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You are an expert at summarizing long articles. Proceed to summarize the following text:
CROSS REFERENCES TO RELATED APPLICATION
[0001] This non-provisional application incorporates by reference the subject matter of Application No. 2003-305218 filed in Japan on Aug. 28, 2003, on which a priority claim is based under 35 U.S.C. § 119(a).
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a holding structure for a trunk lid opening door in which the trunk lid can be opened from an inside of a trunk room of an automobile.
[0004] 2. Description of the Related Art
[0005] Conventionally, there has been generally known such an art that even in a case where a child or the like has been trapped inside a trunk room of an automobile by mistake, the child or the like can open a trunk lid by releasing a latch mechanism of the trunk lid.
[0006] As an example of the art, the trunk room is provided therein with a lever 101 connected to a latch mechanism (not shown) of a trunk lid by way of a wire 103 , as shown in FIG. 9 , and constructed in such a manner that the lever 101 can be operated to release the latch mechanism. In the example shown in FIG. 9 , a base portion 102 of the lever 101 is engaged and held by an engaging portion (a hole) 111 which is formed in an interior member 110 in the trunk room, and the lever 101 has an arrow mark (See numeral 104 ) showing an operating direction which is painted with light storing paint (or fluorescent paint) so that the operating direction can be recognized even in the dark.
[0007] In a case where a man such as a child has been trapped in the trunk room, the trunk lid can be opened from the inside of the trunk room by pulling the lever 101 to release the latch mechanism in the operating direction as shown in FIG. 9 (in a direction of the arrow mark 104 ).
[0008] However, the lever 101 is held by the engaging portion 111 of the interior member 110 , and the operating direction of the lever 101 is only one, that is, the direction of the arrow mark in FIG. 9 . For this reason, unless the lever 101 is pulled only in this direction, the man will be unable to release the latch mechanism to open the trunk lid.
[0009] JP-A-2001-207707 discloses an art of releasing the latch mechanism to open the trunk lid, by rotating a handle provided in the trunk room, instead of the above-described lever.
[0010] However, even with this art, the trunk lid will not be opened, unless the handle is operated only in a specified direction.
SUMMARY OF THE INVENTION
[0011] An object of the present invention is to provide a holding structure for a trunk lid opening lever, which enables the lever to be operated easily, and reliably for improvement of safety.
[0012] For this purpose, according to the invention, a holding portion for holding the lever is provided in the trunk room and an opening portion is provided on the holding portion and formed into a shape of cutout which opens in at least two directions for permitting the lever to be operated in a plurality of operating directions. With this structure, the trunk lid opening lever can be easily and reliably operated, and a man can easily open the trunk lid when he has been trapped in the trunk room.
[0013] In another aspect of the invention, a holding portion for holding the lever is provided in the trunk room, the lever has an operating portion at its one end to be operated by a man and a base portion at the other end to be held by the holding portion, and the lever is held in a manner that the operating portion can be rotated around the other end of the lever. Therefore, the man who has been trapped in the trunk room can pull the lever without caring about the operating direction of the lever, and the trunk lid can be opened favorably.
BRIEF DESCRIPTION OF THE DRAWING
[0014] These and other objects and advantages of this invention will become more fully apparent from the following detailed description taken with the accompanying drawings in which:
[0015] FIG. 1 is a schematic view showing a general structure of an embodiment according to the invention;
[0016] FIG. 2 is a plan view schematically showing the general structure of the embodiment according to the invention;
[0017] FIG. 3 is a perspective view schematically showing a lever holding portion of the invention;
[0018] FIG. 4 is a sectional view taken along a line a-a in FIG. 3 ;
[0019] FIG. 5 is a sectional view taken along a line b-b in FIG. 3 ;
[0020] FIG. 6 is a sectional view taken along a line c-c in FIG. 3 ;
[0021] FIG. 7 is a perspective view schematically showing an example of modification of the invention;
[0022] FIG. 8 is a sectional view schematically showing another example of modification of the invention; and
[0023] FIG. 9 is a schematic view showing an example of a related art.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0024] Now, referring to drawings, a holding structure for a trunk lid opening lever according to an embodiment of the invention will be described. FIG. 1 is a schematic view showing a general structure. FIG. 2 is a plan view of the general structure. FIG. 3 is a perspective view schematically showing a lever holding portion of the same. FIG. 4 is a sectional view taken along a line a-a in FIG. 3 . FIG. 5 is a sectional view taken along a line b-b in FIG. 3 . FIG. 6 is a sectional view taken along a line c-c in FIG. 3 .
[0025] In FIG. 1 , numeral 1 is a lever for opening a trunk lid including a base portion 2 and a grip portion 3 . The lever 1 is disposed in a trunk room, and connected to a latch mechanism (not shown) by way of a wire 4 (See FIG. 2 ). An explanation of the latch mechanism and a mechanism for releasing the latch mechanism is omitted in the embodiment, because they are generally known. Moreover, the lever 1 has an arrow mark as shown in FIG. 1 or other signs schematically showing functions of the lever, which are painted with fluorescent paint or the like.
[0026] Under normal conditions, the lever 1 is held and stored by a holder 10 that is made of resin and disposed in the trunk room. The wire 4 is connected to the base portion 2 along a direction of a centerline CL in FIG. 2 , and configured to release the latch mechanism by operating the lever 1 essentially in a direction of disposing the wire 4 (that is, a direction of an arrow mark A in FIGS. 1 to 3 ).
[0027] Moreover, according to the invention, various contrivances have been made so that the lever 1 can be operated in a plurality of operating directions, besides the above described direction of the arrow mark A. Describing hereinafter specifically, a holding portion 12 capable of storing and holding the lever 1 , as shown in FIGS. 2 and 3 , is formed on the holder 10 , and the base portion 2 of the lever 1 is configured to be engaged with the holding portion 12 to be held therein.
