemical moieties or groups described in conjunction with a particular aspect, embodiment or example of the invention are to be understood to be applicable to any other aspect, embodiment or example described herein unless incompatible therewith.
In view of the many possible embodiments to which the principles of the disclosed invention may be applied, it should be recognized that the illustrated embodiments are only preferred examples of the invention and should not be taken as limiting the scope of the invention. Rather, the scope of the invention is defined by the following claims. I therefore claim as my invention all that comes within the scope and spirit of these claims.
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A method and apparatus are disclosed for dissipating heat from a region of flexible pipe covered by a bend stiffener. The method includes the steps of, via at least one channel in an outer surface around a flexible pipe, providing a flow path for water to flow from a region of the flexible pipe covered by a bend stiffener to an uncovered region of the flexible pipe.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to concrete form framing and positioning structures, and more particularly to a method and apparatus for securing concrete forms and suspending anchor bolts therein prior to pouring concrete.
2. Description of the Prior Art
Pouring wet concrete into temporary forms that determine its eventual shape is a process that occurs with substantial frequency in the course of virtually all construction. In each instance, form integrity against distortion by the weight of the wet concrete and the correct placement retention of various anchors that are to be captured in the hardened concrete are matters of constant concern as cured concrete is absolutely unforgiving of all oversights and mistakes. These concerns over the shape and placement dimensional fidelity are therefore a subject of repeated attention from various governmental and private supervisors and inspectors.
In the past various mechanisms have been devised which in one manner or another suspend anchoring bolts between the walls of a concrete form to be thereafter immersed to the desired depths and at the desired location once the concrete is poured into the form. Examples of such suspending structures can be found in the teachings of U.S. Pat. Nos. 7,103,984 to Kastberg; 5,060,436 to Delgado, Jr.; 4,736,554 to Tyler; and others. While suitable for the purposes intended each of the foregoing describes what is essentially a positioning template for an anchor bolt devoting only a limited focus to concerns over selection and form integrity and inspection convenience.
Those prior art references that appear to attend, at least in part, to form integrity concerns, as exemplified in U.S. Pat. Nos. 5,240,224 to Adams; 7,225,589 to Smith; and also the published continuation in part thereof US 2006/0016140 fail to address the inspection convenience of the anchor bolt selections and placements before the concrete is poured. In large building projects that predominate the industry now this inattention to inspection convenience tends to raise labor costs as employees and equipment stand by to allow the inspectors to finish their job.
Those in the art will appreciate that proper attention to the inspection process has its own inherent benefits. Anticipating the arrival of an inspector will direct the focus of the construction workers to the details that are a part of the inspection check list and these same details are, of course, also the significant aspects of the quality of their work product. Anchor bolt locating mechanisms that are not only useful for their primary function but also useful in enhancing selection and form integrity while assisting the inspection process will, by these combined features, assure proper attention to this detail. A mechanism that accommodates this combination of features is therefore extensively desired and it is one such device that is disclosed herein.
SUMMARY OF THE INVENTION
Accordingly, it is the general purpose and object of the present invention to provide an anchor bolt suspending structure that is also useful to brace the concrete form, that is sized and visually identifiable in coordinated association with several anchor bolt sizes, and that is easily affixed to and removed from the concrete form.
Other objects of the invention are to provide an anchor bolt suspending combination that protects the exposed threads thereof from inadvertent coating by wet cement.
Further objects of the invention are to provide a deployment method for anchor bolts in concrete forms that by the dimensional selection of components used therein determines the appropriate anchor bolt choice and the appropriate spacing thereof from the form edges.
Yet additional objects of the invention are to provide a process for mounting anchor bolts for immersed capture in poured concrete that includes visual indications of the bolt size and its deployed spacing relative the concrete form walls while also providing bracing therefor.
Briefly, these and other objects are accomplished within the present invention by providing a plurality of generally rectangular, flat, polymeric segments each of a longitudinal dimension that is equal or greater than the customary width of a stem wall, concrete footing or other structure formed by pouring wet concrete into a form. Preferably both sides of each segment are scribed with transverse grooves, or visibly indented transverse guide marks, spaced from each other by dimension increments conforming to the customary dimensions of the sill or base piece of a framed wall. In the United States, for example, these customary framing lumber dimensions are 2 by 4 inch, 2 by 6 inch, 2 by 8 or even by 10 inch nominal, selected by the load that is to be carried by the wall, the depth needed for adequate insulation thickness that may be demanded by the local climate, potential local earthquake shear loads, and so on.
These same loading concerns also demand that the sill or base piece forming the wall be firmly anchored to the footing or slab. For these reasons anchoring bolts, sometimes referred to a J-bolts, are suspended to extend into the form before the wet concrete is poured, the spacing therebetween, their depth of immersion into the concrete and the thickness of their shanks being again determined by the loads that are to be carried therein. Since it has been well appreciated in the construction industry that the load transfer from a framed wall into the footing or foundation effected by an anchor bolt can be greatly enhanced by appropriately sized square washers or sill plates, the lateral spacing from the exterior form wall is also predetermined in coordination with the sill width and the sill plate dimensions.
To facilitate this suspension of the severally sized anchor bolts each of the polymeric segments includes a plurality of equally sized circular holes or drillings spaced along the length thereof at spacing intervals that correspond to the sill plate dimensions associated with a one or another sill or base framing piece. Preferably these spaced holes on a segment are each of one common size selected to receive with a small clearance the threaded portion of a correspondingly sized anchor bolt, with the segments then color coded in accordance with the anchor bolt size that can be suspended therein. For example, a segment that is drilled to accept anchor bolts of only a 1 and ¼ inch shank can be color coded bright yellow, a 1 inch shank may be color coded orange, a ⅞ inch shank color coded green, and so on.
A set of polymeric, resiliently deformable split tube retainers are then positioned onto the threaded portions of the anchor bolt shanks that are inserted into the appropriate openings and project above the segment, grasping the bolt shank by resilient compression against the threads formed thereon. The resulting radial dimension increased by the thickness of the mounted retainer results in dimensional interference with the opening, thus effecting a suspending dimensional interference for the received bolt. Of course, once properly positioned the resilient retainers also provide an effective shield for the bolt threads against any splashing by the poured concrete.
To insure a fool-proof bolt selection and suspension process the wall thickness of the split tube retainers is about equal to the smallest increment in bolt shank diameters. By providing a radial clearance between the appropriate bolt shank and its corresponding hole that is about one half this retainer wall thickness a resulting dimensional hierarchy is obtained where the improper hole-to-bolt shank selection is immediately revealed since a bolt shank that is too large for the hole just can not be inserted and a bolt that is too small will simply fall out even with the retainer mounted thereon.
Those skilled in the art will appreciate that an appropriate bolt selection is effectively assured by this inventive dimensional hierarchy and once the appropriate color coding of the segments is determined to comply with the local building code the correct anchoring selection is immediately revealed. Similar considerations are also obtained by the spacing of the holes relative the transverse guide marks which can be labeled in coordinated groupings as corresponding to a 2 by 4, a 2 by 6 or 2 by 8, and so on, sill. These guide marks then set the proper transverse deployment of the segment on a form wall which then also properly spaces the suspended anchor bolt from the wall edge to accommodate the correctly sized sill plate.
In this manner the inspector needs to check only the closest one of the bolt suspensions and thereafter just a generally observe for the proper color coding and similar alignment along the form edge to assure him or herself of the proper complement and position before the concrete is poured. Prior to the inspector's check this same complement also effects a self-checking process for the construction workers by the coordinated dimensional hierarchy obtained in the inventive combination. Once the coordinated details are observed the worker can then safely affix the complement to the form by driving double-headed nails through corresponding nail holes formed in each segment.
It will be appreciated that these conveniences that the invention provides are not just useful in large construction projects, but are also useful to guide a novice along the rigorous path of proper construction practice.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective illustration of the inventive anchor bolt positioning assembly affixed to the form defining structures that confine poured concrete;
FIG. 2 is yet another perspective illustration, separated by parts, illustrating the cooperative parts and components of the inventive anchor bolt positioning assembly that when combined in accordance with the invention cooperate in a manner shown in FIG. 1 ;
FIG. 3 is a sectional view taken along line 3 - 3 of FIG. 1 , illustrating the inventive dimensional interrelationships that assure correct selection and positioning of anchor bolts;
FIG. 4 is a perspective illustration of an array of the inventive positioning assemblies deployed along one linear portion of a concrete form illustrating the inspection convenience thereof;
FIG. 5 is a plan view of exemplary sets of suspension segments and their associated anchor bolts in accordance with the present invention; and
FIG. 6 is a flow chart illustrating the sequence of steps effected in the course of use of the inventive anchor bolt positioning assembly.
DESCRIPTION OF THE PREFERRED EMBODIMENT
As shown in FIGS. 1-3 , the inventive anchor bolt positioning assembly, generally designated by the numeral 10 , comprises a generally rectangular, elongate segment 11 marked on both sides with transversely aligned grooves or guide marks 12 and including spaced along the length thereof a set of equally sized circular openings 14 . The threaded portion 15 t of the shank or shaft of an appropriately sized anchor bolt 15 , sometimes referred to as a J-bolt, is then inserted from below into a selected one of the openings 14 to extend through the plate or segment 11 a projecting portion of the shaft for capture in the interior 211 of a resilient, longitudinally split tube section or retainer 21 .
Preferably, the clearance between the opening 14 and the threaded portion 15 t of the bolt shaft is less than the wall thickness of retainer 21 and once the threaded shaft portion is resiliently captured therein a retaining engagement of the bolt in the segment 11 is effected by the resulting dimensional interference and the lower bolt end 16 . Thus once the proper opening 14 for receiving an appropriately sized bolt shank 15 t is selected an effective dimensional interlock is obtained by the engaged tube retainer 21 .
Those skilled in the art will appreciate that this dimensional interlock is effective only in those instances where the bolt shaft can pass through the opening and also where the combined diameter of the bolt shaft 15 t with the tube section 21 positioned thereon results in a dimensional interference with the periphery of opening 14 . Simply, smaller diameter bolts will fall out of the opening, even when captured by the split tube section, and the shank of the oversized bolt just won't fit at all into the any one of the equally sized openings 14 of the segment 11 . In this manner a coordinated interrelationship is inventively established between a particular set of segments 11 and a corresponding set of bolts 15 that is utilized to further advantage in accordance with the description following.
By particular reference to FIGS. 4 and 5 variously dimensioned segments 11 may be combined into a set shown as segments 11 - 1 , 11 - 2 , 11 - 3 and so on, with the correspondingly sized openings 14 - 1 , 14 - 2 and 14 - 3 formed to match the shank diameters of the anchor bolts 15 - 1 , 15 - 2 and 15 - 3 that is to be received therein. Thus, for example, segment 11 - 1 may be provided with openings 14 - 1 sized to receive an anchor bolt 15 - 1 having a 1 and ¼ inch shank diameter, i.e., openings 14 - 1 of about 1 and 5/16 inch diameter. All the openings 14 - 2 in segment 11 - 2 , in turn, may be of a 1 and 1/16 inch diameter to receive the 1 inch shank of anchor bolt 15 - 2 , the openings 14 - 3 in segment 11 - 3 may be sized at a 15/16 th inch diameter to receive the ⅞ inch diameter shanks of bolts 15 - 3 , and so on.
In this manner a complementary relationship is established by this dimensional selection process where only the appropriately sized anchor bolt is retained in a corresponding segment and by distinctly coloring segments 11 - 1 , 11 - 2 , 11 - 3 and the others, e.g., yellow, orange, green and so on, a visual indication is provided that immediately informs any inspector or supervisor which anchor bolts are suspended into the form. To refresh recollection and/or assist in the comprehension of this color coding a legend card 35 may be provided to the inspecting or managing personnel with the color coding explained thereon.
Those skilled in the construction business have long appreciated the convenience of standardized dimensional increments of available building materials. Simply, the needs of regional commerce require that only a limited variety of construction items be stored in inventory to avoid exorbitant storage costs and this variety differs from one part of the world to another. Recognizing these various dimensional conventions practiced throughout the world, no limitation is intended by the choice of the dimensional practices here in the United States in the description herein, the reference to such standardized dimensional increments being solely to effect a cogent explanation of the instant invention.
The current construction practice in the US utilizes construction lumber in standardized 2 inch dimensional increments with a 12 inch width considered as a practical limit in the width of sawed lumber. Conforming to these practices, each of the segments 11 - 1 , 11 - 2 , 11 - 3 , and so on, are preferably of a 16 inch length with the transverse guide marks 12 spaced in equal 2 inch increments on both sides thereof, each interval between the guide marks also including a pair of laterally spaced nail holes 17 through which double-headed nails 18 are passed to attach the segment in a spanning attachment joining the lateral boards B 1 and B 2 of the concrete form. Of course, the 2 inch spaced guide marks 12 are then useful in aligning this generally orthogonal attachment relative the form boards B 1 and B 2 that are also the conventional 2 inch lumber stock.
To conform with these same dimensional conventions the openings 14 are spaced from the ends of the segment 11 by increment groupings that each include the 2 inch overlap over the form boards B 1 or B 2 and also one half of the true dimension of standard construction lumber. Thus, for example, two of the openings 14 may be spaced from a first end 13 f of segment 11 by 4.75 and 6.75 inches corresponding to nominal base or sill lumber widths of 6 or 10 inches while a second set of openings 14 may be spaced from the second end 13 s by 3.75 and 5.75 inches corresponding to 4 and 8 inch sill lumber. Each of the openings thus spaced can then be appropriately marked by markings MM corresponding to these base plate dimensions.
In this manner all the variables of anchor bolt placement are fully imbedded into the structure itself of the locating piece, i.e., the respective segment 11 . When properly effected visual inspection is greatly simplified by simply examining the locating details of one anchor bolt in a row of anchor bolts and thereafter observing from a distance the relative shank alignments of the rest, the color code of each segment, and the other observables that indelibly ascertain correct structural connections before the concrete is poured. Moreover, by selecting polymeric material structures like Nylon for the respective segments 11 and the split tube retainers 21 any unwanted concrete that may harden thereon is easily removed thus allowing conservation benefits obtained by the repeated use thereof.
It will be appreciated by those skilled in the art that the foregoing complementing combination is particularly effective in assuring proper construction practices by the working personnel, as illustrated in the sequence shown in FIG. 6 . Before even reaching for these cooperating parts the worker, in step 101 , must first determine the correct size of the bolt 15 and the correct dimension of the sill or base. Once this is determined the worker, in step 102 , selects the properly spaced opening 14 and thus the lateral spacing of the bolt from the outer form board B 1 or B 2 and suspends the bolt therein by the retaining section 21 . In step 103 the worker then nails the segments across the form boards while observing dimensional similarities. Then right prior to pouring the wet concrete into the form the assembly is inspected in step 104 .
In this manner a simple, reliable and inexpensive array of cooperative elements assures compliance with the various building codes while also assuring an increased level of care to the several necessary details that must be observed before the unforgiving period during which the poured concrete sets up.
Obviously many modifications and variations of the instant invention can be effected without departing from the spirit of the teachings herein. It is therefore intended that the scope of the invention be determined solely by the claims appended hereto.
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A self-checking anchor bolt suspension assembly includes an array of suspension segments color coded in accordance with the size of the bolt suspending openings formed therein. The threaded shaft of the appropriate anchor bolt is inserted into the properly spaced opening and then grasped in the interior of a resilient split-tube retainer that then rests on the edges around the opening to suspend the bolt therefrom. The segments are then nailed to the concrete form and their correct color code assures the correct bolt selection.
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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 invention relates to a motor vehicle door for closing a door opening in the outside wall of a motor vehicle with at least one door panel which, in the closed position, assumes an essentially flush position with the outside wall, and by means of a pivoting linkage having at least one lever, can be swung into an open position in which the door opening is at least partially exposed, the door panel assuming a roughly parallel position relative to the outside wall of the vehicle.
2. Description of Related Art
Vehicle doors of the type to which the invention is directed are also called outward swinging doors in the trade, and are moved in an arc-shaped motion, by means of two pivoting levers, out of the door opening into an open position which is outside the outside vehicle wall and which is located roughly parallel to it. Because the seals located between the door leaf and door frame, in the initial phase of opening motion and the end phase of closing motion, are exposed to grinding and squeezing almost perpendicular to the outside wall of the vehicle, out of and into the door opening, they are subjected to increased wear. Furthermore, additional locking means, such as key collars located on the vehicle side, are required to keep the door leaf securely in the closed position in the door opening.
SUMMARY OF THE INVENTION
The primary object of the present invention is to devise an outward swinging door with an improved sealing and closing action.
This object is achieved by having the edge of the door panel which is forward during the closing motion, by means of a linkage mechanism, execute a movement by which this forward edge fits from the inside behind the associated edge (door frame) of the outside wall in the closed position or a seal located thereon, or a lock part (tie bar) located on the chassis in this area.
Because the edge of door panel which is forward in the closing motion fits behind the associated edge of the outside wall or a seal located on the wall, or alternatively, some lock part located on the chassis in this area, the edge is securely held in its position at high vehicle speeds despite corresponding suction forces which are caused by the incident wind and which is especially high on this front. Additional locking means as are conventional in the prior art can thus be completely omitted.
Preferably, the pivoting lever is driven in a conventional manner via a rotary shaft and the gear for producing the motion which causes the front edge to fit behind is driven at least indirectly, likewise, from the same rotary shaft. Thus, to actuate a vehicle door, a single drive which causes rotary motion of the rotary shaft, or a part connected to it, is sufficient.
The mechanism for generating the fitting-behind motion is preferably composed of three parts, specifically an auxiliary pivoting lever coupled near the front edge of the door panel, a connecting rod which is connected to the lever and which can pivot around an axis of rotation on the vehicle, and a coupler for joining the connecting rod to the rotary shaft and to a joint on the pivoting lever.
It is furthermore advantageous if the pivoting lever is connected, in the conventional manner, roughly to the middle of the door panel and has a right-angle bend of roughly 90 degrees. This arrangement and right angle bend enable the door opening to be almost completely exposed in the open position.
Especially safe locking in the closed position is achieved by the mechanism assuming a position near dead center in the closed position of the door leaf. This locking is easily achieved by a corresponding arrangement of the auxiliary swivelling lever and the fulcrum of the connecting rod.
The connecting rod is preferably made as a triangular lever; the coupler is connected to its shorter side and the auxiliary swivelling lever to its longer side. This design allows especially favorable kinematic conditions and good matching of required drive force and attainable closing force.
According to one advantageous embodiment of the invention, the pivoting lever has a shoulder which is eccentric relative to the rotary shaft, and on which the joint for connection of the coupling is located.
According to one alternative embodiment, it is provided that the coupler of the mechanism is guided with a guide pin in a crank that is located near the rotary shaft on the vehicle. This crank is composed, preferably, of a first slanted section, which the guide pin traverses during the locking and unlocking phase of the front edge of the door panel, and an arc-shaped segment which is located concentrically to the rotary shaft and which the guide pin transverses during the swinging motion of the door panel. In this alternative embodiment, the pivoting lever is driven, at least during the opening motion, via a cam connected to the rotary shaft.
These and further objects, features and advantages of the present invention will become apparent from the following description when taken in connection with the accompanying drawings which, for purposes of illustration only, show several embodiments in accordance with the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a horizontal cross-sectional view of a motor vehicle door in the closed position of the door panel;
FIG. 2 is a representation as shown in FIG. 1, but with the door panel completely opened;
FIG. 3 is a view corresponding to that of FIG. 1, but of a second embodiment; and
FIG. 4 is a view corresponding to that of FIG. 2, but of the FIG. 3 embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In outside vehicle wall 1, for example, a side wall of a bus, there is door opening 2 which can be selectively closed or at least partially exposed by means of a door panel 3.
In FIG. 1, the direction of forward vehicle travel is labeled X, as is conventional in motor vehicle construction, and the axis transverse to the direction of travel is formed by the Y-axis. Door opening 2 is bounded by a door frame which is formed on the rear edge by a sleeper-like door frame part 4A and on the front edge, in direction X, by a door frame part 4B. Door leaf 3 can be actuated by a linkage mechanism composed of the following linkage components. Force is introduced into door panel 3 for its actuation by pivoting lever 5 which, in a conventional manner, is drive-linked to rotary shaft 6. Rotary shaft 6, for its part, is caused to rotate by a known pneumatic or electric drive (not shown), optionally with the interposition of a belt linkage. Motion of pivoting lever 5 can alternatively also take place by a pneumatic cylinder or hydraulic cylinder located between the lever and the vehicle chassis. The common axis of rotation of pivoting lever 5 and rotary shaft 6 is labeled A in FIGS. 1 and 2. Pivoting lever 5 is made as a crank lever with a bend of slightly less than 90°, the shorter side proceeding from the bend being joined to rotary shaft 6 and the longer side proceeding from the bend being joined in joint C to bracket 34 located roughly in the center of door panel 3 on its inside. Joint C can, as shown in the embodiment, also be slightly offset forward of the center in the direction of forward travel.
Near rotary shaft 6 or rotary axis A, the pivoting lever 5 has an eccentric shoulder 5D to which a coupling link 7 is attached to pivot at a joint D. Coupling link 7, at its other end, is coupled to pivot at a joint E on a connecting rod 8 which, for its part, is supported to pivot around a fixed axis of rotation F. Connecting rod 8 is an acute-angled lever, having a shorter side 8E extending from axis of rotation F to joint E connecting them together, and a longer side 8G extending from the axis of rotation F to the pivot joint G, to which an end of an auxiliary pivoting lever 9 is attached.
The opposite end of the auxiliary pivoting lever 9, at joint B, is coupled to pivot on a bracket 33 located near front edge 31 of door panel 3. The front edge of the door panel 3 has a seal 32 which, in the Y direction toward the outside of the vehicle, has a recess with which seal 32, in the closed position shown in FIG. 1, fits behind door frame part 4B. On rear edge 35 of door panel 3 is a seal 36 which has an outside lip which adjoins the outside vehicle wall 1 in the closed position from outside against door frame part 4A. The inside of door panel 3 in the closed position adjoins a projecting lip of seal 11 which is located on door frame part 4A. In the closed position of the door, in the area of rear edge 35, doubled sealing of the door gap is achieved by the projecting sealing lips on seals 36 and 11.
In the area of front door frame part 4B seal 10 is adjoined by the projecting lip of seal 32 in the closed position. Thus, the door panel 3, in the closed position shown in FIG. 1, in the area of the front edge of the door, has a seal which fits behind it, and in the area of its rear edge, a double seal is formed by means of projecting sealing lips on the door edge and on the door frame.
FIG. 1 also shows a phantom outline 3' of the door panel in a partially opened position. Furthermore, the paths of motion of joints B and C and of front edge 31 of the door panel 3 are shown in dot-dash lines. These path curves show that joint C, as is usual in a conventional outward swinging door, describes a simple circular path, while front hinge point B, and accordingly, also front edge 31 of the door panel, have a curved path composed of three sections. Joint B and front edge 31 describe a small, inwardly directed arc near the closed position, after which the curved path runs essentially obliquely outwardly and then passes into an outwardly bowed arc-shaped section shortly before reaching the full open position.
These paths of motion are generated by the rotary shaft 6 first being caused to rotate clockwise by means of a drive (not shown) in an opening motion proceeding from the position shown FIG. 1. In doing so, on the one hand, joint C moves on the circular path shown, and on the other, the connecting rod 8 is caused to rotate counterclockwise by the connection of coupler 7 to hinge point D. As a result, the auxiliary pivoting lever 9 is first drawn slightly inward by the longer side 8G of connecting rod 8, by which the small inward arc-shaped path of motion is produced, and then, it is guided outwardly along the obliquely running path segment of joint B. As noted above, an intermediate stage 3' of the door panel opening motion is shown in FIG. 1.
When the door panel reaches the completely opened position 3" shown in FIG. 2, it is almost parallel to the outside wall 1 of the vehicle. In doing so, the near right angle bend of the pivoting lever 5 extends around the door frame part 4A at the rear edge of the door opening 2, by which joint C reaches its rearmost position. In addition, hinge point B near the front edge of the door panel has reached its rearmost position in which the auxiliary pivoting lever 9 and longer side 8G of connecting rod 8 assume an almost fully extended position which also ensures stable support in the open position of the door panel.
This stable support also arises in the closed position of door panel 3 according FIG. 1. This is achieved by the axis G of the auxiliary pivoting lever 9 being located with respect to the axis of rotation F of the connecting rod 8 such that it is located behind (inward of) axis F. Door panel 3 is thus pressed in the area of its front edge 31, which is also called the main closing edge, from the inside against door frame part 4B and seal 10 located there. Suction caused by the incident wind on the outside of the vehicle does not lead, as in conventional outward swinging doors, to movement of the door panel to the outside, but causes the door panel to be drawn more strongly against door frame part 4B. Especially good sealing and noise attenuation, especially at high speeds, is thereby guaranteed.
In a second embodiment shown in FIGS. 3 & 4, all parts which are the same as in the first embodiment are labeled with the same reference numbers. The two differences shown in the second embodiment relate, on the one hand, to the force introduced into the coupler 7 in the area of rotary shaft 6, and on the other hand, to locking in the area of front edge 31 of door panel 3.
In this regard, in the area of front edge 31 of the door panel, there is a tie bolt 12 which is located on the chassis and which interacts with the bracket 33 provided on the inside of door panel 3 in the area of the front edge, and notched bar tongue 13 on the bracket 33. This arrangement in which bar tongue 13 engages with the tie bolt 12 can also be provided in the first embodiment according to FIGS. 1 & 2. This engagement is especially feasible when door seal 32, in the area of front edge 31, is made relatively soft.
In the area of rotary shaft 6, the second embodiment has the following differences. Near rotary shaft 6, there is a crank 17 which is located on the chassis and which has a sloped path segment 17A which runs roughly obliquely to inwardly to the rear, and an arc-shaped section 17B which is adjacent thereto to the rear and which is located concentrically with respect to the axis of rotation A. Guide pin 16, which additionally joins pivoting lever 5 to coupler 7, fits into this crank 17. A cam 14, which is finger-shaped and which is joined via pin 15 to pivoting lever 5, is joined to rotary shaft 6. Pivoting lever S also has a stop 18 for cam 14 which points inwardly to the rear in the closed position.
The motion sequence in the second embodiment begins, proceeding from the closed position of FIG. 3, with the cam 14 being caused to rotate clockwise by rotary shaft 6. By the connection via pin 15, when cam 14 turns, pivoting lever 5 is drawn to the rear along oblique path segment 17A of the crank. As soon as cam 14, during its rotary motion, reaches stop 18 on pivoting lever 5, the guide pin 16, at the same time, enters arc-shaped segment 17B of crank 17 from oblique segment 17A. Starting here, the swinging motions of pivoting lever 5 begins, joint C, in turn, describing a circular arc path. The motion sequence of other gear elements 7, 8, 9 and front edge 31 of door panel 3 is thus similar to that of the first embodiment.
In the completely open position, the guide pin 16 has reached the rear end of the arc-shaped segment 17B of crank 17. During the reverse closing motion of door panel 3, the stop 18 is not drive-linked to cam 14. By coupling of the cam 14 to the pivoting lever 5 via pin 15, and the concentric arrangement of arc-shaped segment 17B, the pivoting lever 5 is forced to follow the counterclockwise closing motion of cam 14. In addition, as the closing motion continues, guide pin 16 is guided in oblique segment 17A of the crank 17 by the coupling of cam 14 to the pivoting lever 5 via pin 15.
By means of the invention, completely new kinematics for an outwardly swinging door is made available in which it is especially reliably held in the closed position on the main closing edge as a result of the forward edge's fitting behind it. The drive is comparatively simple and durable in construction. It is completely unnecessary to provide and continually readjust additional key collars, as in conventional outwardly swinging doors.
While only two embodiments have been shown and described, numerous changes and modifications thereto will be apparent to those skilled in the art. Therefore, this invention is intended to include all such changes and modifications as are encompassed by the scope of the appended claims.
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A door arrangement for opening and closing a motor vehicle door in a door opening (2) in an outside vehicle wall (1), having at least one door panel (3) which, in the closed position, assumes a position that is essentially flush position with the outside wall (1) and which can be swung into an open position which at least partially exposes the door opening, and in which the door panel (3), outside of the vehicle, assumes a roughly parallel position to outside wall (1). The door panel (3) is connected to the vehicle to swing via at least one pivoting lever (5). To enhance the sealing action in the closed position, it is provided that a forward edge (31) of the door panel (3), by way of a linkage mechanism (7, 8, 9) executes a movement by which this edge (31) fits from inside behind the associated edge (door frame 4B) of outside wall (1) or a seal (10) located thereon, in the closed position.
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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 kit or cluster package of components suitable for use in unclogging sink drains and disposal units, preventing clogs in the first place and positioning an air freshener at the drain entrance to mask or attack odors emanating from the drain.
2. Description of the Prior Art
Clearing clogged or slow drains resulting from food and/or other particle build-up remains a time consuming and cumbersome task, notwithstanding the advent of modern conveniences. Even with the widespread availability of various plunger devices and chemical solvents that are designed to clear drains, clearing drains remains a time-consuming task and a frustrating experience.
Food particles and other foreign matter may often be released into the drain during the process of cleaning dishes and other objects in a sink. These food particles and other foreign matter may accumulate in the drains and result in a partially or completely clogged drain. Commonly, the kitchen sink is provided with a manually operable hose spray. Such sprays are normally stowed adjacent to the faucet and are connected to the faucet water supply by an extendable flexible hose. The hand spray may be manipulated to deliver a spray to the clogged drain. However, not all food particles and/or foreign matter can be cleared from the drain by the hand spray and resort must be made to other devices for removing more resistant deposits, blockages, and the like.
Preventive measures will reduce the occurrence of clogged drains. Strainers of various forms are common devices placed in drains to prevent debris from ever entering a drain.
Another prior art approach is to place an air freshener in a drain or in a holder positioned in the drain. An example is found in U.S. Pat. No. 6,866,440 in which a consumable air freshener is encapsulated into a garbage disposal drain stopper. U.S. Pat. No. 7,032,253 discloses a screw on plug that engages a straining basket and mentions the possibility of incorporating an antibacterial and/or deodorizer additive into the basket or plug. None of this prior art, however, considers the possibility of a kit that would package or cluster an unclogging device with a strainer, a stopper for a sink drain and an air freshener device that could be employed therewith.
SUMMARY OF THE INVENTION
A kit for treating a sink includes an outer unclogging member, a strainer, and a stopper. The outer member includes a central projection that can enagage a spray nozzle for clearing a clogged drain. The strainer can be packaged within the outer unclogging member. The strainer cap can be removed from the outer member. The strainer has a perforated base and a hollow central column. The central projection on the unclogging device is received within the hollow central column when the strainer is packaged within the outer member. A stopper is packaged on top of the strainer. A basic strainer used only to prevent debris from entering a sink drain can be a molded one-piece member. Another strainer including a chemical cartridge, such as an air freshener, can employ a strainer cap screwed or otherwise attached to a hollow central column to house an air freshening member.
Alternatively the invention comprises a drain treatment cluster. Clustered components include a plurality of stackable components separately useable to maintain a sink drain in a flowing condition. The cluster includes a cylindrical outer member, a cylindrical strainer, and a stopper. The cylindrical outer member being is used to unclog a stopped drain and includes a central projection having a tapered inner surface extending upward from surrounding solid base. The tapered inner surface engages a spray nozzle to concentrate injection of water from the spray nozzle into a stopped drain. The cylindrical has an annular base with a hollow central column extending upwardly therefrom. A top section of the hollow central column and the annular base each have a plurality of perforations for straining debris before it enters a sink drain when the cylindrical strainer is positioned in or over a sink drain. The stopper can be placed over a drain to cover and seal the drain. Different strainers are employed with or without and air freshener.
Either type of strainer includes a perforated base, a hollow central column and an outer wall. The hollow central column extends upwardly from the strainer base. The hollow central column is enclosed by a perforated top section, which can be an integral part or can comprise a strainer cap. A wall extends upwardly from a peripheral edge of the perforated base. The wall is spaced radially outward from the hollow central column to form a toroidal space between the wall and the hollow central column. The top section of the hollow central column is elevated relative to the perforated base. These strainers include a peripheral lip extending radially outward from a top edge of the wall. The strainer is insertable into a drain having a diameter at least equal to the outer diameter of the wall but less than the outer diameter of the peripheral lip. The perforated base and the perforated top sections of the hollow central column permit passage of fluids, but obstruct passage of solid objects that are larger than perforations in the hollow central section and in the base.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded view showing the main components of a basic sink drain treatment kit.
FIG. 2 is an exploded view showing the main components of an alternative sink drain treatment kit that includesan air freshener.
FIGS. 3A-3C show an outer unclogging device suitable for use in either of the sink drain treatment kits shown in FIGS. 1 and 2 . FIG. 3A is a top view of the outer unclogging device. FIG. 3B is a side view, and FIG. 3C is a section view taken along section lines 3 C- 3 C shown in FIG. 3A .
FIGS. 4A-4C are views showing the details of a basic strainer of the type employed in the embodiment of FIG. 1 . FIG. 4A is a top view and FIG. 4B is a side view. FIG. 4C is a section view taken along section lines 4 C- 4 C in FIG. 4A .
FIGS. 5A-5D 5 D are views of a stopper of the type suitable for use with the kits shown in FIGS. 1 and 2 . FIG. 5A is a top view, and FIG. 5B is a side view. FIG. 5C is a section view taken sections lines 5 C- 5 C in FIG. 5A . FIG. 5D shows the manner in which an emblem or logo can be inserted into the stopper.
FIGS. 6A-6C are views of a gasket that can be used on the outer wall of the outer unclogging apparatus so that a wider variation of sink drains can be accommodated. FIG. 6A is a top view. FIG. 6B is a side view. FIG. 6C is a sectional view taken along section lines 6 C- 6 C in FIG. 6A .
FIGS. 7A-7D are views of a strainer that would be used in the kit shown in FIG. 2 and would incorporate an air freshener. FIG. 7A shows the top view of the strainer. FIG. 7B is an exploded side view of the strainer and an air freshening cartridge and strainer cap exploded from the main body of the strainer cap. FIG. 7C is a section view from the perspective of section lines 7 C- 7 C in FIG. 7A , but also showing the air freshener cartridge and the strainer cap exploded from the strainer base. FIG. 7D is an exploded three dimensional view showing the components of the air freshening strainer.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1 and 2 show two alternate versions of a kit 2 or cluster of components that can be employed to help maintain a sink drain, and especially a kitchen sink drain in a clean free flowing state. Each version of the kit 2 includes a plurality of stackable components that can be packaged or stored in a relatively small space. Combination of these components in a relatively small package is significant, because shelf space or space on a pegboard in a retail facility is always limited, especially space in higher traffic areas. Storage in a small space with the components clustered together is also significant both because space in kitchen or other place containing a sink is also generally at a premium and the ability to stack the components in a cluster makes it easier to find the individual components when they are needed.
FIG. 1 shows a version of kit 2 including an unclogging device 10 , a strainer 30 and a stopper 50 , which also functions as a drain cover or seal. The unclogging device 10 forms the outer member of a stack of these components. Both the unclogging device 10 and the strainer 30 have outer walls 16 and 38 respectively in the form of right circular cylinders of a diameter on the same order of magnitude as the inner diameter of a standard sink drain, so that both can normally fit within the sink drain. The strainer 30 can be stacked within the cylindrical outer wall 16 of the unclogging device 10 because the strainer outer wall 38 has an outer diameter that is less than the inner diameter of the outer device wall 16 . An outer peripheral lip 40 on the strainer 30 will fit over the outer peripheral lip 18 on the outer unclogging device 10 when the strainer 30 is stacked or packaged within the outer member 10 . Peripheral lips 18 and 40 will prevent the unclogging device 10 and the strainer 30 from falling into an oversized drain. Lips 18 and 40 also facilitate sealing off the drain opening or the disposal to create a closed loop system and prevent water from splashing out. The unclogging device 10 includes a generally cylindrical central projection 12 , which serves as a support for a standard spray nozzle when the device is used to unclog a sink drain. A central column 32 on the strainer, also having a generally cylindrical configuration, is dimensioned to fit over the central projection 12 when the strainer 30 is stacked on top of or nested with the outer unclogging device 10 .
A generally round stopper 50 forms the top part of the stack of components forming the kit shown in FIG. 1 . This stopper 50 can be used to cover a sink drain. Stopper 50 is formed of a more flexible or rubbery material than the unclogging device 10 or the strainer 30 so that the stopper will form a seal when placed over a sink drain.
The fourth component of kit 2 as shown in FIG. 1 is a gasket 60 that fits around the exterior of outer unclogging member 10 . This gasket 60 allows the unclogging member 10 to be used with sink drains having different inner diameters.
FIG. 2 shows a second version of a kit 2 , which has all of the same components as the kit shown in FIG. 1 , but also includes an air freshening cartridge 100 . The addition of a freshening cartridge 100 has, however, resulted in configuration changes to the basic strainer. Strainer 70 includes means for storing the freshening cartridge 100 , and has replaced strainer 30 in the embodiment of FIG. 2 . In strainer 30 , the central column 32 includes a top section 36 that is integral with the column cylindrical wall 34 . In strainer 70 , the central column 72 comprises a strainer cap 92 , which can be attached to and detached from cylindrical column wall 74 . The freshening cartridge can be inserted into the space within column wall 74 and strainer cap 92 can then be attached entrapping the freshening cartridge 100 . Perforations 94 in the strainer cap 92 allow water to flow over and/or through the freshening cartridge when the strainer 70 is positioned within a sink drain. The unclogging device 10 , stopper 50 and gasket 60 in the kit embodiment of FIG. 2 can be identical to the corresponding components in the embodiment of FIG. 1 .
The one-piece molded outer member 10 is shown in FIGS. 3A-3C . This outer member is a drain unclogging device, and a drain unclogging device is discussed in U.S. Pat. No. 6,934,975, which is incorporated herein by reference. The one piece molded device 10 differs from that shown in U.S. Pat. No. 6,934,975, only as specifically described herein. For example, the groove 24 of the present device as shown in FIGS. 3A-3C is not present in the prior art device shown in U.S. Pat. No. 6,934,975. Outer member 10 can be used with a hand held spray nozzle as shown in the above identified patent. Outer member 10 has a generally circular base 20 with an annular hub or cylindrical projection 12 extending upwardly from the base upper surface. The base 20 can be large enough to fit over conventional kitchen sink drains or it can be sized to fit into a standard drain opening. A groove 24 is provided on the outside of cylindrical outer wall 16 so that a gasket 60 can be mounted on the exterior of the outer member 10 . This gasket 60 will allow use of the unclogging member 10 for drains having different diameters. The upwardly projection annular hub 12 has an inner conical or tapered surface 14 , which diverges in the upward direction, so that its upper open end has a larger diameter than its opening in the base 20 . The cylindrical outer wall 16 of the outer or unclogging member 10 is spaced radially outwardly from the cylindrical projection or hub 12 and separated therefrom by a toroidal gap 22 . An annular lip 18 is formed on the top of the outer wall 16 . The height of the annular hub 12 can be greater than the height of the cylindrical outer wall 16 , although that is not necessary. The outer wall 16 and the lip 18 can be sized so that unclogging member 10 can be inserted into a standard drain with the lip 18 preventing the adapter member 10 from falling into the drain. The lip 18 would also close the drain in that configuration. Alternatively the flat adapter base 20 can be positioned over the drain and held down to close the drain. The conical or tapered surface 14 is sized so that the head of a standard spray nozzle can be inserted into the top of the centrally projecting hub 12 , but the opening at the top of the projecting hub is small enough so that the spray nozzle cannot be inserted completely through the central fluid passage formed by the interior of the projection 12 . The conical surface 14 will also provide a reaction surface against which the spray nozzle can be downwardly pressed. This downward force will also hold the unclogging device 10 securely in or over the drain so that a stream of water can be sprayed into the drain to dislodge tightly impacted material in the drain. The outer unclogging member 10 will also serve to prevent the water spray or stream from backing up into the sink to enhance the effect of the stream injected into the drain. The stopper 50 can also be used in combination with the unclogger. Stopper 550 can be used to close a second opening in a conventional sink to create a closed loop system.
FIGS. 4A-4C show details of the strainer 30 employed in the kit embodiment of FIG. 1 . Strainer 30 is normally fabricated as a one-piece injection molded member, and it can be fabricated from a straight pull mold to lower manufacturing cost. However, the strainer 30 , and other components, can be fabricated using methods other than injection molding. Strainer 30 comprises a cylindrical outer wall 34 spaced from a central hollow column 32 . The column wall 32 and the outer wall 34 are concentric and are separated by a toroidal gap 42 . Both the column wall 32 and the outer wall 34 extend upwardly from the perforated base 44 of the strainer 30 . The perforated column top 36 is integral with the column wall 32 . The column top section 36 is therefore in the shape of a circle or disk and an plurality of perforations 48 extend through the column top 36 . The base 44 also includes a series of perforations 46 . Perforations 46 and 48 are sized to permit relatively free flow of water and so that food and other debris that might clog or contribute to clogging a drain cannot enter a drain when the strainer 30 is in place. The annular peripheral lip 40 extending outward from and integral with the top of outer wall 38 is dimensioned to prevent the strainer 40 from falling into an oversized drain. Lip 40 also seals off the drain opening or the disposal to create a closed loop system and prevents water from splashing out. As shown in FIG. 4C , the peripheral lip 40 is elevated slightly above the column top section 36 .
The strainer 30 is normally not intended to be used at the same time as the unclogging device 10 . The strainer 30 can of course be used with the unclogging device 10 , but the flow of water would be restricted to water passing thought perforations 48 in the top section 36 and through the hollow central projection 12 on the unclogging device 10 . The strainer 30 is, however, stackable on top of the unclogging device 10 . Thus the inner diameter of the column 32 will be greater than the outer diameter of the projecting hub 12 so that the strainer 30 can be stacked on top of or nested with the unclogging device 10 when packaged or stored.
Details of the stopper 50 are shown in FIGS. 5A-5C . The main function of stopper 50 is to seal a sink drain. Stopper 50 is a molded member and is fabricated from a material that is more flexible and rubbery than the strainer 30 or the unclogging device 10 , so that the stopper 50 will seal a drain over which it is placed. Stopper 50 includes an outer section 52 which will extend beyond a drain opening over which the stopper may be placed. A rim or ridge 54 on the bottom surface of the stopper is dimensioned to fit within a drain, and its radiused contour will aid in sealing the drain. This rim 54 will also fit within the top of the annular or toroidal gap 42 of the strainer when the stopper is packaged on top of the strainer 30 or the strainer 70 . The stopper 50 is normally used alone, but it can be used with strainers 30 and 70 when positioned within a sink drain. When packaged as part of a kit the stopper 50 will form the top of the stack of components. Since the stopper 50 will be the most visible packaged component, a recess 56 in formed on the top surface of the stopper 50 . As shown in FIG. 5D , a A disk 57 containing a emblem or logo can be inserted into this recess 56 so that it will be visible to the purchaser. The logo or emblem need not be a permanent part of the stopper 50 so that interchangeable logos or emblems can be mounted on the stopper 50 by different retailers or sellers. Of course the stopper can be manufactured so as to include a permanent emblem.
Although the kit 2 and the unclogging device is intended to be used with standard sink sizes, there is some variation in the diameter of sink drains. Therefore a gasket 60 , shown in detail in FIGS. 6A-6C can be mounted within groove 24 on the outer wall 16 of unclogging device 10 . Gasket 60 is fabricated from a flexible or rubbery material and includes a cylindrical gasket wall 62 with a reversely formed lip 64 extending from one edge thereof. This lip 64 permits insertion of the unclogging device into drain openings having a variation in diameters normally found in commercial available sink drains.
As previously mentioned, the kit 2 shown in FIG. 1 can be converted into a kit including an air freshener by replacing strainer 30 with strainer 70 and with the addition of an air freshening cartridge 100 . This subassembly in shown in more detail in FIGS. 7A-7D . The primary difference between the strainer 70 and the strainer 30 is the replacement of the one-piece hollow central column 32 in strainer 30 with a two piece hollow central column 72 in strainer 70 . A strainer cap 92 can be attached to and detached from the cylindrical wall 74 . In this embodiment, the strainer cap 92 includes inner threads 96 , which will engage outer threads 98 on wall 74 . In addition to the cylindrical wall 74 , strainer 70 also has a tapered or conical inner wall 90 , which extends downwardly from the top edge of cylindrical wall 74 . As shown in FIG. 7C , bottom edges of this tapered wall 90 are joined by a web 91 that includes perforations similar to perforations 86 in the base 84 . Strainer cap 92 also includes a series of perforations 94 on its top surface. A small compartment is formed by tapered inner wall 90 the bottom web 91 and the strainer cap 92 . Into this cap an air freshener cartridge 100 can be introduced. Air freshener cartridge 100 has a generally frusta-conical configuration with a flat upper surface 102 and slanting sides. The air freshener cartridge can be fabricated in a number of different ways and in a number o different shapes. First a liquid or granular active air freshener can be contained within a package have the shape of the cartridge 100 shown in FIG. 7D . Alternatively, a cartridge could be in the form of a cake of material formed into a shape that would be received within tapered walls 90 . Alternatively, the bottom web 91 could be solid and a granular air freshener could be introduced into the interior cavity and the strainer cap 92 could be attached to the hollow column 72 . Perforations 94 would then allow the fragrance to permeate to the surrounding area. The term freshener cartridge, should be understood to refer to each of these alternatives, and there are a number of alternative ways to introduce an air freshening material into strainer 70 . other It would even be possible to introduce a liquid, provided perforations 94 would be small enough to prevent undue spillage. Importantly, however, all of these alternatives would permit the air freshening cartridge or its remnants to be removed when spent, and a new cartridge or material could be added when needed.
It should be understood that other alternative embodiments would be apparent to one of ordinary skill in the art. For instance, the air freshener could be replaced by a cleaner or an antibacterial agent. Thus chemical cartridges other than air freshening cartridges could be employed. The embodiments depicted herein are therefore only representative of various equivalent devices that would be readily apparent to one of ordinary skill in the art.
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A kit for use in treating a sink drain so that drain remains both open and clean includes an unclogging device and a strainer, which though packagable or stackable together would normally be used separately. The unclogging device can be used to concentrate the spray from a nozzle to assist in unclogging a drain. The strainer would normally reside in a sink drain to prevent debris from clogging or restricting the drain. One version of the strainer provides space for an air freshener that can be replaced. These kits also include a sealing stopper and a gasket.
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BACKGROUND OF THE INVENTION
Major problems exist in producing oil from heavy oil reservoirs due to the high viscosity of the oil. Because of this high viscosity, a high pressure gradient builds up around the well bore, often utilizing almost two-thirds of the reservoir pressure in the immediate vicinity of the well bore. Furthermore, as the heavy oils progress inwardly to the well bore, gas in solution evolves more rapidly into the well bore. Since gas dissolved in oil reduces its viscosity, this further increases the viscosity of the oil in the immediate vicinity of the well bore. Such viscosity effects, especially near the well bore, impede production; the resulting waste of reservoir pressure can reduce the overall primary recovery from such reservoirs.
Similarly, in light oil deposits, dissolved paraffin in the oil tends to accumulate around the well bore, particularly in electrode screens and perforations to admit oil into the well and in the oil deposit within a few feet of the well bore. This precipitation effect is also caused by the evolution of gases and volatiles as the oil progresses into the vicinity of the well bore, thereby decreasing the solubility of paraffins and causing them to precipitate. Further, the evolution of gases causes an auto-refrigeration effect which reduces the temperature, thereby decreasing solubility of the paraffins. Similar to paraffin, other condensable constituents may also plug up, coagulate or precipitate near the well bore. These constituents may include gas hydrates, asphaltenes and sulfur. In certain gas wells, liquid distillates can accumulate in the immediate vicinity of the well bore, which also reduces the relative permeability and causes a similar impediment to flow. In such cases, accumulations near the well bore reduce the production rate and reduce the ultimate primary recovery.
Electrical resistance heating has been employed to heat the reservoir in the immediate vicinity of a well bore. Basic systems are described in Bridges U.S. Pat. No. 4,524,827 and in Bridges et al. U.S. Pat. No. 4,821,798. Tests employing systems similar to those described in the aforementioned patents have demonstrated flow increases in the range of 200% to 400%.
Various proposals over the years have been made to use electrical energy for oil well heating, in a power frequency band (e.g. DC to 60 Hz AC), in the short wave band (100 kHz to 100 MHz), or in the microwave band (900 MHz to 10 GHz). Various down-hole electrical heat applicators have been suggested; these may be classified as monopoles, dipoles, or antenna arrays. A monopole is defined as a vertical electrode whose length is somewhat smaller than the depth of the deposit; the return electrode, usually of large diameter, is often located at a distance remote from the deposit. For a dipole, two vertical, closely spaced electrodes are used and the combined extent is smaller than the depth of the deposit. These dipole electrodes are excited with a voltage applied to one relative to the other.
In the past, radio-frequency (RF) dipoles have been used to heat earth formations. These RF dipoles were based on designs used for the radiation or reception of electromagnetic energy in the radio frequency or microwave spectrum. In an oil well an RF dipole is usually in the form of a pair of long, axially oriented, cylindrical conductors. The spacing between these conductors is generally quite close at the point where the voltage is applied to excite such antennas. The use of such vertical dipoles has been described, as in Bridges et al. U.S. Pat. No. 4,524,827, to heat portions of the earth formations above the vaporization point of water by dielectric absorption of short-wave band energy. However, such arrangements have been found to be costly and inefficient in heating moist earth formations, such as heavy oil deposits, because of the cost and inefficiency of the associated short-wavelength generators and because such short wavelengths do not penetrate moist deposits as well as the long wavelengths associated with power-frequency resistive heating systems. Further, if an RF dipole is used to heat moist deposits by resistance heating the heating pattern is inefficient because the close spacing of the cylindrical conductors at the feed point creates intense electric fields. Such high field intensities create hot spots that waste energy and that cause breakdown of the electrical insulation.
Where heating above the vaporization point of water is not needed, use of frequencies significantly above the power frequency band is not advisable. Most typical deposits are moist and rather highly conductive; high conductivity increases losses in the deposits and restricts the depth of penetration for frequencies significantly above the power frequency band. Furthermore, use of frequencies above the power frequency band may require the use of expensive radio frequency power sources and coaxial cable or waveguide power delivery systems.