[0028] The holding portion 12 is formed into such a shape that an upper face 10 a and a front face 10 d of the holder 10 are cut away. In the manner, the holding portion 12 has openings in two directions, namely in a direction of the upper face 10 a and in a direction of the front face 10 d . For reference, the upper face 10 a of the holder 10 is on a plane substantially parallel to a direction of disposing the wire 4 , while the front face 10 d of the holder 10 is on a plane substantially perpendicular to the direction of disposing the wire 4 .
[0029] Since the holding portion 12 is so configured that the openings are formed in the two directions, as described above, on occasion of operating the lever 1 , it is possible to operate the lever 1 not only in the direction of the arrow mark A as shown in FIG. 3 , but also in a direction of upward rotation as shown by an arrow mark B in FIG. 3 and in a diagonal direction as shown by an arrow mark C in FIG. 3 .
[0030] In other words, on occasion of operating the lever 1 , the latch mechanism can be released by conducting at least one of the following operations.
1. Pull the lever 1 straightly in the direction A. 2. Rotate the lever 1 in the direction B in a manner of erecting the lever. 3. Pull the lever 1 in a diagonal direction (the direction C) at an appropriate angle.
[0034] In the manner, the lever 1 can be operated reliably and easily, so that the trunk lid can be opened. The direction as shown by the arrow mark C in FIG. 3 may be at any desired angle between 0 to substantially 90 degree, but need not be limited to a determined angle.
[0035] By the way, the base portion 2 of the lever 1 is integrally formed with an upper face portion 2 a , a lower face portion 2 b and a vertical wall portion 2 c connecting the upper face portion 2 a and the lower face portion 2 b . The upper face portion 2 a is formed larger in width than the lower face portion 2 b.
[0036] On the other hand, side wall faces 10 b of the holding portion 12 are respectively formed with a first rib 14 and a second rib 15 so as to clamp the base portion 2 of the lever 1 from both sides for retaining the base portion 2 . These ribs 14 , 15 are integrally formed with the holder 10 by injection molding, for example.
[0037] As shown in FIG. 4 , the first rib 14 formed on a front side includes an overlapping portion 14 a that slightly interferes with the base portion 2 of the lever 1 when the lever 1 is stored in the holding portion 12 . By providing the overlapping portion 14 a , the first rib 14 presses an edge of the upper face portion 2 a of the base portion 2 while the lever 1 is stored, so that the base portion 2 can be retained by friction between the first rib 14 and the upper face portion 2 a of the base portion 2 .
[0038] The second rib 15 is formed in parallel to the first rib 14 , into a size that the second rib 15 comes into contact with the upper face portion 2 a of the base portion 2 , hardly interfering with the upper face portion 2 a . Accordingly, when the lever 1 is stored, the second rib 15 is brought into contact with the base portion 2 , in such a manner that almost no friction is occurred between the second rib 15 and the upper face portion 2 a . In the embodiment, the second rib 15 is provided for the purpose of restricting a position of the base portion 2 of the lever 1 in a lateral direction (a left to right direction in FIG. 5 ). By providing the second rib 15 in the manner, a backlash of the lever 1 on occasion of storing it can be prevented without requiring a large control force.
[0039] Further, as shown in FIGS. 4 and 5 , the first rib 14 and the second rib 15 are respectively spaced from the vertical wall portion 2 c . More specifically, the ribs 14 , 15 and the vertical wall portion 2 c are so configured that spaces are maintained between them. This is because, in a case where the vertical wall portion 2 c is kept in contact with these ribs 14 , 15 , contact areas of the ribs 14 , 15 with respect to the lever 1 will be too large, and a larger friction than suitable for the operation of the lever 1 (retaining force or engaging force of the lever 1 ) will be occurred, which leads to an inconvenience that the lever 1 can not be pulled out.
[0040] By contrast, in the embodiment, the ribs 14 , 15 are kept in contact with only the upper face portion 2 a of the base portion 2 of the lever 1 , and so, after the upper face portion 2 a has moved away from the ribs 14 , 15 on occasion of operating the lever 1 , the lever 1 will be in such a free state that the friction will not occurred. In the manner, the lever 1 can be easily operated even with a little force. Moreover, because the contact areas between the ribs 14 , 15 and the upper face portion 2 a are minimized, the friction can be easily set.
[0041] In addition, as shown in FIGS. 3 to 6 respectively, a bottom face 10 c of the holding portion 12 is also provided with a rib (ribs on bottom face side) 16 along a direction of disposing the base portion 2 . Since the lever 1 is disposed on the rib 16 , the lever 1 is lifted by a height of the rib 16 and held in the holding portion 12 . Moreover, as shown in FIG. 6 , an upper face side of a backward end of the bottom face 10 c is so-called chamfered (See reference numeral 17 ).
[0042] Since the rib 16 are provided on the bottom face 10 c , and the upper face side of the backward end of the bottom face 10 c are chamfered ( 17 ) in the manner, when the man trapped in the trunk room pulls up the lever 1 (See the arrow mark B in FIG. 3 ) or pulls it diagonally upwardly (See the arrow mark C in FIG. 3 ), he will be able to pull up the lever 1 smoothly, without a trouble that the base portion 2 of the lever 1 may be caught by the backward end of the bottom face 10 , as shown by a phantom line in FIG. 6 .
[0043] Still further, as shown in FIG. 3 , another opening 11 is formed in a deeper position than the holding portion 12 of the holder 10 . An end of the base portion 2 (an opposite end to the grip portion 3 ) is inserted into th opening 11 as shown in FIG. 2 , and when the lever 1 is operated, the lever 1 can be easily rotated around an upper edge 11 a (See FIGS. 2 and 3 ) of the opening 11 as a fulcrum.
[0044] According to the above-described structure, the following actions and effects can be obtained.
[0045] The lever 1 has the arrow mark showing the essential operating direction or the sings schematically showing its function which are painted with the fluorescent paint or the like. Therefore, even in a case where the man has been trapped in the trunk room by mistake, and surroundings are pitch-dark, the lever 1 can be easily found out.
[0046] Moreover, openings are formed in the two directions, namely, in both the directions of the upper face 10 a and the front face 10 d of the holding portion 12 for holding the lever 1 . Since the lever 1 is configured to be operated in a plurality of the operating directions (See the arrow marks A to C in FIG. 3 ), the lever 1 can be easily operated. As the results, the man trapped in the trunk room can easily open the trunk lid by operating the lever 1 in either direction, and can escape from the trunk room. In the manner, safety of the man trapped in the trunk room can be enhanced more than before.
[0047] Further, due to presence of the two ribs 14 , 15 formed in the holding portion 12 , the lever 1 can be reliably retained in the holding portion 12 of the holder 10 under the condition that the lever 1 is not used, and the lever 1 can be prevented from dropping or the like.
[0048] Specifically, the first rib 14 is provided with the overlapping portion 14 a , which slightly interferes with the base portion 2 of the lever 1 while the lever 1 is stored, and therefore, the lever 1 can be reliably retained by the friction between the first rib 14 and the lever 1 . On the other hand, because the second rib 15 is formed so as to come into contact with the lever 1 , the position of the lever 1 is restricted by the second rib 15 when the lever 1 is stored, and a so-called backlash of the lever 1 , on occasion of storing the lever 1 , can be prevented.
[0049] Still further, when the lever 1 is rotated, the lever 1 can be easily rotated by making the edge 11 a of the opening 11 to be the fulcrum. Additionally, by providing the rib 16 on the bottom face 10 c of the holding portion 12 , and chamfering ( 17 ) the upper face side of the backward end of the bottom face 10 c , the lever 1 can be smoothly pulled up.
[0050] Then, referring to FIG. 7 , an example of modification of the invention will be described. In the following description, different portions from the above-described embodiment will be mainly described, and those portions configured in the same manner as in the above-described embodiment will be omitted from the description.
[0051] In the modified example, the side wall faces 10 b of the holding portion 12 are respectively provided with projections 18 which are projected toward the base portion 2 of the lever 1 stored in the holding portion 12 . On the other hand, the base portion 2 is formed with recess portions 21 on its side faces respectively at positions corresponding to the projections 18 which can contain the projections 18 . These projections 18 are appropriately set having a height and shape that the lever 1 can be relatively easily stored on occasion of storing the lever 1 .
[0052] When the lever 1 is stored, the projections 18 are contained in the recess portions 21 of the base portion 2 to hold the lever 1 in the holding portion 2 of the holder 10 .
[0053] In other words, whereas the above described embodiment is so configured that the lever 1 is retained by the friction between the rib 14 and the base portion 2 of the lever 1 , the modified example is so configured that the lever 1 is retained by an engagement between the recess portions 21 of the base portion 2 and the projections 18 . In the respect, the modified example is different from the above-described embodiment. Although the opening and the ribs on the bottom face side (See numerals 11 and 16 in FIG. 3 ) described in the above described embodiment are not provided in the modified example, the opening and the ribs on the bottom face side may be provided in the same manner as in the above described embodiment. It is also suitable to chamfer (See numeral 17 ) the backward end of the bottom face 10 c , in the same manner as in the above-described embodiment.
[0054] As described herein above, the modified example of the invention can also obtain the same actions and effects as the above described embodiment. In addition, it is advantageous that a cost can be decreased in the modified example, because the friction need not be set, and high dimensional precision is not required for the projections 18 .
[0055] The invention is not limited to the above-described embodiment and the modified example, but various modifications can be made within a scope not deviating from a gist of the invention. For example, both or either one of the ribs 14 , 15 may be provided, in an upper area thereof, with a protrusion 19 which is configured to be engaged with the edge of the upper face portion 2 a of the base portion 2 of the lever 1 . In a case where such a protrusion is provided, the first rib 14 need not be provided with the overlapping portion (numeral 14 a in FIG. 4 ). The similar actions and effects as in the above-described embodiment can be also obtained in the case where the protrusion 19 is provided.
[0056] The foregoing description of the preferred embodiments of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed, and modifications and variations are possible in light of the above teachings or may be acquired from practice of the invention. The embodiments were chosen and described in order to explain the principles of the invention and its practical application to enable one skilled in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the claims appended hereto, and their equivalents.
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The invention relates to a holding structure for a trunk lid opening lever which is so configured that the trunk lid can be opened from an inside of a trunk room of an automobile, enabling the lever to be easily and reliably operated for improvement of safety. There is proposed a holding structure for a trunk lid opening lever which is provided in a trunk room and connected to a latch mechanism of the trunk room so as to release the latch mechanism, wherein a holding portion for holding a lever is provided in the trunk room, and the holding portion is formed into a shape of cut-out which opens in at least two directions for permitting the lever to be operated in a plurality of operating directions.
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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 an automatic method and device for filling insulating glazing units with a gas other than air.
Conventional methods are currently divided into manual and automatic methods.
Manual methods can be based on the concept of measuring the gas flow and its injection time, or on the principle of measuring the gas concentration inside the insulating glazing unit during its injection.
In automatic methods usually the gas concentration inside the insulating glazing unit during its injection is measured.
Accordingly, a manual method based on flow and time is known: in this method, the spacer frame of the insulating glazing unit is perforated beforehand, either before or after coupling to the glass plates, but preferably before, in order to prevent shavings from entering the inner space of the insulating glazing unit, in appropriate positions used respectively to inject gas and to vent the air/gas mix, which becomes gradually richer in gas.