Bridges et al. U.S. Pat. No. 5,070,533 describes a power delivery system which utilizes an armored cable to deliver AC power (2-60 Hz) from the surface to an exposed vertical monopole electrode. In this case, an armored cable of the kind commonly used to supply three-phase power to down-hole pump motors is employed. However, the three phase conductors are conductively tied together and thereby form, in effect, a single conductor. From an above-ground source, the power passes through the wellhead and down this cable to energize an electrode embedded in the pay zone of the deposit. The current then returns to the well casing and flows on the inside surface of the casing back to the generator.
A monopole design, such as disclosed in U.S. Pat. No. 5,070,533, represents the state of the art to install electrical resistance heating in vertical wells. However, the use of electrical heating arrangements for vertical wells introduces major difficulties in horizontal well completions. These difficulties must be addressed to make electrically heated horizontal wells practical and economical.
Drilling technology has advanced to a point where horizontal completions are commonplace. In many cases, the length of a horizontal producing zone can be over several hundred meters. Horizontal completions often result in highly economic oil wells. In some oil fields, however, the results from horizontal completions have sometimes been disappointing. This may occur for some deposits, such as certain heavy oil reservoirs where a near-wellbore, thermally-responsive, flow impediment or skin-effect forms. In such cases, the use of electrical, near-wellbore heating offers the opportunity to suppress the skin effects. This can make otherwise marginal heavy-oil or paraffin-prone oil fields highly profitable. To use electrical heating methods, existing vertical well electrical heating technology must be redesigned and tailored for horizontal completions.
Long horizontal well completions, or even long vertical well installations, that employ near well-bore electrical heating introduce several important problems not adequately resolved by application of the aforementioned vertical well electrical heating technology. The spreading resistance of the electrode (the resistance of the formation in contact with the electrode) is approximately inversely proportional to the length of the heating electrode. Typically, the spreading resistance of an electrode a few meters long in a vertical well is in the order of a few ohms. This electrode is supplied power via a cable or conductor that usually has a resistance of a few tenths of an ohm. In the case of a vertical well, the resistance of the cable, the spreading resistance of the small electrode in the pay zone and the spreading resistance of the casing as the return electrode are all in series. In this case the power dissipated in each resistor is proportional to the value of the resistance. (For a vertical well, the spreading resistance of the casing can be neglected.) For this example, only about ten percent of the power applied at the wellhead would be dissipated in the power delivery cable.
In the case of a long horizontal electrode, however, the spreading resistance may be only a few tenths of an ohm because of the long length of the horizontal electrode. This value can be very small compared to the series resistance of the power delivery conductor. The spreading resistance of the horizontal electrode can be comparable to the spreading resistance of the casing, if the casing functions as the return electrode. Because the spreading resistance of the electrode is comparable to the series resistance of the return electrode and also to the resistance of the cable, only a small fraction of the power delivered to the wellhead will be dissipated in the deposit.
Another problem with applying vertical well electrical heating technology horizontally is the large power requirement implied by the long lengths of possible horizontal wells. For example, a producing zone of six meters depth with a five meter vertical electrode may exhibit an unstimulated flow rate of 100 barrels per day. Typically, the vertical well could be electrically stimulated with about 100 kilowatts (kW) to produce up to about 300 barrels of low-water content oil per day. For this example, the energy requirement at the wellhead would be about eight kilowatt hours (kWh) per barrel of oil collected. Assuming a power delivery efficiency of 85%, and a thermal diffusion loss of 20% from the heated zone to adjacent cooler formations, the power delivered to the deposit to increase the temperature of the nearby formation and ingressing oil to a temperature of 55° C. would be in the order of five kWh per barrel. The power dissipation along the vertical electrode would be about 20 to 25 kilowatts (kW) per meter. This rather high power intensity, 20 kW per meter along the electrode, assures that the formation at least several meters away from the well bore will be heated to a temperature where the viscosity is reduced by at least an order of magnitude, thereby enhancing the production rate. The thermal diffusion of energy to adjacent non-deposit formations is suppressed by the compact shape of the heated zone, which has a low surface area to volume ratio and which experiences a high heating rate.
On the other hand, a single screen/electrode combination in a horizontal completion may be as long as 300 meters. Based on vertical well experience, the unstimulated flow rate could be about 300 barrels per day with the expectation that the electrically stimulated rate would be increased to about 900 barrels per day. About 300 kW at the wellhead would be needed to sustain this stimulated flow, assuming conditions similar to the above vertical well example. Further, assuming that the vertical well technology is applied to a horizontal well completion, the power dissipation along the horizontal electrode would be about one kW per meter as opposed to 20 kW per meter in the deposit for the vertical electrode.
In the above example there is a one kW dissipation per meter in the deposit along the horizontal screen/electrode, as opposed to the 20 kW dissipation per meter for the vertical screen/electrode. This low power intensity along the electrode/screen suggests that the temperature rise in the deposit along the horizontal screen may be much lower than that along the screen of a vertical well. The principal reasons are that the surface area to volume of the heated zone is much larger than that for the vertical well, and the heating rate is too slow, enhancing the heat loss by thermal diffusion to the cooler nearby formations. The heat from this one kW per meter dissipation may be insufficient to raise the temperature of the heated zone to where the viscosity of the oil is reduced enough to afford worthwhile flow increase. This suggests that the well head power requirement per barrel of oil of eight kWh that was based on experience with vertical wells may be too low for a horizontal well with a long uninterrupted electrode.
An additional problem is that the electrical current distribution injected into the deposit from the horizontal electrode may also be highly non-uniform. Similar non-uniform distributions have resulted in hot spots near the tips of vertical electrodes and has necessitated the use of expensive, high performance electrical insulation materials near the electrode tips of vertical wells. Similar hot spots can be expected to occur for horizontal completions, especially if the delivered power is in the order of several hundred kilowatts. Aside from the hot spots, such non-uniform heating along the electrode can result in inefficient use of electrical energy.
Another problem is that of heterogeneity of the horizontal formation through which the horizontal well is completed. If the resistivity of the formation varies along the length of the completion, greater heating rates might occur in regions where the resistivity is low. This could be a serious problem, since the location of the producing zone may not be accurately characterized. For example, if a horizontal well unknowingly is directed into a formation that has a low resistivity, most of the electrical heating power may be dissipated in this low resistivity barren region, thereby creating a hot spot and lowering the overall efficiency.
Additional difficulties may arise in the case of very long horizontal completions, as in completions in excess of a few hundred meters. In these cases, the amount of power required, despite energy conserving methods described in the patent application entitled "Iterated Electrodes for Oil Wells" filed concurrently herewith, may be beyond practical values. In a long horizontal well, even with the iterated electrode arrangement, the electrical power consumption and the resulting stimulated flow rate may be intractable. Further, the electrical heating may preferentially heat portions of the deposit, either wasting energy or causing excessive amounts of water to be produced in such locations. Also, long runs of horizontal electrodes may penetrate several barren formations as well as isolated "pools" or sub sections of reservoirs. The production from some of the "pools" may preferably be electrically enhanced prior to electrically enhancing the production from other "pools".
In the case of vertical wells, where two or more electrodes are emplaced between barren and often low resistivity formations, some of the above problems may also be experienced.
STATEMENT OF THE INVENTION
The overall object of this invention is to control the excitation of two or more electrodes in a producing zone such that substantial benefits from the electrical stimulation of oil wells can be realized.
Further, a series of two or more short electrodes are deployed in a long borehole that traverses one or more producing zones, such as might be found in a horizontal well, wherein the excitation of these electrodes are controlled to enhance production, increase the utilization of electrical energy, suppress excessive production of water and optimize the overall reservoir recovery.
The electrical excitation of a specific electrode is controlled such that if the temperature of the electrode exceeds a predetermined limit, the electrical excitation is removed or reduced.
The electrical excitation of a specific electrode is further controlled such that if the temperature of the electrode falls below a predetermined limit, the electrical excitation is increased.
The excitation of one or more electrodes is controlled so as to selectively heat preselected portions, strata, or "pools" that occur along a borehole in an oil reservoir.
The excitation of two or more electrodes is controlled to alter the current distribution along the electrodes so as to suppress hot spots.
Apparatus to control the excitation of one or more electrodes that sends signals via the power delivery system, wherein the excitation to each electrode or group of electrodes is controlled by the signals that appear near the connection point between each electrode or group of electrodes and the power delivery system.
Apparatus to sense the physical phenomena near an electrode or group of electrodes, including apparatus to send data that characterizes the physical phenomena to the surface via the power delivery system, and a receiver to receive the signals at the surface and process and display the data at the surface.
Apparatus to control the excitation of an electrode may consist of a temperature sensor near the electrode, a switch to disconnect the electrode in the event its temperature exceeds a predetermined value, and apparatus to reconnect the electrode in the event that its temperature falls below a predetermined value.
Apparatus to control the excitation of one or more electrodes may consist of downhole sensors near the electrodes, apparatus to telemeter data sensed by the sensors to the surface, means to evaluate the downhole data, further apparatus to telemeter control signals from the surface to telemetry receivers near each electrode, and apparatus to vary the power to each electrode in response to the received telemetered signals.
In line with the foregoing objectives, the following specific benefits are noted:
Very long horizontal wells in heterogeneous reservoirs can be practically heated.
The heating of portions of a well can be controlled to selectively heat "pools" so as to increase overall recovery.
The amount of power needed to realize a significant economic benefit from the electrical heating near the borehole can be reduced to economically attractive values by selectively heating portions of a long, electrically stimulated well, particularly a horizontal well.
The capital equipment costs of the above-ground electrical equipment can be made economically attractive by keeping the power requirements within reason.
The resistance presented to the power delivery conductors by the electrode assembly can be increased to realize an acceptable power delivery efficiency with conventional cable or conductor designs by disconnecting some of the electrodes.
The energy lost to adjacent formations by thermal diffusion can be reduced by selectively and rapidly heating groups of nearby electrodes over a period of time and then rapidly heating other similar groups at other times, thereby permitting more effective and efficient use of the applied electrical power.
The temperature rise in formations near the rapidly heated electrodes can be made great enough to make electrical stimulation heating effective.
The heating of selected portions of the oil reservoir can be implemented to suppress excessive production of water or to increase overall recovery from the reservoir.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a simplified sectional illustration of an oil well showing only the first two electrodes of a multi-electrode array in a horizontal well completion;
FIG. 2 is simplified illustration, in cross-section, of a section of a horizontal completion, showing a series of iterated electrodes;
FIG. 3 is a cross-section, on an enlarged scale, taken approximately on line 3--3 in FIG. 2;
FIG. 4 is a diagram of a circuit to disconnect an electrode when the electrode temperature exceeds a given threshold;
FIG. 5 is a functional block diagram of the surface portion of a telemetering system to control the excitation of one or more selected down-hole heating electrode;
FIG. 6 is a functional block diagram for a downhole telemetry receiver to control the excitation of a selected electrode and the downhole transmitter used to telemeter the status of the temperature near the electrode; and
FIG. 7 is a further enlarged sectional view, similar to FIG. 3, showing passive control of the temperature of a heating electrode by means of a shaped memory alloy or shaped memory composite.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The principal application of this invention is for electrical heating of horizontal oil wells. However, the technology described can also be used for vertical wells that are completed through deep continuous reservoirs or through several producing formations that lie between conductive barren zones. The components can be used to telemeter data to the surface concerning downhole temperatures, resistivity of liquids in the borehole, the specific voltage applied to an electrode, the current that flows out from an electrode, or the down-hole pressures that may be encountered near an electrode, such as may be found in a long horizontal completion. Such data can be used to control the heating of the deposits near specific electrodes such that electrical energy is efficiently employed and improved overall recovery of oil in the reservoir is realized.
A single horizontal well can be realized by slowly changing the angle of the borehole from vertical to horizontal on a large radius (e.g., one hundred meters) and guiding the well bore drill to pass horizontally through the main portion of a deposit. Such apparatus typically can exhibit horizontal penetration of the reservoir in the order of one hundred to one thousand meters.
A major problem, if a long horizontal continuous electrode is used, is that the design complexity and power required by the electrically heated well is nearly directly proportional to the length of such an electrode. On the other hand, it can be demonstrated that the increase in flow rate is not proportional to the length of the electrode, but rather to some reduced fraction of the increase.
The much increased surface-to-volume ratio of the heated formations near a long, uninterrupted horizontal electrode is another cause for inefficiency. Such an increase will greatly augment the thermal diffusion losses to adjacent formations relative to those experienced from conventional vertical wells. The low power injected per meter along an uninterrupted horizontal electrode also makes it difficult to increase the temperature of the formations adjacent a long horizontal electrode to a temperature high enough to significantly reduce the viscosity.
For the present invention groups of shorter electrodes, each of which creates a local region of enhanced dissipation and temperature rise, are deployed along the horizontal borehole. Each of these groups could be spaced such that the production zones of influence created by such high temperature regions would not overlap substantially. However, electrode spacing should still be close enough such that the reservoir pressure near the horizontal borehole at any position is maintained at some predetermined value above the pressure within the horizontal screen/electrode. This value should be some fraction of the difference between the shut-in reservoir pressure and the pressure within the horizontal screen/electrode. As demonstrated in the aforementioned patent application entitled "Iterated Electrodes for Oil Wells", such an approach can result in practical designs for horizontal completions in the order of a few hundred meters long and that are emplaced in producing zones with high resistivities.
Such iterated electrode arrays also suppress thermal diffusion heating effects by using a series of short electrodes that are widely spaced along the horizontal screen. The heated volume near each electrode has a surface-to-volume ratio similar to that experienced for conventional short vertical electrodes, thereby suppressing excessive heat losses due to thermal diffusion that might occur for a long uninterrupted electrode. When properly done, this reduces the power requirements, increases the input resistance, and reduces thermal diffusion losses.
One of the difficulties with extending the conventional short electrode vertical well completion technique to horizontal well applications is that the casing is conventionally used as the return electrode. The electrode length can be comparable to the length of the return electrode, the well casing. Thus, the spreading resistance of a barren formation near the casing would dissipate about as much power as the oil-bearing formation near the horizontal electrode, thereby wasting power. This inefficient design for long electrodes is overcome by the use of the iterated electrode design approach.
One solution is illustrated in FIG. 1, where a heating electrode may also serve as a return electrode in the horizontal borehole. For illustrative purposes, only one pair of electrodes are shown in FIG. 1, but additional pairs are usually employed, as shown in FIG. 2.
Another advantage of using the symmetrical excitation illustrated in FIGS. 1 and 2 is that each electrode pair exhibits about twice as much spreading resistance as for the monopole arrangement used in vertical wells, where each heating electrode in the reservoir is shorter than the return current electrode, such as the well casing. To realize this advantage, the geometry of all heating electrodes should be about the same and the voltage applied to one of the electrodes should be of opposite polarity of that applied to the other electrode of the pair. This can be done simply by not grounding the output terminals of the power source or of the transformer that supplies power to the wellhead. Thus, by using dual excitation, power is more effectively applied to the deposit, power which would otherwise be wasted in a barren formation. Moreover, the power delivery efficiency is improved by increasing the spreading resistance presented to the power delivery system.
While the above techniques, when properly applied, can realize many of the benefits of electrically enhanced oil recovery for horizontal completions, several other difficulties may arise. One arises because oil deposits are seldom homogenous; they are more likely to be heterogenous. Such heterogeneity can result in some electrodes being located in zones that have less resistivity than others. This will result in greater energy dissipation in the zones which have the lower resistivities. Some electrodes may be placed in formations that are less permeable than others. This can cause the electrodes that are located in the low flow rate zone to experience greater temperature rise than those in the high flow rate and more permeable formations. In addition, the length of some horizontal completions may well exceed one thousand meters. Because of this length, heating the entire length of an iterated electrode array may require excessively large amounts of power or may result in power delivery inefficiencies. Therefore, it may be desirable to heat only selected electrodes initially, and then heat the remaining electrodes later on. It may be desirable to heat certain pools first, in order to extend the life of the reservoir. To address these difficulties, a technique for controlling the temperature or power dissipated by individual electrodes is described hereinafter.
FIG. 1 illustrates a well 30 that has been deviated to form a horizontal borehole 37. For illustrative purposes, some dimensions have been greatly foreshortened in FIG. 1. The relative diameters of the casing and screen as illustrated may be different, depending on the depth of the well and the method of installing the screen/electrode assembly. Also, the lengths of the electrodes and intervening fiber reinforced plastic (FRP) screen isolation sections are chosen for easy illustration and may be significantly different for an actual installation. The well 30, FIG. 1, is installed by first drilling a vertical borehole from the earth surface 32 through at least some of the overburden 33. The boring is deviated, in a deeper portion of the well 30, to form the generally horizontal section 37 of the borehole. This horizontal borehole 37 lies in an oil reservoir 34, which is between the overburden 33 and the underburden 35. After the boring tool is removed, a screen/electrode assembly 38 is attached to the casing string and then lowered through the vertical borehole to be inserted into the horizontal borehole 37.
The upper part of the well 30, in the overburden 33, may be identical to the upper portion of the vertical, monopole-type well in FIG. 1 of U.S. Pat. No. 5,070,533 except that the cable 40 and the feed-through connector 41 and cable 42 to the power supply (not shown, but similar to those described in U.S. Pat. No. 5,099,918 for Power Sources for Downhole Electrical Heating) have two conductors. These conductors are insulated one from the other and are supplied with power from an ungrounded two terminal source (or from two terminals of a three terminal source) where one terminal is positive phased with respect to ground and the other terminal is negative phased. Cable 40 within the well may also have a metallic armor. The upper parts of the well 30 include a surface casing 44, a flow line 45 to a product gathering system (not shown), a wellhead chamber 46, a pump rod lubricator or bushing 47, a pump rod 48, a production tubing 49, a pump 50, and a tubing anchor 51. The pump 50 may be located at any depth below the liquid level 59.
The casing string 49 in well 30 has grout 52 down to the packer/hanger 53 that attaches the upper casing to the more horizontal portions of the casing, blank casing spacers 54 and a screen/electrode assembly 38. The outermost portions of the screen/electrode assembly 38 include the blank steel spacer section 54, fiber reinforced plastic (FRP) or other electrical insulator pipe sections 55A, 55B and 55C, the first (positive) electrode 56A and a second (negative) electrode 56B. The heating electrodes 56A and 56B are preferably formed from sections of steel pipe. The polarity designates the positive or negative phased A.C. terminals or connections. Direct current is not used. Both the FRP pipe sections and the electrodes are usually perforated or slotted to admit oil into the interior of the well; the well grouting is ordinarily porous enough for this purpose.
In the vertical portion of well 30 the insulated cable 40 is guided through two or more centralizers such as 60A and 60B; all of the centralizers usually are perforated (perforations not illustrated) to permit liquid flow. There are also flow apertures in the lowermost centralizer 60C. The cable 40 is terminated in a connector assembly 61 that is attached to a dual-wire-cable-to-single-wire-cable insulator distributor block 62, which is also perforated (not shown) for liquid flow. A connector 63 connects one cable conductor to the single conductor in an insulated cable 64A. The conductor in cable 64A is connected to a "T" connector 65 that provides a connection 65A to electrode 56A. The "T" connector 65 may also house a simple switch that will disconnect electrode 56A from the conductor in cable 64A if the temperature of electrode 56A becomes too high. Components 66, 64B, 68 and 68A provide similar functions; electrode 56B is connected to the wire in cable 64B by a "T" connection 68A from connector 68. Connections 65A and 68A are insulated as shown for the "T" connectors 74 and 77 in FIG. 2.
The deposit around the screen/electrode assembly 38 is heated by applying A.C. voltage to the two conductors of cable 42 at the surface 32. This causes A.C. current to flow through cable 40 and thence to the screen/electrode assembly 38. This applies an A.C. voltage between electrodes 56A and 56B, thereby causing current to flow through the reservoir liquids that fill the space between the horizontal borehole and the screen/electrode assembly 38 and portions of the reservoir 34 that are adjacent to the electrodes. One advantage of the arrangement shown in FIG. 1 is that the heating electrodes (e.g., 56A or 56B) are also return electrodes. These electrodes are located in the oil deposit and no power or heat is wasted in barren formations, as might be the case if vertical well technology were routinely applied to the horizontal well 30.
FIG. 2 illustrates the iterated electrode construction in more detail. In this example, two meter long, cylindrical, perforated electrodes 72 and 73 are positioned at ten meter intervals along the horizontal bore. The electrodes 72 and 73 are spaced from each other by means of a perforated or slotted fiber-reinforced plastic pipe (casing) 75. By applying oppositely polarized potentials between adjacent electrodes, currents are injected into the reservoir that will heat the oil-bearing formation near the electrodes. As shown, the positively phased electrodes 72 are each connected to the positively phased conductor in the insulated cable 70 via the conductors 76 in a series of insulated "T" connectors 74. The negatively phased electrodes 73 are each connected to the negatively phased conductor in an insulated cable 71 via the conductors 78 in a series of insulated "T" connectors 77. The perforations in members 72,73, and 75 are not illustrated.
FIG. 3 shows a cross section of the screen/electrode assembly taken approximately along line 3--3 in FIG. 2. FIG. 3 includes some of the perforations or slots 75A that are needed to permit fluids to enter the well bore. Perforations 75A should be small enough to prevent sand particles from entering with the oil. The conductor 79 in cable 70 is covered with insulating material and provides a conductive connection between the conductor in the insulated cable 70 and the electrode 72.
While the described iterated electrode arrangement permits efficient power delivery, at the same time realizing substantial stimulation of the flow rate for many horizontal well completions, other conditions or effects may occur that require control of individual electrodes or groups of electrodes. Such conditions may occur for longer horizontal completions, where the horizontal borehole penetrates formations with different resistivities or flow rates, or where some portions of the formations penetrated by the horizontal completion should be produced before other portions.
In the event that the horizontal borehole passes through a section of the deposit that has a low resistivity, the electrodes in this section will have lower spreading resistances. This will result in these electrodes capturing more of the applied power, thereby overheating the electrodes. A similar effect may occur if an electrode is located in a section that exhibits a low liquid flow rate. To prevent such an electrode from continuously overheating, the electrical current supplied to the electrode can be turned off in response to an excessive temperature, as by the circuit 110 illustrated in FIG. 4, which may be used in any of the connectors 65 and 68 (FIG. 1) or 74 and 77 (FIG. 2). Circuit 110 contains three major sets of components, a D.C. power supply 136, a semiconductor switch 135, and a switch actuator 137. The switch actuator 137 may use a thermosensitive bimetallic spiral 138 and contacts 139 as shown in FIG. 4, or may be the downhole telemetry receiver shown in FIG. 6. The semiconductor switch 135 of FIG. 4 may be a triac 124 that is turned on or off by the output of the switch actuator 137.
The piggy-back D.C. power supply 136 which extracts power from the power delivery system, supplies D.C. power to the semiconductor switch 135, and as needed to the switch actuator 137 or the telemetry receiver shown in FIG. 6. These three circuit groups 135-137 can be packaged to resist the downhole environment in and around the "T" connectors referred to above. A terminal 120 is connected to the conductor in the "T" section that supplies power to the electrode via a terminal 121 (FIG. 4). The triac 124 serves as a semiconductor switch which is turned off and on by the opening or closing of the temperature sensitive bimetallic spiral 138,139 in actuator 137. When the switch contacts 139 in actuator 137 are closed, turn-on current is injected into the triac, via a resistor 133 from the positive terminal 118 of the power supply 136.
When the temperature exceeds a certain limit, the switch contacts 139 in actuator circuit 137 open, thereby turning the triac 124 off. When the contacts 139 close and the triac 124 is turned on, the principal current flow path from terminal 120 to terminal 121 is via the triac 124 and the primary 122 of a transformer 134. The secondary 123 of the transformer 134 supplies power to the diode rectifier 127. This supplies D.C. voltage to a filter capacitor 128 and to a bleed resistor 131 in parallel with the capacitor. A voltage regulator circuit is formed by a series resistor 132 and a voltage regulating Zener diode 125 that supplies a fixed voltage to the current injection resistor 133.
If the triac 124 is turned off, no current will flow in the transformer primary 122, thereby rendering this section of the D.C. supply circuit 136 ineffective. To assure a D.C. supply when the triac 124 is turned off, an A.C. voltage will appear across terminals 120 and 121. This A.C. voltage is rectified and supplies D.C. current to two resistors 129 and 130 and to a diode 126. Diode 126 supplies current to the filter capacitor 128 and bleed resistor 131. This dual D.C. supply arrangement assures that D.C. power will be available whether the triac 124 is conducting or not conducting.
Other alternatives are available to control the temperature of a specific electrode. For example, the on-off circuit described above (FIG. 4) may be replaced by a more continuous control by varying the duty cycle of the triac in response to a temperature-controlled gate-firing circuit. Alternatively, the triac circuit may be replaced by a mechanical switch activated by metallic alloy "memory metal" that changes shape abruptly when the temperature exceeds a specific threshold.
FIGS. 5 and 6 illustrate a telemetry system used to actuate a switching device that connects an electrode to one of the A.C. excited conductors. The actuation can be slow, with on or off conditions lasting hours or minutes to realize a "bang-bang" control wherein the temperature rises to some point and then falls to a lower point during the "off" mode before rising again during the "on" mode. Alternatively, the switch can turn "on" and "off" rapidly with respect to the period of the A.C. power waveform. By varying the "on" time, continuous adjustment of the current flow into the electrode can be realize.
FIGS. 5 and 6 illustrate a carrier frequency or multi-frequency telemetry system. One-way signal sending, from the surface and vice versa, is via the conductors used to deliver power to the heating electrodes. While any group of frequencies can be used, use of frequencies that do not share the same spectral space used by the A.C. power delivery system is preferable to permit operation when the deposit is being heated. One band of frequencies that may be used is above the spectral regions where considerable noise and power frequency harmonics are generated by the power control unit (PCU) for the power source. To eliminate such interference, the output of the power source should be filtered. This is most easily done if the cut-off frequency of the filter is large compared to the frequency of the principal spectral components generated by the PCU or power source. The cut-off frequency may be in the range of three to thirty kHz. This sets the lower limit for the telemetry frequency.
The upper limit of the telemetry frequency range is determined by the attenuation experienced by the telemetered waves as these traverse down or up the well on the power delivery conductors. A study of the propagation loss along typical power delivery conductors suggests that the highest usable frequency could range up to three thousand kHz, with more practical operation up to about one hundred kHz. Thus, more than adequate spectrum space exists to accommodate numerous telemetry channels, especially since the data rates will be small.
While numerous methods of telemetering information exist, the use of single frequency tone bursts will be described. As such, small, frequency-stabilized, narrow bandwidth electro-mechanical resonators, such as quartz-crystal resonators, can be employed to select the desired frequency. Alternatively, the modulation of a single carrier can be varied to provide a unique identifier for each electrode. Other methods, that employ the use of sequences of digitally encoded messages, or time-division multiplex methods, are also possible and can be considered where control of a large number of electrodes is required.
In the case of the simple tone burst method, for example, a 20.0 kHz burst can be transmitted for ten seconds to connect to one electrode. If 22.5 kHz is transmitted for ten seconds, that same electrode would be disconnected. The downhole temperature may be telemetered to the surface by transmitting from a telemetry package mounted near the selected electrode. An FM modulated carrier centered around forty kHz can be used. The frequency of the modulation can be made proportional to temperature, such that a ten Hz modulation would be zero degrees and three hundred Hz would represent one hundred degrees.
FIG. 5 presents a functional block diagram for above-ground telemetry equipment 200. Only the features that are unique to this application of a telemetry system are emphasized. A three-phase 50/60 Hz power line or other power source 201 supplies power to the PCU 203 via insulated cables 202. The PCU Power Conditioning Unit! converts the three-phase power-frequency, typically to single phase with a frequency in a band of three to six hundred Hz. PCU 203 also tailors the output voltage-current range to the impedance of the electrode(s) and the energy needs for the electrical stimulation process. Via insulated cables 204A and 204B, the output of the PCU is connected to a low pass filter 205 that removes noise and harmonics above a given cut-off frequency, which may be about five kHz. Cables 206A and 206B connect the output of the low-pass filter 205 to a diplexer 207. The diplexer contains a tuned transformer 208 that can insert or withdraw the power within a band of telemeter frequencies, into the energized line 209A from the PCU 203 to the wellhead 210 without affecting the performance of the PCU or power delivery efficiency. Insulated dual conductor cables 209A and 209B apply the combined power from the PCU and telemeter source to the wellhead 210. The dual conductor cable 209A and 209B (cable 42 in FIG. 1) is connected to the feed-through connector 41, and thus to cable 40, as shown in FIG. 1.
A specific band of frequencies are selected to be transmitted downhole; in this example that band is below the frequencies used to telemeter information up from the downhole sensors. Each frequency that is to be transmitted can be derived from a frequency synthesizer 220 (FIG. 5) and transmitted via a coaxial cable 221 to a frequency selector unit 222, in which a specific frequency is selected. Via a coaxial cable 223, the waveform of the selected frequency is applied to a power amplifier 224. The output of the amplifier 224 is applied to a coaxial cable 225 connected to a send/receive frequency selection filter unit 231. Filter unit 231 includes a low pass filter 226 and a high pass filter 230; they allow the output from the power amplifier 224 to be applied to the combiner transformer 20 8 in diplexer 207 without affecting a telemetry receiver 229 that is connected to the send/receive selection filter unit 231. The diplexer 207 will also extract the signals that are telemetered from downhole without overlap from the unfiltered spectral content of waveforms from the PCU 20 3 and apply these signals to the send/receive filter unit 231. Additionally, filter unit 231 allows extraction of the higher frequency signals that are telemetered from downhole sensors from the lower band of control signal waveforms from the amplifier 224.
The applied power from the PCU 203 or the telemetry control signal amplifier 224 flows down the borehole via the dual conductors of cable 40, FIG. 1, and then via the single insulated conductors of cables 64A and 64B (FIG. 1) or via the insulated conductors 70 and 71 of FIGS. 2 and 3. In FIG. 6, the telemetry waveforms from the telemetry amplifier 224 are extracted from the power delivery cable 146 in FIG. 6 by means of a current transformer 145; the cable 146 represents any of the downhole cables referred to above. These signals are applied to a band-pass filter 141 that extracts the control signal waveform from the transformer 145 and applies this waveform to the downhole telemetry receiver 147. At the same time, the filter 141 suppresses any undesired waveform into receiver 147 from the downhole telemetry unit 142. The downhole receiver 147 derives power from the d-c power supply 136 shown in FIG. 1 via terminals 118 and 120(see FIG. 4). Terminal 120is connected to one of the dual conductors, such as conductor 146. The extracted telemetry signals from the surface are applied to the downhole telemetry receiver 147 via the filter 141.
When a heating electrode is to be controlled from the surface, the thermal control 137 shown in FIG. 4 is not used. Instead, on/off control signals from the telemetry receiver 147, FIG. 6, are applied to terminals 118 and 119 of the d-c power supply 136 (FIG. 4) to supply a "gate on" firing signal to the triac 124. When one frequency of the telemeter signal is received, the state of a latching circuit in downhole receiver 147, FIG. 6, is set so as to provide turn-on injection current for the triac, as if the switch 139 in the temperature sensor package 137 (FIG. 4) were closed. If another frequency is received, the latching circuit in the receiver 147 can be set such that the triac firing current will be terminated, thereby causing the electrode to be effectively disconnected from cable 146. Direct current power is supplied to the telemetry receiver 147 by terminals 118, 120from the D.C. power supply 136 (FIG. 4).
By the use of additional control frequencies, the firing of the triac 124 can be delayed by discrete intervals with respect to the turn-off current that occurs when the phase of the current through the triac is reversed. This delays application of current to the heating electrode and allows variation in the power dissipated in the deposit near that electrode. This is readily accomplished by known latching circuits (not shown) whose state is determined upon receipt of one or more of the additional frequencies. The state of the latching circuits determines the delay of the firing function. Such delay circuits are well known and any of a number of digital timing methods or monostable time delay circuits can be used for this purpose.
FIG. 6 also shows the downhole telemetry transmitter unit 142, which comprises a thermo-sensitive sensor 143, such as a thermistor. A connection is made, in unit 142, to the terminals 120and 118 of the power supply 136; see FIG. 4. The output of the downhole telemetry transmitter 142 (FIG. 6) is applied to a band-pass filter 140. Filter 140 provides a pass band for the output frequencies of the transmitter 142, while filter 141 prevents entry of these transmitted frequencies into the down hole telemetry receiver 147. The output of the filter 140 is applied to the current transformer 145 such that the power delivery cable 146 is excited to propagate the telemetry signal up to the above-ground receiver.
FIG. 7 presents a cable cross-section, like that shown in FIG. 3 except that a shaped memory metal or composite is employed to actuate a switch that connects a power delivery conductor to an electrode. The shaped memory metal (or composite), when deformed plastically in its low temperature state, has the property of returning to its original shape when heated above its transition temperature. Such materials are available commercially.
In FIG. 7, the heating electrode 72 is connected to the positive phased conductor 81 via a memory metal actuated switch assembly 90. The positive phased conductor 81 and the memory metal switch assembly 90 are covered with electrical insulation 80. Shown below the positive phased insulated conductor 70 is the oppositely phased cable 71, which includes an insulating sheath and a copper or aluminum conductor.
The heating electrode 72 surrounds a fiber reinforced plastic pipe (FRP) 75; other insulator pipe can be used. Both the electrode 72 and the FRP 75 are penetrated by slots or perforations 75A. A shaped composite metal nickel-titanium alloy spiral spring 83 is mechanically connected to a copper metal base section 84 and to a copper metal spring alloy bar 85 that is electrically embedded in a metallic base plate 86 that is connected to the electrode 72. The normal compressed shape of the spring 83 is plastically expanded at low temperature such that the bar 85 will be forced against the contact 82. When the temperature of the electrode substantially exceeds the transition temperature of the nickel-titanium alloy spring 83, the spring 83 will revert to its original compressed shape, thereby pulling bar 85 away from contact 82.
While the foregoing techniques have been described in the context of a long horizontal completion, there are some vertical well installations that may require the use of a similar iterated electrode system. Such wells usually exhibit high unstimulated flow rates and lengths in excess of ten meters. The spacing of the heating electrodes is also governed according to the vertical resistivity profile of the well, with the heating electrodes placed in regions of high resistivity, large oil saturation, and fluid permeability. Regions of low resistivity should be avoided, as well as regions of low oil saturation and/or fluid permeability.
This invention is not limited as to the precise nature of the telemetry communication pathway. Armored cables that deliver power downhole to pump motors often contain small diameter wires embedded in insulation. These wires, or additional wires, can be dedicated to supply power to the downhole sensors and telemetry units and may also serve as a telemetry communication pathway. Such wires can also be used as a telemetry pathway only wherein the power to the downholes electronic circuits of the sensors, switches and telemetry apparatus is supplied from the power delivery system. Other communication means are possible via fiber-optic cables; the control or sensor signals can be telemetered or transmitted via the fiber-optic cable. In the case of fiber-optic cables used for telemetry, the energy to operate the downhole sensor and telemetry circuits may be derived from the power delivery system that supplies energy to the heating electrodes.
In the case of horizontal wells, the assumption that the deposit is precisely horizontally layered may not apply. Therefore the heating electrode considerations just noted for a vertical well also apply for quasi-horizontal wells.
The invention is not limited as to the precise nature of the power delivery system or to the features of the power supply or PCU. For example, the dual conductor pair need not be in the form of a cable, but rather could be a combination of an insulated tubing and the production casing. These could be used to excite a downhole transformer that is located near the horizontal section. The secondary of such a transformer provides the positive phase excitation and the negative phase excitation of the dual conductor delivery system within the horizontal screen section. Rather than use a dual conductor cable, such as cable 40 in FIG. 1, a three conductor cable could be used that is excited by a power source that has a three phase output. In this case, the screen would enclose three insulated conductors that would excite sequences of three electrodes, wherein the phase difference between the excitation of adjacent electrodes would be approximately 120°.
In addition, parameters other than temperature can be sensed. These might include the resistivity of the liquids or the pressures within different portions of the horizontal borehole, as well as electrical parameters such as the current or the open circuit voltage to one or more electrodes.
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A control for an electrical heating system that enhances production from an oil well, particularly a horizontal oil well; the well includes an initial well bore extending downwardly from the surface of the earth through one or more overburden formations and into communication with a producing well bore that extends or deviates outwardly from the initial well bore into an oil producing formation. The heating system includes an array of short, electrically conductive heating electrodes extending longitudinally through the producing well bore. The heating system further includes apparatus for electrically energizing electrodes that are close to each other with A.C. power; the A.C. power supplied to electrodes near each other has a phase displacement of at least 90°, usually 120° or 180°, between electrodes. The control Includes plural power switches, each connected to at least one heating electrode; each power switch is conductive only up to a predetermined limit (usually a temperature limit). In one embodiment, each power switch includes a sensor responsive to the operating condition of its heating electrode. Another embodiment employs a telemeter circuit to actuate the power switches with sensors that are separate from the power switches.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
FIELD OF THE INVENTION
[0001] Exclusion of debris and trash from gutters and storm drains except during high rates of stream flow, and assured opening of the system under flooded conditions.
BACKGROUND OF THE INVENTION
[0002] Gutters and storm drains are commonly placed alongside roadways to drain casual water and storm water into a collection system leading to treatment plants and then to places of ultimate disposition such as oceans, rivers and spreading grounds. A drain opening when open accepts not only the water but also solid material such as trash and debris which falls or is placed in the roadway. For convenience, this material is collectively referred to as “trash”.
[0003] During intervals between rains, municipalities and their service organizations generally attempt to collect trash by mechanical means such as sweepers, and to clean out drain basins manually and with vacuums. The purpose is to clear the drainage system to keep it in readiness for the next rain. A persistent problem is that these measures are not always available in time to keep all of the trash in the street. Even sweepers may deflect much of it into the drain.
[0004] This situation has long been recognized and installations have been made to prevent it. Examples are shown in Martinez U.S. Pat. Nos. 6,217,756, 6,824,677, and 6,869,523. In these devices, a hinged gate is placed in the opening into the drain. At slow rates of flow, water gradually drains, even drips, into the basin through a perforated gate or a gap next to the gate. But the gate remains closed to trash.
[0005] However, when the flow of water reaches a sufficiently high rate, such as in a storm, an actuator responsive to the stream flow will open the gate and admit the entire flow. This may be accompanied by some trash, but that is inevitable. The drain system is still functional.
[0006] Known systems to exclude trash in drier modes commonly include an actuator to open a gate which is somehow responsive to the rate of flow of the water. In the U.S. Pat. Nos. 6,217,756 and 6,869,523 Martinez patents, the weight of water in a bucket which leaks or tilts is used as the actuator (or more precisely the sensor). In Martinez U.S. Pat. No. 6,821,053 it is a rotary actuator responsive to the impact force of the stream, an impulse-type reaction.
[0007] A pervasive problem with systems of these types which must inherently be installed in the basin, is that they are disabled unless they are free for actuation by collecting and retaining a sufficient volume of water for a given period of time, or is available to be directly struck by the entering stream. A “leaky bucket” cannot “leak” when it is totally submerged. A rotor actuated by stream force cannot react to a stream when it is totally submerged. As a result in either case the gate could possibly close at the worst possible time (during very heavy stream flow), resulting in upstream flooding.
[0008] This problem was recognized in the U.S. Pat. No. 6,821,053 Martinez patent, in which a latch, moved by a float, is intended to hold the gate open when the actuator is flooded. This presents the issue of uncertainty when the “powering system” (the sensor) operates independently of water level-responsive latches.
[0009] It is an object of this invention, utilizing an impulse-type rotary actuator, to include a secondary opening force into the system exerted by a buoyant float directly connected to the rotary actuator which tends to apply an opening torque to the rotor that will maintain the gate open when the rotary actuator itself is flooded. There results a system that is proof against being disabled by flooding due to excessive flow rates or by plugged-up downstream systems.
BRIEF DESCRIPTION OF THE INVENTION
[0010] The actuator according to this invention is intended to be incorporated into a system which is installed in a drainage basin adjacent to an entry opening from a source of drainage or storm water, like a curb for example. It includes a pivoted gate intended to remain closed when the rate of water flow is suitably slow, and to be opened when the water flow exceeds that rate. A linkage is provided between the actuator and the gate to effect this objective.
[0011] The actuator itself is a rotor that includes at least one vane. The vane or vanes is or are so disposed and arranged as to be impacted by water which has passed the gate at higher stream rates, but not at slower stream rates. The resulting impulse force (the vane can drain) will cause the rotor to rotate in a first direction to cause the linkage to open the gate and this condition will continue so long as the rate is sufficiently high and the vane is not submerged. When the flow rate decreases sufficiently, the weight of the gate and the linkage will cause the rotor to reverse its direction and the gate will close.
[0012] This situation can prevail while the rotor remains exposed to the stream. However, if somehow the rotor becomes submerged, this effect is masked. For example if the downstream drainage system is plugged and the basin fills above the rotor, the rotor will not receive an actuating water stream and the gate would close. According to this invention, to prevent this event, a buoyant float is linked to (and preferably is directly attached to) the rotor at the side of the rotor opposite from the vanes, whereby when submerged it will exert on the rotor a torque in the same sense as the stream flow did. Thus there will persist a torque that will maintain the gate open so long as the basin is flooded.
[0013] This invention contemplates the actuator itself, and also the actuator in combination with the system installed in a basin.
[0014] The above and other features of this invention will be fully understood from the following detailed description and the accompanying drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is a side elevation partly in axial cross-section showing the preferred embodiment of the invention in its closed condition, experiencing slow flow;
[0016] FIG. 2 is a view similar to FIG. 1 in which the gate starts to open as the consequence of a higher rate of flow;
[0017] FIG. 3 is a view similar to FIG. 1 in which the gate is fully opened during rapid flow;
[0018] FIG. 4 is a perspective view the actuator; and
[0019] FIG. 5 is a side view of the actuator of FIG. 4 .
DETAILED DESCRIPTION OF THE INVENTION
[0020] An opening 10 from a gutter is through a curb 11 is shown in FIG. 1 . It has a bottom sill 13 a top 14 and two sides (not shown) to provide a rectangular aperture leading into a drainage basin 15 into which water drained from the gutter will flow, and will thereafter be passed to a downstream disposal system. A sidewalk 12 or other covering structure is shown, which may be provided with access mean such as a manhole.
[0021] A frame 20 , includes a pair of U-shaped springy identical and spaced apart rigid metal straps (only strap 21 being shown). Arm 22 engages the underside of the opening. Arm 23 engages the sill. When properly attached, these straps, joined by a transverse plate 24 , will support the system in the basin.
[0022] A gate 30 , when closed, extends across opening 10 . As preferred it may be perforated, or may have a portion of its periphery spaced from the side or the sides of the opening to form a gap that permits water presented at slow rates to proceed past the closed gate. These dimensions are such as to stop most trash. At slow rates the water 31 merely dribbles down the side wall of the basin, and does not affect the actuator, as will be described. This will attend to periods of light rain, or merely the runoff from lawn watering or car washing. Trash will be retained.
[0023] As shown in FIG. 1 , gate 30 is hinged by hinge 32 so it can swing upwardly and inwardly. A linkage 33 is responsive to the rotary position of an actuator 35 pivotally attached to the frame below the level of the sill and spaced from it.
[0024] The details of the linkage are unimportant and obvious. Any crank type system that transfers torque from a rotor to a hinged gate will suffice.
[0025] The actuator includes at least one, but preferably two vanes 36 , 37 spaced from pivot 38 . As shown in FIG. 4 , each vane has a respective flange 39 , 40 and open side edges. In the repose condition of FIG. 1 flange 37 is the closer to the wall of the basin, spaced far enough from that wall so that slow flow 31 will by-pass the actuator completely and the gate will remain closed. Also, assuming that the basin is not plugged up and dry, there will be no reaction with water at all. The inherent bias of the system, starting with the weight of the gate and the linkage is to keep the gate closed.
[0026] In order to open the gate, a positive torque shown by arrow 45 ( FIG. 2 ) must be exerted. This will start to occur when water flow 46 ( FIG. 2 ) becomes so fast that a stream reaches and impacts the vanes. The impulse of this stream will drive the vanes in the direction of arrow 45 , opening the gate. As the rate increases there will be increased force, fully to open the gate ( FIG. 3 ). This is the subject of Martinez U.S. Pat. No. 6,821,053, which is incorporated herein by reference in its entirety for its showing of such a system. This assumes that the basin is entirely drained at least to a level below the rotor.
[0027] However, assume now that the rate of flow exceeds the capacity of the downstream opening, or the downstream system is plugged. Then the rotor would be flooded as suggested by wavy line 48 . Without additional features the gate would simply close.
[0028] To avert this, a buoyant float 50 is attached to the rotor in such a way that when in water its buoyant force will be exerted as a torque in the same rotational sense 49 as the rotor when under impact by the water stream. It is so disposed and arranged that when the rotor vanes are submerged, the float will provide a buoyant force at least equal to that which is lost from the vane or vanes.
[0029] The float 50 may be as simple as a hollow block 51 of stiff lightweight material or foam fixed to lever arm 52 . It is useful for the block to be supported so as to be rotatable on the arm, thereby better to withstand vigorous hydraulic forces. If preferred, tubes, even hollow tubes, may be used for this purpose. Whatever the situation, its position will be on the opposite side of pivot 38 so its torque will be in the same sense 49 as that of the vane. Clearly its weight should be such that it does not appreciably adversely resist the torque applied by the water stream.
[0030] FIGS. 1-3 illustrate normal operations with the water level in the basin (if any), below the rotor. In FIG. 3 , line 48 represents a flooded level of water in the basin. Notice that the system will have remained open. The vanes are useless, but the submerged float exerts a torque to hold the system open by reason of its buoyancy.
[0031] This invention thereby provides a system to hold a drain system opening in its closed position at slow and no flow, and to open the system at high rates of flow, and to keep it open even if the system itself becomes flooded.
[0032] This invention is not to be limited by the embodiment shown in the drawings and described in the description, which is given by way of example and not of limitation, but only in accordance with the scope of the appended claims.
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A pivoted gate across an opening from a gutter into a collector basin. An actuator inside the basin is insensitive to slow flow rates, but includes a rotor with vanes that actuate an opening linkage at sufficiently high rates of flow. A float is included in the actuator to exert a gate-opening torque when the rotor is flooded.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation in part of co-pending application U.S. patent application Ser. No. 13/604,464, filed Sep. 5, 2012, which claims priority 35 U.S.C. §119 to Australian Patent application 2011 903582, filed Sep. 5, 2011, the entire contents of each of which are incorporated herein by reference. This application also incorporates by reference Australian patent application No. 2012216652 and New Zealand patent application No. 602265.
TECHNICAL FIELD
The application relates to a height safety anchor for attaching devices, apparatus or equipment to a roof surface and, more particularly, to a height safety anchor for fitment to a building structure clad with metal sheeting, the height safety anchor also including shock absorbing means. The devices, apparatus or equipment to be attached may include safety equipment such as safety harnesses, ropes or other safety devices adapted to secure a height safety worker against falling and injury.
While the disclosure derives particular advantage when used in conjunction with a metal roof, it may also be utilized with any roof where access to the structure supporting the cladding is feasible and accordingly no limitation is implied by a primary reference to metal roofs in the following description.
BACKGROUND
The following references to and descriptions of prior proposals or products are not intended to be, and are not to be construed as, statements or admissions of common general knowledge in the art. In particular, the following prior art discussion does not relate to what is commonly or well known by the person skilled in the art, but assists in the understanding of the inventive step of the disclosure of which the identification of pertinent prior art proposals is but one part.
Several solutions have been proposed for providing anchor points on a roof or building structure, but these are normally intended for permanent fitment. Such anchor points are made available so that a person working on the roof or other building structure, for example, can attach himself to the anchor point by means of a rope or cable, etc., so that in the event of a fall, he will be constrained from falling off the building.
Thus, conventional height safety anchoring devices for permanent fitment require access to the building support structure such as a batten or rafter. Direct access to the support structure is generally required and involves mounting the height safety anchor prior to the application of the external covering of the roof such as tiles, sarking, sheeting or other cladding so that upon application of the external covering to the support structure, the height safety anchor extends beyond the external covering. The anchor will, of course, need to be suitably flashed to provide a weather-proofed fitment.
On the other hand, if the external covering has already been applied to the building support structure, then at least one unit of the external covering, e.g., a single sheet of covering, must be removed to provide access to the building support structure. Thus, for example, where large units of sheeting form the external covering of the roof, considerable time and effort may have to be expended to remove a single unit to gain access to the roof support structure. Furthermore, there is also a risk that damage to the covering may occur or, more particularly, once it is re-laid, the covering might not properly seal against the elements.
However, the removal of the covering as described above may be impractical or inconvenient. Alternatively, so-called retro-fit systems have been developed that provide a solution for securing a permanent anchor point by using a tool through an access facility, i.e., a relatively small opening, for example, which is then later sealed.
In any event, all of the foregoing solutions have as their basic premise that the anchor is left permanently in place once fitted. This, however, may not be convenient or even desirable having regard to aesthetic considerations and may be unnecessarily wasteful as there may be little need for an anchor point at any time in at least the foreseeable future. Furthermore, anchor points may be desired at various locations, particularly as work progresses on a site, once again adding to the total cost if several permanent anchors are utilized.
To this end, a solution that provides for an anchor point, especially one that could be fitted to a metal roof and removed after any necessary work has been completed, would be advantageous. A useful solution to this problem, therefore, presents itself when one takes into account the typical way in which a metal roof is constructed. Typically, metal cladding is affixed with screws at intervals along a batten, which, in turn, is affixed to rafters in typical fashion. A solution is, therefore, available by simply removing sufficient screws from a section of cladding and affixing a suitable temporary anchor over the cladding by replacing the existing screws using the existing holes through the cladding. Thus, the screws would then pass through suitable holes in the temporary anchor and through the existing holes in the cladding and, thence, into the supporting structure below. Upon completion of the work, the screws can then be removed again, the temporary anchor removed, and the screws replaced once more to hold the cladding in place as it was originally affixed.
In this way, there would be no need to disturb the roof structure or cladding in any way other than to remove some of the existing screws in order to attach the temporary anchor, the screws being replaced after the necessary work on the roof has been completed and the temporary anchor has been removed.
This would provide a simple, useful and economic solution to the problem of providing a temporary anchor point for safety equipment and the like, which could then be readily removed once the work was completed. The temporary anchor could then be used at another location on the same site or taken away altogether and used on another site.