A laminar-flow working condition is produced and the gas is injected through a first hole, which is located for example in the lower part of the insulating glazing unit; the gas has a higher relative density than air and therefore it mixes to a relatively limited extent with the overlying air, which is accordingly moved and expelled through a second hole located for example in the upper part of the insulating glazing unit.
The gas motion front in any case entails a certain turbulence, so that the gas mixes with the air nonetheless; accordingly, expulsion through the second vent hole partially affects the injected gas as well.
By measuring the flow, time, and volume of the inner space of the insulating glazing unit it is possible to calculate when to interrupt the gas flow and seal as quickly as possible the first injection hole and the second vent hole.
The uncertainty is related to the dynamics of the formation of a gas/air mixture, which entails the discharge of a part of the gas diluted in the air, which in theory is the only component to be expelled, and entails that the air contained in the inner space of the insulating glazing unit dilutes the gas that has entered.
In order to approximately take into account the interference that is intrinsic to this mixing process, it is possible to introduce a multiplying coefficient, for example equal to approximately two, in calculating the time required to theoretically fill the insulating glazing unit with gas.
Generally, filling stations are capable of simultaneously handling one to six filling positions.
The operations are fully manual, except (at the most) for the automatic closure of the gas feed valve and for the energization of an alarm that warns the operator for sealing the openings formed on the spacer frame.
This sealing action must be prompt, otherwise the great difference between the partial pressures of the gas inside the insulating glazing unit and of the air on the outside, as well as the macroscopic size of the holes formed in the spacer frame for feeding and venting, cause rapid escape of the filler gas.
A manual method based on measuring the gas concentration is also known; it entails a procedure, as regards the preparation of the frame, the injection of the gas, and the expulsion of the air/gas mix, that is identical to what has been described above, except for the additional configuration of having a probe provided with a sensor connected to appropriate instruments for analyzing the concentration of the gas or of the oxygen contained in the inner space of the insulating glazing unit.
Said probe is inserted through the second vent hole, if the size of said hole is sufficient for both functions, or is applied to a third opening provided for this specific purpose.
The attainment of the end of the cycle, the optional closing of the gas feed valve, and the optional alarm that calls for the intervention of the operator are therefore not based on a theoretical calculation of filling completion but are based on the actual attainment of the desired gas concentration in the inner space of the insulating glazing unit.
Generally, filling stations can simultaneously handle one to six filling positions.
This known method essentially suffers a great drawback; it must in fact be noted that there is a pressing need to save on the consumption of gas in industries producing insulating glazing units, since the use of gases having for example sound-absorbing characteristics is increasingly widespread, and the costs of such gases are an order of magnitude higher than those previously used, for which first-generation automatic filling machines had been marketed.
Architectural projects for residential areas proximate to airports and to large public and hotel complexes cannot do without insulating glazing units filled with gases having soundproofing characteristics.
The competitive production of these insulating glazing units filled with gases having soundproofing characteristics cannot therefore be of the previously described manual type.
An automatic method is therefore known based on measuring gas concentration; since automation requires to be able to fill the inner space of the insulating glazing unit in a station included in the line for the automatic production of said unit, various methods have been developed.
However, the goal of all these known methods has been to perform filling in a time that is equal to, or shorter than, the time of the longest step of the automatic production cycle.
As a consequence thereof, it has been observed that all these known processes entail that the gas is fed into the inner space of the insulating glazing unit in a turbulent condition; the consequent process therefore entails displacement by dilution, that is to say, the effect of each introduction of a volume of filling gas equal to the volume of the inner space is to halve the concentration of the air that is present at that time inside the insulating glazing unit.
As a more specific example, each introduction of a volume of gas equal to the volume of the inner space entails the following progression in the concentration of air inside the insulating glazing unit: 1/2, 1/4, 1/8, 1/16, 1/32 . . . ; in other words, as many as 5 volumes of gas are required to reduce the concentration of the air inside the insulating glazing unit to 3%, with a consequent waste of said gas; otherwise it is necessary to accept much higher concentrations.
When using argon gas (the most widely used gas in the initial stages of the development of the technology of insulating glazing unit filling), the problem of gas waste was economically sustainable (since the lire/liter ratio was approximately 10), but when using the SF6 gas (currently used to achieve an attenuation of acoustic transmission of up to 3 dB(A)), the incidence of the corresponding cost (approximately 100 lire/liter) no longer allows to accept the waste that is typical of currently commercially available automatic filling machines.
The automatic systems that have become widespread up to now therefore have the problem of excessive gas consumption, which can be quantified as being even from four to five times the volume of the inner space enclosed in the insulating glazing unit.
Another drawback is furthermore observed: the holes for injecting the gas and for expelling the air tend to compromise the tightness of the spacer frame to water vapor and to gases.
Italian patent no, 1,142,062, filed on Nov. 23, 1981 and claiming an Austrian priority dated May 26, 1981, is known; it discloses a device for filling insulating glazing units with heavy gas, such as for example sulfur hexafluoride, which comprises two plates arranged substantially vertically on the two sides of the insulating glazing unit to be filled; at least one of said plates is movable transversely with respect to its plane.
Said device is characterized in that a gasket is located on the horizontal upper edge and that gaskets are located on the vertical edges; in that said gaskets, in their sealing position, are movable, and below the plates a tank-shaped container is provided, having in an upward region an opening and in which the edges are hermetically connected to the plates; and in that the bottom of the tank-shaped container is associated with a system for lifting the bottom.
The device is intrinsically complicated, since it requires particular solutions for tightness; furthermore, it is necessary to use such an amount of gas as to also saturate the volume that is not occupied by the glass plate (and therefore the intermediate space, designated by the reference numeral 8 in the text); this excess gas is partially vented during the incoming and outgoing transit of the insulating glazing unit.
European patent EP 0276647, claiming an Austrian priority dated Jan. 15, 1987, is also known; it discloses a device in which a pressure is applied to the outer surfaces of the glass plates of an insulating glass unit to be filled while its inner space is being filled with gas, activating a device provided with a system for conveying the filler gas and with a system for discharging the air and/or the gas from the inside of the insulating glazing unit.
Two pressure plates are furthermore provided which can be arranged against the outer surfaces of the glass plates of the insulating glazing unit during the operation for filling at a preselected pressure.
This known solution, too, has some of the drawbacks described above, particularly residing in the high specific consumption of gas, since working occurs in turbulent conditions.
Other drawbacks are essentially constituted by the fact that the gas must be introduced between the glass plates through at least one inlet and that the air or mixture of air and gas must be discharged from the inside through at least one other opening; both of these openings are formed by producing a through hole at the surfaces of the spacer frame that are arranged at right angles to the glass plates: this entails performing an additional machining operation on the spacer frame and the difficulty of sealing said openings, since the sealant might leak out at the surface of the spacer frame that lies inside the inner space.
European patent EP 0324333, claiming an Austrian priority dated Jan. 11, 1988, is also known; it discloses a device for filling an insulating glazing unit with special gas by means of a probe for injection and two probes for venting, which can be inserted through three openings formed in the spacer, and with a device for closing said openings in the spacer once the filling operation has been completed: the probe and the device are located on the exit side of a device adapted to apply pressure to the insulating glazing units.
Both the probes and the device for closing the openings are located on a common structural element, which is movable from a protruding position under the conveyor belt for the insulating glazing unit into a first active position, in which the probe of the filling inlet is located inside the spacer, and then into a second active position, in which the device for closing the openings is located inside the spacer: the probe located on the structural element of the surface for conveying the insulating glazing unit is located in such a manner so as to be movable forwards and backwards.
This device, too, has some of the mentioned drawbacks, including that it needs an opening for the insertion of the probe and openings on the spacer frame that are obtained by providing through holes, with the above mentioned drawbacks; furthermore, these openings require a particular device to close them, and this is not always easy and optimum.
In any case, a high consumption of gas is observed, since said gas is injected in turbulent conditions.
European Patent EP 0444391 is also known; in this patent, in order to fill the inside of an insulating glazing unit with gas, such as for example argon, when the plate is press-molded it is kept spaced from the spacer frame by moving a part of the molding plate, with the aid of suckers; a crack is thus formed, through which a probe for feeding the argon gas and a probe for aspirating air from inside the glazing unit are inserted.
The gas feed probe is arranged parallel to the lower horizontal side of the glazing unit, whereas the probe for aspirating the air and the mixture of air and gas is tilted upwards to prevent the formation of through holes in the spacer frames, and with a replacement of the gas that allows a limited mixing of the gas with the air originating from inside.
However, even this solution has drawbacks, such as the turbulent condition of the process, which is necessarily fast in order to avoid affecting the working timings of the line for the production of the insulating glazing units.
Furthermore, the presence of the crack entails a possible considerable dispersion of gas, with a consequent cost increase.
European Patent EP 0603148 is also known; in this patent, the insulating glazing units are filled with gas while the unit is substantially arranged in a vertical fixed position so that one of the two glass plates constituting it is coupled only at its upper horizontal rim to the spacer frame, which is located on the other glass plate; the horizontal lower edge is spaced from the spacer frame and is open, whereas both vertical edges of the insulating glazing unit are also at least partially open and are closed hermetically.
The filling gas is introduced in the glazing unit in the region of one vertical edge, and the air or mixture of air and gas is discharged through the opposite vertical open edge of the insulating glazing unit.
However, even this solution has drawbacks, since excessive gas consumption occurs.
The use of presses adapted to keep the plates of the unit in an appropriate position in some of the mentioned conventional methods is justified by the high injection pressures of the gas, which can have a flow-rate of up to approximately 40 liters per second; therefore, before sealing the through openings formed on the unit it is necessary to wait for the inner space of said unit to return to ambient pressure, on penalty of the possible explosion of the plates or their deformation.
SUMMARY OF THE INVENTION
A principal aim of the present invention is therefore to solve the described technical problems, by eliminating the drawbacks of the mentioned known art and by providing an automatic method and device for filling insulating glazing units with a gas other than air which, differently from the corresponding conventional automatic methods, allows considerable savings as regards filling gas consumption, at the same time allowing to improve the heat insulation and soundproofing characteristics of the units, as well as other properties linked to the filling of the units with a gas other than air.
Within the scope of the above aim, an important object is to provide a device which, despite being inserted in the lines for the automatic production of insulating glazing units, achieves their same productivity and at the same time allows to achieve an acceptable saving in gas consumption.
Another object is to provide a method and a device allowing to fill insulating glazing units automatically and with at least half the specific consumption of gas with respect to the known art for an equal degree of inner space filling.
Another object is to provide a method and a device allowing to maintain the tightness of the spacer frame to water vapor and gases.
Another object is to provide a device allowing to automatically perform optimum filling of the inner space of the glazing unit starting from the condition in which the glass plates are stably coupled to the lateral surfaces of the spacer frame, said plates being simply adjacent to lateral supporting means without cooperating with presses to maintain their parallel arrangement.