Of course, such a solution would still need to be effective in ensuring adequate safety standards are met, that is to say, the anchor itself, in conjunction with its fitment, would need to meet the necessary safety standards. It should be stressed that anchors that have hitherto been suitable for permanent fitment do not lend themselves to attachment as temporary anchors in this way.
The original disclosure (from which this application claims priority), therefore, advantageously provided a temporary anchor that could not only to meet the desired safety standards, but that was itself designed to be portable so that it could be easily taken from one work site to another.
However, it would also be advantageous to provide a height safety anchor that could be optionally permanently affixed directly to a supporting building structure, e.g., for a metal clad roof, by affixing the anchor through the metal cladding at points already utilized for screwing the cladding to the structure, without otherwise disturbing the metal cladding itself.
It would also be further advantageous if such a height safety anchor system was provided with shock-absorbing means in order to minimize injury from a person utilizing the anchor point in the event of a fall. Further, it would also be desirable if the anchor point were multi-directional to the extent that it worked efficiently no matter from which direction forces might be applied in the event of a fall.
In addition, it would also be advantageous if such an anchor could also be fitted directly to any stable structure, including the supporting structure for a tile roof, albeit with the necessity of removing some tiles or other cladding, etc., to allow access to the underlying structure where applicable.
SUMMARY OF THE DISCLOSURE
Provided is a height safety anchor especially for metal clad roofs which ameliorates one or more of the aforementioned disadvantages associated with the prior art, particularly by providing an anchor point that may be mounted directly over the metal roof cladding, utilizing the existing fixing points for the metal cladding itself, the anchor being so constructed as to progressively absorb the effects of a sudden load applied thereto, and wherein the anchor functions usefully in all directions.
It should also be understood that while the disclosure relates primarily to the attachment of an anchor to a roof as described, it will also be applicable in many other instances where attachment of a device to another surface or structure is required, whether a wall or ceiling, for example. Thus, any reference to a roof, whether metal or otherwise, is also meant to encompass reference to any structure, where, by suitable adaptation, the device may also be utilized.
Provided is a height safety anchor for fitment to a building support structure, the height safety anchor comprising:
first attachment means for fitment to the building support structure by engagement to a flexible and high tensile elongate member comprising a plurality of spaced eyelets that are slidable along the elongate member;
second attachment means remote from the first attachment means for attaching safety equipment; and
shock absorbing means having a deformable region extending between the first and second attachment means in a first length when not subject to a deformation force corresponding to a critical sudden load,
the shock absorbing means lying substantially in a single plane and comprising a substantially rigid structure that, when subject to the critical sudden load, deforms, elongating to a greater length than the first length.
The elongate member may be in the form of a cable. The cable should be relatively flexible in the sense that it can sustain some bending over a portion of its length. The cable should have high tensile strength. The cable may be made from metal or plastic rope. The cable may be formed from galvanized iron, steel and the like materials. It is strongly preferred that the cable is formed from and comprises stainless steel cable. Care should be taken to meet safety standards in fitting any height safety equipment.
The slidable eyelets may comprise a loop surrounding a portion of the cable. The loop may be a sleeve formed from a plate pressed onto and around the cable. The eyelets may, therefore, be formed from any number of metal working methods. The eyelets may be formed from stamped plates or, preferably, by laser cutting. The flat plates so formed are then pressed into shape to form a loop section about the cable. The plate is preferably folded back on itself.
The eyelet may comprise a tab portion include an aperture for receiving a fastener and a folded portion. The folded portion may form a tongue plate that wraps back around the cable with one end of the tongue attached to the tab and the other end adapted to wrap around so that it abuts, or rests close to, the transition or junction between the tab and the tongue plate.
The eyelet may be bisymmetrical and the tongue plate may terminate at each end with a tab comprising an aperture for receiving a fastener. The eyelet is, therefore, preferably adapted to fold generally or substantially symmetrically. Each eyelet may comprise a pair of holes, one at each end of the plate, preferably one hole in each of the tabs that register when the plate is pressed about the cable. The pair of holes may receive a fastener, such as a screw or clamp, and by the fastener be secured to the building support structure.
The building support structure may be a roof or wall on or against which elevated work is required to be performed with attendant risks to unsecured workers. Accordingly, the height safety anchor is structurally sufficient to sustain a critical load that free-falls from work on a vertical structure, such as a building wall. However, more typically, the height safety anchor will be deployed in securing a worker to a roof structure, such as a metal clad and/or timber frame roof. In its preferred form, therefore, the height safety anchor is a roof anchor. The height safety anchor may be installed temporarily whereby the fasteners are undone and the eyelets released, or alternatively, the height safety anchor may be left permanently installed. Preferably, where permanent installation is required and the height safety anchor is likely to be exposed to the weather, the cable, shock absorber, fasteners and the eyelets will be corrosion resistant and made from the same material, such as galvanized or stainless steel.
The slidability of the eyelets along the cable not only permit adjustability in the positioning of the shock absorber, and, therefore, the second attachment, but also provides for further energy dissipation in the event of the application of a sudden critical load to the second attachment.
The height safety anchor preferably further includes end sockets. The end sockets may comprise a swage sleeve. The end sockets may be formed from cable looped back around or on itself. The aligned cable lengths may be welded or clamped. The end socket may be formed by a cable loop with the cable looped back on itself near its end and swaged. The end sockets preferably comprise eyelet bolts threaded into swaged end sleeves.
The shock absorbing means may include the second attachment in the form of a large ring. The shock absorbing means may also include a series of folded portions forming a concertinaed length, one end of which connects to one side of the large ring so that one section of the ring is positioned adjacent a straight edge of the last portion of folded length of the series of folded portions.
The shock absorbing means may engage the elongate member by feeding a length of the elongate member through a pair of spaced holes formed in an end plate of the shock absorbing means. Preferably, the end of the concertinaed length opposed to the end connected to the large ring is connected to one side of the end plate so that one section of end plate is positioned adjacent a straight edge of the last portion of folded length of the series of folded portions.
The second attachment may be in the form of any suitable height safety equipment. Typically, a D-clamp or carabiner may be used to attach the height safety equipment to the second attachment.
In the basic disclosure, there was provided a roof anchor for fitment to a roof support structure or the like, especially a roof support structure having metal cladding affixed thereto, wherein the anchor is provided with a first attachment means for fitment of the roof anchor to the roof support structure, a second attachment means remote therefrom for attaching devices, apparatus or equipment, especially safety equipment, thereto, and shock-absorbing means located therebetween so as to progressively distort under sudden load, and wherein the first attachment means comprises a webbing material having a plurality of spaced apart fixing points by means of which the webbing material may be affixed to the roof support structure utilizing the existing fixing means that hold the metal cladding to the roof structure.
Preferably, the shock absorbing means is in the form of a metal bar or narrow plate, cut so as form a concertina arrangement that can progressively deform under load. Preferably, the shock absorption is provided by one or more suitably shaped portions of material cut or otherwise formed so that when a force is applied thereto, there is created a deformation therein in the form of a generally linear extension of that portion, i.e., by effectively straightening or “unbending” such region. Thus, the anchor is so designed that deformation by bending, i.e., unbending or straightening, of the shock-absorbing region, in combination with either of the attachment regions as described herein, where appropriate, provides an absorption of the forces applied to the anchor from any angle, that is to say, if a load is exerted from any direction, the anchor is able to accommodate that sudden load in suitable fashion. In this way, the anchor will provide a suitable shock-absorbing means against, for example, a sudden load arising from a person attached thereto falling from the roof.
With advantage, the shock absorbing means in the form described may be covered with a rubber sleeve or similar covering to protect it.
This sleeve may also provide a region where safety instructions may be written.
On the other hand, any suitable shock-absorbing means may be utilized that functions to dampen the forces applied under sudden load, such as when a person attached to the roof anchor falls from the roof.
The devices, apparatus or equipment to be attached may include safety equipment such as safety harnesses, ropes or other safety devices adapted to secure a roof worker against falling and injury. While the devices, apparatus or equipment derives particular advantage when used in conjunction with a metal roof, it may also be utilized with any roof where access to the structure supporting the cladding is feasible and, accordingly, no limitation is implied by a primary reference to metal roofs in the following description.
Although any suitable attachment means may be utilized to affix safety equipment and the like, preferably, the second attachment means by which the safety equipment such as a harness, etc., is attached to the shock-absorbing means is in the form of a simple eye located near its extremity, remote from where it is attached to the roof structure, and through which the safety equipment may be attached in known fashion.
The webbing material providing the attachment means for affixing the anchor to the roof structure in the original disclosure was a polyester webbing capable of supporting a high tensile load, for example, in excess of 10 tonnes. While polyester webbing is the preferred material, any webbing material, including nylon and/or composites, having the ability to withstand similar loads may be employed.
The webbing is a single length of webbing material, although other arrangements adapted to perform as described may be utilized. Where a single length of webbing is employed, it has been found that a suitable length is around 1.5 m to 2.5 m in length, preferably about 2 meters to 2.2 meters. With advantage, this length of webbing can be inserted through a slot provided in the end of the shock-absorbing means remote from the end having the means to attach the safety devices, etc., thereto. In this way, the webbing may extend for approximately equal lengths either side of the slot. By affixing the webbing to the roof structure at either side of the slot, allows for the shock-absorbing means to move to some extent between at least the first fixing points located adjacent to and either side of the slot located in the end of the shock absorber. This allows the anchor to function effectively in all directions.
Preferably, the fixing points in the webbing are holes. More preferably, the fixing points are reinforced holes, formed in the webbing.
The preferred method of attaching the webbing to the roof structure in the original disclosure was by utilizing screws inserted through the holes in the webbing and into the supporting structure of the roof material. However, other forms of fixing may also be utilized, as discussed below, and no limitation should be inferred from a general reference to screws as the medium by which the webbing is attached to the roof.
Six such holes may be provided in the webbing material, so as to spread the load, as described later herein. Under conditions where a fall occurs, successive screws will take the load and should the first screws adjacent the shock-absorbing means fail, successive screws will then take up the load, causing a diminishing of the forces as the fall progresses. While six holes has been found to be most preferable, other numbers of holes may be employed, although it will be appreciated they will generally be in pairs, to provide an equal number of holes either side of where the webbing attaches to the shock-absorbing means. In its most simplest form, of course, even one hole may suffice where the length of webbing is, for example, simply looped back on itself and joined. However, given that safety considerations are paramount, it is preferred to utilize additional holes to provide additional attachment points should those closest to the shock-absorbing means fail. Thus, it is preferred to have at least four holes and, more preferably, at least six, where a single length of webbing is passed through a slit in the end of the shock-absorbing means as described above.
While it is preferred that the shock-absorbing means has sufficient energy-absorbing capability so as to deform under load without allowing any of the screws to pull out, the provision of six holes, i.e., three either side of the slot in the shock absorber, provide for additional safety should the first screws adjacent the shock absorber fail. To provide added safety, six, rather than merely four screws, are recommended.
With advantage the holes in the webbing are provided with metal reinforcements in the form of metal eyelets formed through the web. It is preferred that the holes be formed in the webbing material by spreading the fibers apart rather than cutting through the webbing. On the other hand, any means by which holes are formed may be contemplated. Compensation for reduced strength may be made by widening the amount of material in the webbing, for example. In any event, the metal eyelets then provide suitable reinforcement for such holes through which screws may be fitted, the screws then passing through the original holes in the metal cladding and into the support structure. The metal eyelets protect the webbing when inserting the screws and provide a reinforcement so the head of the screw is constrained from passing through the webbing, either during insertion of the screw or subsequently, should the anchor be subjected to a sudden fall from a person attached thereto.
Conventionally, eyelets are formed by utilizing a two-part construction, there being a male portion and a female portion, such that the male portion has a tubular portion that extends through the hole and is pressed over, i.e., crimped or expanded over, the female portion on the other side, forming a flange after the tubular portion passes through the hole in the female portion.
However, as the webbing required for the original disclosure is of necessity one having a very robust construction, conventional eyelets have been found to be inadequate, generally inadequate especially where relatively thick webbing material is utilized, e.g., greater than about 3 mm in thickness. Again, however, where suitable compensation is otherwise made by, for example, using broader webbing to compensate for a narrower thickness, conventional eyelets may be employed.
In relation to the preferred webbing structure, however, having a thickness in excess of, say, 3 mm, a simple alternative has been developed that involves the use of a three-part eyelet assembly, comprising two identical washers placed either side of the hole with a ferrule passing therethrough, each end of which is then caused to be pressed over both washers, i.e., forming flanges from both sides, in the same way as the tubular portion of a conventional eyelet is pressed on one side as described above, but in this case, doubled here to form each side of the eyelet structure.
With advantage, this eyelet, according to the original disclosure, can be inserted in such heavy webbing material by having a series of spikes mounted along a supporting member, over which the webbing can be forced to first create the required holes by spreading the fibers rather than cutting them. With a washer already located below the hole, i.e., on each spike, it is then a simple matter to slide the ferrule down the spike and force it through the hole, and fit another washer over each spike. A simple press arrangement then squeezes from each side, causing each end of the ferrule to form a flange on either side, which then binds each washer to each side of the respective holes formed in the web, creating an effective three-part metal eyelet having greater robustness than is attainable from a two-part eyelet assembly.
Thus, in typical applications where metal sheeting is affixed to a roof structure with existing screws, when affixing the anchor, the screws that hold the metal cladding are simply removed, the anchor located in position and then held in place utilizing those or other screws, if necessary, by inserting the screws through the holes in the webbing, then passing through the original holes in the metal cladding and thence into the supporting structure, generally a batten. Once the work is completed, the screws may then be removed again, the temporary anchor taken away and the screws refitted to hold the metal cladding in the way it was originally found. Alternatively, the anchor may be left in place permanently, as required.
It is, of course, necessary that the screws hold the anchor firmly and to this extent, a different length of screw (albeit with the same gauge) may need to be utilized to ensure proper penetration into the underlying batten. In the case of a timber batten, it has been found that the screws should penetrate at least 35 mm into the batten. Similarly, it is necessary with metal battens that the screw thread engages properly with the batten to avoid so-called overpassing of the thread as most roofing screws have a blank or unthreaded region below the head of the screw.
However, the disclosure is not meant to be limited to the use of screws as aforementioned and any suitable fixing means may be employed, either by affixing to the underlying roof structure through existing holes or even to the roof sheeting itself, provided the fixing of the sheeting to the underlying structure is sufficiently sound and the means by which the webbing is attached to the sheeting or structure is sufficient to withstand the forces discussed above.
In this regard, for example, so-called Klip Lock roofs do not have holes therethrough but are otherwise “clipped” down. By suitable adaptation, other fixing means that allow the webbing to be attached to such sheeting are, therefore, meant to be within the scope of the disclosure.
By utilizing a webbing material in the original disclosure, having as its major advantage complete flexibility, it will be understood that a variety of metal cladding profiles may thus be accommodated, the excess material between each fixing point, i.e., hole, simply allowed to form a loop between each fixing point. In other words, the use of webbing material allows for simple adjustment to accommodate different profiles of metal cladding and different spacings of screws placed therein, while still providing adequate support for the anchor if subjected to a sudden load.
Alternatively, where the roof support structure supports other than metal cladding, the webbing material may be affixed instead directly to the roof support structure after sufficient roof covering material, for example, tiles, has been removed. In such cases, the screws should be fitted preferably at least 100 mm apart along a rafter or batten. Therefore, although primarily intended for use with a metal roof, the anchor, according to the disclosure, could be fitted to a tiled roof or any other suitable stable structure, by attaching directly to the supporting structure, such as a rafter or batten, after removing one or more tiles as necessary to gain access to the underlying support structure.
Preferably, the webbing of the original disclosure and the way in which it is affixed to the roof support structure and/or the roof cladding as described herein, co-operate with the shock-absorbing means to further assist in minimizing the forces experienced should a fall occur.
It will be understood from the embodiments described herein, that the design as described herein is able to function, irrespective of the direction of the load.
BRIEF DESCRIPTION OF THE DRAWINGS
The disclosure will be better understood from the following non-limiting description of various aspects of an embodiment of the disclosure with reference to the drawings in which:
FIG. 1 is a perspective view of a temporary roof anchor according to one embodiment of the original disclosure;
FIG. 2 is a plan view of a suitable energy-absorbing shock absorber for use in the roof anchor shown in FIG. 1 ;
FIG. 3 is cross-sectional side elevation showing a detail of the eyelet for use in the temporary anchor shown in FIG. 1 ;
FIG. 4 is a schematic side elevation of a temporary roof anchor shown in FIG. 1 showing it affixed to a metal or timber batten supporting a metal roof cladding;
FIG. 5 is a simple plan view of a temporary roof anchor shown in FIG. 1 attached to the rafters of a tiled roof after removal of tiles;
FIG. 6 is a schematic side view of a height safety anchor according to an improvement of the disclosure according to one embodiment;
FIG. 7 is a schematic side view of a height safety anchor according to an improvement of the disclosure according to another embodiment;
FIG. 8 is a cross sectional schematic view of a slidable eyelet mounted on a cable according to one embodiment;
FIG. 9 is a top elevation of a pre-pressed slidable eyelet plate according to another aspect of the improvement of the disclosure;
FIG. 10 is a top elevation of a shock absorber according to another aspect of the improvement of the disclosure;
FIG. 11 is a schematic side view of the height safety anchor according to an improvement of the disclosure according to another embodiment; and
FIG. 12 is a perspective view of the height safety anchor attached to a roof according to another aspect of the improvement of the disclosure.
FIG. 12 is a top view of a metal cladded roof with a height safety anchor installed.
DETAILED DESCRIPTION
The webbing is provided with six holes 17 spaced along its length at approximately 300 mm to 400 mm centers. The holes 17 are preferably formed by piercing the webbing 12 to separate the fibers, rather than cutting a hole in the webbing 12 itself, which would weaken the webbing 12 at that point. These holes 17 are further provided with metal eyelets generally referenced 18 to provide reinforcement. The construction of each eyelet 18 is shown in detail in FIG. 3 .
The holes 17 allow for fixing the temporary anchor 11 to a roof structure as shown in FIGS. 4 and 5 .
Referring to FIG. 2 , there is shown in detail the shock absorber 13 , which is made from a sheet of stainless steel, e.g., 3 mm thick, die out to produce the aforementioned slot 15 at one end for receiving a length of webbing 12 and a hole 16 at the other end to which safety devices such as harnesses and the like may be attached. Therebetween is a region of concertina-like bends, generally referenced 19 , formed by die cutting. Upon experiencing a sudden load, such as would occur when a person attached to the temporary roof anchor 11 of which this shock absorber 13 is a part, the shock absorber 13 is caused to extend by, as it were, “unbending,” i.e., concertina region 19 straightening out. This action provides for a cushioning of the initial load when it is first applied, thereby effectively diminishing the energy of the load as the deformation progresses.
The sleeve 14 , described above, protects the shock absorber 13 and may also be usefully used to display safety instructions, etc.
Referring to FIG. 3 , there is shown a three-piece metal eyelet configuration, generally referenced 18 , as used in the temporary anchor of FIG. 1 . The eyelet 18 comprises two washers 20 , which are caused to be pressed against either side of a hole 17 extending through a portion of webbing material 12 , as described above. A ferrule member 21 is located through the hole 17 in the webbing 12 and by means of a press (not shown) has been bent at each end to form flanges 22 , which secures the eyelet assembly 18 in place, thereby reinforcing the hole 17 . The metal construction of the eyelet 18 not only provides stability to the holes 17 formed by separating the fibers, as described above, but also protects each hole 17 formed in the webbing 12 , e.g., when inserting a screw therein (as shown in FIGS. 4 and 5 ), and, furthermore, also maintains the integrity of the webbing 12 in use so that it will not pull away from the head of the screw once fitted to a roofing structure.
Referring then to FIG. 4 , there is shown schematically a temporary anchor 11 as described in FIGS. 2 through 3 , attached to a roofing structure, in this case a batten 23 supporting a sheet of metal roof cladding 24 . Batten 23 is shown schematically as both a metal batten 23 a and a timber batten 23 b . In each case, however, suitable hex-headed roofing screws 25 have been utilized, as is the norm. It is generally preferred that the screws in the timber batten 23 b extend at least 35 mm into the batten 23 , while in the case of the metal batten 23 a , it is necessary to ensure that the threaded portion 26 of the screw 25 engages in the hole of the batten 23 a without over extending as described earlier.
In either case, screws 25 , which initially secured the roof cladding 24 to the respective batten 23 a , 23 b , have been removed and replaced after the temporary anchor 11 has been located thereon. Either the original screws 25 have been utilized or other screws 25 of the same gauge but of an appropriate length as described have been used.
The length of webbing 12 is allowed to simply “buckle up” or concertina along its length between respective screw attachment points.
With reference to FIG. 5 , there is shown an attachment of a temporary roof anchor 11 to a pair of rafters 27 , which have been exposed after a suitable number of tiles 28 have been removed. In this instance, it is preferred that the screws 25 be located at least 100 mm apart.
In either case, as illustrated in FIG. 4 or FIG. 5 , if a sudden load is applied to the temporary anchor 11 as would occur from a person attached thereto falling from the roof, the bulk of the energy absorption will be initially taken up by the shock absorber 13 as it “unbends,” as described above. If, for any reason, the first pair of screws 25 fail, the load will be progressively taken up by the next pair of screws 25 , all the while the energy being dissipated as the fall, and hence the shock absorption, progresses. The provision of six screw holes 17 in the webbing 12 is to provide additional safety against failure.
Should the temporary anchor 11 be used in a fall, then it should be discarded. Otherwise, it may be removed by undoing the screws 25 , taken away and, in the case of a metal roof as shown in FIG. 4 , the original screws reinserted in the existing locations to once again secure the roof, or in the case of the tile roof shown in FIG. 5 , the tiles placed back in position.
Referring to FIG. 6 , there is shown an improved height safety anchor 11 a in which the webbing 12 of the height safety anchor 11 (shown in FIG. 1 ) is replaced with a metal cable, such as a stainless steel cable 12 a . The metal cable 12 a is flexible with high tensile strength. Mounted to the cable 12 a is a shock absorber 13 a that is similar in shape and function to the shock absorber 13 . However, the shock absorber 13 a is threaded onto the cable 12 a , generally at cable's 12 a mid-point, by threading the cable 12 a through a pair of spaced apertures 15 ′, 15 ″ located in an end plate 15 a of the shock absorber 13 a , whereafter the shock absorber 13 a is generally fixed in position at some place along the length of the cable 12 , for example, at its mid-point, when the cable 12 a is generally straightened. The skilled person will appreciate that the flexible cable 12 a may be manipulated to allow the shock absorber 13 a to be shifted in position along the length of the cable 12 a , as required. The apertures 15 ′, 15 ″ are holes formed in the end plate 15 a , so that the region of concertina-like bends 19 a extend between the end plate 15 a and a larger ring 16 a , the large ring 16 a being similar to the hole 16 of the shock absorber 13 . A crook or space 19 ′ is provided between the large ring 16 a and a first fold of the concertinaed region 19 a to permit increased flexibility of the large ring 16 a relative to the folded portion 19 a in the event of activation with a subject attached falling.
Slidably mounted to the cable at intermittent locations along its length are a plurality of eyelets 18 a that are loosely or closely pressed onto the cable 12 a depending on application requirements and may be slidable along the cable's length. This may provide adjustability as to where the eyelets 18 a are secured by fixing points or fasteners 25 , as described with reference to the metal eyelets 18 of the height safety anchor 11 . FIG. 8 provides an example of how the slidable eyelet 18 a can be pressed on to the cable 12 a . The fasteners 25 may be screws or other fixing means, such as clamps or bolts.
At either end of the cable 12 a , a closed swage socket 30 is swaged onto the end of the cable 12 a to form an end eyelet 31 . The closed swage socket 30 comprises a swage sleeve 32 swaged to the end of the metal cable. The swage sleeve 32 may be internally threaded at its remote end and the end eyelet 31 may include a threaded bolt that can be threadably received in the swage sleeve 32 whereby end eyelets 31 may be replaced or substituted for different sized eyelets 31 , or to replace damaged eyelets 31 , for example, following activation of the height safety anchor 11 a after a fall.
FIG. 7 illustrates another improved height safety anchor 11 b in which the same shock absorber 13 a is used as that shown in FIG. 6 and the slidable eyelets 18 a are also similar to that of the embodiment shown in FIG. 6 . However, instead of the closed swage sockets 30 of the height safety anchor 11 a , the height safety anchor 11 b comprises open swage sockets 35 on the respective ends of a flexible metal cable 12 b . The open swage sockets 35 are integrally or unitarily formed with respect to their respective swage sleeve 37 that is swaged onto the respective ends of the cable 12 b , the end eyelet 36 being integrally formed with the swage sleeve 37 .
Accordingly, in use the height safety anchors 11 a , 11 b are mounted to a building structure, such as that shown in FIG. 4 or FIG. 5 . The advantage of the improved height safety anchors, 11 a , 11 b , is in the superior strength of the stainless steel cable, 12 a , 12 b , while retaining adequate flexibility with regard to ease of attachment to available fixing points on the building structure, particularly aided by the adjustability of the slidable eyelets 18 a along its length. Preferably, as shown in FIGS. 6 and 7 , four slidable eyelets 18 a are provided intermediate the length of the cable, 12 a , 12 b . However, of course the number of eyelets 18 a , 18 b may be varied, together with the length of the cable 12 a , 12 b , depending on the application and the requirements of a particular installation, the typical length of cable being between 1-3 meters, and preferably, about 1.8-2 meters in length.
The provision of the apertures 15 ′, 15 ″ in the end plate 15 a of the shock absorber 13 a allow the shock absorber 13 a to be moved in position along the length of the flexible cable, 12 a , 12 b , so that a first length of cable 12 ′ might be longer or shorter than the remainder or the second length of cable 12 ″. Accordingly, both improved height safety anchors 11 a , 11 b have facility for adjustment in situ and the height safety anchor 11 a further provides for replacement or interchangeability of the end eyelets 31 .
In FIG. 9 there is shown a pre-pressed plate 40 that is used to form an eyelet 18 d . The plate 40 is generally diamond shaped and has a pair of opposed rounded ends 41 in each of which there is centrally located an aperture 41 . Extending between the rounded ends 41 is a broad plate region and a centrally located transverse channel section 43 . In this embodiment of the eyelet 18 d , the eyelet plate 40 is gripped at its ends 41 and pressed to fold and wrap around a cable 12 ″ so that the cable 12 ″ rests in a channel 43 formed as the walls of the plate 40 are folded towards one another and as the holes 42 are folded into registration with one another. The length of cable 12 ″, secured in this manner, can then be fastened to a building supporting structure by inserting a fastener 25 through the holes 42 and fastened to the building supporting structure. The pressed fit of the slidable eyelet 40 may be sufficiently loose about the cable 12 ″ so that the eyelet 40 is able to be adjusted in position along the length of the cable 12 ″. Alternatively, the eyelet 40 may be secured by friction fit against sliding along the length of the cable 12 ″ and may be loosened by slightly reversing the pressing process to release the friction grip of the eyelet channel 43 on the cable 12 ″ to permit at least limited movement of the eyelet 40 along the length of the cable 12 ″.
Turning to FIG. 10 , there is shown another version of the applicant's shock absorber 13 c . The shock absorber 13 c comprises slots to enable a cable 12 ″ to be fed through the pair of apertures 15 c to permit the cable to be advantageously fixed at a particular position on the length of the cable 12 ″ and also to be loosened for adjustment along the length of the cable 12 ″, when required. The first attachment loop 16 c comprises flat outer edges to provide a graspable surface 44 .
In FIGS. 11 and 12 , a height safety anchor 11 d similar to that shown in FIGS. 6 and 7 is provided. The height safety anchor 11 d utilizes the pressed eyelet 18 d formed from the plate 40 comprising a pair of apertures 42 and described in FIG. 9 . As shown in FIG. 11 , the height safety anchor 11 d comprises a cable 12 d made from stainless steel or galvanized cable that is flexible but possesses high tensile strength. The cable 12 d is preferably sheathed with a protective plastic sleeve and terminates with a pair of terminal eyelets 30 d in a manner similar to the embodiment shown in FIG. 6 . The cable 12 d is secured at multiple points, preferably 4 points, intermediate its length, spaced from each other, by slidable and adjustable eyelets 18 d that are secured by fasteners 25 in the form of screws to a metal or wooden batten or rafter, or another suitable building support structure 23 d.
Spaced upon approximately halfway between two innermost slidable eyelets 18 d is a shock absorber 13 d covered across its serpentine shock absorbing section by a sleeve 14 d . A first end of the shock absorber 13 d is threaded by the cable 12 d through a pair of slots 15 d similar to the slots 15 c shown in FIG. 10 . At its opposed end, a second attachment means 16 d provides a loop for attachment of a carabiner 60 d for the attachment of individual safety equipment.
In FIG. 12 , the height safety anchor 11 d of FIG. 11 is shown installed on a metal cladded roof 24 . The eyelets 18 d are secured through pre-formed registered holes in the metal cladding 24 to a rafter support (not shown). The fasteners 25 are typically and preferentially inserted at a high ridge point in the cladding where possible to minimize the risk of corrosion and roof leakage. Through a carabiner 60 d , the height safety anchor 11 d further has attached to its second attachment 16 d a safety rope 62 to which a worker may be attached via their personal safety equipment, such as a harness (not shown).
It can be seen from FIGS. 11 and 12 that not only does the shock absorber 13 d provide the potential for absorption of energy in the event of the application of a critical sudden load to the second attachment 16 d , but the ability of the cable to slide against friction resistance and frictional forces applied by the slidable eyelets 18 d also provide a means for absorption of kinetic energy applied through the second attachment.
It will appreciated that many modifications and variations may be made to the embodiment described herein by those skilled in the art without departing from the spirit or scope of the disclosure.
Throughout the specification and claims the word “comprise” and its derivatives are intended to have an inclusive rather than exclusive meaning unless the context requires otherwise.
In the present specification, terms such as “component,” “apparatus,” “means,” “device” and “member” may refer to singular or plural items and are terms intended to refer to a set of properties, functions or characteristics performed by one or more items having one or more parts. It is envisaged that where a “component,” “apparatus,” “means,” “device” or “member” or similar term is described as being a unitary object, then a functionally equivalent object having multiple components is considered to fall within the scope of the term, and similarly, where a “component,” “apparatus,” “assembly,” “means,” “device” or “member” is described as having multiple items, a functionally equivalent but unitary object is also considered to fall within the scope of the term, unless the contrary is expressly stated or the context requires otherwise.
Industrial Applicability
It will be immediately apparent to persons skilled in the art that the height safety anchor may provide an anchor point for a variety of activities carried out on buildings at height. For example, the height safety anchor may provide an anchor point for posts supporting fences or other barriers erected for the safety of workmen working on the building or may be used to secure equipment associated with the actual work on the building, notwithstanding that its primary function is to provide safety for persons engaged on working on a building.
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A height safety anchor for fitment to a building support structure, the height safety anchor comprising: first attachment means for fitment to the building support structure; second attachment means remote from the first attachment means for attaching safety equipment; and shock absorbing means having a deformable region extending between the first and second attachment means in a first length when not subject to a deformation force corresponding to a critical sudden load, the shock absorbing means lying substantially in a single plane and comprising a substantially rigid structure that, when subject to the critical sudden load, deforms, elongating to a greater length than the first length.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention is directed to drilling rigs and to methods for erecting mobile drilling rigs.
[0003] 2. Description of Related Art
[0004] The prior art discloses a variety of rigs used in drilling and various wellbore operations; for example, and not by way of limitation, U.S. Pat. Nos. 3,340,938; 3,807,109; 3,922,825; 3,942,593; 4,269,395; 4,290,495; 4,368,602; 4,489,526; 4,569,168; 4,837,992; 6,634,436; 6,523,319; and 7,306,055 and the references cited in these patents—all these patents incorporated fully herein for all purposes. The prior art discloses a variety of systems and methods for assembling and erecting a drilling rig; for example, and not by way of limitation nor-as an exhaustive listing, the disclosures in U.S. Pat. No. 2,993,570; 3,201,091; 3,262,237; 3,749,183; 4,221,088; 4,269,009; 4,292,772; 4,305,237; 4,478,015; 4,587,778; 4,630,425; and 4,932,175.
[0005] Often drilling rigs and related systems, structures, equipment, and apparatuses are delivered to a site, assembled, raised, disassembled, and transported to a new site. It is important that drilling rigs and their components be easily transported, assembled, and erected.
[0006] In many prior rigs and erection methods, rig components and structures used with a rig are raised by a crane and positioned on a rig's drill floor. Various problems and disadvantages are associated with using a crane. A crane is typically a large apparatus which is transported to a drilling site where it is assembled and/or made ready for lifting and locating rig components.
BRIEF SUMMARY OF THE INVENTION
[0007] The present invention, in certain aspects, provides a drilling rig with structure manipulation and erection apparatus and methods for using such apparatus to erect a rig without using a crane, without winching up cables, and without lifting items and equipment with a drawworks.
[0008] The present invention discloses, in certain aspects, a method for assembling a drilling rig, the method including: assembling a substructure of a drilling rig, the assembly including connecting an upper box to a lower box, the upper box having an upper open space, the lower box having a lower open space, and the upper open space above the lower open space; moving with a vehicle on ground a floor section connected to and supported by the vehicle into open space including the upper open space and the lower open space; and securing the floor section to the substructure.
[0009] The present invention discloses, in certain aspects, a method for assembling a drilling rig, the method including: assembling a substructure of a drilling rig, the assembly including connecting an upper box to a lower box, the upper box having an upper open space, the lower box having a lower open space, and the upper open space above the lower open space; moving with a vehicle on ground a floor section connected to and supported by the vehicle into open space including the upper open space and the lower open space; and securing the floor section to the substructure; disconnecting the floor section from the vehicle; moving the vehicle away from the drilling rig; installing a drawworks (or other rig apparatus) on the substructure; assembling a mast connected to the substructure; erecting the mast on the substructure; installing a rig structure on the substructure; and raising with raising apparatus the substructure to an operational height.
[0010] The present invention discloses, in certain aspects, a system for drilling including: a substructure, the substructure locatable on ground and having an open space; a floor section, the floor section movable with a vehicle on ground adjacent the substructure, the floor section connected to and supported by the vehicle and movable on the vehicle into the open space; and the floor section releasably connected to the substructure.
[0011] The present invention discloses, in certain aspects, a substructure for a drilling rig, the substructure including: an upper box with an upper open space; a lower box with a lower open space; the upper open space above the lower open space and comprising a substructure space; the substructure space sized for selective receipt therein of a vehicle; and a floor section connectable to and supportable by the vehicle for movement into the substructure space, the floor section connected to the substructure.
[0012] Accordingly, the present invention includes features and advantages which are believed to enable it to advance drilling rig technology and rig erection technology. Characteristics and advantages of the present invention described above and additional features and benefits will be readily apparent to those skilled in the art upon consideration of the following detailed description of preferred embodiments and referring to the accompanying drawings.
[0013] Certain embodiments of this invention are not limited to any particular individual feature disclosed here, but include combinations of them distinguished from the prior art in their structures, functions, and/or results achieved. Features of the invention have been broadly described so that the detailed descriptions that follow may be better understood, and in order that the contributions of this invention to the arts may be better appreciated. There are, of course, additional aspects of the invention described below and which may be included in the subject matter of the claims to this invention. Those skilled in the art who have the benefit of this invention, its teachings, and suggestions will appreciate that the conceptions of this disclosure may be used as a creative basis for designing other structures, methods and systems for carrying out and practicing the present invention. The claims of this invention are to be read to include any legally equivalent devices or methods which do not depart from the spirit and scope of the present invention.
[0014] What follows are some of, but not all, the objects of this invention. In addition to the specific objects stated below for at least certain preferred embodiments of the invention, there are other objects and purposes which will be readily apparent to one of skill in this art who has the benefit of this invention's teachings and disclosures. It is, therefore, an object of at least certain preferred embodiments of the present invention to provide the embodiments and aspects listed above and:
[0015] New, useful, unique, efficient, non-obvious drilling rigs; rig erection methods; and new, useful, unique, efficient, nonobvious rig structure for rig erection; and
[0016] Such systems and methods in which a central drill floor portion is connected to a drill floor without a crane.
[0017] The present invention recognizes and addresses the problems and needs in this area and provides a solution to those problems and a satisfactory meeting of those needs in its various possible embodiments and equivalents thereof. To one of skill in this art who has the benefits of this invention's realizations, teachings, disclosures, and suggestions, various purposes and advantages will be appreciated from the following description of preferred embodiments, given for the purpose of disclosure, when taken in conjunction with the accompanying drawings. The detail in these descriptions is not intended to thwart this patent's object to claim this invention no matter how others may later attempt to disguise it by variations in form or additions of further improvements.
[0018] The Abstract that is part hereof is to enable the U.S. Patent and Trademark Office and the public generally, and scientists, engineers, researchers, and practitioners in the art who are not familiar with patent terms or legal terms of phraseology to determine quickly from a cursory inspection or review the nature and general area of the disclosure of this invention. The Abstract is neither intended to define the invention, which is done by the claims, nor is it intended to be limiting of the scope of the invention or of the claims in any way.
[0019] It will be understood that the various embodiments of the present invention may include one, some, or all of the disclosed, described, and/or enumerated improvements and/or technical advantages and/or elements in claims to this invention.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0020] A more particular description of embodiments of the invention briefly summarized above may be had by references to the embodiments which are shown in the drawings which form a part of this specification. These drawings illustrate certain preferred embodiments and are not to be used to improperly limit the scope of the invention which may have other equally effective or equivalent embodiments.
[0021] FIG. 1A is a top view of part of an upper box of a drilling rig according to the present invention.
[0022] FIG. 1B is a top view of the upper box of FIG. 1A above a base box of the rig according to the present invention.
[0023] FIG. 1C is a top view of base box of FIG. 1B .
[0024] FIG. 1D is an top view of the upper box and of the base box of FIG. 1B .
[0025] FIG. 2A is a top view of a step in a method for the assembly of rig according to the present invention for installing a drawworks.
[0026] FIG. 2B is a top view of a further step in the assembly method for the assembly of rig according to the present invention.
[0027] FIG. 2C is a side view of the step of FIG. 2B .
[0028] FIG. 2D is a top view showing the drawworks installed on the rig.
[0029] FIG. 3A is a top view of a step in a method for the assembly of rig according to the present invention for installing a mast.
[0030] FIG. 3B is a side view of a further step in the assembly method for installing the mast.
[0031] FIG. 3C is a side view of a further step in installing the mast.
[0032] FIG. 3D shows the mast erected.
[0033] FIG. 4A is a top view of a step in a method for the assembly of rig according to the present invention for installing a center floor on the rig.
[0034] FIG. 4B is a top view of a further step in the assembly method for installing the center floor.
[0035] FIG. 4C is a side view of a further step in installing the center floor.
[0036] FIG. 4D is a side view of a further step in installing the center floor.
[0037] FIG. 4E is a top view of a further step in the assembly method for installing the center floor.
[0038] FIG. 5A is a side view of a step in a method for the assembly of rig according to the present invention for installing a rig structure, e.g., a doghouse, on the rig.
[0039] FIG. 5B is a top view of a further step in the assembly method for installing the doghouse.
[0040] FIG. 5C is an end view of the step of FIG. 5B .
[0041] FIG. 5D is a side view of a further step in installing doghouse.
[0042] FIG. 6A is a side view of a step in a method for the assembly of rig according to the present invention for raising the rig.
[0043] FIG. 6B is a side view of a further step in the assembly method for raising the rig.
[0044] FIG. 6C is a side view of a further step in raising the rig.
[0045] FIG. 6D is a side view of a further step in raising the rig.
[0046] FIG. 6E is a top view of a further step in raising the rig.
[0047] FIG. 6F is a top view of the rig floor of the rig of FIG. 6D .
[0048] FIG. 7A is a top view of part of a rig as in FIG. 6F .
[0049] FIG. 7B is a side view showing a connection of parts of the rig of FIG. 7A after installation and FIG. 7B is a view along-line-A-A of FIG. 7A .
[0050] FIG. 7C is a side view showing a connection of parts of the rig of FIG. 7A before installation.
[0051] FIG. 7D is a side view showing a connection of parts of the rig of FIG. 7A after installation and FIG. 7D is a view along line B-B of FIG. 7A .
[0052] FIG. 7E is a side view showing a connection of parts of the rig of FIG. 7A before installation.
[0053] FIG. 7F is a side view showing a connection of parts of the rig of FIG. 7A after installation and FIG. 7F is a view along line C-C of FIG. 7A .
[0054] FIG. 7G is a side view showing a connection of parts of the rig of FIG. 7A before installation.
[0055] FIG. 7H is a side view showing a connection of parts of the rig of FIG. 7A after installation and FIG. 7H is a view along line D-D of FIG. 7A .
[0056] FIG. 7I is a side view showing a connection of parts of the rig of FIG. 7A before installation.
[0057] Presently preferred embodiments of the invention are shown in the above-identified figures and described in detail below. Various aspects and features of embodiments of the invention are described below and some are set out in the dependent claims. Any combination of aspects and/or features described below or shown in the dependent claims can be used except where such aspects and/or features are mutually exclusive. It should be understood that the appended drawings and description herein are of preferred embodiments and are not intended to limit the invention or the appended claims. On the contrary, the intention is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the invention as defined by the appended claims. In showing and describing the preferred embodiments, like or identical reference numerals are used to identify common or similar elements. The figures are not necessarily to scale and certain features and certain views of the figures may be shown exaggerated in scale or in schematic in the interest of clarity and conciseness.
[0058] As used herein and throughout all the various portions (and headings) of this patent, the terms “invention”, “present invention” and variations thereof mean one or more embodiment, and are not intended to mean the claimed invention of any particular appended claim(s) or all of the appended claims. Accordingly, the subject or topic of each such reference is not automatically or necessarily part of, or required by, any particular claim(s) merely because of such reference. So long as they are not mutually exclusive or contradictory any aspect or feature or combination of aspects or features of any embodiment disclosed herein may be used in any other embodiment disclosed herein.
DETAILED DESCRIPTION OF THE INVENTION
[0059] FIGS. 6A-6D show a rig 10 according to the present invention erected by a method according to the present invention.
[0060] FIG. 1A shows an upper box 12 of a substructure 20 or the rig 10 according to the present invention. FIG. 1B shows the upper box 12 above a base box 14 of the rig substructure 20 . The upper box 12 includes side floor section 12 a , side floor section 12 b , upper box beam 12 c which includes parts 12 d and 12 e . The parts 12 d and 12 e pivot, respectively, about pivot connections 12 f , 12 g and these have ends which are releasably connectable to each other with a pin 12 h as shown in FIG. 1D . Braces 12 i , 12 j are pivotably connected to pivot connections 12 k , 12 m , respectively and are pivotable to releasably connect to the parts 12 d , 12 e at points 12 n , 12 p , respectively, as shown in FIG. 1D . Optionally, the rig 10 has pivotable suspension arms 121 , 122 which are useful in securing an item, e.g. a rig structure such as a doghouse DH (see FIG. 6F ) to the rig.
[0061] The base box 14 includes a side structure 14 a and a side structure 14 b ; a base box beam 14 c ; a base box beam 14 d ; a base box beam 14 e ; a substructure raising cylinder 14 f ; and a substructure raising cylinder 14 g.
[0062] As shown in FIG. 1C , the base box beam 14 c has been pivoted about a pivotal connection 14 h and releasably connected to a connection 14 i on the side structure 14 a . The base box beam 14 d has been pivoted about a pivotal connection 14 i and releasably connected to a connection 14 k on the side structure 14 a . The base box beam 14 e has been pivoted about a pivotal connection 14 m and releasably connected to a connection 14 n on the side structure 14 a . This releasably connects the base side structure 14 a to the base side structure 14 b with respect to a well center WC.
[0063] As shown in FIG. 1D , the parts 12 d , 12 e of the upper box beam 12 c have been pivoted and their ends have been releasably connected with the pin 12 h . The braces 12 i , 12 j have been pivoted and connected to the parts 12 d , 12 e , respectively.
[0064] The combination of the upper box 12 and the base box 14 form the basic structure of the rig substructure 20 .
[0065] FIGS. 2A-2D illustrate the installation of a drawworks 16 on the substructure 20 . It is within the scope of the present invention for the drawworks 16 to be installed on the substructure 20 in any known way using any known structure, apparatus, machines and devices; and using any known drill floor and/or upper box, including, but not limited to, an upper box with a floor portion for supporting the drawworks. Alternatively, the drawworks 16 is installed as described in the U.S. Patent Application filed on even date herewith, naming Donnally et al as inventors, and entitled “Drilling Rig Drawworks Installation”; co-owned with the present invention and incorporated fully herein for all purposes. FIGS. 2A-2D illustrate one drawworks installation method.
[0066] As shown in FIG. 2A a truck Ta with a trailer Tb pulls alongside the substructure 20 . The trailer Tb supports the drawworks 16 which is on a skid 16 s . As shown in FIGS. 2B and 2C the truck Ta positions the trailer Tb in a desired position with respect to the substructure 20 and the skid 16 s of the drawworks 16 is connected to the substructure 20 . Alternatively the upper box 12 includes a support floor for the drawworks 16 . The substructure 20 includes pivotable supports 20 s , substructure raising cylinder apparatuses 20 a , and mast raising cylinder apparatuses 20 b.
[0067] FIGS. 3A-3D illustrate the installation of a mast 18 on the substructure 20 and the raising of the mast 18 . It is within the scope of the present invention to install any suitable known mast on the substructure 20 and to install the mast using any DQ 210 known method and apparatus. Alternatively, the mast 18 is installed as described in the U.S. Patent Application co-owned with the present invention, naming Donnally et al as inventors, filed on even date herewith, and entitled “Drilling Rig Masts And Methods For Erecting Masts”; and incorporated fully herein for all purposes. FIGS. 3A-3D illustrate one mast installation method. The rig shown includes a doghouse support arm 18 t.
[0068] As shown in FIG. 3A , the substructure 20 has been lowered using the substructure cylinder apparatuses 14 f , 14 g and the base box beam 14 e has been disconnected from the connection 14 n and pivoted out of the way making room for part of the mast to be moved into place between the side structures 14 a , 14 b . Legs 20 a are pivotably connected to the substructure. As shown in FIG. 3B a truck Tc with a trailer Td supporting a bottom mast section 18 a has moved the bottom mast section 18 a between the side structures 14 a , 14 b . The mast raising cylinder apparatuses 20 b are connected to the mast bottom section 18 a and both the substructure raising cylinder apparatuses 14 f , 14 g and the mast raising cylinder apparatuses 20 b are then extended to raise the mast bottom section 18 a above the trailer Td. The truck Tc is then moved away.
[0069] As shown in FIG. 3C , with the bottom mast section 18 a connected to the upper box 12 a truck Te with a trailer Tf supporting a mid mast section 18 b has moved the mid mast section 18 b adjacent the bottom mast section 18 a.
[0070] The bottom mast section 18 a is connected to the mid mast section 18 b ; in one aspect, employing the substructure raising cylinder apparatuses 14 f , 14 g and the mast raising cylinder apparatuses 20 b to position the mast sections and facilitate their interengagement. The truck Te is then moved away; in one aspect, the truck Te is moved away following retraction of the substructure raising cylinder apparatuses 14 f , 14 g , and extension of the mast raising cylinder apparatuses 20 b . As shown in FIG. 3D , but prior to erecting the mast 18 , a racking board 18 r may be opened on the mast 18 .
[0071] As shown in FIG. 3D , the mast 18 is erected, e.g., by extending the mast raising cylinder apparatuses. The mast bottom section 18 a is secured to the mast mid section 18 b and, if used, the mast raising cylinder apparatuses are then retracted.
[0072] FIGS. 4A-4E illustrate a method according to the present invention for the installation of a center floor section 19 .
[0073] As shown in FIG. 4A , the braces 12 i , 12 j have been released from the parts 12 d , 12 e , respectively, pivoted on their respective connections 12 k , 12 m ; and moved out of the way. As shown in FIG. 4B , the base box beam 14 d has been released from its connection 14 k ; pivoted on its connection 14 i ; and moved out of the way.
[0074] As shown in FIG. 4C , a truck Tg with a trailer Th supporting a center floor section 19 has moved the center floor section 19 adjacent the substructure 20 . The center floor section 19 , optionally, includes a rotary table 19 a . As shown in FIG. 4D , the truck Tg moves the center floor section 19 between the parts of the upper box 14 and base box 12 and the center floor section 19 is connected to the upper box 14 . The truck Tg and trailer Th are moved away. The braces 12 i , 12 j are then reconnected (see FIG. 4E ).
[0075] FIGS. 5A-5D illustrate the installation of a rig structure (e.g. house, cabin, control room, doghouse, driller cabin) on the substructure 20 . It is within the scope of the present invention to use any known apparatus and method for installing a rig structure on the substructure. Alternatively, the rig structure (e.g. a doghouse 17 ) is installed on the substructure 20 as described in the U.S. Application filed on even date herewith entitled “Drilling Rig Structure Installation And Methods”; co-owned with the present invention; and incorporated fully herein for all purposes.
[0076] As shown in FIGS. 5A-5C , the doghouse 17 supported on a trailer Tj of a truck Ti is moved into position adjacent the substructure 20 and the substructure 20 has been lowered. The doghouse 17 is connected to the substructure 20 and the truck Ti and trailer Tj are then moved away ( FIG. 5D ).
[0077] FIGS. 6A-6D illustrate the raising of the substructure 20 to move the rig 10 into a working position.
[0078] As shown in FIG. 6A , the substructure 20 is lowered to install drawworks skid support legs 16 a ; various equipment and apparatuses; e.g., (see FIG. 6F ) an iron roughneck 24 ; air tugger winches 25 a ; an independent rotary drive 25 b ; and a rotary table 25 c (if not already installed) over a well center WC and near a mousehole MH (any of which optionally may be installed on the center section before installation on the substructure); and other equipment and hand rails.
[0079] As shown in FIG. 6B , the substructure 20 is raised using the substructure raising cylinder apparatuses, raising the upper box 12 , the mast 18 , and the other equipment. A bottom end of each of the legs 16 a is pinned to the base box 14 . The base box beams 14 d and 14 e are pivoted and reconnected to the connections 14 k , 14 m , respectively. A BOP support beam structure 14 s is connected to the base box 14 . Support legs 14 t are connected between the upper box 12 and the base box 4 . If the mast 18 is a telescoping mast, the mid mast section 18 b is telescoped up from the bottom mast section 18 a ( FIG. 6C ). As shown in FIG. 6D the rig 10 is erected and, optionally, a rig walker 28 (for rig movement) is installed on the base box 14 .