This aim, these objects, and others which will become apparent hereinafter are achieved by an automatic method for filling, with gases other than air, insulating glazing units constituted by two glass plates between which a spacer frame is interposed, said spacer frame being sealed on its lateral edges to the two adjacent glass plates and forming an inner space; characterized in that it comprises a step for injecting the gas between said two glass plates so as to produce a substantially laminar flow and an air expulsion step, both of said steps occurring by means of a manifold constituted by the hollow region of the profile that forms said spacer frame; and
an automatic device for filling, with gases other than air, insulating glazing units constituted by two glass plates between which a spacer frame is interposed, said spacer frame being sealed on its lateral edges to the two adjacent glass plates so as to form an inner space, said device comprising a station for conveying said two glass plates after their coupling to said spacer frame; characterized in that it comprises at least one means for coupling one or more nozzles at at least one insert for joining and closing said spacer frame which has at least two adapted holes, with a dividing wall interposed, said holes being formed only on the side lying outside said inner space, said holes allowing access to a manifold constituted by the hollow region of the profile that forms said spacer frame and being sealable automatically after filling has occurred.
BRIEF DESCRIPTION OF THE DRAWINGS
Further characteristics and advantages of the invention will become apparent from the following detailed description of a particular but not exclusive embodiment thereof, illustrated only by way of non-limitative example in the accompanying drawings, wherein:
FIG. 1 is a schematic view of the components of the device;
FIG. 2 is a sectional view of the device, taken along the plane II--II of FIG. 1;
FIG. 3 is a sectional view of the device, taken along the plane III--III of FIG. 1;
FIG. 4 is a top view of the device;
FIG. 5 is a lateral perspective view of the spacer frame;
FIG. 6 is a partially sectional lateral perspective view of one end of the spacer frame, with the joining and closing insert associated therewith;
FIG. 7 is a longitudinal sectional view of the joining and closing insert;
FIG. 8 is a bottom view of the unit at the joining insert for the spacer frame;
FIG. 9 is a perspective view, of the means for coupling said nozzles at the holes formed on the insert;
FIG. 10 is a sectional view of the holes after sealing them.
FIG. 11 shows the two glass plates with interposed a spacer frame.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to the above figures, the reference numeral 1 designates an insulating glazing unit, constituted by two glass plates 2a, 2b between which a spacer frame 3 is interposed; said spacer frame is constituted by an internally hollow profile 4 a first surface 5 that faces the inner space formed together with the two glass plates 2a and 2b and on which a plurality of small holes 6 are formed.
Second lateral surfaces 7a and 7b are adjacent to the first surface 5, and a first seal for coupling to the glass plates 2a and 2b is formed at said second surfaces.
A third surface 8 lying outside the inner space is provided on the opposite side with respect to the first surface 5; a second seal is formed at said third surface.
The profile 4 of the spacer frame 3 is folded so as to form a polygon and can be coupled, at the joining ends 9a and 9b, to an insert 10 for joining and closing the profile 4 of the spacer frame 3.
Said insert 10 can then be inserted at the hollow region of the profile so as to keep the ends 9a and 9b mutually adjacent.
At the surface 11 that is adjacent to the third surface 8 of the profile 4 directed away from the inner space, said insert 10 has a first hole 12 and a second hole 13, between which a dividing wall 14 is interposed.
The first hole 12 and the second hole 13 are connected respectively to a first channel 15 and to a second channel 16 formed axially to the insert 10 and therefore in turn connected to the hollow internal region of the profile 4 of the spacer frame 3.
Said first and second ducts preferably respectively have, at their end lying opposite to the first and second holes, a first filter 17 and a second filter 18 that are adapted to prevent the escape of the salt grains contained within the profile 4 through said ducts.
A third hole 19 and a fourth hole 20 are formed on the third surface 8 of the profile 4 proximate to the end 9a and 9b and at the same axis as the first hole 12 and the second hole 13; said third and fourth holes or openings allow, by virtue of a means 21, the coupling of one or more nozzles 34 at the first hole 12 and at the second hole 13.
Said means 21 is advantageously constituted by a slider 22 movable along bars 35 arranged transversely with respect to the plane of arrangement of the glass plates 2a and 2b; a mechanism is provided on said slider 22 and comprises a butterfly-shaped element 23 adapted to be centered at the centerline of the third surface 8 of the profile 4.
An additional mechanism runs, along said axis, on guides arranged at right angles to said bars and places said nozzles 34 respectively at the first hole 12 for the injection of gas and at the second hole 13 for venting the air contained in the inner space.
Adapted microvalves, preferably contained inside the slider 22 itself, allow to open the gas injection duct only when the nozzles and the third and fourth holes formed on the profile 4 are coupled.
The complex of all these elements and mechanisms, which constitute the filling device, is arranged along a transmission chain as many times as there are intended stations for filling panels 1, except for one, which is meant to produce the second seal of the glazing unit and to unload it.
The glazing unit, after the coupling of the plates 2a and 2b by means of the first seal at the second lateral surfaces 7a and 7b of the spacer frame 3, is supported in a downward region by means of a first roller conveyor 24 and a first rack 25 located at the exit of the coupling device, so as to arrange the glazing units at a first conveyor 26 and at a second conveyor 27 for movement along an axis lying essentially at right angles to the previous conveyance axis.
The first conveyor 26 essentially constitutes an accumulation buffer for the glazing units 1, and this allows, in the industrial process, to comply with the timings for mutually coupling the glass plates 2a and 2b and the spacer frame 3 before filling and then convey the gas-filled glazing unit at an adapted second rack 28 for conveying the filled glazing unit to the sealing machine along an axis that is preferably approximately parallel to the axis of the first rack 25.
The second conveyor 27 has the same functions as the first conveyor 26 and operates in step therewith but contains the various means 21 for automatic coupling to the first, second, third, and fourth holes formed on the profile 4 and on the insert 10, so as to allow to inject the gas and vent the air contained in the inner space of the glazing unit.
The coupling means 21, located in the second conveyor 27, are actuated by adapted spring-loaded mechanisms controlled by the movement of the conveyor chain during activity with the insulating glazing unit, and by pneumatic cylinders located in the inactive position during reloading of the spring-loaded mechanisms.
The gas is preferably fed to the coupling means 21 by virtue of a deformable loop that runs together with the conveyor chain and is connected to the feed control unit by means of a rotating coupling.
A weighted governor valve prevents the formation of excessive pressure in the inner space of the insulating glazing unit and an alarm reports its intervention in order to eliminate the malfunction that caused it and to restore a condition without vent gas leakage.
A feed control unit 29 is also provided for storing, mixing, and analyzing the gas and contains the cylinders with the filling gas, the optional gas mixing station, and a gas analyzer that is contained in the inner space of the insulating glazing unit; said analyzer, preferably adapted to check the residual oxygen at the vent at the second hole 13, can be of the type based on the concept of the paramagnetic cell, that is to say, highly reliable.
Injection of the gas at the third hole 19 and at the first hole 12 allows to feed the gas into the inner space of the glazing unit so as to produce a substantially laminar flow, since the gas flows through the small holes 6 of the profile 4, which constitutes the manifold for the flow of the gas and the discharge of the air.
The gas in fact flows through the first hole 12 and, by passing at the first duct 15, affects the hollow region of the profile 4, expanding inside the inner space through the small holes 6.
A laminar flow is thus produced and therefore the air contained in the inner space exits through the small holes 6 located in a region that is approximately opposite to the gas inflow region: in this manner, the air contained in the inner space is forced through the small holes 6 at the second hole 13 and at the fourth hole 20 and is thus extracted from the inside of the inner space so as to form a substantially laminar flow.
It should be stressed that the use of a spacer frame 3 provided only with the third hole 19 and the fourth hole 20 allows to keep the filler gas inside the inner space in the course of time, since there is discontinuity at the second lateral surfaces 7a and 7b of the profile 4 where the first butyl seal is produced, and since the holes 12, 13, 19, and 20 can be sealed perfectly because their walls have a valid extension for the adhesion of the sealant; therefore, the provided solution ensures tightness to the gas, which would otherwise flow back towards the outside of said glazing unit, due to the great difference between the partial pressure of the gas inside the inner space of the glazing unit and the partial pressure of the air outside.
A station 30 for analyzing the concentration of the gas fed into the inner space of the glazing unit is furthermore located at the output of the second conveyor 27: in real time, a feedback based on the analog signal of an analyzer controls the stepwise advancement mode of the insulating glazing units so as to control and optimize the process.
After this analysis, which includes an optional additional stop to reach the desired concentration, a sealeant, preferably comprising melted butyl, is injected through adapted nozzles, for example of the type as shown in FIG. 9 (with 34) the first hole 12, the second hole 13, the third hole 19, and the fourth hole 20 being thus automatically sealed hermetically, again at the station 30, as shown in FIG. 10.
It is stressed that this sealing action can be performed in an optimum manner, since the sealant partially or fully closes the first channel or duct 15 and the second channel or duct 16 of the insert 10 and the holes 12, 13, 19, and 20 without altering the aesthetic continuity of the first surface 5 and of the profile 4 that faces the inner space.
The insulating glazing unit 1, while it is being conveyed at the second conveyor 27 at the station 30, can rest at an adapted third conveyor 31 that moves the glazing unit transversely by acting on its vertical edge.
An additional fourth roller conveyor 32 is arranged at right angles to the previous conveyor to transfer the insulating glazing unit at the second rack 28 for subsequent treatments, such as for example the formation of the second seal; if particular insulating glazing sizes and/or thicknesses are used, it is possible to provide an additional upper transverse conveyor.
The reference numeral 33 designates a footing that constitutes the supporting structure for the assembly formed by the first conveyor 26 and by the second conveyor 27.
It has thus been observed that the method and the device have achieved the intended aim and objects, since a finely diffused and therefore laminar flow of the filling gas has been achieved, avoiding any functional contamination, caused for example by sealing, of the first surface 5 of the profile 4 that faces the inner space of the insulating glazing unit.
The achievement of a laminar motion of the incoming gas and of the air escaping through the small holes, by virtue of the particular shape of the insert 10, is very important; furthermore, the tightness to water vapor and to gases of the spacer frame is preserved, since the third hole 19 and the fourth hole 20 coincide with the first hole 12 and the second hole 13 formed on the insert 10 and can thus be easily sealed by virtue of the saturation produced by the butyl at the first duct 15 and at the second duct 12 formed in said insert 10.
The invention is of course susceptible of numerous modifications and variations, all of which are within the scope of the same inventive concept.
The materials and the dimensions that constitute the individual components of the invention may also be the most pertinent according to the specific requirements.
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An automatic method and device for filling, with gases other than air, insulating glazing units. The method entailing a step for injecting the gas and expelling the air so as to produce a laminar flow through a manifold constituted by the hollow region of the profile that forms the spacer frame. The method and the device allow a considerable saving in costs, reducing the amount of gas required for filling to an amount very close to the volume of the inner space provided in the insulating glazing unit.
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RELATED PATENT APPLICATION
This application is related to co-pending U.S. patent application Ser. No. 07/379,323 filed Jul. 12, 1989, now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates generally to piling and pile driving and more particularly to an improved piling connector and a unique method of connecting pilings. It is equally adaptable to both new construction and for repairing existing construction, and has particular utility in the repair of concrete slab foundations on pilings. Similarly, it is applicable in all terrain conditions in which pilings are used but has particular utility in the most difficult conditions such as saturated soils and terrains in which the water content exceeds complete saturation.