[0080] FIG. 6F is a top view of the upper box 12 with the drawworks 16 , doghouse 17 , and center floor 19 installed.
[0081] FIGS. 7A-7F illustrate structure for connection of various parts of the rig as in FIG. 6F ; shown with a drawworks deleted.
[0082] FIGS. 7A-7F illustrate various connection structures both before the center floor 19 is installed and after the center floor 19 is installed.
[0083] FIGS. 7B-7C illustrate the connection of beams B 1 and B 2 with pins Pa.
[0084] FIGS. 7D-7E illustrate the connection of parts P 1 and P 2 .
[0085] FIGS. 7G-7F illustrate the connection of parts P 3 and P 4 .
[0086] FIGS. 7H-7I illustrate the connection of parts P 5 and P 6 .
[0087] The present invention, therefore, provides in some, but not in necessarily all, embodiments a method for assembling a drilling rig, the method including: assembling a substructure of a drilling rig, the assembly including connecting an upper box to a lower box, the upper box having an upper open space, the lower box having a lower open space, and the upper open space above the lower open space; moving with a vehicle on ground a floor section connected to and supported by the vehicle into open space including the upper open space and the lower open space; and securing the floor section to the substructure. Such a method may one or some, in any possible combination, of the following: disconnecting the floor section from the vehicle, and moving the vehicle away from the drilling rig; installing a drawworks (or rig apparatus) on the substructure; assembling a mast connected to the substructure; erecting the mast on the substructure; installing a rig structure on the substructure; wherein the rig structure is one of doghouse, cabin, and control room; installing rig equipment on the substructure; wherein the rig equipment is one of winch, iron roughneck, independent rotary table drive, and rotary table; and/or raising with raising apparatus the substructure to an operational height.
[0088] The present invention, therefore, provides in some, but not in necessarily all, embodiments a method for assembling a drilling rig, the method including: assembling a substructure of a drilling rig, the assembly including connecting an upper box to a lower box, the upper box having an upper open space, the lower box having a lower open space, and the upper open space above the lower open space; moving with a vehicle on ground a floor section connected to and supported by the vehicle into open space including the upper open space and the lower open space; and securing the floor section to the substructure; disconnecting the floor section from the vehicle; moving the vehicle away from the drilling rig; installing a drawworks (or rig apparatus) on the substructure; assembling a mast connected to the substructure; erecting the mast on the substructure; installing a rig structure on the substructure; and raising with raising apparatus the substructure to an operational height.
[0089] The present invention, therefore, provides in some, but not in necessarily all, embodiments a system for drilling including: a substructure, the substructure locatable on ground and including an upper box to a lower box, the upper box having an upper open space, the lower box having a lower open space, and the upper open space above the lower open space; a floor section, the floor section movable with a vehicle on ground adjacent the substructure, the floor section connected to and supported by the vehicle and movable on the vehicle into an open space including the upper open space and the lower open space; and the floor section releasably connected to the substructure. Such a system may one or some, in any possible combination, of the following: a drawworks (or rig apparatus) on the substructure; a mast connected to the substructure; a rig structure on the substructure; wherein the rig structure is one of doghouse, cabin, and control room; rig equipment on the substructure; wherein the rig equipment is one of winch, iron roughneck, independent rotary table drive, and rotary table; and/or raising apparatus connected to the substructure for raising the substructure to an operational height.
[0090] The present invention, therefore, provides in some, but not in necessarily all, embodiments a substructure for a drilling rig, the substructure including: an upper box with an upper open space; a lower box with a lower open space; the upper open space above the lower open space and comprising a substructure space; the substructure space sized for selective receipt therein of a vehicle; and a floor section connectable to and supportable by the vehicle for movement into the substructure space, the floor section connected to the substructure.
[0091] The systems and methods of the inventions described in the following pending U.S. Patent Applications, co-owned with the present invention, filed on even date herewith, naming Donnally et al as inventors, and fully incorporated herein for all purposes, may be used with certain embodiments of the present invention, the applications entitled: “Drilling Rig Masts And Methods Of Assembly and Erection”; “Drilling Rig Structure Installation And Methods”; and “Drilling Rig Drawworks Installation”.
[0092] In conclusion, therefore, it is seen that the present invention and the embodiments disclosed herein and those covered by the appended claims are well adapted to carry out the objectives and obtain the ends set forth. Certain changes can be made in the subject matter without departing from the spirit and the scope of this invention. It is realized that changes are possible within the scope of this invention and it is further intended that each element or step recited in any of the following claims is to be understood as referring to the step literally and/or to all equivalent elements or steps. The following claims are intended to cover the invention as broadly as legally possible in whatever form it may be utilized. The invention claimed herein is new and novel in accordance with 35 U.S.C. § 102 and satisfies the conditions for patentability in § 102. The invention claimed herein is not obvious in accordance with 35 U.S.C. § 103 and satisfies the conditions for patentability in § 103. This specification and the claims that follow are in accordance with all of the requirements of 35 U.S.C. § 112. The inventors may rely on the Doctrine of Equivalents to determine and assess the scope of their invention and of the claims that follow as they may pertain to apparatus not materially departing from, but outside of, the literal scope of the invention as set forth in the following claims. All patents and applications identified herein are incorporated fully herein for all purposes. It is the express intention of the applicant not to invoke 35 U.S.C. § 112, paragraph 6 for any limitations of any of the claims herein, except for those in which the claim expressly uses the words ‘means for’ together with an associated function. In this patent document, the word “comprising” is used in its non-limiting sense to mean that items following the word are including, but items not specifically mentioned are not excluded. A reference to an element by the indefinite article “a” does not exclude the possibility that more than one of the element is present, unless the context clearly requires that there be one and only one of the elements.
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Systems and methods for erecting a drilling rig. This abstract is provided to comply with the rules requiring an abstract which will allow a searcher or other reader to quickly ascertain the subject matter of the technical disclosure and is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims, 37 C.F.R. 1.72 ( b ).
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
The present invention relates to load bearing outer skins for marine structures which are suitable to support a platform for carrying out operations in arctic and sub-arctic regions. Such marine structures are particularly well suited for conducting exploration and drilling in areas such as the Alaskan Beufort Sea and serve equally well for such operations as supporting production equipment, liquefaction plants, gas compression plants, crude oil storage and offshore loading facilities in this and other such regions.
Since in most arctic and sub-arctic locations, only about two months of acceptable weather for construction per year are available, structures employing the load bearing outer skin of the present invention should ideally require a minimum amount of construction effort at the job site. Structures adapted for use in ice laden environments typically employ load bearing outer skins designed to safely resist substantial ice forces encountered when such structures are installed in an offshore location. Structures designed for offshore use in arctic environments have to withstand highly concentrated local loads from first year and multi-year ice features. Typical designs for load bearing outer skins of such structures include heavily reinforced or stiffened skin plate members for resisting local loads caused by ice formations. In the alternative, such load bearing outer skins may be formed from high strength, heavily reinforced and prestressed concrete or similar materials.
Since such offshore structures used in exploration in arctic areas must be relocated from one drilling site to another in the event a first drilling site proves unsuccessful, the overall structure needs to be light enough to be able to be floated from one location to the next with a very shallow draft.
Similarly, due to the short period available for construction in arctic or sub-arctic regions, construction techniques for building a load bearing outer skin must be simple, thereby permitting quick assembly.
DESCRIPTION OF THE PRIOR ART
In the past, load bearing outer skins for offshore arctic marine structures have been made from reinforced concrete or similar cementitious materials. A concrete load bearing outer skin required the use of costly high strength yet lightweight concrete. Furthermore, in order to achieve sufficient rigidity to resist point loads from adjacent ice formations, the concrete had to be highly reinforced and prestressed to achieve the required strength. Since flexural reinforcement, such as reinforcement bars, could not be placed at the most advantageous position near the top and bottom of the concrete surfaces, such structures were inherently inefficient. Since the forms used for pouring concrete load bearing outer skins were so congested with reinforcement in order to withstand local ice loads, workmen frequently experienced difficulty in placing and adequately vibrating the concrete to remove air voids. Vibrating the concrete was necessary not only to remove air voids within the slab but to insure the concrete was sufficiently compacted around all the reinforcement bars. Furthermore, since a concrete load bearing outer skin required structurally substantial top and bottom forms in order to support the fresh concrete, workmen frequently experienced difficulties in removing the forms from the inside of the structure once the concrete had set. Finally, although ice-bond reducing coatings have been successfully applied to metallic surfaces, such coatings have yet to be successfully applied to concrete surfaces. Accordingly, concrete load bearing outer skins for offshore structures in arctic environments incorporate several drawbacks involving high weight, high cost, and difficult assembly.
Other designs for load bearing outer skins for arctic offshore structures used various types of steel construction. One design featured a load bearing outer skin comprising an assembly of thick steel skin plates welded together. The thick steel skin plates were stiffened by T-shaped structural members connected to the underside of the thick steel skin plates to transmit ice loads to the underlying structure. The T-shaped main stiffeners were generally disposed at spaced intervals parallel to each other and welded to the inside surface of those thick steel skin plates which were to contact the ice formations. The outer skin was further stiffened by a series of secondary structural stiffeners disposed at spaced intervals parallel to each other and perpendicular to the main stiffeners. The secondary stiffeners were typically welded between the main stiffeners. The main stiffeners were continuously welded to the thick steel skin plates.
These load bearing outer skins employing a stiffened steel design suffered from several drawbacks. In order to withstand local ice loads the steel plates spanning the stiffeners had to be relatively thick and heavy thereby increasing the weight of the overall structure. A considerable amount of labor was required to cut and weld the thick steel plates as well as the structural reinforcing members. Local loads applied by ice formations to the outer skin were transferred directly and virtually without dispersal to the supporting members through the main stiffeners. Accordingly, the main stiffeners had to be sufficiently rigid to resist high local loads. Accidental impact from multi-year ice features could damage or distort the outer skin plates and the underlying stiffeners.
Another design for a load bearing outer skin for an arctic offshore structure has been to use an inner and an outer thick steel skin plate joined together by a number of steel web plates continuously welded at each end to the inner and outer thick steel skin plates. In some applications cavity formed between the inner and outer thick steel skin plates was filled with concrete or some other cementitious material. The problem with this type of design for a load bearing outer skin was that the continuous welds necessary to form the structure had to be made in a confined space. Similarly, inspection and rectification of defective welds was also impeded due to the confined quarters between the inner and outer steel skin plates during fabrication.
SUMMARY OF THE INVENTION
The present invention provides an economical and lightweight load bearing outer skin for an offshore structure used in an arctic environment and a method for its erection. The load bearing outer skin of the present invention allows loads applied to a skin plate member in contact with ice formations to be spread through a concrete in-fill thereby permitting the use of lighter structural members due to the interaction between the concrete in-fill and the skin plate members and their underlying stiffeners.
The load bearing outer skin of the present invention contains an inner assembly and an outer assembly. Both the inner and outer assemblies include a skin plate member which is stiffened by stiffeners welded to one side of the skin plate member. The stiffeners are located at spaced intervals from each other and are disposed substantially perpendicular to the skin plate member. The inner and outer assembly are placed substantially parallel to each other to form a composite structure having an internal cavity defined by the inner and outer plates. The stiffeners of the inner assembly and the outer assembly are disposed in the cavity at a spaced relation to each other and extend partly into the cavity. A cementitious material substantially fills the cavity thereby completing the load bearing outer skin structure. The stiffeners may be flat steel plates or may have the profile of structural shapes such as angles or T's among others.
The load bearing outer skin of the present invention allows horizontal shearing stress between the skin plates and the in fill cementitious material to be transferred by a bond between the two or through the weld between the skin plate member and the stiffeners followed by usage of the bond between the stiffeners and the infill cementitious material.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a part sectional elevation of a supporting structure located in an offshore arctic environment for supporting the load bearing outer skin of the present invention;
FIG. 2 is a section taken along lines 2--2 of FIG. 1;
FIG. 3 is a section of the load bearing outer skin taken along lines 3--3 of FIG. 2;
FIG. 4 shows an alternate embodiment of the load bearing outer skin employing L-shaped stiffeners;
FIG. 5 is an alternate embodiment of the load bearing outer skin shown in FIG. 3 using T-shaped stiffeners;
FIG. 6 is a section through the load bearing outer skin taken along lines 6--6 of FIG. 4 show in openings in the stiffeners.
FIG. 7 is a sectional view of the load bearing outer skin showing the usage of connecting members.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A marine structure containing the load bearing outer skin of the present invention is shown in FIG. 1. The structure S is typically designed for installation in arctic and sub-arctic waters upon which ice features 1 may be formed. The entire structure S may be constructed in a less hostile environment, towed to location under its own buoyancy, and installed on location by sea water ballasting. The structure S is held in place on the sea bottom 3 by its own weight plus the weight of any ballast added to the structure (not shown). The structure S extends above the water line 5 and supports the load bearing outer skin 7 of the present invention. The structure S employing load bearing outer skin 7 is suitable for supporting a stable platform from which a variety of offshore operations may be performed. These operations include, but are not limited to, exploration drilling, production drilling, hydrocarbon production, gas compression, water flood operations, enhanced hydrocarbon recovery, gas liquifaction, mineral ore extraction and processing, coal handling, storage of materials and equipment, offshore loading of tankers and other vessels, and offshore housing of personnel.
Referring to FIG. 3, the load bearing outer skin 7 is composed of an inner assembly I and an outer assembly O. The inner assembly I contains a skin plate member 9 which is made of steel or another suitable high strength material compatible with the marine environment. A series of stiffeners 11 are continuously welded to skin plate member 9 and disposed in a plane perpendicular to skin plate member 9. In the preferred embodiment, stiffeners 11 are disposed parallel to each other at spaced equal intervals however, unequal intervals may be used without departing from the spirit of the invention.
The outer assembly O comprises of skin plate member 13 which is of similar construction as skin plate member 9. Skin plate member 13 is stiffened via stiffeners 15 which are disposed in a plane perpendicular to skin plate member 13. Stiffeners 15 are disposed at spaced intervals parallel to each other although a spacing employing unequal intervals is within the scope of the invention.
To form the load bearing outer skin 7 of the present invention, inner assembly I and outer assembly O are aligned substantially parallel to each other thereby forming a cavity C therebetween. As seen in FIG. 3, stiffeners 11 and stiffeners 15 extend partly into cavity C. In the preferred embodiment, stiffeners 11 extend into cavity C without reaching skin plate member 13. Similarly stiffeners 15 span a significant portion of cavity C without coming in contact with skin plate members 9. The length of stiffeners 11 and 15 is a design element determined by the requirements of each application. Accordingly, stiffeners 11 and 15 may extend less than halfway across cavity C or substantially across the entire cavity C as shown in FIG. 3.
As seen in FIG. 3, inner assembly I is juxtaposed next to outer assembly O so that stiffeners 11 straddle stiffeners 15. Although FIG. 3 displays a pattern of one stiffener 15 disposed between two stiffeners 11 and vice versa, some alternate staggering pattern between stiffeners 11 and stiffeners 15 can be employed without departing from the spirit of the invention. As shown in FIGS. 2 and 3, stiffeners 11 and 15 are elongated flat plates. Stiffeners 11 have an elongated longitudinal edge 17 which is continuously welded to skin plate members 9. Similarly, stiffeners 15 have an elongated longitudinal edge 19 continuously welded to skin plate members 13. Stiffeners 11 have a longitudinal free end 21 and stiffeners 15 have a longitudinal free end 23.
As best seen in FIGS. 4 and 5, stiffeners 11 and 15 rather than being simply elongated flat plates may have an L or a T-shape. As seen in FIG. 4 stiffeners 11, attached to skin plate member 9, have an elongated flat plate section 25 and a flat anchor segment 27 perpendicular to elongated flat plate section 25 and attached at free end 21. Similarly, stiffeners 15 may have an elongated flat plate section 29 and a flat anchor segment 31 disposed perpendicularly to elongated flat plate section 29 and connected to free end 23 of elongated flat plate section 29. It should be noted that flat anchor segments 27 or 31 may be separate pieces connected to elongated flat plate sections 25 and 29 respectively, or stiffeners 11 and 15 may have the L-shape displayed in FIG. 4 by bending such stiffeners adjacent their free ends 21 or 23.
Stiffeners 11 and 15 may also have a T-shape (FIG. 5) by attaching flat segments 33 and 35 to free ends 21 and 23 of stiffeners 11 and 15, respectively. Flat segments 33 and 35 are disposed in cavity C substantially parallel to each other and substantially perpendicular to both elongated flat plate sections 25 and 29 of stiffeners 11 and 15, respectively. Although flat, L-shaped, and T-shaped configurations for stiffeners 11 and 15 have been described, elongated stiffeners having a different cross-section are within the purview of the present invention.
Having placed the outer assembly O substantially parallel to the inner assembly I as described hereinabove, a cementitious material 41 can be poured between skin plate members 9 and skin plate members 13 thereby completing the load bearing outer skin 7 of the present invention. In order to facilitate the distribution of the cementitious material 41, to cut down on the overall weight of the load bearing outer skin 7 of the present invention, and to improve bonding, stiffeners 11 and/or 15 may contain a plurality of openings 43 as shown in FIG. 6. It is understood that although FIG. 6 represents openings 43 shown in an L-shaped stiffener 11 of FIG. 4, such openings may be used in flat plate stiffeners 11 and 15 shown in FIG. 1 as well as alternative embodiments (such as FIGS. 4 and 5) employing L-shaped or T-shaped stiffeners. In forming openings 43, elongated flat plate section 29 may be constructed in one piece with openings 43 cut out from it or, as shown in FIG. 6 elongated flat plate section 29 may be formed from two pieces each of which having had material removed from its edge.
Referring to FIG. 7, inner assembly I and outer assembly O can be held in place during the time when a cementitious material 41 is poured therebetween via a plurality of connecting members 45 and 47. A plurality of holes 49 are cut in skin plate member 9. Similarly, a plurality of holes 51 are cut in skin plate member 13. Connecting members 45 which can be threaded rods, or long bolts or another suitable fastening device are welded to stiffeners 15 adjacent their free end 23. Similarly, as an alternative to connecting members 45 or in addition thereto, connecting members 47 are welded to stiffeners 11 adjacent their free ends 21. Connecting members 45 extend beyond free end 23 through holes 51 in skin plate members 13. Similarly, connecting members 47 extend beyond the free ends 21 of stiffeners 11 and through holes 49 of skin plate members 9. Nuts 53 and 55 are threaded onto connecting members 45 and 47, respectively. Accordingly, nuts 53 and 55 when placed on connecting members 45 and 47 resist the tendency of inner assembly I and outer assembly O to separate when cementitious material 41 is poured therebetween. After the cementitious material 41 has been poured between inner assembly I and outer assembly O and has further had a chance to set up, nuts 53 and 55 as well as that portion of connecting members 45 and 47 protruding through the skin plates 13 and 9, respectively, may be cut off. After the cutting off operation is completed, holes 49 and 51 can be patched thereby insuring that skin plate members 13 form a continuous surface for application of any coatings, as desired. It is understood that the details of each application determine the quantity and location of connecting members 45 and 47. Similarly, only connecting members 45 or alternatively only connecting members 47 or both may be used to retain the relative positions of inner assembly I and outer assembly O during the pouring of the cementitious material 41.
Once the cementitious material 41 has hardened the load bearing outer skin 7 will function as an efficient structural system. The horizontal shearing stress distribution between skin plate member 9 and skin plate member 13 and the cementitious material 41 therebetween can be transferred in one of two ways. The shearing stress may be transferred by the bond between the cementitious material 41 and the skin plate members 9 and 13 though the bond between the two or through the welds between the skin plate members 9 and 13 to stiffeners 11 and 15, respectively, thereby relying on the bond between stiffeners 11 and 15 and the cementitious material. A similar system of horizontal shear stress transfer exists in the orthogonal direction also enabling the assembly to function as a two-way system.
Due to this interaction between the cementitious material and the inner assembly I and outer assembly O, the load bearing outer skin 7 can provide adequate strength while using concrete of a lower strength than that required in conventional prestressed concrete construction. Furthermore, placing of the cementitious material is much simpler due to the absence of complex reinforcing arrangements required in traditional pre-stressed concrete construction for load bearing outer skins of arctic offshore structures.
Due to the support provided by the cementitious material 41 to the skin plate member 13 coming in contact with the ice features 1, thinner steel or other equivalent high strength material can be used. Similarly, stiffeners 11 and 15 may also be thinner than conventional steel construction due to the restraint against buckling provided by the cementitious material 41 which completely surrounds stiffeners 11 and 15. Importantly, local loads applied to the outer surface of skin plate member 13 by ice features 1 (which are typically in a normal direction as shown by arrows 60 in FIG. 1) are spread through the cementitious material 41 within cavity C thereby reducing loads on support members of structure S thereby reducing overall costs. Furthermore, since skin plate members 9 and 13 are placed at the furthest possible distance from the neutral axis 57 (see FIG. 7), thinner plates than in conventional steel construction may be used.
From a construction standpoint, the load bearing outer skin 7 of the present invention provides many construction economies. Skin plate members 9 and 13 act as a formwork for the cementitious material 41 thereby eliminating a substantial cost item as compared to using a concrete load bearing outer skin. Inner assembly I and outer assembly O may be easily constructed in a fabrication shop in a relatively open environment as opposed to load bearing outer skins employing steel construction wherein stiffeners must be continuously welded to an inner and an outer steel plate in a confined space. For the same reasons, inspection and rectification of faulty welds is considerably simpler.
The composite structure of the load bearing outer skin 7 of the present invention further enables the structure S to absorb accidental impact from multi-year ice features 1 without distorting skin plate member 13 or stiffeners 15 attached thereto. Finally, ice bond reducing coatings, may be confidently applied to the steel skin plate member 13 since such coatings have a known efficacy when applied to steel surfaces. The efficacy of such coatings on concrete surfaces is yet unproven.
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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The load bearing outer skin contains an inner assembly and an outer assembly. Both the inner and outer assemblies include a skin plate member which is stiffened by stiffeners welded to one side of the skin plate member. The stiffeners are located at spaced intervals from each other and are disposed substantially perpendicular to the skin plate member. The inner and outer assembly are placed substantially parallel to each other to form a composite structure having an internal cavity defined by the inner and outer plates. The stiffeners of the inner assembly and the outer assembly are disposed in the cavity at a spaced relation to each other and extend partly into the cavity. A cementitious material substantially fills the cavity thereby completing the load bearing outer skin structure. The stiffeners may be flat steel plates or may have the profile of structural shapes such as angles or T's among others.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of provisional application U.S. Ser. No. 60/522,500 filed Oct. 7, 2004.
BACKGROUND OF THE INVENTION
[0002] The present invention generally relates to subsurface safety valves. More particularly, the present invention relates to an apparatus and method to install a replacement safety valve to a location where a previously installed safety valve is desired to be replaced. More particularly still, the present invention relates to communicating with a production zone through a bypass-conduit when a replacement safety valve is closed.
[0003] Subsurface safety valves are typically installed in strings of tubing deployed to subterranean wellbores to prevent the escape of fluids from one production zone to another. Absent safety valves, sudden increases in downhole pressure can lead to catastrophic blowouts of production and other fluids into the atmosphere. For this reason, drilling and production regulations throughout the world require safety valves be in place within strings of production tubing before certain operations can be performed.
[0004] One popular type of safety valve is known as a flapper valve. Flapper valves typically include a flow interruption device generally in the form of a circular or curved disc that engages a corresponding valve seat to isolate one or more zones in the subsurface well. The flapper disc is preferably constructed such that the flow through the flapper valve seat is as unrestricted as possible. Usually, flapper-type safety valves are located within the production tubing and isolate one or more production zones from the atmosphere or upper portions of the wellbore or production tubing. Optimally, flapper valves function as large clearance check valves, in that they allow substantially unrestricted flow therethrough when opened and completely seal off flow in one direction when closed. Particularly, production tubing safety valves can prevent fluids from production zones from flowing up the production tubing when closed but still allow for the flow of fluids and/or tools into the production zone from above.
[0005] Flapper valve disks are often energized with a biasing member (spring, hydraulic cylinder, etc.) such that in a condition with zero flow and with no actuating force applied, the valve remains closed. In this closed position, any build-up of pressure from the production zone below will thrust the flapper disc against the valve seat and act to strengthen any seal therebetween. During use, flapper valves are opened by various methods to allow the free flow and travel of production fluids and tools therethrough. Flapper valves may be kept open through hydraulic, electrical, or mechanical energy during the production process.
[0006] Examples of subsurface safety valves can be found in U.S. Provisional Patent Application Ser. No. 60/522,360 filed Sep. 20, 2004 by Jeffrey Bolding entitled “Downhole Safety Apparatus and Method;” U.S. Provisional Patent Application Ser. No. 60/522,498 filed Oct. 7, 2004 by David R. Smith and Jeffrey Bolding entitled “Downhole Safety Valve Apparatus and Method;” U.S. Provisional Patent Application Ser. No. 60/522,499 filed Oct. 7, 2004 by David R. Smith and Jeffrey Bolding entitled “Downhole Safety Valve Interface Apparatus and Method;” all hereby incorporated herein by reference. Furthermore, applicant incorporates by reference U.S. Non-Provisional application Ser. No. 10/708,338 Filed Feb. 25, 2004, titled “Method and Apparatus to Complete a Well Having Tubing Inserted Through a Valve” and U.S. Provisional Application Ser. No. 60/319,972 Filed Feb. 25, 2003 titled “Method and Apparatus to Complete a Well Having Tubing Inserted Through a Valve.”
[0007] Over time, a replacement subsurface safety valve may be desired. An existing subsurface safety valve can become stuck or otherwise inoperable either through failure of various safety valve components or because of caked-up hydrocarbon deposits, for example. In these circumstance, sudden increases in production zone pressure can lead to dangerous surface blowouts if the safety valves are not repaired. Because the repair or replacement of a subsurface safety valve formerly required the removal of the string of production tubing from the wellbore, these operations were frequently prohibitively costly for marginal wells. An improved apparatus and method to repair or replace existing subsurface safety valves would be highly desirable to those in the petroleum production industry.
SUMMARY OF THE INVENTION
[0008] In one embodiment, a replacement safety valve to hydraulically isolate a lower zone below the replacement safety valve from a first bore of an existing safety valve comprises a main body having a clearance passage through a longitudinal bore and an outer profile, the outer profile removably received within a landing profile of the existing safety valve, a flow interruption device located in the clearance passage pivotably operable between an open position and a closed hydraulically sealed position, and a bypass-conduit extending from a surface location through the replacement safety valve to the lower zone, the bypass-conduit wholly contained within a second bore of a string of tubing carrying the existing safety valve.
[0009] In another embodiment, the bypass-conduit can be in communication with the surface location and the lower zone below the valve when the flow interruption device is in the closed hydraulically sealed position. The bypass-conduit can be in communication with the surface location and the lower zone below the valve when the flow interruption device is in the open position. The lower zone can be a production zone.
[0010] In yet another embodiment, the bypass-conduit passes through the existing safety valve en route to the lower zone. The main body can retain a second flow interruption device of the existing safety valve in an open position. The existing safety valve can include a first hydraulic conduit in communication with the replacement safety valve through a second hydraulic conduit therein. The existing safety valve can include a nipple profile.
[0011] In yet another embodiment, the replacement safety valve of claim can further comprise hydraulic seals hydraulically isolating the replacement safety valve from the existing safety valve. The bypass-conduit can extend through the main body of the replacement safety valve. The bypass-conduit can be a hydraulic fluid passage, a continuous string of tubing, or a hydraulic capillary tube. The hydraulic capillary tube can be a fluid injection hydraulic capillary tube. The fluid can be a foam or a gas. The fluid can be selected from the group comprising surfactant, acid, miscellar solution, corrosion inhibitor, scale inhibitor, hydrate inhibitor, and paraffin inhibitor.
[0012] In another embodiment, the bypass-conduit can be a logging conduit, a gas lift conduit, an electrical conductor, or an optical fiber. The bypass-conduit can further comprise a check valve below the replacement safety valve. The bypass-conduit can further comprise a check valve between the replacement safety valve and a wellhead. The bypass-conduit can further comprise a hydrostatic valve between the replacement safety valve and a wellhead. The bypass-conduit can further comprise a hydrostatic valve below the replacement safety valve.
[0013] In another embodiment, the replacement safety valve further comprises an operating conduit in communication with a source of an energy, the energy actuating the flow interruption device between the open position and the closed hydraulically sealed position. The operating conduit can extend from the surface location through the first bore of the existing safety valve to the main body. The operating conduit can extend from the surface location to the replacement safety valve through a wall of the existing safety valve.
[0014] In yet another embodiment, a method to hydraulically isolate a zone below an existing safety valve from a string of tubing carrying the existing safety valve in communication with a surface location comprises deploying a replacement safety valve through the string of tubing to a location of the existing safety valve, engaging the replacement safety valve within a landing profile of the existing safety valve, extending a bypass-conduit from the surface location, through the replacement safety valve, to the zone below the existing safety valve, and communicating between the surface location and the zone below the existing safety valve through the bypass-conduit when a flow interruption device of the replacement safety valve is in a closed hydraulically sealed position. The zone below the existing safety valve can be a production zone.
[0015] In another embodiment, a method can further comprise the step of communicating between the surface location and the zone below the existing safety valve through the bypass-conduit when the flow interruption device of the replacement safety valve is in an open position. A method can further comprise the step of retaining a second flow interruption device of the existing safety valve in an open position with an outer profile of the replacement safety valve. The bypass-conduit can be a hydraulic fluid passage, a continuous tube, or a hydraulic capillary tube. The bypass-conduit can comprise a plurality of a jointed pipe section deployed from the surface location. A method can further comprise the step of including a check valve in the bypass-conduit above the replacement safety valve or below the replacement safety valve.
[0016] In another embodiment, a method can further comprise the step of injecting a foam or a fluid to the zone below the existing safety valve through the bypass-conduit. The fluid can be selected from the group consisting of corrosion inhibitor, scale inhibitor, hydrate inhibitor, paraffin inhibitor, surfactant, acid, and miscellar solution. The bypass-conduit can be a logging conduit. The logging conduit can be greater than about one and a half inches in diameter. A method can include a bypass-conduit which can be a gas lift conduit, an electrical conductor, or an optical fiber.
[0017] In yet another embodiment, the method can further comprise the step of operating the flow interruption device between the closed hydraulically sealed position and an open position with an operating conduit. The method can further comprise the step of extending the operating conduit from the surface location to the replacement valve through the string of tubing. The method can further comprise the step of communicating hydraulic pressure through the operating conduit, through a first passage in the existing safety valve to a second passage in the replacement safety valve.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is schematic representation of a replacement safety valve assembly installed in an existing safety valve in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0019] Referring initially to FIG. 1 , a schematic representation of a replacement subsurface safety valve assembly 100 is shown engaged within an existing subsurface safety valve 102 . Existing safety valve 102 includes a generally tubular valve body 104 , a flapper 106 , a landing profile 108 , and a clearance bore 110 . Likewise, replacement valve assembly 100 includes a main body 112 , an engagement profile 114 , a flapper 116 , and a clearance bore 118 .
[0020] With a replacement safety valve desired to be located within an existing safety valve 102 , replacement valve assembly 100 is disposed downhole through the string of tubing or borehole where preexisting safety valve 102 resides. Once replacement valve 100 reaches existing safety valve 102 , replacement valve 100 is actuated through clearance bore 110 until engagement profile 114 of replacement valve 100 engages and locks within landing profile 108 of existing safety valve 102 . Landing and engagement profiles 108 , 114 are shown schematically in FIG. 1 but any scheme for mounting a tubular or a valve downhole known to one of ordinary skill in the art may be used.
[0021] For example, to lock into place replacement subsurface safety valve assembly 100 within landing profile 108 of existing safety valve 102 , engagement profile 114 can be constructed with a collapsible profile, a latching profile, or as an interference-fit profile. In an interference-fit scheme (as shown schematically in FIG. 1 ), the outer diameter of engagement profile 114 is slightly larger than the diameter of the clearance bore 110 but slightly smaller than a minimum diameter of landing profile 108 of existing safety valve 102 . Using this scheme, replacement valve 100 is engaged within clearance bore 110 until engagement profile 114 abuts valve body 104 . Once so engaged, replacement valve 100 can be impact loaded until engagement profile 114 travels through clearance bore 110 and engages within landing profile 108 . Alternatively, engagement profile 114 can be constructed to be retractable or extendable via wireline or hydraulic capillary such that the full dimension of engagement profile 114 is not reached until it is in position within landing profile 108 .
[0022] Once installed, replacement valve body 112 opposes any biasing force remaining to retain flapper 106 of existing safety valve 102 out of the way within recess 120 . Hydraulic seals 122 , 124 , and 126 isolate fluids flowing from production zones below valves 100 , 102 through clearance bores 118 , 110 from coming into contact with, and eroding components ( 106 , 120 ) of existing safety valve 102 and the outer profile of replacement valve 100 . Otherwise, paraffin and other deposits might clog the space defined between valve bodies 112 and 104 and could prevent subsequent repair or removal operations of either replacement valve 100 or existing safety valve 102 .
[0023] In operation, fluids will flow from downhole zone 130 , through clearance bore 118 of replacement valve 100 , and through upper end of clearance bore 110 of existing safety valve 102 to upper zone 132 . Typically, downhole zone 130 will be a production zone and upper zone 132 will be in communication with a surface station. Flapper 116 of replacement valve 100 pivots around axis 134 between an open position (shown) and a closed position (shown by dashed lines in FIG. 1 ). A valve seat 136 acts as a stop and seals a surface of flapper disc 116 to prevent hydraulic communication from lower zone 130 to upper zone 132 when flapper 116 is closed. With flapper 116 closed, increases in pressure in lower zone 130 act upon the bottom of and thrust flapper 116 against seat 136 with increased pressure to enhance any hydraulic seal therebetween. Typically, a torsional spring (not shown) acts about axis 134 to bias flapper disc 116 against seat 136 if not held open by some other means. Various schemes can be and have been employed to retain flapper 116 in an open position when passage from lower zone 130 to upper zone 132 is desired (or vice versa), including using a slidable operating mandrel or a hydraulic actuator housed within valve body 112 . Regardless of how activated from open to closed position, flapper 116 acts to prevent communication from lower zone 130 to upper zone 132 when closed.
[0024] Additionally, replacement valve 100 can optionally be configured to have flapper 116 or any other component operated from the surface. An operating conduit (not shown) can optionally be deployed from a surface unit, through tubing and existing safety valve 102 to replacement valve 100 to operate flapper 116 from closed position to open position (or vice versa). Furthermore, referring again to FIG. 1 , an existing operating conduit 140 emplaced with existing safety valve 102 can be used to operate flapper 116 of replacement valve 100 . Specifically, operating conduit 140 extends from a surface location to existing safety valve 102 to operate flapper disc 106 . While operating conduit 140 is shown schematically as a hydraulic conduit, it should be understood by one of ordinary skill in the art that any operating scheme including, electrical, mechanical, pneumatic, and fiber optic systems can be employed. A passage 142 connects operating conduit 140 to inner bore 110 of existing safety valve 102 to allow operating conduit 140 to communicate with replacement valve 100 through a corresponding passage 144 . A pressure accumulator 146 is housed within main body 112 of replacement valve 100 and acts to store and convert pressure from operating conduit 140 into mechanical energy to displace flapper 116 between open and closed positions. Hydraulic seals 124 , 126 ensure that any pressure in operating conduit 140 is maintained through passages 142 , 144 and accumulator 146 with little or negligible loss. To prevent operating conduit 140 from communicating with bore 110 of existing safety valve 102 before replacement valve 100 is present, a rupture disc (not shown) can be placed within passage 142 . Rupture disc can be configured to rupture at a pressure that is outside the normal operating range of existing safety valve 102 . To install replacement valve 100 , an operator increases pressure in operating conduit 140 to “blow out” rupture disc in passage 142 and then can install replacement valve 100 . Once rupture disc is ruptured, operating conduit 140 can be used as normal to operate flapper 116 of replacement valve 100 .
[0025] It is often desirable to communicate with lower zone 130 when flapper valve 116 is closed. For instance, there are circumstances where pressures within producing zones are such as to not allow the opening of flapper 116 but the injection of chemical, foam, gas, and other material to lower zone 130 is either beneficial or necessary. To accommodate such situations, a bypass-conduit 150 can be incorporated in replacement valve 100 such that communication between upper zone 132 and lower zone 130 can occur irrespective of the position of flapper 116 . The upper zone 132 can be a surface location. Bypass-conduit 150 includes an upper segment 152 , a lower segment 154 , and a passage 156 through replacement valve body 112 of replacement valve 100 . Bypass-conduit 150 can be of any form known to one of ordinary skill in the art, but can be a single continuous hydraulic tube, a string of threaded tubing sections, an electrical conduit, a fiber-optic conduit, a gas lift conduit, or, depending of the size of replacement valve 100 , a logging conduit. Typically, bypass-conduit 150 will most often be constructed as hydraulic capillary tubing allowing the injection of a chemical stimulant, surfactant, inhibitor, solvent, and foam from a surface location to lower zone 130 .
[0026] Furthermore, if bypass-conduit 150 is constructed to allow the injection of fluid to lower zone 132 from above, a check valve (not shown) may be included to prevent increases in downhole pressure from blowing out past replacement valve 100 through bypass-conduit 150 to the surface. The term capillary tube is used to describe any small diameter tube and is not limited to a tube that holds liquid by capillary action nor is there any requirement for surface tension to elevate or depress the liquid in the tube. The term hydraulic and hydraulically are used to describe water or any other fluid and are not limited to a liquid or by liquid means, but can be a gas or any mixture thereof.
[0027] While the invention has been described with respect to a limited number of embodiments, those skilled in the art will appreciate numerous modifications and variations therefrom. It is intended that the appended claims cover all such modifications and variations as fall within the true spirit and scope of the invention.
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A safety valve ( 100 ) replaces an existing safety valve ( 102 ) in order to isolate a production zone from a tubing string when closed. Preferably the safety valve ( 100 ) includes a flow interruption device ( 106 ) displaced by an operating conduit extending from a surface location to the safety valve ( 100 ) through the inside of the production tubing. A by-pass conduit ( 150 ) allows communication from a surface location to the production zone through the safety valve ( 100 ) without affecting the operation of the safety valve ( 100 ).
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TECHNICAL FIELD
The present invention relates to portable supports for supporting persons or objects above the ground, a floor, a stage or the like. More particularly, the present invention relates to a portable riser that can be moved and re-shaped quickly, quietly and conveniently into a variety of configurations.
BACKGROUND OF THE INVENTION
Collapsible or portable staging is known in the prior art. U.S. Pat. No. 4,580,766 (Burkinshaw) discloses a collapsible staging or raised platform for presenting various types of entertainment. The staging is formed by staging modules having first and second end frames at either end and side frames between the end frames, and may include collapsible stairs that have different widths, as well as different heights. The side frames each comprise hingedly connected sub-frames whereby the entire module may fold inwardly in "concertina fashion". Though connected, the platforms and flames are distinct elements and a platform to frame and frame to frame locking or engaging means is required.
Somewhat similarly, U.S. Pat. No. 2,841,831 (Mackintosh) discloses a folding stage wherein floor slabs or panels are collapsibly supported by leg frames and guide braces. The panels are hinged so they may be collapsed "zig-zag fashion".
Although well suited for their intended purpose, the stages disclosed in the Burkinshaw and Mackintosh patents require a frame mechanism or structure that is discrete from the platform or panels that form the platform. Additionally, the manipulation of the stages disclosed in Burkinshaw and Mackintosh will create substantial noise.
U.S. Pat. No. 310,226 (Rice et al.) is directed to providing foldable or folding steps. The Rice et al. patent discloses folding steps consisting of a box or platform "A" provided with a series of preferably triangular steps "B" hinged or pivoted therein by a vertical bolt or rod "a". The steps may be pivoted relative to each other as at "b", and are adapted to be drawn out of or entirely folded within the box. One end of each step is provided with a casing to hide the space beneath the steps. There are several problems the Rice et al. steps do not solve. Because of the space beneath the steps, moving and folding the steps will create noise. The triangular step shape is not as safe for supporting persons as a rectangular shape because of the small horizontal support surface at the apex area of each triangular step. There is no disclosure of a way to join and secure more than one set of the folding steps to each other.
U.S. Pat. No. 3,035,671 (Sicherman) is directed to providing portable folding steps for use in an exercise test. The steps consist of two folding steps nine inches wide and nine inches high hingedly mounted on opposite sides of a central step nine inches wide and eighteen inches from the floor. The two steps are supported by pivotally collapsible braces and are movable from a storage position wherein they are folded over the top of the central step to an unfolded, extended position. A tubular framework is required, and only two arrangements or configurations are possible: a storage configuration and a use configuration. In use, the steps can be unfolded only to a shape wherein they have equal top upper surface areas. The hinges connecting the steps are exposed and have raised areas, therefore presenting an uneven surface. Tubular leg braces and spring clips are required and, if the clips or braces are not fully locked or deployed, the steps could be unstable.
Step-like display stands, such as that disclosed in U.S. Pat. No. 1,514,055 (Lawson), are also known. The Lawson stand includes treads, risers and upright side support plates, all connected by rule joint hinges. The stand may be collapsed by folding the upright sides, treads and risers into close parallel relation. There is no disclosure of a way to join and secure together more than one set of the step-like display units, and they will be noisy during deployment and collapse.
It is clear that with current collapsible staging and portable risers, safety, cost efficient fabrication, convenient, quiet rapid setup and movement, and the capacity for achieving multiple configurations are not provided to an optimum degree. Accordingly, there is a need for a strong, efficient, easily moved and re-shaped, safe and quiet portable riser for supporting persons or objects above the ground, a stage, a floor or the like.
SUMMARY OF THE INVENTION
In accordance with the present invention, a portable riser unit for supporting persons or objects above the ground, a floor, a stage or the like is provided. The riser broadly comprises a base, generally rectangular step members, and hinge means for pivotally, hingedly connecting the step members to the base. By manipulating the step members, the riser may be re-shaped into a variety of operable configurations, including a storage shape. The base has a generally hollow single-piece body formed by a substantially continuous relatively thin wall or skin and an integral convoluted interior or internal support and baffle wall structure, and may be substantially filled with an appropriate low density, high volume material. Each step member also may be of this construction; however, the step members may or may not have an internal support wall. Each step member is operably coupled to the base by at least one double or twin axis hinge, including a hinge block received in complementary hinge wells in the base and step members. The hinges are self-leveling to present a substantially smooth, level riser support surface in every possible configuration. The riser may be rotationally molded of a plastic material and includes integral hand grips to facilitate moving the individual step members or the riser as a whole. Two or more adjacent risers may be used to form a riser assembly, and the invention encompasses a connector key for connecting adjacent risers.
An object of the present invention is to provide an articulated portable riser unit strong enough to support people safely, yet light enough to move quickly and easily.
Another object of the present invention is to provide a portable riser adapted for quick and easy re-shaping into a variety of configurations, whereby the riser facilitates supporting persons or objects above the ground, a floor, a stage or the like in a variety of heights and arrangements. Advantageously, the configurations include at least a platform configuration, wherein the riser presents a single, generally flat, raised uppermost support surface, a seated riser configuration wherein two parallel support surfaces having unequal surface areas are provided, and a standing riser configuration presenting a stair-like shape with three support surfaces, each in a different plane and having a substantially equal area.
An advantage of the present invention is that it provides a portable, reconfigurable riser unit or assembly that is suitably durable and rigid, yet does not require a discrete support frame mechanism. Further, no special tools, nor an extended period of time, are required to assemble, reshape or move the riser. The portable riser of the present invention may be used for many purposes in institutions, including elementary and secondary schools, day care facilities, and churches. It is particularly useful in the performing arts wherein rapid, quiet redeployment or rearrangement of scenery or persons is required during the course of a performance.
Still another object of the present invention is to provide a portable riser to support persons or objects above the ground, a floor, a stage or the like, wherein the riser presents substantially smooth, uniformly finished and level visible horizontal and vertical surfaces.
Yet another object of the present invention is to provide a riser that is quiet to use, move and reshape. The riser has at least one integral, convoluted support and baffle interior wall structure and the remainder of the substantially hollow base and step members may or may not be filled with an expanded material. Whether filled or not, another advantage of the riser of the present invention is that it tends to minimize noise, both the hollow "booming" noise generated as people step on prior art risers and the noise caused by moving or folding prior art risers, yet it remains light enough to be moved easily.
Other advantages of the riser of the present invention are that it provides for efficient use of labor by minimizing the number of persons required to move and reconfigure it. Additionally, the base, and each step member, are molded as a single integral piece, thus eliminating the need for separate folding support or frame structures and other components.
Other objects and advantages of the present invention will become more fully apparent and understood with reference to the following specification and to the appended drawings and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the portable hinged riser unit of the present invention, arranged in a three step shape.
FIG. 2 is a perspective view of the present invention in a two step, seated riser configuration.
FIG. 3 is a perspective view of the riser of the present invention in a stage or platform configuration.
FIG. 4 is a top plan view of the larger high step member of the riser of the present invention.
FIG. 5 is a side elevational view of the high step member.
FIG. 6 is a fragmentary sectional detail taken along line 6--6 in FIG. 4.
FIG. 7 is a fragmentary sectional detail taken along line 7--7 in FIG. 5.
FIG. 8 is a fragmentary sectional detail taken along line 8--8 in FIG. 5.
FIG. 9 is a top plan view of the base member of the portable riser assembly of the present invention, and includes a fragmentary view of a second riser shown in phantom.
FIG. 9A is a fragmentary section detail taken along line 9A--9A in FIG. 9.
FIG. 10 is a sectional elevation taken along line 10--10 in FIG. 9.
FIG. 11 is a sectional elevation taken along line 11--11 in FIG. 9.
FIG. 12 is a fragmentary detailed section taken along line 12--12 in FIG. 9.
FIG. 13 is a perspective view of two of the riser units of the present invention joined to form a two-unit riser assembly.
FIG. 14 is a fragmentary sectional elevation taken along line 14--14 in FIG. 13.
FIG. 15 is a fragmentary top plan detailed view depicting two adjacent hingedly connected members of the hinged riser of the present invention, with portions cut away.
FIG. 16 is an enlarged fragmentary detail of the area encircled at 16 in FIG. 15.
FIG. 17 is a top plan view of a hinge block for use with the riser of the present invention.
FIG. 18 is a sectional elevation taken along line 18--18 in FIG. 17.
FIG. 19 is a sectional elevation taken along line 19--19 in FIG. 17.
FIG. 19A is a sectional elevation depicting another embodiment of the hinge block for use with the riser of the present invention.
FIG. 20 is a perspective view depicting a key connector for use in connecting together the risers of the present invention to form a riser assembly.
FIG. 21 is a sectional elevation taken along line 21--21 in FIG. 20.
FIG. 22 is a fragmentary sectional detail depicting the hinged connection between two members of the riser of the present invention.
FIG. 23 is a view similar to that in FIG. 22, but depicting the hinged connection when the members of the riser are in another position.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The portable hinged riser unit 30 in accordance with the present invention broadly includes a base 32, at least two step members 34 and a plurality of connecting hinge joints 36. In FIGS. 1-3 and 13 the riser 30 is depicted resting generally horizontally on the ground, a floor, a stage or the like.
Referring to FIGS. 1 and 9, the base 32 has a substantially closed, polygonal, plane figure body with two opposed generally parallel side walls 38, a front wall 40, a rear wall 42 parallel to the front wall 40, a generally flat top support surface 44, and a bottom 45. A plurality of ground, stage or floor contacting feet 47 are connected to the bottom 45. The feet 47 may be threadably coupled to the base 32, but other connective methods may be employed as well. The top surface 44 includes a lower level 46 and an upper level 48 in different, but parallel planes. A front facing midwall 50 extends generally perpendicularly between and connects the lower and upper levels 46, 48. All of the aforementioned walls, surfaces and levels are in substantially parallel or perpendicular relationship with respect to each other and those joined together are continuously and rigidly joined along straight intersecting edges.
At least two spaced, integrally formed lift handles 54 are formed in the lower regions of each side wall 38 and in the rear wall 42 of the base 32. Referring to FIGS. 10 and 11, each hand receiving lift handle 54 includes an opening 56 with rounded edges 58. An angled continuous inside wall 60 tapers generally outwardly, at approximately five degrees, from bottom to top in the direction of the surface of the upper level 48 of the base 32. A finger receiving relieved area 62 is provided at the uppermost portion of each lift handle 54.
Referring to FIG. 9, a first pair of hinge wells 64, 66 is adjacent the edge formed by the intersection of the outside surface of the upper level 48 and the rear wall 42 of the base. Each hinge well 64, 66 is above, and substantially in-line with, one of the lift handles 54. A second pair of hinge wells 68, 70 is adjacent the edge formed by the intersection of the midwall 50 and the outside surface of the upper level 48 of the base 32. Referring to FIG. 12, each hinge well 64, 66, 68, 70 in the base 32 has opposed, parallel hinge well end walls 72, 74 and a smoothly curved or arcuate hinge well wall 76. A hinge pin bore 78 is formed in each hinge well end wall 72, 74.
Referring to FIGS. 1 and 4, the step members 34 include at least a first, low step member 80 and a second, high step member 82 (depicted in FIG. 4). The two step members 80, 82 are polygonal, generally rectangular, having end walls 84, 86, front and rear side walls 88, 90, respectively, and interchangeable, reversible top and bottom walls 92, 94, respectively. All references to front and rear and top and bottom, particularly as to the walls of the step members 80, 82, are made with reference to the position and orientation of the members 80, 82 depicted in FIG. 3. All of the walls of the step members 80, 82 are arranged in generally parallel or perpendicular relationship with respect to one another, and the junction of the walls are generally straight, continuous edges. The step members 80, 82 are substantially similar, but the high step member 82 is relatively larger than the low step 80. Both step members 80, 82 have an equal length between their end walls 84, 86, also equal to the length of the base 32 between the side walls 38. Additionally, the width of the step members 80, 82 between their front and rear walls 88, 90 is substantially equal. The volume of the high step member 82 is larger than the volume of the low step member 80 because the height or thickness of the high step 82 between the top and bottom walls 92, 94 is greater than that of the low step 80.
At least one handhold 98 is set in each end wall 84, 86 of the step members 34. FIGS. 5, 7 and 8 depict one of the handholds 98, particularly the handhold 98 in the end wall 86 of the high step 82. Each of the plurality of handholds 98 is substantially identical, being a shallow, handhold well 100 integrally formed in the end walls 84, 86 of the step members 80, 82 and having rounded edges 102.
Referring back to FIG. 3, a first pair of spaced hinge wells 104, 106 is adjacent the edge formed by the intersection of the rear side wall 90 and the top wall 92 of the low step member 80. The low step member hinge wells 104, 106 compliment the hinge wells 68, 70 of the base 32. Similarly, a second pair of spaced hinge wells 108, 110 is adjacent the edge formed by the intersection of the front side wall 88 and the top wall 92 of the high step 82. The second pair of hinge wells 108, 110 compliment the hinge wells 64, 66 at the edge of the base 32 formed by the intersection of the upper surface of the upper level 48 and the rear wall 42.
The connecting hinge joints 36 include the base hinge wells 64, 66, 68, 70, the complimentary step member hinge wells 104, 106, 108, 110, and a plurality of hinge blocks 112. FIGS. 4, 6, and 12 depict additional details of the plurality of substantially identical hinge wells, using hinge well 108 of the high step member 82 as representative of all the hinge wells. Each hinge well includes parallel, opposed hinge well end walls 72, 74 and a curved, generally rear hinge well wall 76. In-line hinge pin bores 78 are adjacent each end wall 72, 74. More specifically, each bore 78 is located through a hinge pin mount 114 integrally associated with each end wall 72, 74. A raised bead 116, 118 is immediately adjacent the outermost region of the curved hinge well wall 76. The parallel raised beads 116, 118 extend from end wall to end wall 72, 74.
All of the hinge wells receive, or partially receive, substantially identical hinge blocks 112, depicted in FIGS. 17, 18 and 19. Each hinge block 112 is a generally rectangular body having a pair of voids 122, a bottom wall 124, a top wall 126, side walls 127, and end walls 128. Each side wall 127 has a linear, longitudinally extending rib stop 130 that runs the length of the wall 127. Each hinge block 112 includes four hinge pin holes 132, 134 and 136, 138, a pair of the holes 132, 134 and 136, 138 being preformed in each end wall 128. As depicted in FIGS. 18 and 15, the hinge pin holes 132, 134, 136, 138 are drilled to form two parallel hinge pin bores 140, 142 for receiving hinge pins 144. The hinge pins 144 are parallel with respect to each other and extend continuously through the hinge pin bores 140, 142 and into hinge pin bore mounts 114 formed in the base 32 and in the step members 80, 82.
Referring to FIGS. 15 and 16, intended to be representative of all the hinge joints 36, one of the hinge blocks 112 is depicted connecting the low step member 80 to the base 32. The end wall 84 of the lower step 80 and the end wall 38 of the base 32 include integral hinge pin receiving shoulders 148 and apertures 150. The apertures 150 may be formed during the molding process, drilled, punched or formed in other suitable ways, and are in line with the hinge pin mounting bores 140, 142 through the hinge block 112. A button head plug 152 is received in each aperture 150 after the pins 144 are inserted into the block 112.
Referring to FIGS. 9, 9A, 10 and 11, the base 32 of the riser 30 includes a convoluted, integrally formed interior support and baffle wall structure 154 comprising a pair of wavy, ribbon-like continuous web structures 156, 158. The interior webs 156, 158 extend continuously at a slight angle from vertical between the bottom wall 45 and top surface 44 of the base 32 to define a generally "FIG. 8" shaped, substantially hollow, closed tubular body for the base 32. Each web structure 156, 158 is integrally formed with the walls or skin forming the remainder of the base 32, and includes two opposed parallel longer sides 160, 162 parallel to the front and rear sides 40, 42, respectively, of the base 32, and two opposed parallel shorter sides 164, 166 parallel to the side walls 38 of the base 32. Each interior web 156, 158 is formed to include a plurality of alternating trapezoidal buttress support panels 168. Adjacent panels 168 of the longer sides 160, 162 lie in parallel planes, as do the panels 168 of the shorter sides 164, 166.
The two open central areas 170, 172 of the "FIG. 8" shaped base 32 are formed by the webs 156, 158. The areas 170, 172 have an open lower region adjacent to the bottom 45 of the base 32 and are closed by a flat subfloor wall 174 closely adjacent and parallel to the underside of the upper surface 44 of the base 32. The subfloor wall 174 is connected to the webs 156, 158 to form two closed cell subfloor voids 176, 178. The void 176 closest to the front wall 40 of the base 32 partially underlies the lower level 46 of the base 32 and is generally "L-shaped". The volume of the voids 176, 178 is substantially less than the volume of the tubular base 32.
Referring to FIGS. 9, 10 and 11, base fill holes 184 are formed in the rear walls 76 of the base hinge wells 64, 66, 68, 70. Base vent holes 185 are formed in the lift handles 54. Referring to FIGS. 4, 5, and 6, step fill holes 186 are formed in the step member hinge wells 104, 106, 108, 110 and step member vent holes 187 are formed any selected handhold 98.
The hinged riser units 30 of the present invention may be connected to one another to form a riser assembly 188, depicted in FIGS. 13 and 14. A connector key 190 for connecting individual risers 30 is depicted in FIGS. 20 and 21. Each key 190 has inclined side walls 192 that match the draft angle of the walls 60 defining the lift handles 54 formed in the side walls 38 and rear wall 42 of the base 32. Key end walls 194 closely compliment the end walls of the lift handles 54. Opposite the key base 196, each key 190 has a crown area 198 comprising an inwardly curved cusp 200 between a pair of parallel rounded ridges 202, 204. The key connectors 190 have a hollow interior 206.
One of the hinge joints 36 connecting the step members 80, 82 to the base 32 is depicted in FIGS. 22 and 23. The joint 36 depicted is between the high step member 82 and the base 32, but is typical of all the connecting hinge joints 36 of the present invention. The joint 36 includes the base hinge well 64, step hinge well 108, and a hinge block 112. Two parallel hinge pins 144, each providing an axis for rotation and movement of the hinge block 112 within the hinge wells 64, 108, extend through the hinge block 112. Referring specifically to FIG. 22, the upper surface 207 of the hinge block 112 is substantially level with the surfaces of the base 32 and the step 82, whereby the overall support surface 210 is substantially smooth and level.
If the high step 82 is raised or lowered slightly relative to the base 32, the hinge block 112 will float about the two axes provided by the hinge pins 144 until one or the other of the ribs 130 comes in contact with one of the beads 116, 118 of the hinge wells 64, 108. Thus, without requiring the raised portions typical of piano or rule joint hinge structures, the hinge joint 36 compensates for unevenness of the surface upon which the riser is resting without damaging the joint 36. Additionally, even if the base 32 and steps 80, 82 are misaligned with respect to one another, the hinge 36, and specifically the hinge block 112, always presents a substantially smooth and continuous visible surface.
FIG. 23 depicts the hinge joint 36 of FIG. 22 in another position and illustrates the control function of the ribs 130 and hinge well beads 116, 118. Because the hinge block 112 is free to move within the limits provided by the beads 116, 118 and ribs 130, the step 82 is easy to move relative to the base 32, any misalignment between the base 32 and the step 82 will be compensated for, and a smooth visible surface is provided.
Referring to FIG. 19A, the hinge joint 36 of the present invention may include another embodiment or form of hinge blocks 208 and split hinge pins 210. This hinge block 208 is substantially similar in size and exterior features as the hinge block 112 described above (and depicted in FIGS. 17, 18 and 19), and includes similar internal voids and pin bores. The hinge block 208 includes two parallel pre-formed hinge-pin bores 212, each with a lining sleeve 214. The sleeve 214 may be formed of suitable material including various metals or plastics. The pin 210 includes first and second pivot rods 216, 218, each having chamfered ends 220, 221. A compression spring 222 is between the rods 216, 218. Although not depicted, the ends 224 of the spring 222 may be partially received in or connected to the rod ends 221.
The riser base 32 and step members 80, 82 are rotationally or centrifugally molded from a suitable plastic material. After formation, the substantially hollow base 32 and step members 80, 82 are filled with an expanded material using the fill holes 184 and 186, which then may be closed. The hinge blocks 112, specifically the bores 140, 142, are drilled and placed in the aligned, complimentary base and step hinge wells (base wells 64, 66, 68, 70 and step wells 104, 106, 108, 110) and the hinge pins 144 are inserted through the drilled apertures 150 in the shoulders 148, the drilled bores 140, 142 in hinge block 112 and the drilled bores 78 in mounts 114. The plug 152 is counter sunk in the aperture 150 and the riser 30 is ready for use.
If the second form of the hinge block 208 and pins 210 is used, the shoulders 148 and apertures 150 in the base 32 and step members 80, 82 may be eliminated. The bores 78 are not drilled through the mounts 114, but have a closed bottom end in the mounts 114. To use the hinge block 208 and pins 210, the rods 216, 218 and a spring 222 are axially aligned end-to-end with the spring 222 in the middle and are placed in the bores 212 in the hinge block 208, as depicted in FIG. 19A. The rods 216, 218 are urged toward each other in the bores 212 against the bias of the spring 222. The block 208 is placed in aligned base and hinge step wells and the rods 216, 218 are released and snap into the bores 78.
Referring to FIGS. 1-3 and 13, the hinged riser 30, and riser assemblies 188, of the present invention may be shaped and reshaped into various alternative shapes. A completely deployed, open stage or platform configuration is depicted in FIG. 3. The stage configuration presents a smooth, flat, substantially continuous, horizontal top supporting surface 228.
A seated riser configuration is depicted in FIG. 2. To achieve the seated riser configuration, the high step 82 has been pivotally lifted in the direction of arrow A in FIG. 3 until the top surface 92 of the step 82 is closely adjacent and parallel to or in contact with the surface of the upper level 48 of the base 32. The handholds 98 in either the end wall 86 of the high step 82 may be used conveniently to lift and rotate the high step 82 into the position depicted in FIG. 2. A lower foot surface 230 and an elevated seat surface 232 are formed. The seat surface 232 has a smaller surface area than the foot surface 230.
FIG. 1 depicts the riser 30 arranged in a standing riser configuration. The high step 82 remains in the position depicted in FIG. 2. The low step 80 has been pivotally raised or moved, using the handholds 98, in the direction of arrow B (FIG. 2) until the outer surface of the top wall 92 is closely parallel to or touching the outside surface of the upper level 48 of the base 32. Three uppermost step support surfaces 234a, 234b, and 234c, each with a substantially equal surface area, are thus formed. The vertical rise between the lowest step surface 234a and the surface beneath the base bottom 45, and between each successive step surface 234b and 234cis equal.
For moving the entire riser 30 and for storing it, the riser 30 may be lifted by the lift handles 54 and carried to the place of storage where it may be placed or stacked in any convenient configuration.
A number of variations of the present invention can be made. For example, although a riser 30 having a polygonal plane figure shape is described, other suitable shapes, such as circular or oval risers are possible. The described base 32 has two interior webs 156, 158, but any member of the webs may be used. Additionally, although the webs 156, 158 form generally polygonal (specifically rectangular) open central areas 170, 172, the areas may be oval or circular. The risers 30, including the base 32 and the step members 80, 82, and riser assemblies 188, could be provided in various sizes to accommodate various institutional, staging or presentation needs. The riser 30, and the component members thereof, are formed advantageously by rotational molding, but other conventional fabrication and assembly methods might be used as well. The low density filler material used to fill the substantially hollow base 32 and the hollow step members 80, 82 may be an expanded s tyrene, but other low density materials may be used as well. The locations of the fill and vent holes 184, 186 providing access to the hollow interior of the base 32 and steps 80, 82 may be varied. The hinge blocks 112 (or 208) and pins 144 (or 210) may be formed from any suitable materials, but it would be advantageous to select a material that maintains the light weight and overall uniform appearance of the riser 30. The exterior of the riser 30, and riser assemblies 188, may be coated with appropriate substances to impart desirable characteristics such as a particular color or a non-slip feel. Although foot pads 47 are described, the riser 30 may be equipped with other ground or floor contacting devices including casters or wheels. An appropriate lock mechanism such as hook/eye, friction or snap, interlocking fabric, or pin/aperture arrangements may be used to hold the step members 80, 82 in their various positions relative to the base 32. Such lock mechanisms may be used in conjunction with the hinge joints 36 or may also be used as the functional equivalents of the hinge joints 36 to couple the step members 80, 82 and the base 32.
It should be understood that the steps 80, 82 may be easily separated or disassembled from the riser base 32 by removing the button plugs 152, then pulling the hinge pins 144 (or compressing the alternative pins 210). Thus, the purchaser has the option of how to purchase the riser 30; it may be purchased fully assembled with the steps 80, 82 connected to the base 32, or as separate component pieces. Additionally, bases 32 and step members 80, 82 may be interchanged easily.
Although a description of the preferred embodiment has been presented, it is contemplated that various changes, including those mentioned above, could be made without deviating from the spirit of the present invention. It is therefor desired that the described embodiments be considered in all respects as illustrative, not restrictive, and that reference be made to the appended claims rather than to the foregoing description to indicate the scope of the invention.
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In accordance with the present disclosure, a portable riser unit for supporting persons or objects above the ground, a floor, a stage or the like is provided. The riser broadly comprises a base, generally rectangular step members, and hinge joints for pivotally, hingedly connecting the step members to the base. The base has an integrally formed, convoluted internal or interior support and baffle wall structure and may be filled with an appropriate low density, high volume material. Each step member also may be of this construction; however, the step members may or may not have an internal support wall. The step members are operably coupled to the base by double axis hinges including hinge blocks received in complementary hinge wells in the base and step members. The hinges are self-leveling to present a substantially smooth, level riser support surface in every possible configuration. The riser may be molded of a plastic material and includes integral hand grips to facilitate moving step members or the entire riser. By manipulating the step members, the riser may be re-shaped into a variety of operable configurations. The invention also encompasses connector keys for connecting two or more risers into a riser assembly.
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CROSS-REFERENCE TO RELATED APPLICATIONS
None
BACKGROUND OF THE INVENTION
The present invention generally relates to apparatuses and methods to perform rotary steerable directional drilling operations. More particularly, the present invention relates to downhole actuators to position a drill bit assembly in a desired trajectory by a rotary steerable assembly. More particularly still, the present invention relates to a bi-directional actuator to be used in a rotary steerable system to accommodate more precise positioning of a drill bit assembly.
Boreholes are frequently drilled into the Earth's formation to recover deposits of hydrocarbons and other desirable materials trapped beneath the Earth's crust. Traditionally, a well is drilled using a drill bit attached to the lower end of what is known in the art as a drillstring. The drillstring is a long string of sections of drill pipe that are connected together end-to-end through rotary threaded pipe connections. The drillstring is rotated by a drilling rig at the surface thereby rotating the attached drill bit. The weight of the drillstring typically provides all the force necessary to drive the drill bit deeper, but weight may be added (or taken up) at the surface, if necessary. Drilling fluid, or mud, is typically pumped down through the bore of the drillstring and exits through ports at the drill bit. The drilling fluid acts both lubricate and cool the drill bit as well as to carry cuttings back to the surface. Typically, drilling mud is pumped from the surface to the drill bit through the bore of the drillstring, and is allowed to return with the cuttings through the annulus formed between the drillstring and the drilled borehole wall. At the surface, the drilling fluid is filtered to remove the cuttings and is often used recycled.
In typical drilling operations, a drilling rig and rotary table are used to rotate a drillstring to drill a borehole through the subterranean formations that may contain oil and gas deposits. At downhole end of the drillstring is a collection of drilling tools and measurement devices commonly known as a Bottom Hole Assembly (BHA). Typically, the BHA includes the drill bit, any directional or formation measurement tools, deviated drilling mechanisms, mud motors, and weight collars that are used in the drilling operation. A measurement while drilling (MWD) or logging while drilling (LWD) collar is often positioned just above the drill bit to take measurements relating to the properties of the formation as borehole is being drilled. Measurements recorded from MWD and LWD systems may be transmitted to the surface in real-time using a variety of methods known to those skilled in the art. Once received, these measurements will enable those at the surface to make decisions concerning the drilling operation. For the purposes of this application, the term MWD is used to refer either to an MWD (sometimes called a directional) system or an LWD (sometimes called a formation evaluation) system. Those having ordinary skill in the art will realize that there are differences between these two types of systems, but the differences are not germane to the embodiments of the invention.
A popular form of drilling is called “directional drilling.” Directional drilling is the intentional deviation of the wellbore from the path it would naturally take. In other words, directional drilling is the steering of the drill string so that it travels in a desired direction. Directional drilling is advantageous offshore because it enables several wells to be drilled from a single platform. Directional drilling also enables horizontal drilling through a reservoir. Horizontal drilling enables a longer length of the wellbore to traverse the reservoir, which increases the production rate from the well. A directional drilling system may also be beneficial in situations where a vertical wellbore is desired. Often the drill bit will veer off of a planned drilling trajectory because of the unpredictable nature of the formations being penetrated or the varying forces that the drill bit experiences. When such a deviation occurs, a directional drilling system may be used to put the drill bit back on course.
A traditional method of directional drilling uses a bottom hole assembly that includes a bent housing and a mud motor. The bent housing includes an upper section and a lower section that are formed on the same section of drill pipe, but are separated by a permanent bend in the pipe. Instead of rotating the drillstring from the surface, the drill bit in a bent housing drilling apparatus is pointed in the desired drilling direction, and the drill bit is rotated by a mud motor located in the BHA. A mud motor converts some of the energy of the mud flowing down through the drill pipe into a rotational motion that drives the drill bit. Thus, buy maintaining the bent housing at the same azimuth relative to the borehole, the drill bit will drill in a desired direction. When straight drilling is desired, the entire drill string, including the bent housing, is rotated from the surface. The drill bit angulates with the bent housing and drills a slightly overbore, but straight, borehole.
A more modern approach to directional drilling involves the use of a rotary steerable system (RSS). In an RSS, the drill string is rotated from the surface and downhole devices force the drill bit to drill in the desired direction. Rotating the drill string is preferable because it greatly reduces the potential for getting the drillstring stuck in the borehole. Generally, there are two types of RSS, “point the bit” systems and “push the bit” systems. In a point system, the drill bit is pointed in the desired position of the borehole deviation in a similar manner to that of a bent housing system. In a push system, devices on the BHA push the drill bit laterally in the direction of the desired borehole deviation by pressing on the borehole wall.
A point the bit system works in a similar manner to a bent housing because a point system typically includes a mechanism to provide a drill bit alignment that is different from the drill string axis. The primary differences are that a bent housing has a permanent bend at a fixed angle and a point the bit RSS typically has an adjustable bend angle that is controlled independent of the rotation from the surface. A point RSS typically has a drill collar and a drill bit shaft. The drill collar typically includes an internal orienting and control mechanism that counter rotates relative to the rotation of the drillstring. This internal mechanism controls the angular orientation of the drill bit shaft relative to the borehole. The angle between the drill bit shaft and the drill collar may be selectively controlled, but a typical angle is less than 2 degrees. The counter rotating mechanism rotates in the opposite direction of the drill string rotation. Typically, the counter rotation occurs at the same speed as the drill string rotation so that the counter-rotating section maintains the same angular position relative to the inside of the borehole. Because the counter rotating section does not rotate with respect to the borehole, it is often called “geo-stationary” by those skilled in the art.
A push the bit RSS system typically uses either an internal or an external counter-rotation stabilizer. The counter rotation stabilizer remains at a fixed angle (geo-stationary) with respect to the borehole while the drillstring above is rotated. When borehole deviation is desired, an actuator presses a pad against the borehole wall in the direction opposite the desired trajectory. This operation results in a drill bit that is pushed in a desired direction. Typically, one or more actuator pads are located on a geo-stationary counter-rotating collar of the push the bit apparatus.
Historically, push the bit and point the bit rotary steerable systems use their geostationary components either to aim, or to force the drill bit in a desired direction. When subterranean formations are either unknown or especially treacherous, forcing the bit is not always feasible. In those circumstances, aiming the bit may be preferable to forcing the bit in a wrong direction. Because uncertainty of the formation is always an issue in subterranean drilling, a system having the capabilities of both point and push the bit rotary steerable systems is desirable.
BRIEF SUMMARY OF THE INVENTION
The deficiencies of the prior art are addressed by apparatuses and methods to manipulate a hybrid steering sleeve with actuator devices that are capable of positive and negative manipulation on a particular thrust axis. Preferably, the hybrid sleeve includes a plurality of bi-directional actuators to aim and force the hybrid sleeve into a preferred position and under a preferred force. The positions and forces of and exerted by the actuators are fully monitorable and controllable either by a downhole or a surface control device. The actuation of the bi-directional actuators is preferably controlled by drilling fluid pressures. A shielding mechanism is disclosed to protect any sealing components from the abrasive characteristics of the drilling fluids.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more detailed description of the preferred embodiments of the present invention, reference will not be made to the accompanying drawings, wherein:
FIG. 1 is a schematic cross-sectional view of a bi-directional actuator assembly in the context of a directional drilling tool in accordance with a preferred embodiment of the present invention;
FIG. 2 is a schematic cross-sectional view of the bi-directional actuator assembly of FIG. 1 in positively biased state;
FIG. 3 is a schematic cross-sectional view of the bi-directional actuator assembly of FIG. 1 in a negatively biased state;
FIG. 4 is a schematic cross-sectional view of the bi-directional actuator assembly of FIG. 1 further including a protective membrane; and
FIG. 5 is a schematic top-view drawing of a directional drilling tool utilizing two bi-directional actuator assemblies in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring initially to FIG. 1 , a schematic drawing for a bi-directional actuator assembly 100 in a downhole directional drilling tool 102 is shown. Directional drilling tool 102 uses actuator assembly 100 to displace hybrid sleeve 104 into a desired position on a single axis. Hybrid sleeve 104 preferably steers a drill bit (not shown) through a geostationary universal joint (not shown) that directs drill bit as hybrid sleeve 104 is displaced relative to directional drilling tool 102 . Preferably, two bi-directional actuator assemblies 100 would be employed by drilling tool 102 to form two orthogonal axis that define a plane normal to the axis of drilling tool 102 , but only a single bi-directional actuator 100 (single axis) is shown for the purposes of simplicity.
Bi-directional actuator assembly 100 includes a piston 110 housed within a seal bore 112 . Piston 110 is allowed to reciprocate within seal bore 112 between stops 114 , 116 . Piston 110 has a first thrust face 118 and a second thrust face 120 to transmit pressure forces thereupon into mechanical movement of piston 110 . A first arm 122 extends from first thrust face 118 and a second arm 124 extends from second thrust face 120 . Arms 122 , 124 extend through ports 126 , 128 of directional drilling tool 102 and engage load pads 130 , 132 located upon an inside surface of hybrid sleeve 104 . The movement of piston 110 within seal bore 112 transmits force through arms 122 , 124 to deflect hybrid sleeve 104 in a desired position along the axis of piston 110 .
Bi-directional actuator assembly 100 operates under hydraulic pressure supplied by drilling fluids. Typically, drilling fluids are delivered to the bit through the central bore of drill pipe and various drilling tools. These fluids are then used, under pressure, to lubricate the drill bit, clean the drill bit, and carry the cuttings from the borehole back to the surface. At the surface, the cuttings and impurities are filtered out and the drilling fluid, or “mud,” is recycled for use again. Therefore, drilling fluids are transmitted to the bottom of a wellbore under high pressures through the bore of the drillstring and are returned to the surface at a relatively lower pressure in the annulus formed between the drillstring and the borehole wall. Because of this difference in delivery and return pressure, drilling fluids are often used to performed work in various drilling tools downhole.
Returning to FIG. 1 , high-pressure drilling fluids from the bore of the drillstring enter bi-directional actuator assembly 100 at a high-pressure manifold 134 through an inlet 136 . Because drilling fluids are typically slurry compositions, inlet 136 preferably includes some filtration mechanism to prevent solids in the drilling fluid from entering bi-directional actuator assembly 100 . Low-pressure fluids of the annulus between the drillstring and the borehole are in communication with the bi-directional actuator assembly 100 through a low-pressure manifold 138 and a port 140 . Manifolds 134 , 138 are shown schematically as simple manifolds, but complex systems utilizing various ducts, valves, and controls may be employed. High-pressure manifold 134 communicates with piston 110 through ports A and B. Low-pressure manifold 138 communicates with piston 110 through ports C and D.
A seal 142 mounted to piston 110 reciprocating within seal bore 112 creates a first pressure chamber 144 and a second pressure chamber 146 of bi-directional actuator assembly 100 . Seal 142 is shown schematically as a single o-ring seal but it should be known by one of ordinary skill in the art that any type of dynamic seal may be used. For example, double o-rings, wipers, and backup rings may be used to improve the reliability and integrity of seal 142 .
First pressure chamber 144 acts on first face 118 of piston 110 and tends to urge piston 110 to the right when pressure therein is increased relative to second pressure chamber 146 . Second pressure chamber 146 acts on second face 120 of piston 110 and tends to urge piston 110 to the left when pressure therein is increased relative to first pressure chamber 144 . Seals 148 , 150 maintain integrity of first and second pressure chambers 144 , 146 , respectively, by preventing annulus fluid from communicating with chambers 144 , 146 . High-pressure port A and low-pressure port C are in communication with first pressure chamber 144 . High-pressure port B and low-pressure port D are in communication with second pressure chamber 146 . Valves 152 , shown schematically within ports A, B, C, and D, selectively allow or restrict the flow of drilling fluids from manifolds 134 , 138 in or out of chambers 144 , 146 . While valves 152 are shown schematically as integral to ports A, B, C, and D, it should be understood by one of ordinary skill in the art that various configurations and locations for valves 152 may be used. Particularly, ports A, B may be integral to manifold 134 and ports C, D may be integral to manifold 138 . Valves 152 are shown as is for illustrative purposes only and are not meant to be limiting on the scope of the claims.
Optionally, a dynamic feedback system may be used with the bi-directional piston actuator assembly 100 of FIG. 1 . Particularly, a series of pressure transducers 160 may be installed in communication with first and second chambers 144 , 146 to monitor the relative pressure difference between chambers 144 , 146 . Next, a N-S magnet device 162 may be mounted to the piston 110 such that a magnetic proximity (Hall Effect) detector 164 can determine the absolute position of piston 110 within seal bore. The information from the proximity detector 164 and the pressure transducers 160 can be either relayed to a processing unit (not shown) within directional drilling tool 102 or may be sent, via telemetry, to an operator at the surface. This information and the data created therefrom can be analyzed and used by to determine performance of bi-directional actuator assembly 100 and to determine what corrections, if any, are needed to steer the directional drilling tool 102 into its desired trajectory. Furthermore, using the data from transducers 160 and detector 164 , an operator can know the position of hybrid sleeve 104 with respect to drilling tool 102 at all times. Therefore, the controller or the operator can know the difference between the desired bid direction and the actual bit direction and be able to make adjustments thereof. While pressure transducers and magnetic sensors are shown to obtain pressure and position data for piston 110 and chambers 144 , 146 , it should be understood by one of ordinary skill in the art that other
Referring now to FIG. 2 , piston 110 is shown displaced to the right, thus placing a “positive” bias upon hybrid sleeve 104 . To displace piston 110 in this manner, high-pressure drilling fluid from the bore of drillstring and directional drilling tool 102 enters high-pressure manifold 134 through filtration screen 136 . A controller (not shown) selectively opens port A and closes port B, thus allowing pressure within first chamber 144 to increase. The controller simultaneously opens port D and closes port C of the low-pressure manifold 138 , thereby allowing pressure within second chamber 146 to decrease. As pressure builds within first chamber 144 , that pressure acts upon face 118 and drives piston 110 toward the right side (positive displacement) until stop 116 is engaged. The movement of piston 110 to the right, likewise displaces second arm 124 to the right enabling the application of force to hybrid sleeve 104 through load pad 132 . Hybrid sleeve 104 displaces to the right under the force of piston 110 , arm 124 , and pad 132 , thereby directing the drill bit (not shown) into a desired trajectory. Pressure transducers 160 , if present, are able to report the pressure difference between first chamber 144 and second chamber 146 so that the operator or controller knows the amount of force applied to hybrid sleeve 104 . Furthermore, proximity detector 164 and magnet 162 , if present, are able to report the absolute position of piston 110 so that controller or operator knows the amount of deflection experienced by hybrid sleeve 104 .
Referring briefly to FIG. 3 , piston 110 is shown displaced to the left, thus placing a “negative” bias upon hybrid sleeve 104 . To displace piston 110 in this manner, high-pressure drilling fluid enters second chamber 146 as high-pressure port B is opened and high-pressure port A is closed. Simultaneously, low-pressure port C is opened and low-pressure port D is closed to allow first chamber 144 to communicate with the low-pressure annular drilling fluids of through manifold 138 and port 140 . High-pressure fluids are thus allowed to enter second chamber 146 and press against face 120 to deflect piston 110 to the left, in a “negative” direction of travel. The displacement of piston 110 to the left thus allows force to be transmitted from piton 110 through first arm 122 and first pad 130 to hybrid sleeve 104 . As before, pressure transducers 160 , and magnetic sensors 162 , 164 , if present, allow a controller, or an operator to monitor the load and displacement of hybrid sleeve 104 resulting from bi-directional actuator assembly 100 .
Referring now to FIG. 4 , a bi-directional piston actuator assembly 200 with an integrated membrane shield system is shown. Piston actuator assembly 200 , like assembly 100 , includes a piston 210 that reciprocates within a seal bore 212 between two stops 214 , 216 . Because the operating fluid of piston 110 is drilling fluid, problems with wear and abrasion of sealing surfaces often arises through frequent use. Drilling fluid, as a slurry composition, includes many solid and particulates within the fluid itself. These particulates can often be of elevated hardness and can scratch or abrade seal bore 212 over time. Any such abrasions would severely limit the amount of force transferable from piston 210 to hybrid sleeve 104 through arms 222 , 224 , severely reducing the effectiveness of piston actuator assembly ( 100 of FIGS. 1-3 ). To overcome this problem, the present invention includes the addition of membrane shields 270 , 272 within first and second pressure chambers 244 , 246 . Membrane shields 270 , 272 preferably extend, in a conical-like shape, from first and second stops 214 , 216 to first and second arms 222 , 224 , respectively. Membranes 270 , 272 are preferably constructed from a durable, wear resistant flexible material such as a reinforced elastomer. Membranes 270 , 272 , in effect, create two new “clean” pressure chambers 274 , 276 where a “clean” hydraulic fluid (or oil) is maintained against faces 218 , 220 of piston 210 , seal 242 , and seal bore 212 . Clean hydraulic fluid within clean chambers 274 , 276 will be free of particulates and impurities that would otherwise harm the integrity of seal 242 .
In operation, valves A, B, C, and D are opened and shut as with actuator assembly 100 of FIGS. 1-3 to deflect piston 210 either in a positive or negative direction. With membranes 270 . 272 and clean pressure chambers 274 . 276 . drilling fluids never come into contact with sensitive seal components. For example, in actuating piston to the right (positive direction), high-pressure drilling fluid is allowed to communicate with first chamber 244 through port A and low-pressure drilling fluid is allowed to communicate with second chamber 246 through port D, leaving ports B and C closed. The high-pressure fluid would build up in chamber 244 and would impact force and pressure upon membrane 270 , thus transferring the force and pressure thereupon to clean hydraulic fluid contained within clean chamber 274 . The elevated pressure of clean fluid within chamber 274 would thereby exert force upon face 218 and drive piston 210 to the right. Similarly, to drive piston 210 to the left (negative direction), ports B and C would be opened with ports A and D closed to allow high-pressure fluid to flow into second chamber 246 . Fluid in chamber 246 would likewise press upon membrane 272 and transmit pressure to clean fluid in chamber 276 , thereby exerting force upon face 220 and displacing piston 210 to the left.
Preferably high-pressure ports A and B are constructed so that the high-pressure flow of drilling fluid flowing into chambers 244 , 246 does not impact membranes 270 , 272 directly. Any direct impact of high-pressure drilling fluid thereupon could abrade away or tear membranes 270 , 272 , thus sacrificing their integrity. To accomplish this, either ports A, and B can be constructed to direct flow of high-pressure fluids away from membranes 270 , 272 or shields (not shown) can be constructed within chambers 244 , 246 to direct the flow. As with actuator assembly 100 of FIGS. 1-3 , pressure transducers 260 , and magnetic proximity components 262 and 264 can be employed to allow a controller or an operator to monitor the position of and forces upon hybrid sleeve 104 .
Typical downhole actuator assemblies use actuators to engage or disengage three kick pads about the periphery of the directional drilling tool. These traditional pads operate only in one direction and therefore are either engaged or disengaged. Therefore, the number of possible force conditions that are possible are limited to 6 non-zero states (2 3 −1 [all disengaged]−1 [all engaged=cancels out]=6). Actuators in accordance with the present invention are capable of 3 states each, positive engagement, negative engagement, and non-engagement. Furthermore, a drilling tool using a pair of actuators of the type describe above (preferably oriented 90° from each other) can obtain 8 different non-zero force states (3 2 −1 [all disengaged]=8). By employing three bi-directional actuator assemblies, a drilling tool can likewise obtain 26 non-zero states. Therefore, a drilling tool using bi-directional actuator assemblies can obtain more control and precision with respect to steering the drill bit than a drilling tool with the same amount (or more) unidirectional actuators.
Referring finally to FIG. 5 , a two bi-directional actuator assembly arrangement 300 is shown schematically. Actuator arrangement 300 is shown using two actuator assemblies ( 100 of FIGS. 1-3 or 200 of FIG. 4 ) spaced 90° apart inside a hybrid sleeve 104 . Arrangement 300 preferably includes parallel bearing surfaces 380 that allow load pads 330 A, 330 B, 332 A, and 332 B to slide thereupon. Parallel bearing surfaces 380 are necessary to allow hybrid sleeve 104 to move relative to drilling tool (not shown) freely and to prevent the arms 322 A, 324 A of one axis from restricting the arms 322 B, 324 B of another axis. This arrangement allows hybrid sleeve 104 to be manufactured of a relatively inflexible material, thereby maintaining its rigidity and strength.
Numerous embodiments and alternatives thereof have been disclosed. While the above disclosure includes the best mode belief in carrying out the invention as contemplated by the named inventors, not all possible alternatives have been disclosed. For that reason, the scope and limitation of the present invention is not to be restricted to the above disclosure, but is instead to be defined and construed by the appended claims.
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Methods and apparatuses to direct a drill bit of a directional drilling assembly are disclosed. The methods and apparatuses employ the use of bi-directional actuators that are capable of displacing a hybrid steering sleeve in positive and negative directions. The bi-directional actuators are capable of greater control and precision in their actuations than traditional “engaged-disengaged” unidirectional actuators, thereby allowing for more precise directional drilling operations. The bi-directional actuators are preferably driven by drilling fluids and may optionally be shielded to lessen the erosive effects thereof.
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CROSS REFERENCE TO RELATED APPLICATIONS
Not Applicable
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH
Not Applicable
REFERENCE TO APPENDIX
Not Applicable
BACKGROUND OF THE INVENTION
A. Field of the Invention
This relates to the plugging of certain drain waste and vent and sanitary sewer maintenance access points with a removable device for the purpose of inhibiting rainwater, surface water, or other undesirable fluids from entering into sanitary sewer collection systems.
B. Prior Art
Other devices relative to storm drains or wastewater systems have been devised primarily to keep debris from entering a man hole such as in Johnson, U.S. Pat. No. 5,733,444. Other examples where drain pipes are plugged exist in Tash, U.S. Pat. No. 6,062,262. Another device dealing with storm drain diverters is Grandinetti, U.S. Pat. No. 6,135,140.
The specific object of the device that is the subject of this particular patent application is to prevent the intrusion of rainwater, surface water or any other unwanted fluids into the sanitary sewer system in order to reduce the load on the waste water collection, transmission and treatment systems.
None of the prior devices perform that particular function.
BRIEF SUMMARY OF THE INVENTION
This is a friction fit plug, which is specifically designed to be inserted into drain waste and vent pipe (hereafter “DWV”) and sewer pipe and associated clean-out fittings related to sanitary sewer collection systems.
The purpose of this friction plug is to inhibit infiltration and inflow of surface water or other undesirable fluids into the sanitary sewer collection system via broken or damaged maintenance access points such as cleanout caps and plugs.
The access to the DWV or sewer line is usually a plumbing “clean-out adaptor” “T” or “Y”, which is generally capped or plugged and is located at the point or points of connection to the facility being served. A broken, damaged, ill fitting, or missing plug or cap thus facilitates the unnecessary overloading of the sanitary sewer collection, transmission, and treatment systems with rain water or other undesirable fluids.
The friction plug can be easily removed for maintenance and/or cleaning of the pipes and other traditional maintenance. An integral handle is provided to easily install or remove the device. The friction plug allows for traditional smoke and pressure testing of the sanitary sewer collection system with the device in place by means of a check or purge valve, which is installed on the top surface of the device and covers the hole on the top surface of the device. It is anticipated that the device will be manufactured by a blow molding or similar process.
One of the key features of this device is that this friction fit plug can be inserted in the plumbing clean adaptor out “T” or “Y” and allow for pressure or smoke testing. Another key feature is the presence of chevrons and guide rings that are designed to prevent over insertion and to provide an effective seal against unwanted fluids.
A passageway is provided to connect the tapered, hollow center to the top surface of the device. In normal operation the purge valve completely covers the opening created by the connective passageway.
It is anticipated that the device will be constructed from high density polyethylene or similar material that is chemically resistant to the corrosive gasses that exist in a sanitary sewer system.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of the plug.
FIG. 2 is a top view of the device.
FIG. 3 is a perspective view of the device.
FIG. 4 is a cross sectional view of the device.
FIG. 5 is a cross sectional view of the device installed in a typically piping system.
DETAILED DESCRIPTION OF THE EMBODIMENTS
This device 10 will be installed in sanitary sewer collection systems and will serve as a means to exclude rain water, surface water and other unwanted fluids from entering the sanitary waste coming from the property being served. FIGS. 1 , 4 The intrusion of rainwater or surface water, or other undesirable fluids adds to the load, which is placed on the utilities' wastewater collection, pumping, transmission, waste water treatment, and effluent disposal systems.
In effect the wastewater treatment system is treating rainwater or other fluids that do not require treatment or should not enter the system.
This device 10 , if used properly, will result in substantial cost savings to the wastewater utility and will allow the treatment facility to be correctly certified for the appropriate plant capacity thus freeing up additional capacity to be utilized to extend treatment plant useful life or add wastewater plant connections.
The plug 10 is cylindrical and is manufactured from high density polyethylene or similar material.
It is also anticipated that semi rigid plastic may be used although the device should have some degree of elasticity. It is cylindrical and is designed to be an interference fit into the standard plumbing, and sewer pipe used with “clean-out” adaptors “T's” or “Y's” for most homes or other connections to the sanitary system, but allow a free flow of sanitary waste from the home or business. FIG. 4 Other size plugs will be used depending on the specifics of the plumbing or utility systems but all should fit snugly in the pipes.
The typical sanitary waste system is comprised of piping leading from the home or business to the sewer main and eventually to the wastewater treatment facility. Most sanitary waste system are equipped with a cleanout assembly 45 , located at the point of connection between the home or business and the sanitary sewer collection system, which allows for maintenance and testing of the system. Additionally the cleanout assembly 45 is equipped with a cleanout plug or cap 40 . FIG. 4
The cleanout plug or cap 40 is usually installed at all normal times that the system operates and is only removed during times when access to the system is needed. A cleanout assembly is needed because at certain times access to the system is needed for routine maintenance or to address problems in the system such as blockages.
Occasionally the cleanout cap or plug 40 is damaged accidentally thereby allowing rainwater, surface water and other undesirable fluids to enter the system if this device 10 has not been installed. Without the current device 10 in place the infiltrated fluids would eventually be routed to the sanitary waste system. As has been stated previously this unnecessary intrusion of rainwater or other fluids adds load to the wastewater treatment facility. This additional load is unneeded and unnecessary.
An additional benefit to this device is to prevent other contaminants into the sewer system such as mulch, parts of trees, and other objects that may fall into the system. These contaminants in addition to being unnecessary also have the potential of causing a blockage in the sewer system.
This plug 10 will be inserted into the pipe at the cleanout adaptor, “T” or “Y” below the plug or cap 40 . FIG. 4 The plug or cap is necessary in order to access the waste water system for routine maintenance and testing through the cleanout assembly 45 . FIG. 4
The plug 10 would fit snugly within the interior of the plumbing, which is installed under the cleanout plug or cap 40 and in the piping 50 which forms part of the cleanout adaptor, “T” or “Y” and carries the waste from the home or business to the wastewater treatment facility. The use of flexible chevrons 15 or pieces of material, which protrude from the respective sides of the device 10 , are designed to insure a tight fit against the side of the pipe 50 and prevent over insertion of the device 10 . FIG. 4 The plurality of chevrons 15 would be used in order to prevent fluid intrusion and to insure this plug would fit in the pipe systems and sizes for which it is designed.
Additionally the device is constructed with a tapered hollow center 55 that is a multi functional. FIG. 4 The tapered hollow center 55 is designed as an integral handle and allows the required degree of flexibility to be able to insert the device into the pipe through the cleanout assembly 45 by squeezing the sides of the device 10 to insert it. FIG. 4 The tapered hollow center 55 also allows for the inclusion of a purge valve 70 on the top surface of the device that allows the system to be smoke or pressure tested periodically as required without needing to remove the device 10 . A thin passageway 70 connects the tapered hollow center 55 to the top surface of the device 10 , which accommodates the check or purge valve. In normal operation the purge valve 70 would completely cover the opening on the top surface. The purge valve 70 would prevent the intrusion of rain water yet allow the system to be tested.
From time to time the caps or plugs may be broken or displaced and would lead to the intrusion of rainwater and other undesirable fluids into the system. Additionally the piping should also be tested initially to check the integrity of the system. This testing is typically done by means of a smoke test. Smoke is introduced into the main sewer system and forced in the general direction of the house or business.
Sanitary sewer collection systems may be tested at any given time either for routine maintenance or in the event that a leak or fault is suspected. As the smoke filters through the system it will exit through any breakage in the system. The device 10 in this case is equipped with a purge valve 70 , which is located on the top surface of the device 10 . FIG. 4 As the smoke filters through the system, it will exit through the purge valve 70 and exit through a broken cracked or missing plug or cap. If the cap or plug 40 is in place and not damaged no smoke will exit the system.
The purge valve 70 is in the nature of a check valve and will only allow the smoke to exit the system but not allow the rainwater to enter in the event that rainwater, and not other unwanted fluids, enters through a broken, cracked or missing plug.
The device 10 will be equipped with a means to connect the bottom of the device and the center of the top surface to insert the purge valve by means of a passageway. It is contemplated that this will occur during the molding or similar manufacturing process. It is contemplated that a thin hollow boring or passageway in the interior of the device will connect the top of the device and the purge valve 70 to the tapered hollow center 55 . FIG. 4 The tapered hollow center may occupy from one-third to two-thirds of the interior of the device. This passageway 70 and purge valve is necessary in order to be able to conduct the testing of the system without having to remove the device from its position.
The device 10 would be inserted by squeezing the sides of the device 10 to install it. A feature of the device is that it cannot be over inserted into the pipe. The removal of the device would be accomplished by pulling on the internal conical handle.
In order to achieve insertion and removal the hollowed tapered center 55 is necessary as well as the plurality of chevrons 15 which ensure the tight fit against the sides of the pipe below the clean out adaptor, “T” or “Y”.
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This device will prevent intrusion of rainwater, groundwater and other unwanted fluids into a sanitary sewer system thereby alleviating the load on the sanitary sewer, collection, transmission and waste water treatment facilities thereby reducing costs.
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TECHNICAL FIELD OF THE INVENTION
The present invention relates in general to static structures, such as buildings or residences, and in particular to protecting the interior ceilings of those structures from adverse effects associated with moisture in an attic of the structure.
BACKGROUND OF THE INVENTION
Leaky roofs can be a pernicious problem. Even if one doesn't see signs of a roof leak in the rooms below the attic, it is possible that the water is collecting in the attic insulation or running into unseen areas like the wall cavities.
Water impinging on the ceiling of a building can be caused by means other than a leaky roof. For example, a chimney is often a source of leaks because the masonry and roof surfaces expand and contract at different rates with fluctuations in temperature. Gaps frequently open up as the surfaces pull away from each other. Builders try to prevent this by installing flashing, thin sheets of flexible metal, between the roof and chimney. If the flashing is correctly installed, it should come up the sides of the chimney and fold into the mortar joints between the chimney bricks.
Flashing leaks occur around the chimney if the flashing deteriorates or if the top edge was not correctly inserted into the mortar joints. High-grade urethane roof sealant can be injected into the gaps around the chimney. Over time, however, the gaps will open up again and the roof will leak again.
Another source of such water is condensation. If a surface is at a temperature that is below the dew point of the ambient air. In such a case, water will collect on the surface. As that water collects, it may drip off the surface. Such water may fall onto the ceiling of a building if the surface is in the attic. Such surfaces include pipes, equipment as well as the building walls and underside of the roof.
In building structures having overhead supported, suspended ceiling panels, significant damage can result from fluid leaks that may develop above a ceiling panel arrangement. Typically, ceiling panels are manufactured from compressed fibrous or the like materials and have interstitial spaces for improved sound absorption. Such arrangement of material typically tends to absorb fluids and typically fluid flowing onto ceiling panels manufactured from such materials saturates a first panel which in turn can cause fluid flow to adjacent panels such that several panels can become wetted and stained from a single above-ceiling leak source.
Eventually the fluid can flow through the ceiling panel or panels and drain downwardly to an area under the ceiling. Typically when fluid wets through such ceiling panel, it drains from more than one location on the surface of the panel and may even shift locations depending upon the amount of fluid being drained and the flow patterns that develop within the panel. Because of the inconsistent and multiple locations of fluid drainage the collection of the draining fluid can be problematical and the protection of valuables under the ceiling becomes difficult.
When a leak occurs in a place of business, such as an office, store or warehouse, the leaking fluid is often channeled by pipes, duct work, ceiling structure, etc., so that fluid from a single leak will drip onto a room's contents from more than one ceiling location. Although the amount of fluid flowing from a ceiling leak may not be great, leaking fluid is especially disruptive to businesses. Electronic equipment such as computer and communications equipment are especially sensitive to damage by liquids. Inventory stored below a leaking ceiling can be damaged beyond repair. Damage can also occur to inventory as well as works of art or the like that are often located inside buildings. Office workers cannot work in a leaking room. Office files and records may be damaged beyond the ability of a business to recover.
In addition to the above-discussed damage, a leaky roof may lead to water collection in the attic, and such water collection may lead to standing water. Standing water may be a source of toxic mold. Toxic mold can be exacerbated by darkness and poor ventilation. It is more common in buildings constructed after the 1970s, which are more airtight, and is more likely to occur in buildings with persistent water leaks. While water damage to equipment and the building is quite undesirable, toxic mold can be dangerous and can be lethal in some instances. In fact, some cases of toxic mold may require total destruction of the building. Thus, water infiltration into a building is not only undesirable, it is imperative that it be taken care of if toxic mold is a possibility.
When ceiling leaks occur, it is the usual practice to place a pot, pail, bucket or other receptacle under the leak in order to catch the dripping water. If the leak takes the more usual form of dripping from spaced points, a number of receptacles are required. This is generally found to be an ineffective remedy since the receptacle must be constantly attended and frequently emptied to prevent overflowing. Further, if the leak tends to grow wider or be channeled to new locations, some of the dripping liquid will miss the positioned receptacle.
Therefore, there is a need for a means for preventing moisture that may be present in an attic of a static structure, such as a building or a residence, from contacting the ceiling of that structure.
SUMMARY OF THE INVENTION
These, and other, objects are achieved by a blanket that can be unfurled in the attic space of a static structure between a roof and a ceiling to absorb water that has either leaked through the roof or has been otherwise generated above the ceiling. The blanket is formed by a plurality of individual units that are releasably coupled together. Each unit includes a base formed of water-absorbing material. One form of the invention includes visual and/or audible alarms when the materials in the blanket becomes damp so a building manager will be alerted to the presence of moisture in the attic.
Other systems, methods, features, and advantages of the invention will be, or will become, apparent to one with skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features, and advantages be included within this description, be within the scope of the invention, and be protected by the following claims.
BRIEF DESCRIPTION OF THE DRAWING FIGURE
The invention can be better understood with reference to the following drawing and description. The components in the figure are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention. Moreover, in the figures, like referenced numerals designate corresponding parts throughout the view.
FIG. 1 is a perspective view of a unit which is included in the ceiling-protecting blanket embodying the principles of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring to the figure, it can be understood that the present invention is embodied in a blanket which is located in an attic of a static structure, such as building or a residence or the like, so it is interposed between the roof of the structure and the ceiling of that structure. The blanket will thus be positioned to intercept moisture that is located in the attic before that moisture reaches the ceiling, which may be a finished ceiling. As will be understood from the teaching of this disclosure, the blanket is designed to absorb that moisture. As will also be understood, the blanket has means for generating a signal that will alert a homeowner or a property manager of the presence of moisture.
The blanket is formed of a plurality of individual units 10 each of which is positioned in an attic of a building between the ceiling of the building and the roof of the building for protecting the ceiling of a building from moisture which may be present in the attic either due to leaks in the roof or due to condensation. All of the units are identical, and each unit 10 comprises a flexible base 20 that is located in an attic of a building between a roof of the building and the ceiling of a room within the building when in use. Base 20 includes moisture-absorbing materials so that moisture which would otherwise impinge on the ceiling will be absorbed by the unit 10 .
A ceiling will be covered by a blanket formed of a plurality of units 10 . Therefore, each unit 10 further includes coupling elements on the base for releasably coupling the base to adjacent bases. The releasable coupling permits removal of a damaged unit and replacement thereof without requiring removal of an entire blanket.
The coupling elements can include snaps 30 located on one end edge 32 of base 20 and snap-accommodating elements 40 located on another end edge 42 of the base. The snaps and the snap-accommodating elements are located so that snaps on one base will be accommodated in snap-accommodating elements of an adjacent base. Other releasable coupling means, such as hook-and-loop elements, or the like, can be used without departing from the scope of the present disclosure.
A blanket is formed by coupling a plurality of the units together by means of the coupling elements on each base. An adjacent unit is indicated in the figure by dotted lines.
Unit 10 also includes alarm elements 50 embedded in the base. The alarm elements are sensitive to moisture and which generate an alarm signal when moisture in the base reaches a preset level. In the form of the invention shown, the alarm elements include an element 60 , such as moisture-sensitive paint which changes color when moist and thereby generates a visual alarm signal when moisture has contacted unit 10 . Unit 10 can also include circuitry which includes wires 70 embedded in base 20 . The circuitry associated with wires 70 will generate a signal, either visual or audible, when a wire is contacted by moisture. The embedded wires are electrically connected to the coupling elements in a manner which completes a circuit through the entire blanket. Such circuitry is known to those skilled in the art, and the details of the circuitry are not important to this invention. As such the details of the circuitry will not be discussed or claimed.
The alarm elements can be used individually or in combination as suitable.
The absorbent material in the units can be a hygroscopic material which can be made out of a mixture of cellulose pulp together with super absorbent polymers. Another material sodium polyacrylate. Desiccants and various deliquescent compounds may be used to enhance the efficiency of the liner embodying the principles of the present invention. Deliquescent salts include calcium chloride, magnesium chloride, zinc chloride, and carnallite as well as other such chemicals as will occur to those skilled in the art based on the teaching of the present disclosure.
While various embodiments of the invention have been described, it will be apparent to those of ordinary skill in the art that many more embodiments and implementations are possible within the scope of this invention. Accordingly, the invention is not to be restricted except in light of the attached claims and their equivalents.
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A water-absorbent blanket that is located between a roof and the ceiling of a building, such as a residence, to catch and absorb any water that may leak through the roof or which is a result of condensation and prevent that water from reaching a finished ceiling.
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CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of pending U.S. patent application Ser. No. 09/517,555 filed on Mar. 2, 2000, now U.S. Pat. No. 6,318,462 the entirety of which is incorporated herein by reference.
FIELD OF THE INVENTION
The invention relates to a tool for preventing rotation of a tubing string or progressive cavity pump in the bore of a casing string.
BACKGROUND OF THE INVENTION
Oil is often pumped from a subterranean reservoir using a progressive cavity (PC) pump. The stator of the PC pump is threaded onto the bottom of a long assembled string of sectional tubing. A rod string extends downhole and drives the PC pump rotor. Large reaction or rotor rotational forces can cause the tubing or PC pump stator to unthread, resulting in loss of the pump or tubing string.
Anti-rotation tools are known including Canadian Patent No. 1,274,470 to J. L. Weber and U.S. Pat. No. 5,275,239 to M. Obrejanu. These tools use a plurality of moving components, slips and springs to anchor and centralize the PC Pump stator in the well casing.
Further, the eccentric rotation of the PC Pump rotor imposes cyclical motion of the PC Pump stator, which in many cases is supported or restrained solely by the tool's slips. Occasionally a stabilizing tool is added to dampen or restrain the cyclical motion to failure of the anti-rotation tool.
SUMMARY OF THE INVENTION
A simplified anti-rotation tool is provided, having only one jaw as a moving part but which both prevents rotation and stabilizes that to which it is connected. In simplistic terms, the tool connects to a progressive cavity (PC) pump or other downhole tool. Upon rotation of the tool in one direction a jaw, which is biased outwardly from the tool housing, engages the casing wall to arrest tool rotation. This action causes the tool housing to move oppositely and come to rest against the casing opposing the jaw. The tool housing and the downhole tool are thereby restrained and stabilized by the casing wall.
In a broad apparatus aspect, an anti-rotation tool comprises: a tubular housing having a bore and having at least one end for connection to a downhole tool and a jaw having a hinge and a radial tip. The jaw is pivoted at its hinge from one side of the housing, so that the jaw is biased so as to pivot outwardly to a first casing-engaging position, wherein the radial tip engages the casing, and the housing is urged against the casing opposite the jaw. The jaw is also inwardly pivotable to a second compressed position towards the housing to enable movement within the casing during tripping in and tripping out.
Preferably, the jaw is biased to the casing-engaging position by a torsional member extending through the hinge, which is rigidly connected to the housing at a first end and to the jaw at a second end. Compression of the jaw twists the torsional member into torsion which then acts to bias or urge the jaw outwardly again.
Preferably, the swing of the jaw is arranged for tools having conventional threaded connections wherein the jaw is actuated under clockwise rotation and is compressed by counter clockwise rotation of the tool.
More preferably, the jaw is formed separately from the housing so that the housing and bore remain independent and the bore can conduct fluid.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 a and 1 b are isometric views of one embodiment of the tool showing the jaw with its radial tip in its extended position (FIG. 1 a ) and the stored position (FIG. 1 b );
FIG. 1 c is a side view of an optional housing embodiment in which the threaded portion has its center offset from the housing center;
FIG. 2 is an enlarged view of the hinge pin, inset into the housing before welding to the housing;
FIGS. 3 a and 3 b are cross sectional views of the tool through the hinge, illustrating the jaw open and engaging the casing (FIG. 3 a ) and closed for installation (FIG. 3 b );
FIG. 4 is an isometric view of a third embodiment of the tool showing the jaw with its radial tip in its extended position; and
FIGS. 5 a and 5 b are cross sectional views of the tool according to FIG. 4, viewed through the hinge with the jaw open and engaging the casing (FIG. 5 a ) and closed for installation (FIG. 5 b ).
FIG. 6 a , is an isometric view of another embodiment of the anti-rotation tool of the present invention showing the jaw with its radial tip in its extended position;
FIG. 6 b is an isometric view according to FIG. 6 a with the jaw removed to show the orientation of a hinge spring in the extended position;
FIG. 7 is a perspective view of the jaw of FIG. 6 a , removed from the housing;
FIG. 8 is a perspective view of a stationary hinge spring holder according to FIG. 6 a;
FIG. 9 is a perspective view of a rotational hinge spring holder and retaining pin according to FIG. 6 a;
FIG. 10 a is a perspective view of the hinge spring and first and second end spring holders showing their respective orientation when the jaw has been biased to its to extended position;
FIG. 10 b is a perspective view of the hinge spring and first and second end spring holders showing their respective orientation when the jaw is urged against the spring to the closed position; and
FIGS. 11 a and 11 b are cross sectional views of the tool through the hinge, illustrating the jaw open and engaging the casing and showing the ends of the hinge spring substantially aligned at the first and second spring holders (FIG. 10 a ) and then compressed for tripping in and tripping out (FIG. 10 b ), showing the ends of the hinge spring out of plane as the hinge spring is in torsion.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Having reference generally to FIGS. 1 a , 1 b , 5 a , and 5 b , a tool 10 is provided for preventing rotation relative to casing 6 in a wellbore. The tool 10 comprises a tubular housing 1 with a bore 2 . The bore 2 has at least one threaded end 3 for connection to a downhole tool such as the bottom of a PC pump (not shown). A jaw 5 is pivotably mounted to the housing I and swings between a stowed position (FIGS. 1 b , 5 b ) and a casing-engaging position (FIGS. 1 a , 5 a ).
In a first embodiment, as illustrated in FIGS. 1 a - 3 b , the jaw 5 pivots out of the housing, interrupting the housing and opening the bore to the wellbore. As a variation of the first embodiment, a second embodiment demonstrates a specialized housing which centralizes the bore in the wellbore, as illustrated in FIG. 1 c . In a third embodiment, an alternate arrangement of the jaw is shown which does not compromise the tool's housing or bore.
More particularly, in the first embodiment and having reference to FIGS. 1 a , 1 b , 3 a and 3 b a portion of the housing wall 4 is cut through to the bore 2 to form a trapezoidal flap or jaw 5 . The jaw 5 has an arcuate profile, as viewed in cross-section, which corresponds to the curvature of the housing wall 4 . Accordingly, when stowed, the jaw 5 projects minimally from the tubular housing 1 and avoids interfering with obstructions while running into the casing 6 (FIG. 3 b ).
Referring to FIGS. 1 a - 2 , the jaw 5 is pivoted to the housing 1 along a circumferential edge 7 at hinge 30 . The jaw 5 has a radial tip edge 11 .
Hinge 30 comprises tubing 9 welded to the hinge edge 7 with a pin 8 inserted therethrough. Pin 8 is welded to the housing wall 4 at its ends. In a mirrored and optional arrangement (not shown), the jaw's hinge edge 7 has axially projecting pins and the housing wall is formed with two corresponding and small tubular sockets for pinning the pins to the housing and permitting free rotation of the jaw therefrom.
The hinge edge 7 and hinge 30 are formed flush with the tubular housing wall 4 .
The running in and tripping out of the tool 10 is improved by using a trapezoidal jaw 5 , formed by sloping the top and bottom edges 12 , 13 of the jaw 5 . The hinge edge 7 is longer than the radial tip edge 11 . Accordingly, should the radial tip 11 swing out during running in or tripping out of the tool 10 , then incidental contact of the angled bottom or top edges 12 , 13 with an obstruction causes the jaw 5 to rotate to the stowed and non-interfering position.
The jaw's radial tip 11 can have a carbide tip insert 14 for improved bite into the casing 6 when actuated.
If the wall thickness of the jaw 5 , typically formed of the tubular housing wall 4 , is insufficient to withstand the anchoring stress, then a strengthening member 15 can be fastened across the chord of the radial tip 11 to the hinge edge 7 .
The strengthening member 15 can include, as shown in FIGS. 3 a , 3 b , a piece of tool steel or the equivalent which substitutes for the carbide insert.
In operation, the tool 10 is set by clockwise rotation so that the jaw 5 rotates out as an inertial response and is released simply by using counter-clockwise rotation. Specifically, as shown in FIG. 3 b , when the tool is rotated counter-clockwise as viewed from the top, the jaw's radial tip edge 11 rotates radially inwardly and becomes stowed flush with the housing wall 4 , minimizing the width or effective diameter of the tool 10 . Conversely, as shown in FIG. 3 a , when the tool 1 is rotated clockwise as viewed from the top, the jaw 5 rotates radially outwardly from the housing 1 , increasing the effective diameter of the tool 10 , and the radial tip engages the casing 6 . Further, the housing 1 is caused to move in an opposing manner and also engages the casing 6 opposite the jaw 5 , the effective diameter being greater than the diameter of the casing 6 .
Significant advantage is achieved by the causing the tool's housing 1 and its associated downhole tool (PC Pump) to rest against the casing 6 . The casing-engaged jaw 5 creates a strong anchoring force which firmly presses the tool housing 1 and the PC Pump stator into the casing 6 . Accordingly, lateral movement of the PC Pump is restricted, stabilizing the PC Pump's stator against movement caused by the eccentric movement of its rotor. It has been determined that the stabilizing characteristic of the tool 10 can obviate the requirement for secondary stabilizing means.
Referring back to FIG. 1 c , in an optional second embodiment, the threaded end 3 can be formed off-center to the axis of the housing 1 , so that when the radial tip 11 engages the casing 6 , the axis of the threaded end 3 is closer to the center of the casing 6 than is the axis of the housing 1 . This option is useful if the PC Pump or other downhole tool requires centralization.
In the first and second embodiment, the jaw 5 is conveniently formed of the housing wall 4 , however, this also opens the bore 2 to the wellbore. If the tool 10 threaded to the bottom of a PC Pump, this opening of the bore 2 is usually irrelevant. However, where the bore 2 must support differential pressure, such as when the PC Pump suction is through a long fluid conducting tailpiece, or the tool 10 is secured to the top of the PC Pump and must pass pressurized fluids, the bore 2 must remain sealed.
Accordingly, and having reference to FIGS. 4-5 b , in a third embodiment, the housing wall 4 is not interfered with so that the bore 2 remains separate from the wellbore. This is achieved by mounting the jaw 5 external to the housing 1 . The profile of jaw 5 conforms to the housing wall 4 so as to maintain as low a profile as possible when stowed (FIG. 5 b ).
More specifically as shown in FIG. 4, as was the case in the first embodiment, the profile of the jaw 5 corresponds to the profile of the housing wall 4 . In this embodiment however, the jaw 5 is pivoted along its circumferential edge 7 at a piano-type hinge 30 mounted external to the housing wall 4 . Corresponding sockets 9 are formed through the circumferential edge of the jaw and the hinge 30 . Pin 8 is inserted through the sockets 9 . A carbide insert 14 is fitted to the radial tip edge 11 of the jaw 5 .
In operation, as shown in FIG. 5 a , if the tool 1 is rotated clockwise as viewed from the top, the radial tip edge 11 of the jaw rotates radially outwardly from the housing and the carbide insert 14 engages the casing 6 . The housing wall 4 moves and also engages the casing 6 , opposite the jaw 4 for anchoring and stabilizing the tool. As shown in FIGS. 3 a and 5 a , the overall dimension of the extended jaw 5 and the housing 1 is greater than the diameter of the casing 6 so that contact of the radial tip edge 11 with the casing 6 forces the housing against the casing opposing the jaw.
As shown in FIG. 5 b , if the tool is rotated counter-clockwise as viewed from the top, the jaw's radial tip edge 11 rotates radially inwardly and becomes stowed against the housing wall 4 .
Having reference to FIGS. 6 a - 11 b , in a fourth embodiment, a novel jaw 105 is provided, which is biased outwardly from the housing 1 . The jaw 105 is pivotally connected to wall of the housing 1 with a hinge 107 , the hinge 107 having first and second ends 113 , 114 and which lies along a rotational axis. The jaw 105 comprises a tubular conduit 120 , having first and second ends 109 , 110 , formed along edge 106 , which co-operates with a linearly extending, flexible torsional member 121 , shown as having a rectangular section, to bias hinge 107 and jaw 105 outwardly from the housing 1 . The torsional member or spring 121 extends through the tubular conduit 120 and is attached to the tool housing 1 using a first hinge spring holder 122 , and to the jaw 105 using a second hinge spring holder 123 . A preferred hinge utilizes a coupled pin and cavity arrangement at each end of the jaw 105 .
One of either the first or second spring holders 122 , 123 rigidly connects a first end 124 of the hinge spring 121 to the housing 1 , preventing it from rotating with the pivoting jaw 105 . The other spring hinge holder 123 , 122 rotatably connects a second end 125 of the hinge spring 121 to the housing 1 , causing it to rotate therein, with the jaw 105 . Accordingly, as the jaw 105 is rotated from the outwardly extending position to a more compressed position, the hinge spring 121 is twisted into torsion.
As shown in FIGS. 6 b and 8 , a first stationary spring holder 130 , fixes the spring's first end 124 to the tool housing 1 . The stationary spring holder 130 comprises a body 131 having a tubular shaped edge 132 , corresponding to the tubular conduit 121 of the jaw 105 . The body 131 further comprises a counter-sunk screw hole 135 for attaching the stationary holder 130 to the housing 1 , using a suitable fastener 136 . A cylindrical retaining pin 133 extends outwards from the holder's tubular edge 132 , along the same axis, for insertion into the cavity of the jaw's tubular conduit 120 . A spring-retaining slot 134 is formed in the retaining pin 133 for engaging the hinge spring's first end 124 . The orientation of the slot 134 relative to the pin 133 is such that when the stationary holder 130 is affixed to the housing 1 , the jaw 105 is biased to the outwardly extending position.
Having reference to FIGS. 6 b and 9 , a second rotating spring holder 140 is shown, which fixes the spring 121 to the jaw 105 . The rotating holder 140 comprises a body 141 having a tubular edge 142 , corresponding to the jaw's tubular conduit 120 . The tubular edge 142 has a bore 143 . The body 141 further comprises a counter-sunk screw hole 149 for attachment of the holder 140 to the housing 1 , using a suitable fastener 136 . A connector body 144 comprises a first end or retaining pin 145 , which extends into the cavity or bore 143 for free rotation therein, enabling pivoting of the hinge 107 . The connector body 144 further comprises a profiled middle portion 146 (such as an oval or polygonal shape; hexagonal shown) which is inserted into and co-operates with a correspondingly profiled first end 109 of the jaw's conduit 120 , to rotationally fix connector body 144 to the jaw 105 . Lastly the connector body 144 has a spring-retaining end 147 . The spring retaining end 147 further comprises a slot 148 for retaining the hinge spring's second end 125 .
As shown in FIG. 10 a , the hinge spring 121 attached to the housing 1 and the jaw 105 (partially shown-hidden lines) is oriented with the first and second ends 124 , 125 in the same plane, biasing the jaw 105 to the open outwardly extending position as a result of the orientation of the spring 121 relative to the stationary hinge spring holder 122 . Further, showing the spring action in greater detail in FIG. 10 b , when the jaw 105 (hidden lines) is urged to a more compressed position, the stationary holder 122 retains the spring's first end 124 orientation, however, the rotating spring holder 123 allows the spring's second end 125 to be rotated with the jaw 105 . Rotation of the spring's second end 125 , as the jaw 105 is compressed, twists the spring 121 into torsion. As soon as the force causing the jaw 105 to pivot to the compressed position is released, the spring 121 biases the jaw 105 to return the jaw 105 to the casing-engaging position once again. Further, the preferred construction of the hinge 107 avoids supporting loads imposed on the jaw 105 when in the casing-engaging position. The jaw's conduit 120 and the bore 143 of the rotational spring holder are both oversized relative to their respective retaining pins 133 , 145 , allowing limited lateral movement of the jaw 105 relative to the housing I without interfering with the jaw's pivoting action. Accordingly, when the jaw is in the outwardly extended, casing engaging position, the reaction on the jaw 105 drives the jaw sufficiently into the housing 1 so that the back of the tubular conduit 120 at edge 106 engages the housing 1 , transferring substantially all of the forces directly from the jaw 105 to the housing 1 , and avoiding stressing of the retaining pins 133 , 145 and spring holders 122 , 123 .
In operation, as shown, viewed from the top, in FIGS. 11 a and 11 b , the tool 10 is set into a casing 6 by clockwise rotation with the jaw 105 in the biased open position and is released from the casing 6 simply by using counter-clockwise rotation, contact of the jaw 105 and casing to compressing the jaw 105 towards the housing 1 . Specifically, as shown in FIG. 11 b , when the tool 10 is rotated counter-clockwise, the interaction of the jaw 105 and casing 6 causes the jaw to pivot inwardly towards the housing 1 , minimizing the width or effective diameter of the tool 10 . The inward rotation of the jaw 105 causes the hinge spring's rotational end 125 to rotate relative to the hinge spring's stationary end 124 , putting the hinge spring 121 into torsion. Conversely, as shown in FIG. 11 a , when the jaw 105 is not being compressed, such as when the tool 10 is at rest or when rotated clockwise, the jaw 105 is biased outwardly by the hinge spring 121 to return to the outwardly extending casing-engaging position, increasing the effective diameter of the tool 10 . The radial tip 8 engages the casing 6 and the housing 1 is caused to move in an opposing manner so as to engage the casing 6 and brace itself opposite the jaw 105 , the effective diameter being greater than the diameter of the casing 6 .
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A tool is provided for preventing the rotation of a downhole tool or rotary pump stator, the tool comprising a tubular housing and a jaw which is biased radially outwardly from the tool to engage the casing wall for arresting tool rotation and providing significant stabilization of a rotary pump. In doing so, the tool housing moves oppositely to rest against the casing opposite the jaw. The tool housing and the downhole tool are thereby restrained and stabilized by the casing wall. The tool's jaw is released by opposite tool rotation. Preferably, the jaw is biased outwardly from the tool housing to a casing-engaging position by a torsional member, housed along the axis of the hinge of the jaw. The tool is released from the casing by opposite tool rotation which increasingly compresses the jaw toward the housing, twisting the torsional member into torsion, which then acts to urge the jaw outwardly again.
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RELATED APPLICATIONS
[0001] This is a continuation of U.S. patent application Ser. No. 15/018,618, filed Feb. 8, 2015, which claims priority under 35 U.S.C. 119(e) to U.S. Provisional Patent Application Ser. No. 62/204,668, filed Aug. 13, 2015; both of which are hereby incorporated by reference herein in their entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to adjustors for maintaining a tailgate, automobile hatchback or door in a desired position fixed in at least one direction, i.e., opposing a force having a vector in a substantially constant direction. Thus, the invention relates to the automotive and trucking industries, the building and moving industries and other fields in which maintaining a structure rotatable about an axis in a fixed position against at least one directional force vector (such as gravity and/or wind) is desired.
BACKGROUND OF THE INVENTION
[0003] A common feature of most trucks, such as pickup trucks, and some cars is a tailgate. The term “tailgate” generally refers to a door or gate comprising a hinged gate at the back of the cargo bed of a truck or car (such as a station wagon) that can be lowered or otherwise moved to facilitate loading or unloading the vehicle. Generally, a tailgate has two fixed positions: it may be locked and fastened e.g., to the side panels of the truck bed, or may be unlocked and permitted to freely move about the axis defined by a hinge—this may be, for example, generally in an “up and down” direction or less commonly from side to side.
[0004] Originally, tailgates, such as pickup truck tailgates, were designed without support in the “open” position; this when opened, the tailgate was simply permitted to fall down to an angle of about 180° to its closed position (unless hindered by the bumper or other vehicle features). Most modern trucks, station wagons, and the like are built to support the tailgate when it is the “open” position, in which the gate is generally horizontal and substantially parallel to the axis of the front-to-back aspect of the car and at about a 90° angle to its closed position. Support is generally provided by one or more cable or by one or more pneumatic cylinder. These support means may have one end anchored to the truck (for example, to the side panel(s) of the truck) and the other end may be mounted on the back or side of the tailgate itself.
[0005] Similarly, some vehicles, such as some trucks, hatchback cars and station wagons, have rear gates, windows, or doors that open by being raised rather than lowered. Some of the gates, windows or doors have springs and/or pneumatic cylinders that automatically cause the door to raise to the fullest extend when they are opened.
[0006] In one illustration, occasionally the bed or cargo area of a vehicle may be used to transport an item (such as e.g., a motorcycle, lumber, surfboards) that is larger than, or extends beyond the rear tailgate or window thereof. In such cases it is difficult to assure that the cargo remains firmly secured within the bed when the vehicle is in motion. It is therefore common practice in such situations to use twine, rope or cords to maintain the gate, door, or window in a partially closed position, and/or to otherwise to tie the cargo down within the bed or cargo area. This practice can be inconvenient, time consuming and potentially dangerous.
[0007] Tailgates that are supported only in a horizontal position, or which are supported only by cables, make the loading and unloading of cargo, particularly wheeled cargo such as motorcycles, ATV's tractors and the like more difficult, as the tailgate cannot be used as a ramp. It would be helpful in some instances to securely support the tailgate at an angle greater than about 90° to its closed position so as to permit the tailgate to be used as a ramp.
[0008] Furthermore, many owners put a load on their tailgate without knowing the integrity of the installed cables or pneumatic cylinders.
[0009] Zelinsky (U.S. Pat. Nos. 8,075,038, 8,070,207, 8,070,208 and 8,087,710) discloses systems for installation on pickup trucks employing a cable element, in certain cases having a rigid portion comprising an adjustor or lever to lengthen or shorten the cable between 2 positions, or wherein the cable has a long and a short end than can be hooked to the tailgate or truck body, or where the cable fits into a slider built into the tailgate to permit the tailgate to rest in more than two positions, or have a cable section and a rigid section to hook the cable onto. In each case, the systems are somewhat complex to adjust, provide for adjustment of the tailgate between a limited set of positions, and/or require significant alternation of the tailgate and/or truck panels to function.
[0010] Cauley, U.S. Patent Publication 2014/0028046 discloses a tailgate system using two straps (one on each side of the tailgate) and provides for continuous adjustment of the length of the straps and thus the tailgate position. However, each strap must be adjusted and then matched to the length of the opposing strap in order to attain full support of the tailgate.
[0011] Kuzmich, U.S. Pat. No. 6,267,429 discloses a cable-based system in which a hinge provides first and second (primary and secondary) open positions.
[0012] These cable or strap systems may have the disadvantage of lacking rigidity resisting forces in the “upward” direction. That is, they may permit the tailgate to bounce up and down on a bumpy road, or of a quick braking was applied.
[0013] Lisk, U.S. Pat. No. 6,857,678, which uses a threaded rod and a roller to provide continuous adjustment of the tailgate height. This system may be time-consuming and difficult to use to balance the support of each side of the tailgate when in place.
[0014] Casey, U.S. Pat. No. 6,206,444 shows a tailgate spoiler apparatus which involves a rigid rod that can be extended or retracted into a pivoted housing constructed on the inside of the truck bed; this can be adjusting using a hydraulic cylinder or a motor to optimize the passage of air over the tailgate to create a spoiler effect. This system is complex and may take up valuable bed space.
[0015] Sauri, U.S. Pat. No. 5,630,637 discloses a somewhat complicated tailgate adjustment apparatus having shafts and a pair of chains traveling around sprockets. This invention would seem to require a major and expensive rebuilding of the truck bed.
[0016] Vars, U.S. Pat. No. 2,561,081 discloses the use of two rigid metal straps that a permanently affixed to the truck. Each is hinged to a swivel the side panel of the truck. These straps have keyhole apertures placed along their length to engage studs fixed at the outer edges of the tailgate; in this way the tailgate can be adjusted to a particular angle, and held in place using the corresponding keyhole apertures.
[0017] Thus, there is a need in the art for a simple and easily installed apparatus capable of rigidly holding a gate, door or window in a fixed position with respect to the direction of a force. There is also a need for a simple and easily installed apparatus for permitting the tailgate or be rigidly and adjustably supported in a variety of positions, which may include a position of greater than about 90° relative to the locked, closed position of the tailgate to facilitate the use of the tailgate as a ramp for the loading and unloading of cargo into the truck or car bed.
SUMMARY OF THE INVENTION
[0018] The present invention is directed to apparatus and methods for maintaining and supporting structures movable around at least one axis, such as hinged doors, gates and windows, rigidly in a desired and fixed position. In particularly useful examples, the apparatus and methods pertain to vehicle tailgates and hatchbacks (collectively “tailgates” unless indicated otherwise) that rotate around a substantially horizontal axis positioned proximate an edge (for example, a lower edge) of the tailgate. Furthermore, in some examples, the apparatus and methods of the present invention may be used to secure a window, such as a horizontally opening window of a camper shell, sports utility vehicle, or a recreational vehicle, in a partially open position.
[0019] In addition to helping secure a payload to the vehicle, and preventing it from falling or being ejected from the vehicle during transit, the apparatus and methods of the present invention may be used to provide a securely positionable, adjustable tailgate and/or window locking device to provide less drag and thereby increase gasoline, diesel and electrical mileage. As used herein, the word “payload” shall mean goods or other objects being transported or arranged for transport.
[0020] In other examples, the apparatus and method of the present invention may be useful for purposes other than, or in addition to, those related to motor vehicles, such as to provide a way to adjustably maintain a door wholly or partially open (for example, for ventilation purposes) in strong winds or another resisting force.
[0021] It therefore will be understood that as used in the present specification the term “tailgate adjustor(s)” shall refer to the apparatus of the invention without specific regard to where or how the apparatus is used, unless specifically indicated otherwise.
[0022] In certain examples, tailgate adjustors are provided which comprise a sprocketed support apparatus (e.g., a rotatable bracket) preferably comprised of a rigid metal, a metal alloy, a polymer, or a mixture of a polymer and a strengthener such as carbon fiber, and having a first end structured to be rotatably fixed to a vehicle panel located proximal to the rear gate or hatch opening of the vehicle, and a second end structured to be rotatably fixed to a tailgate, for example to a lateral side of a tailgate. The apparatus comprises a plurality of rigid approximately rectangular shanks (preferably, but not invariably, two shanks), pairs of shanks being joined and rotatable with respect to each other around a common axis thereby permitting the apparatus to be folded around the at least one common axis to shorten its reach, or unfolded around the at least one common axis to extend its reach. By “shank” is meant a generally rectangular rigid material (such as a stainless steel, a carbon fiber polymer, or a similarly strong material) having dimensions of length greater than their width, and dimensions of width greater than their thickness; shanks may have rounded ends. Preferably, the shanks are made from cold rolled steel or a similarly hard material. On one example, at least two shanks may be of unequal length and/or width to each other. Those of ordinary skill in the art will recognize that in certain embodiments of the invention three more shanks may be serially linked in a similar manner.
[0023] In a particular example two shanks may be used, with a first shank preferably being shorter than the second shank. The first shank may have exact or approximate dimensions of ¼×1×7¼ inches, while the second shank may have exact or approximate dimensions of 3/16×1×9⅝ inches; those of ordinary skill in the art will be aware that these dimensions may be varied considerably depending upon the application, such as the dimensions of the vehicle, the dimensions and spacing of the attachment points for the shanks, the dimensions of the space between the window, door or gate and the side or frame panels, etc., without departing from the spirit or scope of the present invention.
[0024] The first end of the apparatus is located distally along the length of a first shank from the point of connection between the first shank and another shank; while the second end of the apparatus is located distally along the length of a second shank from the point of connection between the second shank and another shank. In a preferred example, the first and second shanks are rotatably connected to each other, for example, by a hinge, rod, bolt, screw, or rivet. In some examples, the first and second shanks are of equal length; in currently preferred examples the first and second shanks are of unequal length.
[0025] Preferably, the first end, the second end, or both ends of the apparatus are structured to be rotatably fixed to a vehicle panel and/or tailgate, respectively, by means of a hole or channel in the shank proximal to each said end. The hole or channel permits a shank to be rotatably fixed to the vehicle by bolting or screwing the shank, for example, by using a machine screw, to affix the shank to the truck side panel or tailgate, preferably using washers, such as a spacer washer and a shoulder washer. For tailgates, preferably, the existing cable systems may be removed from both the truck side panel and the tailgate, and the shanks of the present support apparatus joined thereto using the same tap holes (e.g., 10 mm×1.25 mm) as were used to join the cable system to these parts. For example, in certain cases a 10 mm×1.25 mm×30 mm machine screw may be used. The machine screws may be placed within polymer bushings having an opening slightly larger than the screw such that the screws can be tightened without inhibiting the ability of the support apparatus to swivel around them during use. It will be recognized that specialized systems may also be devised or used to facilitate the swiveling of the shanks when attached to the vehicle side panel and/or tailgate.
[0026] One of the shanks (preferably, but not necessarily, the long shank) has a sprocket firmly (i.e., non-rotatably) attached thereto, such as by gluing, screwing, bolting, riveting or welding. Preferably, the sprocket comprises a plurality of teeth, circumferentially or semi-circumferentially arranged around the sprocket body, biased and oriented towards the opposing end of the shank on which the sprocket is mounted; that is toward the second end of the apparatus if the sprocket is mounted on the shank joined to the tailgate, or toward the first end of the apparatus if the sprocket is mounted on the shank joined to the truck panel. The number of the sprocket teeth may be between about 6 and about 10 or more, such as about 8. The sprocket teeth may be spaced apart so as to orient the rotatably connected shanks in conveniently chosen increments with respect to each other; for example, in about 11.25 degree increments, or about 22.5 degree increments. It will be understood that for any given spacing of sprocket teeth, the addition of a greater number of teeth will permit the tailgate adjuster to be locked at an increased number of angles relative to the closed position of the tailgate.
[0027] The sprocket teeth are used to lock the tailgate adjuster in place (i.e., with the shanks locked at a specific angle) by a trigger component rotatably mounted on the shank that does not bear the sprocket, at a location proximal to the sprocket when the support apparatus is assembled and mounted. When the shanks are moved about the rotatable connection with respect to each other, the sprocket teeth are rotated with respect to the trigger component. The trigger has a hook-shaped sprocket-engaging tooth that is shaped and oriented to catch and securely hold a chosen sprocket tooth, thereby causing the shanks to be locked at a chosen angle with respect to each other in at least one dimension when the trigger is engaged. When the shanks are mounted on the tailgate and truck side panel, moving the tailgate up or down without the trigger component in an engaged position causes the shanks to rotate about the rotatable connection with respect to each other.
[0028] In preferred examples, the other shank (preferably the short shank) is rotatably joined to the sprocket-containing shank; the means of joining may be any suitable means, such as a rivet or a screw; preferably the shanks are joined by a rivet made of the same material as the shank. The sprocket (firmly joined to, and sufficiently braced against rotational movement due to torque forces on, the longer shank) may also be sandwiched between the shanks at this point. Preferably, the sprocket has a hole through which the rivet or machine screw joining the shanks can be inserted.
[0029] The trigger component may be biased in one position (e.g., the “closed” position), for example, with a spring. In preferred embodiments, a clip may be joined (e.g., screwed or bolted) to the shank carrying the trigger component; the trigger component may comprise an arm component for closing (e.g., engaging) and opening (e.g., disengaging) the trigger. The clip may be structured to capture and hold the arm of the trigger component (e.g., in an open position) with enough holding force to counteract the spring or other biasing means. The clip may comprise a flexible element, such as a channel, to engage and hold the trigger handle; this flexible element may, without limitation, comprise a rubber, a plastic such as PVC, or an elastomer. Alternatively, the clip and/or flexible element may comprise a metal such as a spring steel clip element.
[0030] The apparatus may be mounted in a pickup truck as follows: first the factory installed cable system is removed from one side of the truck side panel and the tailgate by removing the screws attaching the cables to the panel and tailgate. The short shank bearing the trigger component may be connected to the truck side panel with the original screw, and the long shank bearing the sprocket may be connected to the tailgate with the original screw. In both cases, preferably a spacer washer is placed between the shank and the truck panel or tailgate, then the shank, followed by a shoulder washer and finally the screw. The same thing is then done with the truck side panel and the tailgate on the other side of the car. A person of ordinary skill will recognize that the adjustor apparatus on each side of the tailgate are mirror images of each other. In presently preferred embodiments the maximum weight to be placed on the tailgate when the apparatus of the invention is mounted and engaged is about 200 pounds, or about 250 pounds or about 300 pounds or more.
[0031] The adjustor apparatus of the present invention thus permits the tailgate to, for example, be locked in an open position in which the tailgate is at a greater than 90° angle with respect to the fully closed position. This position conveniently permits the loading and unloading of items such as wheeled vehicles into the cargo bed.
[0032] The adjustor apparatus may also be used to lock the tailgate in a slightly open position (for example, approximately 20 to 30 degrees) to act as a spoiler and to direct airflow over the rear of the truck more efficiently while the truck is in motion; this can result in reduced gasoline, diesel and/or electricity usage, thereby increasing mileage and fuel efficiency.
[0033] The adjustors of the present invention may be adapted for use in adjusting the hatchback of a car or the window of a camper shell (both of which, unlike the tailgate, open in an “up” position) so as to lock the window or hatch in a stable, partially closed position when an oversized load is placed in the cargo area, thereby securing the load within the cargo area.
[0034] When made of a metal or alloy, preferably the shanks of the apparatus are electrocated, galvanized, or otherwise covered with an anticorrosion material. Such a material may, without limitation, be a zinc-containing material, a nickel-containing material, a polymeric material, and mixture of such materials. Exemplary anti-corrosion materials are well known to those of skill in the art.
[0035] In some uses, the support apparatus of the present invention may be used in conjunction with one or preferably two reinforcing sheaths, which may be installed on each lateral end of a truck tailgate. Modern truck and SUV tailgates are made using relatively thin metal sheeting, which can lack sufficient strength or rigidity to support heavier objects (such as motorcycles loaded using the tailgate, held at a desired angle by the support apparatus, as a ramp) without the tailgate bending or becoming distorted.
[0036] The sheaths may be made from similar material as the support apparatus, such as stainless steel (e.g., 440C and/or 304 stainless steel) or a similar hard metal, or a polymer or carbon fiber material. The sheathes are generally shaped and sized to fit the lateral end profiles of the tailgate, and are preferably bout 3 to about 9 inches wide, surrounding the top and bottom sides of the tailgate and preferably covering the ends thereof as well. If the reinforcing sheaths include end coverings, the ends may have a hole, for example a tapped hole, for rotatable connection of the support apparatus to the tailgate, as described above.
[0037] Although the foregoing invention has been exemplified and otherwise described in detail for purposes of clarity of understanding, it will be clear that modifications, substitutions, and rearrangements to the explicit descriptions may be practiced within the scope of the appended claims. To the extent that a plurality of inventions are disclosed herein, any such invention shall be understood to have disclosed herein alone, in combination with other features or inventions disclosed herein, or lacking any feature or features not explicitly disclosed as essential for that invention. For example, the inventions described in this specification can be practiced within elements of, or in combination with, other any features, elements, methods or structures described herein. Additionally, features illustrated herein as being present in a particular example are intended, in other aspects of the present invention, to be explicitly lacking from the invention, or combinable with features described elsewhere in this patent application, in a manner not otherwise illustrated in this patent application or present in that particular example. Solely the language of the claims shall define the invention. All publications, patents and patent documents cited herein are each hereby incorporated by reference in its entirety for all purposes to the same extent as if each were so individually denoted.
BRIEF DESCRIPTION OF THE DRAWINGS
[0038] FIG. 1A is a side view of the tailgate adjuster of the present invention installed on a truck having an oversized flat payload.
[0039] FIG. 1B is a side view of the tailgate adjuster of the present invention installed on a truck having a motorcycle as payload.
[0040] FIG. 2 is an exploded view showing the components of an adjustably locking rotatable bracket (tailgate adjustor) of the present invention.
[0041] FIG. 3A is a side view of an assembled example of the adjustably locking rotatable bracket shown in FIG. 2 , in a locked, angled position.
[0042] FIG. 3B is a side view of the adjustably locking rotatable bracket locked in a fully extended position.
[0043] FIG. 3C is a side view of the adjustably locking rotatable bracket in a fully extended position with the trigger component unengaged.
[0044] FIG. 3D is a partial cutaway top view of the adjustably locking rotatable bracket in a fully extended position with the trigger component unengaged.
[0045] FIG. 4 is a close-up of the rotatable joint between shanks of an example of the support apparatus of the present invention.
[0046] FIG. 5A is a top view of a tailgate reinforcing sheath of the present invention.
[0047] FIG. 5B shows a side view of the tailgate reinforcing sheath shown in FIG. 5A .
DETAILED DESCRIPTION OF THE INVENTION
[0048] The present invention is directed to methods and compositions for adjustably maintaining a structure at least partially rotatable about a hinge. Preferably the structure to be maintained in a given position has a substantially flat, planar shape, such as a door, a window or a truck tailgate. As used in the present application, a shape that is “substantially flat and/or planar” is not limited to a two dimensional surface, but may include three dimensional shapes as well. For example, a cuboid shape having a relatively thin depth (such as a window or door) is within this definition, as is the shape of a truck tailgate, which may have a curve in an interior or exterior surface thereof, but nevertheless has the general essential shape and interchangeable function of a flat gate.
[0049] Thus, FIG. 1A is a side view of a pickup truck 101 having a cargo bed 103 . The cargo bed in this figure contains a flat payload 107 . As shown in the figure, the payload 107 is longer than the length of the cargo bed 103 ; such a payload may comprise, for example, planks of lumber or sheets of drywall. Such loads of substantially flat, substantially planar payloads are notoriously difficult to secure for transit, since they generally do not have any easily securable “hold down” features, such as holes, hooks, or protrusions, to which a rope or length of line can be conveniently made fast. If the truck tailgate 105 is left open, the payload can easily slide out of the truck bed, for example, during turns or acceleration of the vehicle. Contrarily, if the tailgate is maintained in a completely raised position the driver's rear view visibility may be compromised.
[0050] As shown, this problem is solved by the present invention wherein one end of an adjustably locking rotatable bracket (tailgate adjuster) 109 is rotatably connected to an outside surface of one side of the tailgate, and the other end of adjustably locking rotatable bracket 109 is rotatably connected to a vehicle panel 111 located proximal and opposing the same side of the tailgate, and the tailgate is raised to about 45° from the horizontal. Preferably, the tailgate is equipped with adjustably locking rotatable brackets 109 on each side of the tailgate, with each such bracket rotatably connected to the vehicle panel 111 located proximal and opposing the side of the tailgate to which the other end of the bracket is connected. The use of two adjustably locking rotatable brackets 109 aids in firmly and securely retaining the tailgate locked at the desired angle, and increases the possible mass of the load that can be placed on the tailgate during use.
[0051] FIG. 1B is a side view of a pickup truck 101 having a cargo bed 103 , wherein the figure is identical to FIG. 1A except the payload comprises a motorcycle 109 . Those of ordinary skill will immediately envision other possible payloads, for example other oversized payloads, for which the present invention will prove useful.
[0052] Turning now to FIG. 2 , there is shown an exploded side view of an example of the adjustably locking rotatable bracket of the present invention. The adjustably locking rotatable bracket apparatus as shown comprises two rigid shanks, a longer shank 203 and a shorter shank 205 . The shanks are preferably approximately cuboid—as shown in FIG. 2 the ends of the shanks 221 are rounded, but the top and bottom surfaces and the side surfaces are flat and parallel, and such shapes are within the definition of “approximately cuboid” as used herein. The shanks may be comprised of, without limitation, a metal, a metal alloy, a carbon fiber composition, or a strong, durable polymer. In preferred example, the shanks are made of stainless steel, but may be made of any suitable metal, such as a hardened bronze or a titanium alloy. Each of the shanks comprise a hole, preferably an elongated circular or stadium shaped hole 217 , proximate to one end thereof.
[0053] The longer shank 203 comprises a sprocket 213 fitted proximate to the end of the shank that does not contain hole 217 . The sprocket may be affixed to the longer shank by any suitable means, such as by welding, cementing, gluing, bolting, or riveting. As shown in FIG. 2 , the longer shank comprises a circular larger diameter hole 215 and three small pins 223 arranged in an equidistant arrangement from each other, with each small pin also equidistant from hole 215 , thereby defining an equilateral triangle around hole 215 .
[0054] The sprocket 213 likewise comprises a hole 225 , preferably of the same diameter as that of the longer shank, as well as small holes 227 slightly larger than the smaller holes 223 of the longer shank. Hole 225 and smaller holes 227 of the sprocket are arranged to exactly overlay those of the longer shank, such that bolts, screws, and or rivets may be used to join the sprocket 213 to the longer shank 203 . In some examples, holes 215 and 225 may be tapped to permit machine screws to connect the longer shank 203 , the sprocket 231 , and the shorter shank 205 . Those of ordinary skill in the art will be aware that this is simply one description of how the sprocket may be fastened to and supported on the shank, and other methods, and variations of these methods, will be easily apparent based upon this disclosure and may be used instead.
[0055] The sprocket 213 comprises a plurality of teeth 229 arranged biased and oriented towards the opposing end (in this case, the end having the elongated circular or stadium shaped hole 217 ) of the shank on which the sprocket is mounted. Preferably, although not necessarily to the functioning of the invention, the sprocket teeth 229 are arranged and oriented substantially around one side or “hemisphere” of the body of the sprocket, while the remainder of the circumference of the sprocket 231 remains rounded, i.e., without teeth. It will be understood that in other examples, the sprocket teeth may extend further or even entirely around the sprocket body. The sprocket is affixed to the longer shank 203 in an orientation that places the teeth of the sprocket along one edge of the shank. In other example of the invention the sprocket may comprise curved plates on each side of the sprocket teeth to prevent the sprocket-engaging trigger tooth 237 from becoming disengaged or slipping from the sprocket teeth during use.
[0056] The shorter shank 205 comprises hole 233 having the same or similar diameter as hole 215 . Additionally, shank 205 comprises hole 235 , located in this example, about ⅝ inches along the length of the shank from hole 233 ; holes 233 and 235 may have the same or similar diameter as holes 215 and 225 , or may have different diameters, In preferred examples the shanks 203 and 205 , and/or the trigger component 207 and shank 205 , may be joined using rivets.
[0057] Trigger component 207 comprises handle 235 , the main body 241 of the trigger, comprising sprocket-engaging tooth 237 , and spring component 239 . In some examples, the majority of the trigger may, for example, be cut out from one sheet of metal, except for the spring component 239 ; in other examples the handle 235 may be welded, bolted or otherwise affixed to the main body of the trigger. The trigger component 207 is rotatably joined to the shorter shank 205 , for example, by means of a rivet or machine screw of suitable length, size and diameter to fit hole 233 . The spring component may be of any suitable design to bias the trigger to apply torque to the trigger towards an “engaged” position (i.e., in the direction of the sprocket engaging tooth; counter-clockwise in FIG. 2 ).
[0058] In one preferred example, the spring component 239 comprises a length of spring wire or a narrow ribbon of bent spring steel affixed and anchored at one end thereof to the shorter shank 205 by way of, without limitation a shallow protrusion and or a hole or slit located on the shorter shank, proximal to the hole 233 . The other end of the spring component is affixed to, or made to engage with a protrusion, shelf, hole or slit on the trigger component in a manner that applies torque to the trigger towards an “engaged” position.
[0059] FIG. 3A is a side view of an assembled example of the adjustably locking rotatable bracket shown in FIG. 2 wherein the longer shank 203 has been joined to the shorter shank 205 with sprocket 213 placed in between, using a rivet through holes 215 , 235 and 225 (see FIG. 2 ), respectively, to grip and join shanks 203 and 205 , and sprocket 213 . The sprocket 213 is non-rotatably joined to longer shank 203 , for example, by welding. The rivet permits the longer shank and the shorter shank to articulate with respect to each other about the axis of the machine screw projecting through and aligning holes 215 , 235 and 225 . In other examples, the rivet may be replaced by, for example, a machine screw.
[0060] In the view shown in FIG. 3A the adjustably locking rotatable bracket 301 is shown in a locked position with the angle between the two shanks 203 and 205 being about 115°. The trigger component 207 is held in the counterclockwise direction by torque forces generated by spring component 239 so that sprocket-engaging tooth 237 fits between selected sprocket teeth 229 . The engagement of the trigger sprocket-engaging tooth with the teeth of the sprocket effectively prevents further articulation of shanks 203 and 205 with respect to each other to increase the angle between them, thereby locking the articulated joint in one direction. However, due to the shape of the sprocket teeth and the trigger tooth, this angle can still be readily reduced (and the reach of the bracket shortened) when the trigger is engaged by articulating the joint in the other direction; that is by moving the shorter shank 205 in a counter clockwise direction (or the longer shank 203 in a clockwise direction).
[0061] Those of skill in the art will quickly recognize that in some cases it may be useful for the adjustably locking rotatable bracket to be structured to be capable of locking in both directions. This can be accomplished by various methods, such as (without limitation) by making the teeth of the sprocket and the sprocket-engaging tooth of the trigger substantially triangular and extending generally radially outward from the sprocket rather than in the counterclockwise-biased arrangement shown in FIGS. 2, and 3A-3C .
[0062] FIG. 3B shows the adjustably locking rotatable bracket 301 locked in a fully extended position, in which the angle about the machine screw joining holes 215 , 235 and 225 and rotatably linking the shorter shank 205 and the longer shank 203 is about 180°.
[0063] FIG. 3C shows the adjustably locking rotatable bracket 301 in a fully extended position (in which the angle about the rivet joining holes 215 , 235 and 225 and rotatably linking the shorter shank 205 and the longer shank 203 is about 180°), but wherein the trigger component 213 is not engaged, and the bracket is thus in an “unlocked” position. As can be seen, the handle 235 of the trigger component 207 has been pulled down and inserted into trigger clip 331 , thus raising the sprocket-engaging trigger tooth 237 away from the sprocket, and permitting the longer shank and shorter shank to freely rotate with respect to each other (thus initially shortening the bracket as a whole).
[0064] Also shown in FIG. 3C is trigger clip 331 , which is affixed to the shorter shank 205 . The trigger clip may be screwed, cemented, glued, or otherwise fastened to a base or side of the shank. As shown, the trigger clip is screwed to the underside of the shank. The trigger clip contains or consists of a flexible material, which may comprise, for example, a plastic such as polyvinyl chloride (“PVC”), a natural or synthetic rubber, or another elastomeric material. A narrow horizontal channel (not shown) extends along an outside side of the clip; the channel is preferably slightly narrower than the width of trigger handle 235 such that, when the trigger handle is inserted into the channel, it is retained there against, and to counter, the force of compressed spring component 239 . In some examples, the channel, or trigger clip as a whole, may comprise a flexible metal clip such as one made of spring steel.
[0065] FIG. 3D is a partial cutaway top view of the adjustably locking rotatable bracket 301 in a fully extended position, as also shown in side view in FIG. 3C . As shown the longer shank 203 is connected by a rivet 327 through holes 215 , 235 and 225 (see FIG. 2 ) to shorter shank 205 , with sprocket 213 affixed in between. A shorter rivet 329 connects trigger component to the shorter shank 205 . Screws 321 are inserted through shoulder washer 323 , then through hole 217 and spacer washer 325 before being inserted in a tapped hole in either the side of the tailgate (preferably, longer shank), or a side panel of the truck or truck cargo bed (preferably, shorter shank). Usually, the preexisting standard issue flexible wire cables are fastened by screws and tapped holes to the same locations of the tailgate and cargo bed, and the same tapped holes can be reused to connect the adjustably locking rotatable bracket 301 of the present invention to the vehicle truck and tailgate, although if necessary, suitable holes can be drilled and tapped de novo. As will be apparent to a person of ordinary skill in the art, it is very preferable that an adjustably locking rotatable bracket of the present invention be connected to each side of the tailgate to provide stability and structural strength to the tailgate when locked in a position intermediate between fully open and fully closed.
[0066] FIG. 4 shows another example of the support apparatus of the present invention, and comprises a close-up of the sprocket 213 and trigger component assembly 207 . In this example, longer shank 203 is joined to sprocket 213 by welding at three locations 401 . Rivet 403 rotatably joins the longer shank 203 with sprocket 213 attached and the shorter shank 205 through hole 215 (and holes 225 and 233 ; not shown). Pins 227 secure the sprocket 213 to the longer shank 203 to prevent torque displacement of the sprocket during use.
[0067] Trigger component 207 is shown in both engaged and disengaged configurations. When the trigger component is in the disengaged position, the handle 235 is inserted into clip 331 . As described above, the trigger component is biased in an engaged position by torsion spring 239 , which is anchored to the trigger component by protrusion 405 and protrusion 407 (in this example, the spring is bent around the protrusions.) In this example, sprocket component 213 comprises two curved sheets of metal ( 409 ; only one curved sheet is shown in this side view) formed on each side of the sprocket teeth 229 . The trigger component is rotatably joined to the shorter shank 205 by a rivet 411 through hole 235 .
[0068] FIG. 5A is a top view of another example of the present invention comprising a tailgate-reinforcing sheath 501 . The sheath is very preferably made from a strong metal or metal alloy such as steel, and is effective to prevent bending of the tailgate when the support apparatus of the invention is employed in concert with a large load, such as a one or more motorcycle or all terrain vehicle (ATV). As shown in this figure, the sheath has a rear surface 509 , side surfaces 505 , front surface 507 , and top surface 513 . Optional U-shaped brackets 511 may be welded to top surface 509 ; these are also preferably made of a strong metal or metal alloy.
[0069] The tailgate-reinforcing sheath also has a plurality of holes on facing surface 513 for fastening to the underlying tailgate surface near the end of the tailgate, preferably using blind rivets.
[0070] FIG. 5B shows a side view of the same exemplary tailgate-reinforcing sheath. Thus, Surfaces 513 , 509 and 507 are shown, as is optional U-shaped bracket 511 with a removable hook 515 . Dotted line 521 shows the underlying end portion of the vehicle tailgate. Holes 519 are available on side surface 505 for the insertion of screws to join the sheath to the side of the tailgate. As can be seen in this figure, the tailgate-reinforcing sheath comprises a hollow void within shaped to receive and closely fit and cover the end portion of the tailgate 521 .
[0071] The various descriptions of the invention provided herein illustrate presently preferred examples of the invention; however, it will be understood that the invention is not limited to the examples provided, or to the specific configurations, shapes, and relation of elements unless the claims specifically indicate otherwise. Based upon the present disclosure a person of ordinary skill in the art will immediately conceive of other alternatives to the specific examples given, such that the present disclosure will be understood to provide a full written description of each of such alternatives as if each had been specifically described.
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A tailgate adjuster in a preferred example comprises an adjustably locking rotatable bracket comprising a plurality of rotatably linked shank components, with at least one shank component joined to a sprocket component having a plurality of sprocket teeth, and at least one other shank component joined to a rotatable trigger component having a sprocket-engaging trigger tooth. The trigger component is preferably spring biased to maintain the trigger tooth in an engaged position with the sprocket teeth, and can be adjusted to disengage the trigger component from the sprocket teeth. The sprocket teeth are spaced to permit the locking of shank components at a desired angle to each other. Holes at each end of the tailgate adjuster permit the rotatable mounting of one such end to a vehicle tailgate or hatchback and the other end to a fixed location of the vehicle. In other examples the invention concerns a tailgate-reinforcing sheath and methods for maintaining a vehicle tailgate or other hinged door, gate or window in a one of a plurality of partly open positions.
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BACKGROUND AND SUMMARY
[0001] The present invention relates to a method for automatically limiting a pressure generated during operation in a hydraulic system when needed, said system being adapted to deliver a pressurized hydraulic fluid to at least one actuator adapted to perform a work function.
[0002] Below, the invention will be described in connection with a working machine in the form of a wheel loader. This is a preferred, but by no means limiting application of the invention. The invention can for example also be used for other types of working machines (or work vehicles), such as a backhoe loader, an excavator, or an agricultural machine such as a tractor.
[0003] A wheel loader can be utilised for a number of fields of activity, such as lifting and transportation of rock and gravel, loading pallets and logs. In each of these activities, different equipment is used, including implements in the form of a bucket, a fork implement and gripping arms. More particularly, the equipment comprises a load-arm unit, or boom, which is pivotally arranged relative to the wheel loader frame. Two actuators in the form of hydraulic cylinders are arranged between the frame and the load-arm unit in order to achieve a lifting and lowering movement of the load-arm unit. The implement is pivotally arranged on the load-arm unit. An additional actuator in the form of a hydraulic cylinder is arranged between the implement and the load-arm unit in order to achieve a tilting movement of the implement.
[0004] The hydraulic system comprises a pump adapted to supply the hydraulic cylinders with pressurized hydraulic fluid via a hydraulic circuit comprising a plurality of control valves.
[0005] As a rule, a wheel loader has more hydraulic functions than the above-mentioned lift and tilt function. Such additional hydraulic functions include steering, 3rd, 4th, and in some cases even more functions. Each function generally needs two shock valves, except lift which has one shock valve. For a machine with a 3rd and a 4th function, this implies nine shock valves.
[0006] Different functions require different flow rates. Furthermore, the same function requires different flow rates for piston and piston rod side. Machines of different sizes also have different flow rate requirements. In practice, only a few shock valves are used, where the one having the highest flow requirement decides the flow rate. This implies that most functions have unnecessarily large shock valves.
[0007] It is desirable to achieve a method which creates prerequisites for a more cost efficient system with maintained or improved service life.
[0008] A method according to an aspect of the present invention includes
detecting a pressure in at least one position in the system;—comparing the detected pressure value, or a value associated with the detected pressure value, with a first predetermined limit value; and opening a flow communication between the actuator and a tank via a first conduit if the detected pressure value, or the value associated with the detected pressure value, exceeds the predetermined limit value.
[0011] Thus, in this way, drainage to tank is actively controlled when needed. Preferably, at least one pressure sensor is adapted to detect the pressure to the respective function.
[0012] In this way, the limit value (for example the opening pressure) can be set as low as possible in all situations, which results in a smaller load on the constituent components.
[0013] According to a preferred embodiment, the flow communication is opened via a control valve being arranged on the first conduit and having the function to control the supply of the hydraulic fluid to and from, respectively, the actuator with the object of performing the work function. In case of an unexpected pressure increase, this control valve functions as a controlled shock valve. Preferably, separate inlet and outlet valves to the actuator are provided in order to control the function (for example a lifting and lowering movement).
[0014] According to another preferred embodiment, the method further comprises the step of opening a flow communication between the actuator and the tank via a second conduit via a shock valve. The shock valve is also called pressure limiting valve. The shock valve is preferably arranged in a conventional way as a passive (directly controlled by the pressure), for example spring-loaded, shock valve. By means of combining the opening of the control valve and the shock valve, drainage to tank at a desired rate can be obtained in case of a pressure shock.
[0015] Owing to the smaller size of the possibly included directly controlled shock valves and to fewer variants, a lower cost can be achieved. Furthermore, owing to the smaller directly controlled shock valves, the valve housing can be made smaller.
[0016] As a rule, the control valve opens more slowly than the shock valve, which in many cases implies that said flow communication between the actuator and the tank via the first conduit is opened after the shock valve has opened the flow communication between the actuator and the tank via the second conduit. In other words, the control valve is opened with a certain delay, so that the shock valve is opened first. It is possible, however, to ensure that the control valve opens substantially simultaneously as, or before the shock valve.
[0017] Preferably, a shock valve of a smaller size, i.e. with a lower nominal flow rate, than the electrically controlled outlet valve is used. The directly controlled shock valve, which is fast-acting, opens directly and flow drainage is initiated. Then, the electrically controlled control valve, which is capable of handling the larger flow requirement and draining it to tank, is opened.
[0018] According to another preferred embodiment, the method comprises the step of determining the flow rate to the tank on the basis of the detected pressure. In this way, the characteristics of the shock control function can be determined. The opening degree of the control valve is controlled, for example, on the basis of the pressure change in the actuator.
[0019] Further preferred embodiments of the invention and advantages associated therewith are apparent from the remaining claims and the following description.
BRIEF DESCRIPTION OF FIGURES
[0020] The invention will be described more closely in the following, with reference to the embodiments shown in the attached drawings, wherein
[0021] FIG. 1 shows a side view of a wheel loader, and
[0022] FIG. 2 shows a system for performing the method during operation of the wheel loader.
DETAILED DESCRIPTION
[0023] FIG. 1 shows a side view of a wheel loader 101 . The wheel loader 101 comprises a front vehicle section 102 and a rear vehicle section 103 , said sections each comprising a frame and a pair of drive shafts 112 , 113 . The rear vehicle section 103 comprises a driver's cab 114 . The vehicle sections 102 , 103 are connected to each other in such a way that they can be pivoted relative to each other about a vertical axis by means of two actuators in the form of hydraulic cylinders 104 , 105 which are connected to the two sections. Accordingly, the hydraulic cylinders 104 , 105 are disposed on different sides of a centre line in the longitudinal direction of the vehicle for steering, or turning the wheel loader 101 .
[0024] The wheel loader 101 comprises an equipment 111 for handling objects or material. The equipment 111 comprises a load-arm unit 106 and an implement 107 in the form of a bucket which is fitted on the load-arm unit. Here, the bucket 107 is filled with material 116 . A first end of the load-arm unit 106 is pivotally connected to the front vehicle section 102 in order to achieve a lifting movement of the bucket. The bucket 107 is pivotally connected to a second end of the load-arm unit 106 in order to achieve a tilting movement of the bucket.
[0025] The load-arm unit 106 can be raised and lowered relative to the front section 102 of the vehicle by means of two actuators in the form of hydraulic cylinders 108 , 109 , each of which is connected at one end to the front vehicle section 102 and at the other end to the load-arm unit 106 . The bucket 107 can be tilted relative to the load-arm unit 106 by means of a third actuator (hydraulic cylinder) 110 , which is connected at one end to the front vehicle section 102 and at the other end to the bucket 107 via a link arm system.
[0026] A first embodiment of the system is shown in FIG. 2 . The system 201 comprises a pump 205 adapted to supply the hydraulic cylinders with pressurized hydraulic fluid via a hydraulic circuit. The pump 205 is driven by the vehicles propulsion engine 206 , in the form of a diesel engine. The pump 205 has a variable displacement. The pump 205 is preferably adapted for infinitely variable control. The system 201 comprises a valve device 208 (se the dash-dotted line) which comprises a hydraulic circuit having a plurality of control valves for controlling the lift and tilt function.
[0027] Two control valves, in the form of flow valves, 207 , 209 , are arranged between the pump 205 and the lift cylinders 108 , 109 in the circuit in order to control the lifting and lowering movement. While a first one of these valves 207 is arranged to connect the pump 205 to the piston side, a second one of these valves 209 is arranged to connect a tank 243 to the piston rod side. Furthermore, the first valve 207 is arranged to connect the tank 243 to the piston side and the second valve 208 is arranged, correspondingly, to connect the pump 205 to the piston rod side. This offers large possibilities for varying the control. In particular, it is not necessary to connect the pump and tank simultaneously to the function.
[0028] The system 201 further comprises a control unit 213 , or computer, which contains software for controlling the functions. The control unit is also called a CPU (central processing unit) or ECM (electronic control module). The control unit 213 suitably comprises a microprocessor.
[0029] An operator-controlled element 211 , in the form of a lifting lever, is operatively connected to the control unit 213 . The control unit 213 is adapted to receive control signals from the control lever and to actuate the control valves 207 , 209 correspondingly (via a valve control unit 215 ). The control unit 213 preferably controls more general control strategies and the control unit 215 controls basic functions of the valve unit 208 . Naturally, the control units 213 , 215 can also be integrated into a single unit. When controlling the pump 205 , there is an oil flow out to the cylinders 108 , 109 , the level of which depends on the extent to which the actuated valves 207 , 209 are opened.
[0030] An operator-controlled element 219 , in the form of a steering-wheel, is hydraulically connected to the steering cylinders 104 , 105 , via a valve unit in the form of an orbitrol unit 220 , for direct-control thereof.
[0031] Similarly as for the lift function, two control valves 223 , 225 are arranged between the pump 205 and the tilt cylinder 100 for controlling the forward and return movement of the implement relative to the load-arm unit. An operator-controlled element 227 , in the form of tilt lever, is operatively connected to the control unit 213 . The control unit 213 is adapted to receive control signals from the tilt lever and to actuate the control valves 223 , 225 correspondingly.
[0032] A prioritizing valve 220 is arranged at the outlet conduit 245 from the pump in order to automatically prioritize that the steering function receives the required pressure before the lift function (and the tilt function).
[0033] The system 201 is load-sensing and comprises, for this purpose, a plurality of pressure sensors 229 , 231 , 233 , 235 , 237 for detecting load pressures of each of said functions. The lift function of the system comprises two pressure sensors 229 , 231 , out which one is arranged on a conduit to the piston side of the lift cylinders and the other on a conduit to the piston rod side of the lift cylinders. In a corresponding way, the tilt function of the system comprises two pressure sensors 235 , 237 , out of which one is arranged on a conduit to the piston rod side of the tilt cylinder and the other on a conduit to the piston side of the tilt cylinder. The steering function comprises a pressure sensor 233 on a conduit connected to the steering cylinders 104 , 105 . More precisely, the pressure sensor 233 is situated on the LS-conduit which receives the same pressure as on one cylinder side when steering in one direction and as on the other cylinder side when steering in the other direction. In neutral, the LS-conduit is connected to tank.
[0034] The system further comprises an electrically controlled valve 241 adapted to control the output pressure of the pump via a hydraulic signal. The system 201 comprises an additional pressure sensor 239 for detecting a pressure which is indicative of an output pressure from the pump. More precisely, the pressure sensor 239 is adapted to detect the pressure in a position downstream the electrically controlled valve 241 . Accordingly, the pressure sensor 239 senses the pump pressure directly when the valve 241 is fully open. In normal driving conditions, the pressure sensor 239 detects the output pressure from the valve 241 . Accordingly, the control unit 213 is adapted to receive a signal from the pump pressure sensor 239 with information about of the pressure level.
[0035] Accordingly, the control unit 213 receives electrical signals from the pressure sensors 229 , 231 , 233 , 235 , 237 , 239 and generates an electrical signal for controlling the electrical valve 241 .
[0036] As previously stated, the control unit 213 is adapted to receive signals from the control levers 211 , 227 . When the operator wants to lift the bucket, the lift lever 211 is operated. The control unit receives a corresponding signal from the lift lever 211 and actuates the control valves 207 , 209 to such a position that the pump is connected to the piston side of the lift cylinders 108 , 109 and the piston rod side of the lift cylinders is connected to the tank 243 . Furthermore, the control unit receives signals from the load pressure sensor 229 on the piston side of the lift cylinders and from the pressure sensor 239 downstream the pump. Based upon the received signals, a desired pump pressure at a level above the detected load pressure is determined, and the electrically controlled pump control valve 241 is actuated correspondingly.
[0037] The control unit 213 is preferably adapted to coordinate the opening degree of the control valves 207 , 209 and the output pressure of the pump 205 for optimum operation.
[0038] The tilt function is controlled in a corresponding manner as the lift function. When steering the machine, the pressure sensor 233 of the steering function detects a load pressure of the steering and generates a corresponding load signal. The control unit 213 receives this load signal and a signal from the pressure sensor 239 on the outlet conduit of the electrically controlled valve 241 . Based upon the received signals, a desired pump pressure at a level above the detected load pressure is determined, and the electrically controlled pump control valve 241 is actuated correspondingly.
[0039] When several functions are used simultaneously, the detected load pressures are compared and the pump 205 is controlled corresponding to the highest of the detected load pressures.
[0040] Accordingly, the electrically controlled pump control valve 241 is adapted to be infinitely adjustable between two end positions, a first end position which corresponds to the pump producing a minimum pressure and a second end position which corresponds to the pump producing a maximum pressure.
[0041] A hydraulic means 253 , in the form of a reversing valve, is arranged on a conduit 251 between the electrically controlled pump control valve 241 and the pump. The reversing valve 253 is adapted to receive the hydraulic signals from the steering function and the pump control valve 241 .
[0042] Furthermore, the reversing valve is adapted to control the pump 205 corresponding to the received signal having the largest load pressure. Accordingly, the hydraulic means (reversing valve) 253 selects the higher pressure in an output signal made up of two input pressure signals.
[0043] The system further comprises a sensor 255 for detecting lift cylinder position. The sensor 255 is operatively connected to the control unit 213 . In this way, the control unit 213 can decide whether a lifting or lowering movement of the load is performed.
[0044] The system 201 further comprises a number of shock valves 261 , 263 , 367 , for the lift function and the tilt function, for draining hydraulic fluid to the tank 243 in case of a strong pressure increase. The lift function of the system comprises a shock valve 261 which is arranged on a conduit 273 to the piston side of the lift cylinders. The tilt function of the system comprises two shock valves 263 , 267 , out of which one 263 is arranged on a conduit 277 to the piston rod side of the tilt cylinder and the other 267 on a conduit 279 to the piston side of the tilt cylinder.
[0045] Below, a method for automatically limiting a pressure generated during operation in the system when needed is described in a few different examples. The method is described with respect to the lift function, but the corresponding also applies to, for example, the tilt function.
[0046] An external force initiates a movement of the hydraulic cylinders 108 , 109 . The control unit 213 detects that the pressure exceeds a certain first level (for example 350 bar) via the pressure sensor 229 . The control unit 213 then emits a signal to the outlet valve 207 to drain oil to the tank 243 via a first conduit 271 . Accordingly, the outlet valve 207 acts like a shock valve by means of software control. The directly controlled shock valve 261 opens when the pressure exceeds a certain second, predetermined level (for example 360 bar) and initiates draining of flow to the tank 243 via a second conduit 273 . The electrically controlled outlet valve 207 now has had time to open for a larger drainage flow to the tank 243 . The pressure, which is recorded continuously, drops and the electrically controlled outlet valve 207 and the directly controlled shock valve 261 close at specific pressure levels.
[0047] The first level can be equal to the second level, but preferably the first level is smaller than the second level. This in order to obtain a substantially simultaneous, or earlier, opening of the control valve relative to the shock valve.
[0048] As a supplement or an alternative to the foregoing, the electrically controlled outlet valve 207 is controlled on the basis of the pressure derivative (in order to obtain faster opening of the electrically controlled outlet valve 207 ). For example, the control valve is controlled to serve as a shock valve as soon as the pressure derivative in the cylinder 108 , 109 exceeds a certain level, irrespective of whether the pressure level is low. If an external force initiates a movement of the cylinder, the control valve will initiate its opening procedure before the pressure level reaches the upper limit (for example 350 bar). If the upper limit is not reached, the control valve will still close when the pressure derivative falls short of a certain level.
[0049] According to a further variant, the electrically controlled shock valve 207 has a variable opening pressure. Preferably, the pressure level is set depending upon the operating condition (such as load-arm position and/or bucket position). The directly controlled shock valve 261 is then set to open only at the maximum pressure level. In certain situations, a large shock resistance is needed, for example when the bucket is pushed into a material pile with maximum propulsion, and in other situations, the shock function can open at a lower pressure. This means that the machine/iron is subjected to less stress.
[0050] The opening pressure of the electrically controlled valve 207 is, for example, dependent on the following operating parameters:
[0051] Cylinder positions for different functions. For example, when the bucket is pushed with maximum propulsion into the material pile (when the unit is lowered and the bucket is in a level position) an exceptionally high resistance is needed on the piston side of the lift cylinder.
[0052] Type of implement. Implements which are not influenced by the propulsion (for example a pallet fork assembly) do not need as high an opening pressure as a bucket.
[0053] Type of handling. One handling example is loading timber onto a truck. Another example is bucket handling for loading gravel/rocks. Furthermore, it is conceivable to use the same implement, for example a bucket, for different handling operations. Accordingly, type of handling can be independent of type of implement.
[0054] According to one example, the system is adaptive. The control unit can then record how the wheel loader is operated during a certain period of time through detecting operating parameters and concluding which handling operation is performed and/or which implement type is used. Alternatively, or as a supplement, the limit value is determined on the basis of a signal from an operator-controlled element, such as a lever, button, or another control means in the cab.
[0055] Machine speed. At high machine speeds, it is safer if the opening pressures of the shock valves are at a higher level.
[0056] According to a further variant, the electrically controlled valve 207 has different pressure drops for the same flow rate, wherein the pressure drop is dependent on the following:—the function concerned and/or—the cylinder position. When subjected to shock loading with the load-arm in a high position, it is not desirable that the unit falls to the ground, but is lowered at a controlled speed. With this system all functions and all machine sizes can have the same shock characteristics, that is to say, when the shock function opens, the same degree of resistance can be felt irrespective of the type of machine concerned.
[0057] Furthermore, an adaptive shock control on the basis of a pressure level can be utilized. The basic idea is to have as low an opening pressure as possible, with the purpose of “sparing” the machine. The machines which are handled most aggressively are the ones which to a great extent decide the opening levels. Therefore, according to a further variant, an adaptive opening pressure is introduced. Thereby, most of the machines can be at lower levels and the machines which require higher levels will also get such levels. The idea is that the control unit 213 records the extent of shock loading which occurs. If this exceeds a certain level, the opening pressure for the electrically controlled shock valve 207 is temporarily increased within certain limits. The opening pressure can be a function of all or certain of the following: shock loading frequency, shock loading time, shock loading time expressed as a percentage of total machine time (with diesel engine running) and/or shock loading time expressed as a percentage of total active time for the function concerned.
[0058] Similar adaptive action can also occur when the electrically controlled shock valve 207 opens at a certain pressure derivative. The pressure derivative limit can be adjusted depending upon how often/much the electrically controlled shock valve 207 opens as a result of the pressure derivative. The same function dependent parameters as described above can be used, but where, as mentioned before, only those cases where the shock loading control occurs as a result of the pressure derivative are taken into consideration.
[0059] The invention should not be regarded as limited to the above-described exemplary embodiments, but a number of further variants and modifications are conceivable within the scope of the following claims. In particular, the preferred embodiments can be combined in a number of different ways.
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A method is provided for, when necessary, automatically limiting a pressure in a hydraulic system during operation. A system is arranged to deliver pressurized hydraulic fluid to at least one fluid actuated device arranged to perform a work function, where the procedure includes sensing a pressure in at least one position of the system, comparing the detected pressure value, or an associated value, with a first predefined pressure limit, and opening a communication of fluid between the fluid actuated device and a reservoir through a first conduit if the sensed pressure value, or an associated value, exceeds the predefined limit.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a Continuation of U.S. patent application Ser. No. 10/223,169 filed on Aug. 19, 2002, which is a Continuation-in-Part of U.S. patent application Ser. No. 09/794,964 filed on Feb. 27, 2001, now U.S. Pat. No. 6,626,253, each of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to drilling fluid telemetry systems and, more particularly, to a telemetry system incorporating an oscillating shear valve for modulating the pressure of a drilling fluid circulating in a drill string within a well bore.
[0004] 2. Description of the Related Art
[0005] Drilling fluid telemetry systems, generally referred to as mud pulse systems, are particularly adapted for telemetry of information from the bottom of a borehole to the surface of the earth during oil well drilling operations. The information telemetered often includes, but is not limited to, parameters of pressure, temperature, direction and deviation of the well bore. Other parameter include logging data such as resistivity of the various layers, sonic density, porosity, induction, self potential and pressure gradients. This information is critical to efficiency in the drilling operation.
[0006] Mud pulse valves must operate under extremely high static downhole pressures, high temperatures, high flow rates and various erosive flow types. At these conditions, the valve must be able to create pressure pulses of around 100-300 psi.
[0007] Different types of valve systems are used to generate downhole pressure pulses. Valves that open and close a bypass from the inside of the drill string to the wellbore annulus create negative pressure pulses, for example see U.S. Pat. No. 4,953,595. Valves that use a controlled restriction placed in the circulating mud stream are commonly referred to as positive pulse systems, for example see U.S. Pat. No. 3,958,217.
[0008] The oil drilling industries need is to effectively increase mud pulse data transmission rates to accomodate the ever increasing amount of measured downhole data. The major disadvantage of available mud pulse valves is the low data transmission rate. Increasing the data rate with available valve types leads to unacceptably large power consumption, unacceptable pulse distortion, or may be physically impractical due to erosion, washing, and abrasive wear. Because of their low activation speed, nearly all existing mud pulse valves are only capable of generating discrete pulses. To effectively use carrier waves to send frequency shift (FSK) or phase shift (PSK) coded signals to the surface, the actuation speed must be increased and fully controlled.
[0009] Another example for a negative pulsing valve is illustrated in U.S. Pat. No. 4,351,037. This technology includes a downhole valve for venting a portion of the circulating fluid from the interior of the drill string to the annular space between the pipe string and the borehole wall. Drilling fluids are circulated down the inside of the drill string, out through the drill bit and up the annular space to surface. By momentarily venting a portion of the fluid flow out a lateral port, an instantaneous pressure drop is produced and is detectable at the surface to provide an indication of the downhole venting. A downhole instrument is arranged to generate a signal or mechanical action upon the occurrence of a downhole detected event to produce the above described venting. The downhole valve disclosed is defined in part by a valve seat having an inlet and outlet and a valve stem movable to and away from the inlet end of the valve seat in a linear path with the drill string.
[0010] All negative pulsing valves need a certain high differential pressure below the valve to create sufficient pressure drop when the valve is open. Because of this high differential pressure, negative pulse valves are more prone to washing. In general, it is not desirable to bypass flow above the bit into the annulus. Therefore it must be ensured, that the valve is able to completely close the bypass. With each actuation, the valve hits against the valve seat. Because of this impact, negative pulsing valves are more prone to mechanical and abrasive wear than positive pulsing valves.
[0011] Positive pulsing valves might, but do not need to, fully close the flow path for operation. Positive poppet type valves are less prone to wear out the valve seat. The main forces acting on positive poppet valves are hydraulic forces, because the valves open or close axially against the flow stream. To reduce the actuation power some poppet valves are hydraulically powered as shown in U.S. Pat. No. 3,958,217. Hereby the main valve is indirectly operated by a pilot valve. The low power consumption pilot valve closes a flow restriction, which activates the main valve to create the pressure drop. The power consumption of this kind of valve is very small. The disadvantage of this valve is the passive operated main valve. With high actuation rates the passive main valve is not able to follow the active operated pilot valve. The pulse signal generated is highly distorted and hardly detectable at the surface.
[0012] Rotating disc valves open and close flow channels perpendicular to the flow stream. Hydraulic forces acting against the valve are smaller than for poppet type valves. With increasing actuation speed, dynamic forces of inertia are the main power consuming forces. U.S. Pat. No. 3,764,968 describes a rotating valve for the purpose to transmit frequency shift key (FSK) or phase shift key (PSK) coded signals. The valve uses a rotating disc and a non-rotating stator with a number of corresponding slots. The rotor is continuously driven by an electrical motor. Depending on the motor speed, a certain frequency of pressure pulses are created in the flow as the rotor intermittently interrupts the fluid flow. Motor speed changes are required to change the pressure pulse frequency to allow FSK or PSK type signals. There are several pulses per rotor revolution, corresponding to the number of slots in the rotor and stator. To change the phase or frequency requires the rotor to increase or decrease in speed. This may take a rotor revolution to overcome the rotational inertia and to achieve the new phase or frequency, thereby requiring several pulse cycles to make the transition. Amplitude coding of the signal is inherently not possible with this kind of continuously rotating device. In order to change the frequency or phase, large moments of inertia, associated with the motor, must be overcome, requiring a substantial amount of power. When continuously rotated at a certain speed, a turbine might be used or a gear might be included to reduce power consumption of the system. On the other hand, both options dramatically increase the inertia and power consumption of the system when changing from one to another speed for signal coding. Another advantage of the oscillating shear valve is the option to use more sophisticated coding schemes than just binary coding. With the fast switching speed and large bandwidth of the oscillating shear valve, multivalent codes are possible (e.g. three different conditions to encode the signal). The large bandwidth also enables the operator to use chirps and sweeps to encode signals.
[0013] The aforesaid examples illustrate some of the critical considerations that exist in the application of a fast acting valve for generating a pressure pulse. Other considerations in the use of these systems for borehole operations involve the extreme impact forces, dynamic (vibrational) energies, existing in a moving drill string. The result is excessive wear, fatigue, and failure in operating parts of the system. The particular difficulties encountered in a drill string environment, including the requirement for a long lasting system to prevent premature malfunction and replacement of parts, require a robust and reliable valve system.
[0014] The methods and apparatus of the present invention overcome the foregoing disadvantages of the prior art by providing a novel mud pulse telemetry system utilizing a rotational oscillating shear valve.
SUMMARY OF THE INVENTION
[0015] The present invention contemplates a mud pulse telemetry system utilizing an oscillating shear valve system for generating pressure pulses in the drilling fluid circulating in a drill string in a well bore. In one aspect of the invention, a mud pulse telemetry system comprises a drillstring having a drilling fluid flowing therein, where the drill string extends in a borehole from a drilling rig to a downhole location. A non-rotating stator is disposed in the flowing drilling fluid, the stator having a plurality of flow passages to channel the drilling fluid. A rotor is disposed in the flowing drilling fluid proximate the stator, the rotor having a plurality of flow passages. A motor driven gear system is adapted to drive the rotor in a rotationally oscillating manner for generating pressure fluctuations in the drilling fluid.
[0016] In another aspect, a method for providing a high data rate in a mud pulse telemetry system by generating a fast transition in a mud pulse telemetry multivalent encoding scheme, wherein the combination of an amplitude shift key encoding (ASK) scheme and a frequency shift key encoding scheme (FSK) comprises driving a rotor in an oscillatory periodic motion through at least one first predetermined rotational angle at at least one first frequency generating at least one first pulse amplitude at the at least one first frequency. A drive signal is changed to drive the rotor in an oscillatory periodic motion through at least one second predetermined rotational angle at at least one second predetermined frequency according to the multivalent encoding scheme. At least one second pulse amplitude at the at least one second frequency is attained in no more than one rotor oscillatory period.
[0017] Examples of the more important features of the invention thus have been summarized rather broadly in order that the detailed description thereof that follows may be better understood, and in order that the contributions to the art may be appreciated. There are, of course, additional features of the invention that will be described hereinafter and which will form the subject of the claims appended hereto.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] For detailed understanding of the present invention, references should be made to the following detailed description of the preferred embodiment, taken in conjunction with the accompanying drawings, in which like elements have been given like numerals, wherein:
[0019] FIG. 1 is a schematic diagram showing a drilling rig engaged in drilling operations;
[0020] FIG. 2 is a schematic of an oscillating shear valve according to one embodiment of the present invention;
[0021] FIG. 3 a is a schematic of a typical torque signature acting on an oscillating shear valve according to one embodiment of the present invention;
[0022] FIG. 3 b is a schematic of a magnetic spring assembly according to one embodiment of the present invention;
[0023] FIG. 3 c is a cross section view of the magnetic spring assembly of FIG. 3 b;
[0024] FIG. 3 d is a schematic of a shaped torque profile according to one embodiment of the present invention;
[0025] FIG. 4 is schematic which describes Phase Shift Key encoding using an oscillating shear valve according to one embodiment of the present invention;
[0026] FIG. 5 is a schematic which describes Frequency Shift Key encoding using an oscillating shear valve according to one embodiment of the present invention;
[0027] FIG. 6 a illustrates a continuously rotating shear valve;
[0028] FIG. 6 b illustrates an oscillating shear valve according to one embodiment of the present invention;
[0029] FIG. 6 c illustrates the jamming tendency of a continuously rotating shear valve;
[0030] FIG. 6 d illustrates the anti-jamming feature of an oscillating shear valve according to one embodiment of the present invention;
[0031] FIG. 7 is a schematic which describes a combination of a Frequency Shift Key and an Amplitude Shift Key encoding using an oscillating shear valve according to one embodiment of the present invention;
[0032] FIG. 8A is a schematic of an oscillating shear valve incorporating a motor-gear system combination for oscillating the shear valve rotor according to one preferred embodiment of the present invention;
[0033] FIG. 8B is a section view through the gear system of FIG. 8A ;
[0034] FIG. 8C is a schematic showing the torque limits for a motor driven—versus a motor-gear driven system;
[0035] FIG. 9A is a schematic of an oscillating shear valve incorporating a motor-cam shaft gear combination according to one preferred embodiment of the present invention;
[0036] FIG. 9B is a section view through the gear system section of FIG. 9A ;
[0037] FIG. 9C shows a mechanism to change the eccentricity and therefore the resulting oscillation angle of the gear system according to one preferred embodiment of the present invention;
[0038] FIG. 9D shows an example of a cam shaft gear torque vs. speed ratio according to one preferred embodiment of the present invention;
[0039] FIG. 10 shows an example of multivalent coding according to one preferred embodiment of the present invention;
[0040] FIG. 11 shows an example of using chirps to encode a signal according to one preferred embodiment of the present invention;
[0041] FIG. 12 shows an example of a measured, time-varying frequency signal at the location of a receiver according to one preferred embodiment of the present invention;
[0042] FIG. 13 shows another example of a measured time varying frequency signal at the location of a receiver at another location different from that of FIG. 12 according to one preferred embodiment of the present invention; and
[0043] FIG. 14 shows discrete signals of different shapes according to one preferred embodiment of the present invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0044] FIG. 1 is a schematic diagram showing a drilling rig 1 engaged in drilling operations. Drilling fluid 31 , also called drilling mud, is circulated by pump 12 through the drill string 9 down through the bottom hole assembly (BHA) 10 , through the drill bit 11 and back to the surface through the annulus 15 between the drill string 9 and the borehole wall 16 . The BHA 10 may comprise any of a number of sensor modules 17 , 20 , 22 which may include formation evaluation sensors and directional sensors. These sensors are well known in the art and are not described further. The BHA 10 also contains a pulser assembly 19 which induces pressure fluctuations in the mud flow. The pressure fluctuations, or pulses, propagate to the surface through the mud flow in the drill string 9 and are detected at the surface by a sensor 18 and a control unit 24 . The sensor 18 is connected to the flow line 13 and may be a pressure transducer, or alternatively, may be a flow transducer.
[0045] FIG. 2 a is a schematic view of the pulser, also called an oscillating shear valve, assembly 19 , for mud pulse telemetry. The pulser assembly 19 is located in the inner bore of the tool housing 101 . The housing 101 may be a bored drill collar in the bottom hole assembly 10 , or, alternatively, a separate housing adapted to fit into a drill collar bore. The drilling fluid 31 flows through the stator 102 and rotor 103 and passes through the annulus between the pulser housing 108 and the inner diameter of the tool housing 101 .
[0046] The stator 102 , see FIGS. 2 a and 2 b , is fixed with respect to the tool housing 101 and to the pulser housing 108 and has multiple lengthwise flow passages 120 . The rotor 103 , see FIGS. 2 a and 2 c , is disk shaped with notched blades 130 creating flow passages 125 similar in size and shape to the flow passages 120 in the stator 102 . Alternatively, the flow passages 120 and 125 may be holes through the stator 102 and the rotor 103 , respectively. The rotor passages 125 are adapted such that they can be aligned, at one angular position with the stator passages 120 to create a straight through flow path. The rotor 103 is positioned in close proximity to the stator 102 and is adapted to rotationally oscillate. An angular displacement of the rotor 103 with respect to the stator 102 changes the effective flow area creating pressure fluctuations in the circulated mud column. To achieve one pressure cycle it is necessary to open and close the flow channel by changing the angular positioning of the rotor blades 130 with respect to the stator flow passage 120 . This can be done with an oscillating movement of the rotor 103 . Rotor blades 130 are rotated in a first direction until the flow area is fully or partly restricted. This creates a pressure increase. They are then rotated in the opposite direction to open the flow path again. This creates a pressure decrease. The required angular displacement depends on the design of the rotor 103 and stator 102 . The more flow paths the rotor 103 incorporates, the less the angular displacement required to create a pressure fluctuation is. A small actuation angle to create the pressure drop is desirable. The power required to accelerate the rotor 103 is proportional to the angular displacement. The lower the angular displacement is, the lower the required actuation power to accelerate or decelerate the rotor 103 is. As an example, with eight flow openings on the rotor 103 and on the stator 102 , an angular displacement of approximately 22.5° is used to create the pressure drop. This keeps the actuation energy relatively small at high pulse frequencies. Note that it is not necessary to completely block the flow to create a pressure pulse and therefore different amounts of blockage, or angular rotation, create different pulse amplitudes.
[0047] The rotor 103 is attached to shaft 106 . Shaft 106 passes through a flexible bellows 107 and fits through bearings 109 which fix the shaft in radial and axial location with respect to housing 108 . The shaft is connected to a electrical motor 104 , which may be a reversible brushless DC motor, a servomotor, or a stepper motor. The motor 104 is electronically controlled, by circuitry in the electronics module 135 , to allow the rotor 103 to be precisely driven in either direction. The precise control of the rotor 103 position provides for specific shaping of the generated pressure pulse. Such motors are commercially available and are not discussed further. The electronics module 135 may contain a programmable processor which can be preprogrammed to transmit data utilizing any of a number of encoding schemes which include, but are not limited to, Amplitude Shift Keying (ASK), Frequency Shift Keying (FSK), or Phase Shift Keying (PSK) or the combination of these techniques.
[0048] In one preferred embodiment, the tool housing 101 has pressure sensors, not shown, mounted in locations above and below the pulser assembly, with the sensing surface exposed to the fluid in the drill string bore. These sensors are powered by the electronics module 135 and can be for receiving surface transmitted pressure pulses. The processor in the electronics module 135 may be programmed to alter the data encoding parameters based on surface transmitted pulses. The encoding parameters can include type of encoding scheme, baseline pulse amplitude, baseline frequency, or other parameters affecting the encoding of data.
[0049] The entire pulser housing 108 is filled with appropriate lubricant 111 to lubricate the bearings 109 and to pressure compensate the internal pulser housing 108 pressure with the downhole pressure of the drilling mud 31 . The bearings 109 are typical anti-friction bearings known in the art and are not described further. In a preferred embodiment, the seal 107 is a flexible bellows seal directly coupled to the shaft 106 and the pulser housing 108 and hermetically seals the oil filled pulser housing 108 . The angular movement of the shaft 106 causes the flexible material of the bellows seal 107 to twist thereby accommodating the angular motion. The flexible bellows material may be an elastomeric material or, alternatively, a fiber reinforced elastomeric material. It is necessary to keep the angular rotation relatively small so that the bellows material will not be overstressed by the twisting motion. In an alternate preferred embodiment, the seal 107 may be an elastomeric rotating shaft seal or a mechanical face seal.
[0050] In a preferred embodiment, the motor 104 is adapted with a double ended shaft or alternatively a hollow shaft. One end of the motor shaft is attached to shaft 106 and the other end of the motor shaft is attached to torsion spring 105 . The other end of torsion spring 105 is anchored to end cap 115 . The torsion spring 105 along with the shaft 106 and the rotor 103 comprise a mechanical spring-mass system. The torsion spring 105 is designed such that this spring-mass system is at its natural frequency at, or near, the desired oscillating pulse frequency of the pulser. The methodology for designing a resonant torsion spring-mass system is well known in the mechanical arts and is not described here. The advantage of a resonant system is that once the system is at resonance, the motor only has to provide power to overcome external forces and system dampening, while the rotational inertia forces are balanced out by the resonating system.
[0051] FIG. 3 a shows a typical torque signature acting on an oscillating shear valve. The torque acting on the rotating disc is subdivided into three main parts, the torque due to the fluid force 310 , the dynamic torque caused by the inertia and acceleration 315 , and the counterbalancing spring torque 320 (example is taken for 40 Hz). If the dynamic torque 315 and the spring torque 320 are added, the spring torque 320 will cancell out most of the dynamic torque 315 and essentially only the fluidic torque 310 remains.
[0052] In an alternative prefered embodiment, the spring, that is primarily designed to cancell out the dynamic torque at high oscillating frequencies, is also used to cancel a portion of the fluidic torque at low oscillating frequencies. FIG. 3 c shows another example of a the hydraulic torque 330 acting on the valve. In this case the valve is designed in a way that results in a hydraulic torque, that can be compensated with a spring. As shown, the shaped hydraulic valve torque 330 is partly compensated 331 by the spring torque 332 . The maxima 333 of the compensated curve 331 are smaller than the maxima 334 of the orignal hydraulic torque 330 . The spring can therefore serve to balance the inertia forces at higher frequencies and to compensate hydraulic forces at low frequencies.
[0053] In an alternative preferred embodiment, the spring used in the spring-mass system is a magnetic spring assembly 300 , as shown in FIG. 3 b . The magnetic spring assembly 300 comprises an inner magnet carrier 303 being rigidly coupled to the shaft 106 , inner magnets 301 fixed to the inner magnet carrier 303 , and an outer magnet carrier 304 , carrying the outer magnets 302 . The outer magnet carrier 304 is mounted to the pulser housing 108 . The outer magnet carrier 304 is adapted to be moved in the axial direction with respect to the tool axes, while remaining in a constant angular position with respect to the pulser housing 108 . The magnetic spring assembly 300 creates a magnetic torque when the inner magnet carrier 303 is rotated with respect to the outer magnet carrier 304 . Using an appropriate number of poles (number of magnet pairs) it is possible to create a magnetic spring torque which counterbalances the dynamic torques of the rotor 103 , the shaft 106 , the bearings 108 , the inner magnet carrier 303 , and the motor 104 . With axial displacement of the outer magnet carrier 304 with respect to the inner magnet carrier 303 , the magnetic spring rate and, therefore, the spring-mass natural frequency can be adjusted such that this spring-mass system is at its natural frequency at, or near, the desired oscillating pulse frequency of the pulser.
[0054] The above described rotor drive system provides precise control of the angular position of the rotor 103 with respect to the position of the stator 102 . Such precise control allows the improved use of several encoding schemes common to the art of mud pulse telemetry.
[0055] In contrast to an axial reciprocating flow restrictor, the torque to drive a flow shear valve is not as dependent on the pressure drop being created. Hence the power to drive a shear valve at the same frequency and the same pressure drop is lower. Commonly used rotational shear valves that rotate at a constant speed consume relatively low power when operating at a constant frequency. A high power peak is required when those devices switch from one frequency to a second frequency, for example in an FSK system. With the oscillating spring mass system, the encoding or switching between phase/frequency/amplitude does not require a high actuation power, because the speed is always zero when the valve is fully closed or open. Starting from the zero speed level a phase/frequency/amplitude change does not substantially affect the overall power consumption. In a preferred embodiment of the shear valve, the main power is used to drive the system at a high frequency level. Once it is capable of creating a high frequency it can switch to another one almost immediately. This quick change gives a very high degree of freedom for encoding of telemetry data. The characteristic used for the encoding (frequency, phase or amplitude change) can be switched from one state to a second state, thereby transmitting information, within one period or less. No transition zone is needed between the different levels of encoded information. Hence there will be more information content per time frame in the pressure pulse signal of the oscillating shear valve than with a conventional shear valve system.
[0056] In another embodiment, the encoding characteristic change is initiated at any rotor position, with the new state of phase, frequency, or amplitude still achieved within one oscillating period.
[0057] FIG. 4 displays a graph which shows Phase Shift Key encoding of the oscillating shear valve as compared to a continuously rotating shear valve. The continuous phase shift signal 400 requires 1½ signal periods of the reference signal 405 to achieve a full 180° phase shift. In the transition time between 0.5 s and 0.9 s the information of the continuous phase shift signal 400 can not be used because it contains multiple frequencies. With the oscillating shear valve, the DC motor allows the rotor to be started at essentially any time thereby effectively providing an essentially instant phase shift. As shown in FIG. 4 , the oscillating shear valve phase shift signal 410 starts at 0.5 s already in the proper phase shifted relationship with the reference signal 400 such that the following signal period can already be used for encoding purposes. Thus, there is more information per time frame with a phase shift keying signal generated with an angular oscillating shear valve than with a continuously rotating shear valve.
[0058] FIG. 5 displays a graph showing a Frequency Shift Keying signal of the angular oscillating shear valve compared to a signal of a continuously rotating shear valves using the same encoding scheme. This example shows a frequency shift from 40 Hz to 20 Hz and back to 40 Hz. At 0.10 s the frequency is shifted from 40 Hz to 20 Hz, with the signal 500 from the continuously rotating shear valve, shifting only one full amplitude 500 a of the low frequency at 0.16 s before it must shift back to the high frequency signal at 500 b . Only the peaks at 500 a and 500 b are suitable for encoding information. The transition periods before and after the frequency shift contain multiple frequencies which can not be used for coding purposes. With the signal 505 from the angular oscillating shear valve, there are still two fully usable amplitudes 505 a and 505 b at the lower frequency and two usable peaks at the higher frequency 505 c and 505 d . As with phase shift keying, there is more information content per time frame with the angular oscillating shear valve than with a continuously rotating shear valve. This can provide higher detection reliability by providing more cycles to lock onto, or alternatively the frequency changes can be more rapid, thereby increasing the data rate, or a combination of these.
[0059] An Amplitude Shift Key (ASK) signal can be easily generated with the oscillating shear valve of the present invention. The signal amplitude is proportional to the amount of flow restriction and thus is proportional to the amount of angular rotation of the rotor 103 . The rotor rotation angle can be continuously controlled and, therefore, the amplitude of each cycle can be different as the motor 104 can accurately rotate the rotor 103 through a different angular rotation on each cycle according to programmed control from the electronics module 135 .
[0060] In addition, because the rotor can be continuously and accurately controlled, combinations of ASK and FSK or ASK and PSK may be used to encode and transmit multiple signals at the same time, greatly increasing the effective data rate. FIG. 7 is a schematic showing one scheme for combining an ASK and an FSK encoded signal. Both signals are carried out in a constant phase relationship with an amplitude shift from A1 to A2 or from A2 to A1 representing data bits of a first encoded signal and the frequency shifts from F1 to F2 or from F2 to F1 representing data bits of a second encoded signal. This type of signal is generated by changing both the oscillating frequency of the rotor and simultaneously changing the rotor oscillation angle, as previously described. Similarly, a signal combining ASK and PSK encoding (not shown) can be generated by changing the phase relationship of a constant frequency signal while simultaneously changing the amplitude by changing the rotor oscillation angle. Here, the amplitude shifts represent a first encoded signal and the phase shifts represent a second encoded signal.
[0061] One problem for rotating valves used in a drill string is plugging the valve during operation, for example, with either lost circulation materials or foreign bodies in the flow stream. FIG. 6 a - 6 d illustrates the anti-plugging feature of the angular oscillating shear valve as contrasted to a continuously rotating shear valve. FIG. 6 a and 6 b show a continuously rotating shear valve and an oscillating shear valve, respectively. A rotor 603 rotates below a stator 602 . Rotor 603 and stator 602 have a plurality of openings 607 and 606 , respectively serving as a flow channels. Because of the rotor rotation, the flow channel is open when the flow channels 606 and 607 are aligned and the flow channel is closed when the both flow channels 606 and 607 are not aligned. A continuously rotating shear valve opens and closes the flow passage only in one rotational direction as seen in FIG. 6 a . An angular oscillating valve opens and closes the flow passage by alternating the rotational direction as illustrated in FIG. 6 b . A foreign body 605 enters and traverses a flow passage in both the stator 602 and the rotor 603 . FIG. 6 c demonstrates that the continuously rotating shear valve jams the foreign body between the rotor 603 and the stator 602 , and fails to continue to rotate, possibly requiring the downhole tool to be retrieved to the surface for maintenance. However, an oscillating shear valve, as illustrated in FIG. 6 d , opens the valve again in the opposite direction during its standard operation. The flow channel recovers to its full cross section area and the foreign body 605 is freed, and the valve continues to operate.
[0062] FIG. 8A ,B show another preferred embodiment, similar to that of FIG. 2 but incorporating a commonly known type of gear system 210 between the shaft 206 and the motor 204 . Preferably the gear system 210 is a planetary gear arrangement. The motor 204 is connected to the sun wheel 219 (high speed) of the gear system 210 . The shaft 206 is connected to multiple satellite wheels 217 (low speed) of the gear system 210 . The torsion spring 205 is connected to shaft 206 and end cap (not shown). Alternatively, the torsion spring 205 may be connected to motor 204 . If the spring 205 is connected to shaft 206 , smaller spring torsion angles are required than connecting the spring to the motor 204 . Depending on the selected gear ratio, the high speed—and low speed driven side can also be reversed. The annular gear 218 of the gear system 210 is fixed to the pulser housing 208 .
[0063] FIG. 8B is a section view through the gear system 210 of FIG. 8A , showing a planetary gear arrangement with 4 satellites 217 . It is obvious to one skilled in the art, that also other gear systems arrangements are possible. The gear ratio of such a planetary gear arrangement is given by Speed rotor =Speed Motor /1 (Radius Annulargear /Radius Sungear ) where the rotor 203 is directly coupled to the shaft 206 . The gear system 210 allows more precise control of rotor 203 rotation. The motor shaft rotates more than the rotor 203 as determined by the gear ratio. By controlling the motor shaft angular position, the rotor 203 position can be controlled to a higher precision as related by the gear ratio. To keep the power demands of the pulser as small as possible, the gear ratio is optimized in regards to the spring-mass system and the inertias of the drive- and load side.
[0064] FIG. 8C shows a 3-dimensional plot based on a spring-mass system driven by a motor/gear combination. The plot is based on keeping the natural frequency of the spring-mass system constant for all shown combinations. Gear inertia and friction are neglected to simplify the model and to ease understanding. The plot shows the relation β=T M /T MO (motor torque with gear/motor torque without gear) versus gear ratio “n” (motor speed/rotor speed) and inertia ratio α=J M /J L (motor inertia to load inertia). The line, which separates the dark- and bright gray areas, is the line of equal motor torque. Using a gear above this line (dark grey area) will result in an unfavorably large motor torque, when the spring-mass system is oscillating. The plot shows, that for the given system only a certain gear ratio is advantageous. An example is shown by following the arrow on the chart. If the load-inertia is three times bigger than the motor-inertia, the gear ratio should not exceed 3 to avoid higher power consumption of the pulser due to using a gear system as compared to a pulser without the gear system.
[0065] FIG. 9A shows another preferred embodiment similar to that described in FIG. 8A incorporating a cam, or crank, shaft system 220 between the shaft 206 and the motor 204 . Two preferred operating modes are possible with such a system. In one preferred embodiment, the gear system transmits oscillating(rotating back and forth) motor 204 movements into oscillating rotor 203 movements. Alternatively, continuous motor 204 rotation may be converted into oscillating rotor 203 movements.
[0066] The system 220 features two gears 229 , 231 and crank shaft 226 . Crank shaft 226 is fixed to shaft 206 . Drive gear 229 is positioned on motor shaft 204 and drives the secondary gear 231 fixed on drive shaft 230 . Bearings (not shown) to keep the drive shaft 230 in position are incorporated into support plate 228 . Support plate 228 is fixed to pulser housing 208 . Drive shaft 230 features on it's opposite end an eccentric displaced drive pin 227 . Drive pin 227 reaches into a slot of crank shaft 226 .
[0067] FIG. 9B shows an example of the crank shaft gear system 220 movement. Driven by the electrical motor 204 , drive shaft 230 and drive pin 227 are continuously rotated. Drive pin 227 rotates eccentrically around the axes of drive shaft 230 . Due to the eccentric movement of drive pin 227 , crank shaft 226 is forced to the left and to the right hand side, oscillating around the axes of shaft 206 . The oscillation angle of shaft 206 is related to the eccentricity and diameter of drive pin 227 and the distance between the axes of drive shaft 230 and shaft 206 . Alternatively, for an oscillating motor 204 movement (instead of rotating motor movement), the oscillation angle of shaft 206 is, in addition to above mentioned geometrical parameters, also related to the oscillation angle of motor 204 . While the system is moving, the effective gear ratio is continuously changing depending on selected drive pin eccentricity, distance between axes of shaft 206 to drive pin 226 , and the gear ratio between drive gear 229 and secondary gear 231 . Practically a gear ratio of Ito 6 may be realized in the design space of a common tool size. It is obvious to someone skilled in the art that other common cam shaft gears or crank shaft gears might be used to transmit a continuous motor rotation into an oscillating rotor movement.
[0068] FIG. 9C serves as an example to show how to adjust the eccentricity of drive pin 227 . Drive shaft 230 has an bore, placed eccentric from its axes. Adjustment shaft 235 is placed inside the bore of drive shaft 230 . Drive pin 227 is eccentrically fixed onto adjustment shaft 235 . The eccentricity 231 of drive pin 227 to the axes of adjustment shaft 235 is the same as the eccentricity of adjustment shaft 235 to axes of drive shaft 230 . To change the resulting eccentricity 237 of drive pin 227 to drive shaft 230 , the adjustment pin 235 must be turned. Between a 0-180° turn, the resulting eccentricity 237 changes from zero to the maximum eccentricity, which equals two times the original eccentricity.
[0069] FIG. 9D shows an example of the gear ratio across the oscillation angle of motor 204 . The abscissa 401 shows the motor oscillation angle from 0-360°. The ordinate 403 shows the torque ratio and ordinate 402 shows the speed ratio (the reverse of the torque ratio). At position 407 and 406 , the rotor 203 reaches it maximum displacement and reverses the direction of movement. If hydraulic disturbances or loads are acting on the rotor shaft 206 the resulting torque at the motor shaft 204 is zero. Close to these positions, extremely large loads of valve shaft 206 can easily be supported by the motor 204 .
[0070] FIG. 10 shows an example of multivalent coding. Instead of using a binary code with only two different conditions (on/off condition) advanced coding schemes can be used with the novel shear valve pulser of the present invention. In one preferred embodiment, in FIG. 10 , three different frequencies f1, f2, f3 are used to explain multivalent coding. Using the change from one frequency into another one, six different conditions can be defined by using three frequencies. Changing from f1 to f2 is one condition 501 . Other conditions are f2-f1 502 , f1-f3 503 , f3-f1 504 , f3-f2 505 , f2-f3 (not shown). Instead of frequency changes, phase shift changes, amplitude shift changes, or combinations thereof can be used for multivalent coding.
[0071] FIG. 11 shows an example how a chirp, or sweep (means a time dependent change in frequency), can be used to encode signals. Advantage of using a chirp is the larger bandwidth of the signal. Signal distortion and attenuation, due to e.g. reflections, is less critical than in a signal using just one—(e.g. Phase shift keying) or two frequencies to modulate/encode the data. In a binary code (on/off), as shown in FIG. 11 , the presence of a chirp pattern signifies an “on” 601 , and absence of a chirp pattern signifies an “off” 602 . The bandwidth and the chirp pattern may be adjusted according to operational conditions.
[0072] The envelope curve of the chirp can also be considered as a discrete signal or discrete pulse. The chirp or any other frequency pattern inside the envelope curve gives an additional information to enhance detection of a single pulse at a receiver station.
[0073] FIG. 12 shows the measured signal of different frequencies at the location of a receiver. Due to reflections and interactions of the signal with the system boundaries, commonly used frequencies may be substantially attenuated. With the oscillating shear valve it is possible to choose frequencies exhibiting low attenuation to send and encode signals. As an example given in FIG. 12 , for a frequency dependent binary code, the optimum frequencies might be the strong signal at 25 Hz 702 which is easy to detect and the weak signal at 20 Hz 701 which is nearly fully attenuated. Other frequencies of interest might be two low attenuated frequencies 703 , 704 at 30 Hz and 35 Hz.
[0074] FIG. 13 shows, that in a different application, the frequency transmission characteristics may change and other frequencies might be better suited to send a binary signal. In FIG. 13 , 20 Hz 802 and 35 Hz 804 could be selected for a binary coding scheme.
[0075] FIG. 14 shows two different shapes of a discrete square type signal. Both signals are generated by using the same rotor shape. Signal 901 features a sinusoidal increase in signal amplitude, followed by a plateau and a sinusoidal decrease in amplitude. Signal 902 is a true square signal. To generate signal 901 requires substantially less power, because less acceleration and deceleration of rotor masses is required to create the signal. Signal 902 requires very fast acceleration and deceleration of the rotor masses. Further more, the high frequency content of the sharp edges of signal 902 will suffer strong attenuation. At a far receiver station both signals will therefore look the same.
[0076] The foregoing description is directed to particular embodiments of the present invention for the purpose of illustration and explanation. It will be apparent, however, to one skilled in the art that many modifications and changes to the embodiment set forth above are possible without departing from the scope and the spirit of the invention. It is intended that the following claims be interpreted to embrace all such modifications and changes.
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An oscillating shear valve system for generating pressure fluctuations in a flowing drilling fluid comprising a stationary stator and an oscillating rotor, both with axial flow passages. The rotor oscillates in close proximity to the stator, at least partially blocking the flow through the stator and generating oscillating pressure pulses. The rotor passes through two zero speed positions during each cycle, facilitating rapid changes in signal phase, frequency, and/or amplitude facilitating enhanced, multivalent data encoding. The rotor is driven by a motorized gear drive. In one embodiment, a torsional spring is attached to the motor and the resulting spring mass system is designed to be near resonance at the desired pulse frequency. The system enables the use of multivalent encoding schemes for increasing data rates.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
I. Field of the Invention
This invention relates to a turnout unit for railway tracks, and more particularly, this invention relates to a turnout unit which has an improved sliding surface on which a tongue rail slides.
II. Description of the Prior Art
Turnout points are the most important parts of railway tracks from the point of view of track safety and their upkeep is a key item in rail track maintenance.
In general, turnout point construction comprises a tongue rail which slides on a base plate made of steel. In order to ensure smooth sliding of the tongue rail, it is necessary to keep the base plate well lubricated. Thus, it is necessary to periodically apply lubricating oil to the sliding surface of the base plate.
To eliminate this periodical application of lubricating oil, it was proposed in Japanese Utility Model Disclosure (Kokai) Nos. 140507/77 and 125501/84 to embed a solid lubricant in the sliding surface of the base plate.
However, the solid lubricant has an unsatisfactory weatherability and wear resistance. Further, since the solid lubricant is embedded in a copper alloy layer formed on the base plate made of steel, manufacturing of the structure is laborious and costly.
SUMMARY OF THE INVENTION
Accordingly, the object of the present invention is to provide a tournout unit which eliminates the necessity of periodical application of lubricant, of which sliding surface for the tongue rail has an excellent weatherability and wear resistance, and which is easy to manufacture.
It was found by the present inventors that the above-mentioned object of the present invention may be accomplished by forming on the base plate a spray-coated ceramic layer serving as a sliding surface for the tongue rail. Thus, the present invention provides a tournout unit comprising a base plate, a stock rail fixed on the base plate, a spray-coated ceramic layer formed on the base plate, and a tongue rail slidably mounted on the ceramic layer, the tongue rail sliding on the ceramic layer.
According to the present invention, the spray-coated ceramic layer ensures the smooth sliding of the tongue rail, so that periodical application of a lubricant to the base plate is not necessary. The ceramic layer has an excellent weatherability and wear resistance. Since the ceramic layer may be formed by a spray-coating method, the ceramic layer may be formed easily.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a turnout point structure in which the turnout units of the present invention are employed;
FIGS. 2 to 4 show a first embodiment of the turnout unit of the present invention wherein FIG. 2 is a cross-sectional view taken along the line II--II in FIG. 1, FIG. 3 is a plan view of the turnout unit shown in FIG. 2, from which the stock rail, the tongue rail, the rail holder and the like are removed for the purpose of clarity, and FIG. 4 is a cross-sectional view taken along the line IV--IV in FIG. 3;
FIGS. 5 to 7 show a second embodiment of the turnout unit of the present invention wherein FIG. 5 is a cross-sectional view corresponding to FIG. 2, FIG. 6 is a plan view of the turnout unit shown in FIG. 5, from which the stock rail, the tongue rail, the rail holder and the like are removed for the purpose of clarity, and FIG. 7 is a cross-sectional view taken along the line VII--VII in FIG. 6;
FIGS. 8 and 9 show a third embodiment of the turnout unit of the present invention wherein FIG. 8 is a plan view of the turnout unit from which the stock rail, the tongue rail, the rail holder and the like are removed for the purpose of clarity, and FIG. 9 is a cross-sectional view taken along the line IX--IX in FIG. 8;
FIGS. 10 to 12 show a fourth embodiment of the turnout unit of the present invention wherein FIG. 10 is a plan view of the turnout unit from which the stock rail, the tongue rail, the rail holder and the like are removed for the purpose of clarity, FIG. 11 is a longitudinal sectional views taken along the line XI--XI in FIG. 10, and FIG. 12 is a cross-sectional view taken along the line XII--XII in FIG. 10;
FIGS. 13 to 15 show a fifth embodiment of the turnout unit of the present invention wherein FIG. 13 is a plan view of the turnout unit from which the stock rail, the tongue rail, the rail holder and the like are removed for the purpose of clarity, FIG. 14 is a longitudinal sectional view taken along the line XIV--XIV in FIG. 13, and FIG. 15 is a cross-sectional view taken along the line XV--XV in FIG. 13; and
FIGS. 16 and 17 show a sixth embodiment of the turnout unit of the present invention wherein FIG. 16 is a plan view of the turnout unit from which the stock rail, the tongue rail, the rail holder and the like are removed for the purpose of clarity, and FIG. 17 is a longitudinal sectional view taken along the line XVII--XVII in FIG. 16.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The turnout unit of the present invention, like a conventional tournout unit, has a base plate and a stock rail fixed thereto. Although not restricted, the base plate is usually made of steel. The stock rail is usually fixed to the base plate by a conventional rail holder. A spray-coated ceramic layer serving as a sliding surface is formed on the base plate, and a tongue rail is slidably mounted on the ceramic layer, which tongue rail slides on the ceramic layer.
The most characteristic feature of the tournout unit of the present invention is that it has the spray-coated ceramic layer formed on the base plate, which serves as a sliding surface for the tongue rail. The ceramic layer should have excellent weatherability and wear resistance. In a preferred embodiment, the spray-coated ceramic layer consists essentially of an Al 2 O 3 -based ceramic. In the most preferred embodiment, the ceramic layer consists essentially of 80-100% by weight of Al 2 O 3 and 20-0% by weight of Ni and Al, the Ni to Al wight ratio being 80:20 to 95:5, or the ceramic layer consists essentially of 80-95% by weight of Al 2 O 3 and 20-5% by weight of Ni, Cr and Al, the weight ratio of Ni:Cr:Al being, for example, 75:20:5. By incorporating these metals in the ceramic layer, the adhesiveness with the base plate or a bonding coat layer (hereinafter described in detail) may be promoted. Further, the hardness or brittleness may be reduced, and the tenacity of the ceramic layer is increased. The ceramic layer may preferably be porous, and lubricating oil may be impregnated in the porous ceramic. By impregnating the lubricating oil in the porous ceramic layer, the smoothness of the ceramic layer is further promoted. The thickness of the ceramic layer may preferably be 0.2 mm to 0.4 mm. The ceramic layer is formed by spray-coating method which is well-known in the art.
Although it is possible to form the spray-coated ceramic layer directly on the steel base plate, it is preferred that an bonding coat layer be formed on the base plate and the ceramic layer be formed on the bonding coat layer. The bonding coat layer may be formed of a metal having a good adhesiveness with the ceramic layer and the steel base plate. The bonding coat layer may preferably be made of a Mo-based metal, and in the most preferred embodiment, the bonding coat layer consists essentially of 80-100% by weight of Mo and 20-0% by weight of Ni and Al, the Ni to Al weight ratio being, for example, 80:20 to 95:5, or the bonding coat layer consists essentially of 80-100% by weight of Mo and 20-0% by weight of Ni, Cr and Al, the weight ratio of Ni:Cr:Al being, for example, 75:20:5. By incorporating Ni, Al (and Cr), the adhesiveness with the steel and ceramic may be increased, the binding force among Mo metal particles may be strengthened and the brittleness of the Mo metal may be reduced. The thickness of the bonding coat layer may be, for example, about 0.10 mm to 0.30 mm. The bonding coat layer may also be formed by a spray coating method which is well-known.
Preferred embodiments of the present invention will now be described referring to the drawings.
Referring to FIGS. 1 and 2, a typical tournout point structure in which a plurality of the tournout units of the present invention are employed is shown in FIG. 1. The turnout unit of the present invention, like a conventional turnout unit, has a base plate 52 (see FIG. 2) fixed to a switch sleeper 50. The base plate 52 is fixed to the switch sleeper typically by dog spikes 54. A stock rail 56 is fixed to the base plate 52 by a rail holder 57 which is fixed to the base plate 52 by a bolt 59. A spray-coated ceramic layer 58 is formed on the base plate 52, and a tongue rail 60 is slidably mounted on the ceramic layer 58. When the turnout point is switched, the tongue rail 60 slides on the ceramic layer 58.
FIG. 3 shows the base plate structure employed in the turnout unit shown in FIG. 2, and FIG. 4 shows a cross-sectional view taken along the line IV--IV in FIG. 3. The base plate structure shown in FIG. 3 has through holes 62 at the both end portions thereof, in which dog spike 54 is inserted. A stock rail-receiving hollow 64 for receiving the base portion of the stock rail 56 is formed in the base plate. Further, a groove 66 for receiving the base portion of the rail holder 57 and a through hole 68 in which the bolt 59 is inserted are formed. Referring to FIG. 4, a shallow recess 69 having a depth of, for example, about 0.3 mm to 0.7 mm is formed in the base plate 52, and the above-mentioned bonding coat layer 70 is formed on the recess 69 and on the non-recessed portions of the base plate 52. The ceramic layer 58 is spray-coated on the portion of the bonding coat layer 70, which is formed on the recess 69 of the base plate 52. In this embodiment, the upper surface of the ceramic layer 58 is made flush with, or is slightly protruded from the upper surface of the bonding coat layer 70 formed on the non-recessed portions of the base plate 52.
FIGS. 5 to 7 show another preferred embodiment. Like reference numerals are employed for designating like elements shown in FIGS. 2 to 4. In this embodiment, a recess is not formed in the base plate 52, but instead, the ceramic layer 58 has tapered edges 58a (see FIG. 7). The taper is formed such that the upper surface of the ceramic layer is smaller than the base surface thereof. Such a ceramic layer having the tapered edges may be formed by employing a mask 72 having a reverse-tapered edge 72a and spray-coating the ceramic layer 58 on the bonding coat layer 70 while covering the edge portion of the bonding coat layer 70 with the mask 72. Since the sprayed ceramic reaches the portion under the reverse-tapered edge 72a, the tapered edges 58a are formed. By providing the ceramic layer 58 with the tapered edges 58a, peeling off of the ceramic layer 58 may be prevented.
Another preferred embodiment of the present invention is shown in FIGS. 8 and 9. In this embodiment, the spray-coated layer 58 has a waveform. By providing the wave-shaped ceramic layer 58, the friction between the ceramic layer 58 and the tongue rail 60 is further reduced because the friction surface area is reduced, and the amount of ceramic material used for forming the ceramic layer 58 may be reduced.
Still another preferred embodiment is shown in FIGS. 10 to 12. In this embodiment, like the embodiment described referring to FIGS. 2 to 4, a recess 69 is formed in the base plate 52, but a substantially non-recessed portion 74 exists between the hollow 64 for receiving the stock rail and the recess 69, and substantially non-recessed portions 76 exist along the longitudinal edge of the base plate. The bonding coat layer 70 is formed on the recess 69 and on the substantially non-recessed portions 74 and 76, and the ceramic layer 58 is formed on the bonding coat layer 70 on the recess 69, such that the upper surface of the ceramic layer 58 is made flush with the upper surface of the bonding coat layer 70 formed on the substantially non-recessed portions 74 and 76 of the base plate 52. The width of the unrecessed portion 74 may be, for example, 20 mm to 40 mm, and that of the unrecessed portion 76 may be, for example, 10 mm to 20 mm. By employing this structure, the ceramic layer 58 may be prevented from being peeled off.
Still another embodiment is shown in FIGS. 13 to 15. Like the embodiment shown in FIGS. 10-12, the base plate 52 has a substantially non-recessed portion 74 between the stock rail-receiving hollow 64 and the ceramic layer 58, and substantially non-recessed portions 76 along the longitudinal edge thereof. However, in this embodiment, the substantially non-recessed portion 74 has an extension 74a which extends in the ceramic layer 54 and which is substantially parallel to the non-recessed portions 76 so that the ceramic layer 58 is separated into two portions. The width of the extension 74a may be, for example, 10 mm to 20 mm. The upper surface of the ceramic layer 58 is made flush with the upper surface of the bonding coat layer 70 formed on the non-recessed portions 74, 74a and 76. By employing this structure, prevention of the peeling off of the ceramic layer may be further promoted, and the material forming the ceramic layer 58 may be saved.
Still another preferred embodiment of the present invention is shown in FIGS. 16 and 17. This embodiment is similar to the embodiment described referring to FIGS. 10 to 12, but in this embodiment, a groove 80 is formed in the base plate 52 between the recess 69 and the hollow 64, and a hard metal 78 such as stainless steel is embedded in the groove 80 by overlay welding, such that the upper surface of the metal is made flush with the upper surface of the ceramic layer 58. The depth of the groove 80 may be, for example, 2 mm to 3 mm. Since the hard metal 78 receives the shock given by the tongue rail, the prevention of the ceramic layer 58 from being peeled off is further promoted.
Although the invention is described based on the specific embodiments thereof, it is apparent for those skilled in the art that many modification may be made without departing from the spirit and scope of the present invention. Thus, it is understood that the above description should not be interpreted restrictively.
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Disclosed is an improved turnout unit to be employed in turnout point of railway tracks, which does not necessitate maintenance of the sliding surface of the base plate. In the turnout unit of the present invention, a spray-coated ceramic layer is formed on the base plate and the tongue rail slides on the ceramic layer.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a security locking mechanism for enhancing the security provided by a lock carried by a wing such as a door or window.
2. Description of the Related Art
It has always been advantageous to provide a door, window or the like with a number of locking devices so as to deter or prevent a would-be intruder. Conventionally, this has been achieved by installing on the wing, or indeed on a frame associated with the wing, a plurality of separate locking devices each requiring a separate key or handle. Naturally, the operation of such a system is a relatively arduous and time consuming task.
DE 19723361 discloses a novel and simple locking system that has, to some extent, alleviated the problems associated with the aforementioned system. This document describes a system wherein the insertion of a single bolt from a door into a keeper in the associated frame simultaneously causes the extension of auxiliary bolts from the frame member into housings provided on the door. This system enhances the security between, and the engagement of, the door and the frame.
Although door security is improving continuously, the majority of the development carried out in this field is primarily concerned with improving the strength of the door or, as discussed in DE 19723361, improving the strength of engagement between the door and its frame.
Insofar as the applicant is aware, there has not been a comparable improvement in the security provided between the door frame and the surrounding masonry to which it is affixed. A member of the public may choose to install a system such as that disclosed in DE 19723361 into a door and its associated frame. This undoubtedly would improve the strength of engagement between the two members and any force exerted on the door would be transmitted directly to the frame. However, repetitive forcing or barrage of the door induces stress within the frame and eventually the frame, which is normally quite a weak member, would yield.
Accordingly, the present invention seeks to redress the problems discussed above by providing an easy to use and cost effective locking mechanism which improves the security between the frame and the surrounding masonry as well enhancing the strength of engagement of the door and the frame. The mechanism reduces the stress induced in the frame by transmitting a substantial proportion of the force exerted on the door directly to the masonry surrounding the frame. Furthermore, this new locking device can be retrofitted to existing doors without the need for providing a new lock.
BRIEF SUMMARY OF THE INVENTION
A security locking mechanism for enhancing the security provided by a lock carried by a wing such as a door or window, the security locking mechanism comprising an auxiliary bolt mechanism for mounting in a frame for the wing and an auxiliary keeper for mounting in the wing, wherein extension of a bolt of the lock into a keeper of the auxiliary bolt mechanism causes extension of an auxiliary bolt of the auxiliary bolt mechanism into the auxiliary keeper against a resilient bias, the auxiliary bolt mechanism comprising a metal housing which in use is received in a recess in the frame and an actuating lever which is pivotally mounted intermediate its ends in the housing, is pivotally connected at one end portion to a keeper plate positioned to be depressed by extension of the bolt into the keeper, and is pivotally connected at the opposite end portion to the auxiliary bolt, wherein the auxiliary bolt is slidable in a tubular metal anchorage which projects rearwardly from the metal housing and in use is received in and anchored by the masonry or other structural support for the frame; and when extended against the resilient bias the auxiliary bolt has one end portion received in the tubular metal anchorage and the other end portion received in the auxiliary keeper of the wing.
Preferably, the keeper plate is fast to a shaft which is axially slidable in a tubular metal guide which projects rearwardly from the metal housing and in use is received in and anchored by the masonry or other structural support for the frame.
The security locking mechanism may be used in association with a surface-mounted lock, wherein the keeper in use is located outside the width of the frame alongside the surface-mounted lock, and the keeper plate bridges the width of the frame and the keeper so that extension of the bolt of the lock into the keeper outside the width of the frame is communicated by the keeper plate to the lever and auxiliary bolt within the width of the frame. Such a surface-mounted lock is one which has as its sole bolt a latch bolt.
Alternatively, the security locking mechanism may be used in association with a lock which has both a latch bolt and a deadbolt, wherein the keeper plate is positioned in the housing so as to be depressed by extension of either the latch bolt or the deadbolt into the keeper.
Preferably, the auxiliary bolt mechanism comprises a second actuating lever on the opposite side of the keeper plate to the actuating lever, the second actuating lever being pivotally mounted intermediate its ends in the housing, being pivotally connected at one end portion to the keeper plate and being pivotally connected at its opposite end portion to a second auxiliary bolt which is slidable in a second tubular metal anchorage which projects rearwardly from the metal housing and in use is received in and anchored by the masonry or other structural support for the frame.
The security locking mechanism may further comprise a metal face plate securable to the front of the metal housing. Additionally, a pair of tubular metal structural members can be secured to the back wall of the metal housing and extending from the back wall to the metal face plate, and in alignment with the tubular metal structural members fixing holes formed through the face plate and the back wall of the metal housing, for fixing the face plate and housing directly to the masonry or other structural support for the frame by means of securing screws or bolts passing through the fixing holes, the tubular metal structural members and the frame and obtaining an anchorage in the masonry or other structural support.
The housing may be provided with a deformable member or housing portion in the region of the keeper plate, positioned so that if an attempt is made to force open the wing while it is locked, the deformable member will bend into a position blocking keeper plate movement, in which position it prevents the keeper plate from returning from its depressed condition even when the bolt is withdrawn.
Additionally, the security locking mechanism can be provided with a release mechanism connected to the actuating lever and passing through a side wall of the housing and in use through the frame to one side only of the frame, for moving the actuating lever so as to disengage the auxiliary bolt mechanism in the event that the mechanism sticks in the locking condition.
The security locking mechanism may be extended using a supplementary locking mechanism. Such a supplementary locking mechanism can be used for securing the door to the frame, and includes: a supplementary bolt, housed within and extensible from the door, for spanning the gap between the door and the frame, the supplementary bolt being resiliently biased to a retracted condition in which the door is movable relative to the frame; a supplementary actuating lever pivotally mounted at a position intermediate of its ends in the door and having one end portion engagable with the supplementary bolt to move the supplementary bolt against the resilient bias to a position spanning said gap, the other end portion of the supplementary actuating lever being engagable with the auxiliary bolt of the security locking mechanism such that extension of the auxiliary bolt into the auxiliary keeper in the wing causes pivotal rotation of the supplementary actuating lever to move the supplementary bolt against the resilient bias for receipt within a keeper formed in the frame.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded perspective view of a first embodiment of a security locking mechanism according to the invention;
FIG. 2 is an exploded sectional side view of the locking mechanism of FIG. 1 in an open or unlocked position;
FIG. 3 is an exploded sectional side view of the locking mechanism of FIGS. 1 and 2 in a closed or locked position; and
FIG. 4 is an exploded perspective view of a second embodiment of a security locking mechanism according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 1, 2 and 3 show a security locking mechanism according to the invention. The locking mechanism comprises an auxiliary bolt mechanism 2 which is mounted within a recess 8 provided in a door frame 6 and anchored to the masonry or other structural support 4 surrounding the frame 6 . The auxiliary bolt mechanism 2 is activated by extension of a bolt from a lock carried by a door (depicted in dotted lines in FIGS. 2 and 3 ).
FIG. 1, in particular, shows an embodiment of the present invention which is for use in conjunction with a sash-type lock provided in a door.
The auxiliary bolt mechanism 2 has a metal monocoque housing 10 having a single exposed open surface. The housing 10 is anchored through the door frame 6 and embedded therein within the recess 8 . Anchorage to the surrounding masonry is achieved by means of two hollow tubular metal anchorages 12 and a hollow tubular metal guide 14 . The tubular metal anchorages 12 are located substantially at either end of the auxiliary bolt mechanism 2 on the rearwardly facing side of the monocoque housing 10 (that side which opposes the open surface of the monocoque housing 10 ) and extend therefrom into the surrounding masonry 4 through the recess 8 formed in the frame 6 . The tubular metal guide 14 is positioned substantially in the middle of the auxiliary bolt mechanism 2 on the rearwardly facing side of the monocoque housing 10 and extends therefrom, in a similar manner, into the masonry 4 .
The moving parts of the auxiliary bolt mechanism 2 are contained within the monocoque housing 10 and these will be described later on in the description.
The exposed open surface of the monocoque housing 10 is covered with a metal face plate 20 which is fitted flush with the exposed surface of the door frame 6 . Fixing screws 22 are used to fasten the face plate 20 to the housing 10 and to secure the face plate 20 to the frame 6 . Two long tapered masonry screws 24 are used to secure the auxiliary bolt mechanism 2 to the masonry 4 surrounding the frame 6 . These masonry screws 24 are inserted through holes in the face plate 20 and pass through hollow cylindrical metal shafts 26 extending from the face plate 20 to the rear of the housing 10 . The masonry screws 24 then extend through holes provided in the rearwardly facing surface of the monocoque housing 10 , through the base of the recess 8 provided within the frame 6 and into the masonry 4 surrounding the frame 6 .
The metal face plate 20 is further provided with a keeper 30 into which a latch bolt and/or a deadbolt extensible from the door may be inserted to abut a keeper plate 32 provided within the monocoque housing 10 thereby activating the auxiliary bolt mechanism 2 . The keeper plate 32 is provided with a guidance shaft 34 which is slidably received within the hollow tubular guide 14 mounted on the rearward face of the housing 10 . The guidance shaft 34 is of such a length that when the keeper plate 32 is in its non-depressed condition (in abutment with the face plate 20 ), a portion of the guidance shaft 34 is still received in the hollow tubular guide 14 . This ensures smooth, non-fouling movement of the keeper plate 32 when a bolt is inserted into the monocoque housing 10 through the keeper 30 on the face plate 20 .
The inner face of the keeper plate 32 engages with two actuating levers 40 . The first of these actuating levers 40 extends upwards from the keeper plate 32 , while the second of the actuating levers 40 extends downwards from the keeper plate 32 .
A pivot pin 42 is inserted through a pivot hole 46 provided on each of the actuating levers 40 at an intermediate position thereof. Each such pivot pin 42 is secured to the metal monocoque housing 10 at a pivot point 44 . A plurality of pivot points 44 and corresponding pivot holes 46 are provided on the monocoque housing 10 and actuating lever 40 respectively. This enables the user to select one out of a range of moments that the actuating lever 40 may have about the pivot pin 42 depending upon the circumstances of installation.
The other end of each actuating lever 40 is double pronged and an auxiliary bolt 50 is positioned in the gap provided between the prongs 48 . The auxiliary bolt 50 is provided with a holding pin which engages with a holding recess in one or each of the prongs 48 of the actuating lever 40 . The holding recess may be in the form of a simple hole through which the holding pin is inserted. Alternatively, the holding recess may be arcuate in which case the holding pin can be snap-fitted into the holding recess.
The auxiliary bolt 50 is slidably housed within the tubular metal anchorage 12 and is of such a length that on full extension (the locked condition), a portion of the auxiliary bolt 50 remains within the tubular metal anchorage 12 . Thereby, when the auxiliary bolt mechanism 2 assumes the locked position, a substantial portion of the force exerted on the door will be transferred to the surrounding masonry 4 through auxiliary keepers 52 formed within the door 5 , the auxiliary bolts 50 , the metal monocoque housing 10 , the masonry screws 24 , the tubular metal guide 14 and the tubular metal anchorages 12 .
A leaf spring 60 is mounted on each of the actuating levers 40 at an intermediate section thereof at the side of the pivot pin 42 which is remote from the keeper plate 32 . Each leaf spring 60 is disposed between the actuating lever 40 and the metal face plate 20 for engagement with the face plate 20 on rotation of the associated actuating lever 40 .
As illustrated in FIG. 3, in operation, on extension of the latch bolt or deadbolt through the keeper 30 and into the metal monocoque housing 10 , the keeper plate 32 is pushed to the rear of the housing 10 and the actuating levers 40 rotate resulting in extension of the auxiliary bolts 50 out from the housing 10 against the biasing force developed by the leaf springs 60 through auxiliary bolt holes provided on the face plate 20 for engagement with auxiliary keepers 52 housed within the door 5 .
Conversely, as shown in FIG. 2, as the latch bolt or deadbolt is removed from the keeper 30 , the leaf springs 60 are of sufficient strength to withdraw the auxiliary bolts 50 from the auxiliary keepers 52 and into the housing 10 and are simultaneously capable of traversing the keeper plate 32 to the front of the monocoque housing 10 .
There may be occasions when the auxiliary bolts 50 fail to retract back into the monocoque housing 10 when the bolt from the door is withdrawn from the keeper 30 . For this reason there is provided an emergency release cam mechanism 70 within the monocoque housing 10 which engages with one of the actuating levers 40 of the auxiliary bolt mechanism 2 . The cam mechanism 70 is accessible from one side of the frame through an access hole 72 provided therein. If necessary, a screw driver can be inserted into the access hole 72 for rotatable engagement with the cam mechanism 70 which in turn rotates the actuating lever 40 which it engages thereby traversing the keeper plate 32 to the front of the monocoque housing 10 and retracting both auxiliary bolts 50 back into the housing 10 .
FIG. 4 shows a further embodiment of the security locking mechanism. It differs from the embodiment previously described in that it is used in conjunction with a door provided with a surface mounted night latch. In this instance, the keeper 30 on the metal face plate 20 is located outside the width of the frame 6 and the keeper plate 32 bridges the width of the frame 6 and the keeper 30 so that extension of the bolt of the lock into the keeper 30 is communicated by the keeper plate 32 to the actuating levers 40 and auxiliary bolts 50 housed within the metal monocoque housing 10 . This embodiment functions in a similar manner to that previously described.
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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The present invention provides a cost effective security locking mechanism for improving the security between a frame member and the masonry surrounding the frame member and additionally for enhancing the strength of engagement between the frame and a door associated with the frame. A substantial proportion of any force exerted on the door, when in the locked condition, is transmitted directly to the masonry surrounding the frame by means of auxiliary bolts and tubular metal anchorages.
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RELATED PATENTS
This application is related to our U.S. Pat. No. 6,371,698, issued Apr. 16, 2002, entitled “Post Stressed Pier.”
FIELD OF THE INVENTION
The invention relates generally to techniques for increasing the load bearing capacity of structural foundation piers and piles, and more particularly to the use of structures or devices placed beneath or within piers and piles to enhance load bearing.
BACKGROUND OF THE INVENTION
Drilled shafts, or piers, are often used in the deep foundation industry because they provide an economical alternative to other types of deep foundation s. Drilled piers are typically formed by excavating a cylindrical borehole in the ground and then placing reinforcing steel and fluid concrete in the borehole. The excavation may be assisted by the use of drilling fluids, casements or the like. When the concrete hardens, a structural pier suitable for load bearing results. These piers may be several feet in diameter and 50 feet or more deep. They are typically designed to support axial and tensile compressive loads.
Alternatively, driven piles may be used as foundation elements. Particularly in soft soils, where shaft excavation may be difficult due to caving of the soil, driving piling has long been a suitable alternative to drilled-shaft piers. Conventionally, a pre-formed or pre-cast element is driven into the soil using either a high-speed vibratory driving tool or large percussive hammers. Typically, driven piles may be solid pre-cast concrete; solid steel beam; or steel pipe piling. A wide variety of materials and shapes for driven piling is known to those skilled in the art, including tapered piles, I-beams, and the like.
A finished structural foundation element such as a pier or pile has an axial load bearing capacity which is conventionally characterized by components of end bearing (q b ) and side bearing, which is a function of skin friction (f s ). Loads applied at the top end of the element are transmitted to the sidewalls of the element and to the bottom of the element. The end bearing capacity is a measure of the maximum load that can be supported there, and it will depend on numerous factors including the diameter of the element and the composition of the geomaterial (soil, rock, etc.) at the bottom of the shaft. The side bearing capacity is a measure of the amount of load capable of being borne by the skin friction developed between the side of the pier/pile and the geomaterial. It depends on numerous factors, including the composition of the foundation element and the geomaterial forming the side of the element, which may vary with length (depth). The sum of the end bearing and side bearing capacities generally represents the total load that can be supported by the element without sinking or slippage, which could cause destructive movements for a finished building or bridge atop the foundation.
Although it is desirable to know the maximum end bearing and side bearing for a particular pier or driven pile, it is difficult to make such measurements with a high degree of confidence. Foundation engineering principles account for these difficulties by assigning end bearing and load bearing capacities to a foundation element based on its diameter and depth, the geomaterial at the end of the element and along its side, and other factors. A safety factor is then typically applied to the calculated end bearing and side bearing capacities. These safety factors are chosen to account for the large number of unknown factors that may adversely affect side bearing and end bearing, including geomaterial stress states and properties, borehole roughness generated by the drilling process, geomaterial degradation at the borehole-shaft interface during drilling, length of time the borehole remains open prior to the placement of concrete, residual effects of drilling fluids, borehole wall stresses produced by concrete placement, and other construction-related details. For example, it is common to apply a safety factor of 2 to the side bearing so as to reduce by half the amount calculated to be borne by skin friction. Likewise, a safety factor of 3 is often applied to the calculated end bearing capacity, reflecting the foregoing design uncertainties and others.
The use of safety factors, although judiciously accounting for many of the uncertainties in drilled shaft pier construction and driving piling, often results in such foundation elements being assigned safe load capacities that are too conservative. To compensate, builders construct larger, deeper, and/or more elements than are necessary to safely support a structural load, unnecessarily increasing the time, effort and expense of constructing a suitable foundation.
As a partial solution, it has been known to directly measure the end bearing capacity and skin friction of a drilled-shaft pier. Osterberg (U.S. No. 4,614,110) discloses a parallel-plate bellows placed in the bottom of the shaft before a concrete pier is poured. The bellows are pressured up with fluid communicated through a pipe coaxial with the pier. Skin friction is determined by measuring the vertical displacement of the pier (corresponding to the movement of the upper bellows plate) as a function of pressure in the bellows. Likewise, end bearing is determined by measuring pressure against the downward movement of the lower bellows plate, as indicated by a rod affixed thereto and extending above the surface through the fluid pipe. Upon completion of the load test, the bellows are depressurized. The bellows may then be abandoned or filled with cement grout, and in the latter case becomes in essence an extension of the lower end of the pier.
The method of Osterberg most often serves only the purpose of load testing. In practice, most often a drilled shaft employing the “Osterberg cell” is abandoned after testing in favor of nearby shafts that do not contain a non-functioning testing cell at their base. The method of Osterberg also is limited to use with drilled shaft piers, because with driven piling, there is no open shaft into which the “Osterberg call” may be placed so that it is positioned beneath the foundation element of interest.
Other methods have been developed for enhancing the load bearing capacity of drilled shaft piers by permanently pressuring up the base, but they lack the testing capabilities of the Osterberg cell. For example, it is known to inject pressurized cement grout under the base of concrete piers to enhance load bearing. In post-grouting, the pressurized grout increases end bearing, but neither the resultant increase nor the absolute end bearing capacity can be determined from the pressure or volume of the grout. In some soils, skin friction may also be increased by allowing the pressurized grout to flow up around the sides of the shaft, but this side bearing capacity, too, is not determinable with this technique.
SUMMARY OF THE INVENTION
It is therefore desirable to enhance the load bearing capacity of a drilled shaft foundation pier or a driven foundation pile in a manner that permits direct measurement of the resultant end bearing and side bearing capacities of the pier or pile.
Accordingly, an object of the present invention is to provide a simple and convenient technique for directly measuring the end bearing and side bearing capacities of a foundation pier or pile.
Another object of the present invention is to allow a reduction in the safety factors in determining the load bearing capacity of a pier or pile.
Another object of the present invention is to increase the end bearing and side bearing capacities of a foundation pier or pile in a known amount.
Another object of the present invention is to use the same device to aid in measuring the load bearing capacity of a pier or pile, and increase its load bearing capacity.
In satisfaction of these and other objects, the invention preferably includes a bladder, cell, or other supporting enclosure placed at the base or within the length of a pier for receiving pressurized grout. The enclosure is filled with pressurized grout to stress the base of the pier. The known pressure of the grout can be used to calculate end bearing and side bearing capacities of the pier. Upon hardening under pressure, the supporting enclosure permanently contributes to increased end bearing and side bearing in a known amount. In the resulting pier assembly, the supporting enclosure in essence becomes an extension forming the lower end of the pier. The post-base-stressed pier assembly has end bearing and side bearing capacities that are enhanced, and are determinable by direct measurement, thus reducing the safety factor used in the pier load bearing capacity calculation.
The invention may take the form of a post-stressed driven pile where driven piling is selected as the foundation element instead of drilled-shaft piers. Even in this form, the invention preferably includes a bladder, cell, or other supporting enclosure placed at the base or within the length of a pile prior to driving the pile into the ground. After the pile is driven into the ground, the enclosure is filled with pressurized grout to stress the base of the pier. As with a pier, the known pressure of the grout can be used to calculate end bearing and side bearing capacities of the pile, and the supporting enclosure permanently contributes to increased end bearing and side bearing in a known amount. The post-stressed pile assembly has end bearing and side bearing capacities that are enhanced, and are determinable by direct measurement, thus reducing the safety factor used in the pile load bearing capacity calculation.
In one embodiment, the supporting enclosure for either a pier or a driven pile is a bladder made of a strong material such as thick rubber. The bladder is filled with pressurized grout via a conduit extending axially down the pier or pile to be post-base-stressed. The grout hardens under pressure, and the actual end bearing capacity is calculated from the pressure and the area of the bottom of the shaft (or the bottom of the pile, in the case of driven piles). Pressurization of the bladder pushes upward on the foundation element, resulting in additional opposing skin friction in a known amount. Subsequent downward load is opposed by the end bearing, the original skin friction, and the additional skin friction created by the pressurization of the bladder. This additional skin friction is closely related to the end bearing capacity. Accordingly the post-base-stressed element advantageously has at least twice the known overall load bearing capacity of an unstressed element.
In another embodiment, the supporting structure for either a pier or a driven pile comprises hard plates forming opposite ends of bellows. The regular geometry of such plates ensures more uniform application of pressure from the grout against the lower end of the pier or pile and the soil interface at the lower end of the bellows.
In yet another embodiment, the post-base-stressed foundation element assembly need not be formed with an enclosure, but may simply rely on the natural boundaries provided by the soil interface and the lower end of the pier or pile to receive and contain the pressurized grout.
In yet another embodiment, the supporting assembly is placed within the length of the concrete pier to be post-base-stressed. In one such embodiment, a distal pier portion forming a portion of the length of the pier may be formed first, and the supporting assembly placed thereon before the remainder of the length of the pier is formed. The supporting assembly may be either the bladder or bellows structure described above, or post-stressing may occur by injection of grout into an enclosure defined by the side of the shaft and the previously-formed pier portion in the distal end of the shaft.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention is more easily understood with reference to the drawings, in which:
FIG. 1 is a cross-sectional view of a post-base-stressed pier assembly and apparatus for injecting pressurized grout into a supporting bladder thereof.
FIG. 2 is a cross-sectional view of a post-base-stressed pier employing bellows apparatus to stress the pier.
FIG. 3 is a cross-sectional view of a post-base-stressed pier in which the shaft and concrete pier portion contain the pressurized grout of the invention.
FIG. 4 is a cross-sectional view of another embodiment in which a pier is post-stressed by grout injected intermediate two pier portions along the length of a pier.
FIG. 5 is a cross-sectional view of the driven pile assembly according to the present invention and apparatus for injecting pressurized grout into a supporting bladder thereof.
FIG. 6 is a cross-sectional view of an embodiment of the invention employing bellows apparatus to stress the pile.
FIG. 7 is a cross-sectional view of another embodiment in which the lower portion of the driven pile and its soil interface contain the pressurized grout of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring in more detail to the drawings, there is shown in FIG. 1 apparatus for post-base stressing a concrete pier 6 . Any suitable technique for producing a shaft 1 having a shaft wall 2 and a shaft floor 4 may be employed to commence construction of the pier in earthen material 28 . Pier 6 is preferably made of cementitious material such as concrete, and may be formed by conventional techniques, which include the use of steel reinforcing bars or cages to increase the strength of the pier under the influence of torsional forces or tensile loading. Shaft wall 2 exerts skin friction against pier wall 8 commensurate with the weight of the pier and any load placed on it.
Enclosure 24 is placed in the lower end of the shaft 1 before the pier 6 is poured. Enclosure 24 may be any structure capable of containing pressurized grout, and is preferably a thick rubber bladder or cell. After placement of enclosure 24 , pier 6 , which is preferably cylindrical, is formed in the usual manner. Enclosure 24 is adapted to receive pressurized grout 26 via conduit 12 , which is preferably a pipe extending coaxially along the length of pier 6 . Conduit 12 may be coupled to enclosure 24 in a variety of ways known to those skilled in the art. Further, it will be apparent to those skilled in the art that pressurized fluid grout may be transmitted to enclosure 6 in a variety of ways, for example, by a conduit extending down the side of the shaft.
Conduit 26 is in fluid communication with reservoir 22 containing fluid grout. In simple fashion, upon opening of valve 20 , grout may be pumped from reservoir 22 through a lateral 14 , which is joined by elbow 16 to conduit 12 . The pressure of grout 26 within enclosure 24 is measured at the surface by a pressure gauge 18 . Fluid grout is pumped into enclosure 6 until it fills the cavity bounded by shaft wall 2 , shaft floor 4 and lower end 10 of pier 6 , whereupon further pumping requires significantly greater pressures due to the weight of pier 6 , the skin friction between shaft wall 2 and pier wall 8 , and the relative incompressibility of the fluid grout.
Injection of grout under pressure creates an upward force exerted by enclosure 24 against pier 6 at its lower end 10 . Injection continues until the pressure indicated by gauge 18 reaches a predetermined threshold or until some other criterion is reached. The maximum load bearing will ordinarily be obtained if pressurization continues until the onset of gross upward movement of pier 6 in the shaft, indicating incipient ejectment of the pier from the shaft. At the desired point, valve 20 is closed and the quiescent pressure within enclosure is obtained by gauge 18 .
Direct measurement of the end bearing capacity of the resulting post-base-stressed pier assembly is thereby obtained from the quiescent pressure and the area of shaft floor 4 . In a similar manner, the side bearing capacity is directly measured from the quiescent pressure and the area of lower end 10 of the pier. Advantageously, the skin friction exerts a downward force on the post-base-stressed pier to resist the tendency of the pier to be ejected out of the borehole. A load placed on the pier must overcome this skin friction before returning the pier to its initial state, wherein the skin friction exerts an upward force in reaction to the weight of the pier itself. The pier 6 enjoys the benefit of the same skin friction, whether exerted upward or downward against the pier. The post-base-stressing of the pier therefore results in an increase in side bearing capacity in an amount corresponding to the pressurization of the bladder. In addition, because direct measurements of end bearing and side bearing are made, reduced safety factors can be employed. Once the necessary pressure measurements are made, pressurized grout 26 is allowed to harden so that enclosure 24 forms a permanent pressurizing extension of pier 6 .
Where it is desired to employ driven piling, instead of piers formed in drilled shafts. FIG. 5 illustrates the construction of such a post-base-stressed driven pile in a manner similar to that described for FIG. 1 . In this embodiment, the foundation element is a driven pile 6 ′, which is illustrated as a concrete cylinder. In practice, the material and shape are a matter of design choice based on criteria known to those skilled in the art, such as soil type and conditions, size of load, and the like. Pile 6 ′ is driven into the soil by driving mechanism 3 , which may be a pneumatic hammer or any other driving apparatus known to those skilled in the art. Prior to driving the pile 6 ′ into the soil, it is pre-fitted or pre-formed to retain grout conduit 12 , and grout enclosure 24 is secured proximate the lower end 10 ′ of the pile. Driving action from the driving mechanism 3 pushes pile 6 ′ into the ground, creating vertical soil surface 2 ′ adjacent pile wall 8 ′ and lower soil interface 4 ′ adjacent enclosure 24 . Enclosure 24 is preferably constructed of material sufficiently thick and tough to resist puncturing or tearing as it is driven downward with pile 6 ′. Once the driven pile and grout enclosure are in place, grout filling and hardening under pressure proceeds as described with reference to FIG. 1 , with corresponding advantages and benefits as described above.
Another embodiment is shown in FIG. 2 , wherein the grout enclosure comprises bellows 30 including hard upper plate 32 and lower plate 34 . Plates 32 and 34 are preferably steel disks, but may be made from any sufficiently hard material. Upper plate 32 is adapted to receive conduit 12 . Bellows 30 ensure that the enclosure fills substantially all of the cavity under the pier by minimizing the risk of folding or gathering that may occur with a rubber bladder. Likewise, bellows 30 provide more uniform pressure application at the shaft floor 4 and the lower end 10 of pier 6 .
The use of a metallic-plate bellows 30 is particularly suited to an embodiment employing driven piling rather than a cast-in-place pier, as shown in FIG. 6 . Bellows 30 directly applies the driving force to lower soil interface 4 ′. Rigid plates 32 and 34 , if constructed of metal, may be better adapted to resist damage from driving action than an enclosure made of rubber or other easily deformable material. Other than the use of bellows 30 in lieu of enclosure 34 , the construction and use of post-stressed driven pile 6 ′ is as described above with respect to FIG. 5 .
FIG. 3 shows another embodiment of the post-stressed pier assembly in which the pressurized grout 26 is not contained by a structural enclosure such as a bladder or bellows. In suitable hard earthen material 28 , such as rock, shaft wall 2 and shaft floor 4 may be used to contain the pressurized grout beneath lower end 10 of pier 6 . In this embodiment, conduit 12 is lowered into shaft 1 without an attached enclosure. A cage or other suitable apparatus may be employed to position conduit 12 and hold it in place while concrete pier 6 is poured. Snug-fitting blow-out plug 36 ensures that fluid concrete poured for the pier will not enter the conduit 12 in advance of the pressurized grout and cause blockage. Plug 36 is ejected when pressurized grout is forced through conduit 12 after pier 6 hardens. The hardness of earthen material 28 prevents pressurized grout 26 from being forced substantially upward alongside pier wall 8 . The post-base-stressed pier is thus formed by concrete pier 6 and hardened pressurized grout 26 contained by the shaft wall and floor. Pressurized grout 26 exerts an upward force against pier 6 at its lower end 10 , in a manner similar to the enclosure of FIGS. 1 and 2 .
In an analogous manner, post-stressing a driven pile without a bladder or defined enclosure may be accomplished, as shown in FIG. 7 . In this embodiment, driven pile 6 ′ is pre-formed or pre-fitted with grout conduit 12 , which terminates proximate the lower end 10 ′ of the pile. If desired, a blow-out plug 36 is employed to keep conduit 12 clear during pile driving action. As with the pier described above with reference to FIG. 3 , plug 36 is ejected when pressurized grout is forced through conduit 12 . Earthen material 28 is typically relatively loose soil where driven piling is employed. Even so, the earthen material 28 functions to contain the pressurized grout generally between the lower soil surface 4 ′ and the lower end 10 ′ of pile 6 ′. The post-base-stressed pile assembly is thus formed by pile 6 ′ and hardened pressurized grout 26 contained therebeneath.
An alternative embodiment of a post-stressed pile according to the invention is shown in FIG. 4 . In this embodiment, the pier 6 comprises a proximal portion of a pier together with a distal portion 40 within shaft 1 . Distal pier portion 40 is formed in conventional fashion in shaft 1 . Enclosure 24 is thereafter placed in shaft 1 . Pier 6 is formed, resulting in a bisected pier 38 . Enclosure 24 is filled with pressurized grout 26 according to the procedures for constructing a continuous post-base-stressed pier given with respect to FIG. 1 hereinabove. In lieu of enclosure 24 , pressurized grout may be delivered to bellows 30 as in FIG. 2 , or shaft wall 2 and distal pier portion 40 of the bisected pier may be used to contain the pressurized grout beneath lower end 10 of pier 6 . A bisected pier configuration according to this embodiment may be selected when, for example, earthen material 28 near the shaft floor 4 is too soft to adequately contain enclosure 24 when filled with pressurized grout 26 , and harder ground conditions prevail higher in shaft 1 .
While particular embodiments of the invention have been illustrated and described, it will be obvious to those skilled in the art that various changes and modifications may be made without sacrificing the advantages provided by the principles of construction and operation disclosed herein.
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A structural pile assembly includes a driven pile and pressurized grout contained beneath the pile so as to exert an upward force on the pile. An enclosure, such as a bladder or bellows, is filled with grout from a reservoir via a conduit which preferably extends axially along the length of the pile and is left in place after the grout hardens. A pressure gauge measures the pressure of the grout within the enclosure, permitting the direct measurement of end bearing and side bearing capacities of the resulting pile assembly. The load bearing capacity of the pile is enhanced by the pressurized grout, and is preferably at least twice the end bearing capacity of an unpressurized pile.
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