The problems which the present invention overcomes are long-standing and have been known for decades if not longer. For example, friction pilings of the type and size for which this invention is expected to be frequently employed typically might have a ten ton maximum rating. That is to say, such pilings typically are not able to resist a total downward force in excess of twenty thousand pounds. If the environment in which such pilings are to be used is expected to produce a downdrag force of two tons, the pilings may be analyzed as consisting of a two-ton downdrag portion and only an eight-ton frictional resistance portion. The conservative designer will then subtract the two tons of downdrag force from the eight tons of frictional resistive force to obtain a net maximum of six tons per piling and then, in order to have a reasonable margin of safety, use one-half that number, or three tons, as the design capacity of such pilings. Knowing the maximum load which the particular foundation must support, the designer would then calculate the number of pilings needed and distribute that number about the foundation.
The difficulty with super-saturated soils, and even in many soils that are less than saturated but near saturation, is that such soils usually will not remain uniformly wet. When dry, or even when only partially dry, such soils experience enormous contractions, and as they settle, extremely strong downward forces are created. When the downdrag exceeds the maximum resistive force of the friction pilings, failure results.
Due to the difficulty of access, repair of such a failed foundation is typically quite expensive. For reasons of economy, most friction pilings are wooden poles or, literally, de-barked trees. To prevent decay, and subsequent foundation failure as a result therefrom, wooden pilings are commonly treated with preservatives. However, full-length treated pilings typically cost from twice as much as untreated pilings of the same length and diameter, up to three times as much.
Generally, the deeper a piling is set, the greater is its capacity to resist downward forces. In fact, it is not at all uncommon for the resistive force or resistive capacity of such pilings to increase in a non-linear manner with depth. A typical soil profile in which pilings are normally used may provide three tons of resistive capacity at thirty feet of piling length, four tons at forty feet, but perhaps eight tons at sixty feet. Thus it is apparent that the deeper the designer places the pilings, the greater the capacity, perhaps non-linearly greater, and the fewer the number of pilings needed. Offsetting this advantage, however, is the fact that the longer the one-piece piling, the greater is the cost—also a non-linear function. If the installed cost of a treated thirty-foot residental or light commercial piling (e.g., a Modified Class Five piling) in a particular locale is fifty-two dollars, for example, the cost for a forty-foot piling might be seventy-five dollars, and the nearest comparable sixty-foot piling, three hundred thirty dollars.
The dramatic increase in costs for exceeding forty feet is due to several factors, one of which is that the piling material itself must be of a larger class in order to achieve the desired length; this necessitates a non-linear increase in the cost of the material employed. In addition, small “house rigs” can be used to drive pilings up to forty feet; the costs for driving piles with such equipment is typically as low as fifty cents per foot. Going beyond the 40-foot limit, however, exceeds the capacity of such small equipment; much larger driving rigs must be used, the cost of which may be as much as five dollars per foot. Combined with the non-linear cost-of-material increase, the final, installed cost of a sixty-foot piling might typically be as much as four or five times the final, installed cost of a forty-foot piling.
The cost for treating extra-long pilings also increases non-linearly because of the more expensive equipment needed to treat such pilings. It is known that a piling need not be treated along its entire length in order to preserve it; only the portion above the lowest water table need be treated. However, since most treatment means call for the preservatives to be forced into the wood pores under high pressure, and since the non-uniformity of the raw materials makes consistent sealing around the circumference of the work pieces difficult to achieve, equipment which will pressure-treat only an end of a piling is typically either not available or so expensive as to not afford any savings.
The prior art has therefore looked to various means of connecting shorter pilings, i.e., each of forty feet or less, so as to make an effective and economically affordable longer piling. One such early attempt is that of U.S. Pat. No. 1,073,614, “Pile Splice”, to W. A. McDearmid. McDearmid employs a specially-cast tubular body with an integral transverse partition dividing the body into two chambers of equal diameters. The device is placed over a snugly fitting lower pile, a short pin is driven longitudinally into the lower pile with one end protruding, the upper pile is then dropped into the upper chamber onto the pin, and a bolt is then passed horizontally through each chamber and secured by a nut on the distal end thereof. Several disadvantages are presented by this approach, however. One such disadvantage, if the holes in the pilings are pre-drilled, is the difficulty of precisely aligning the holes in the environment intended, i.e., under water or in semi-watery mud. If the holes are not pre-drilled in the pilings, it is virtually certain that a bolt secured through the piling in that environment would often not meet the opposite hole in the chamber.
Perhaps a greater disadvantage of the McDearmid splice, however, is the necessity to adapt or pre-prepare the ends of the pilings to be received in the connector. Not only is this step an additional expense, but if the pilings do not fit quite snugly within both chambers, there will be a tendency for the splice to act not like a rigid connection but pin-like about one or both horizontal bolts until further rotation is prohibited by the walls of the chambers. At this point an eccentricity—perhaps a destabilizing eccentricity—will already have been introduced into the system. The amount of resistance which the small, vertical pin would provide to such a moment is expected to be negligible.
Another approach is that of U.S. Pat. No. 4,525,102, “Timber Pile Connection System”, to Gerard J. Gillen, which also discloses a number of other prior approaches to this problem. Gillen appears to call for a hollow splice to be driven internal to each piling with a confined levelling material therebetween to avoid point or edge stresses and to distribute the forces at the interface more widely. Such an internal splice is of course at least partially destructive of the piling material. In addition, the piling itself becomes the “weakest link” in that only a small fraction of the piling material remains exterior to the splice to hold the splice in place. A small error in aligning the splice along the longitudinal axis could easily cause failure during subsequent driving.
Further, it is apparent that the technique of Gillen will not produce a rigid mechanical joint. The joint will be held together only by the force of friction between a piling end and the connector, and once that resistive force is exceeded, the joint will be expected to come apart. This is equally true whether the disrupting force is due to a moment about the joint or to an in-line force applied during driving. The Gillen technique may be expected to “drive off” the lower pile from time to time during routine pile driving, and to buckle the joint if a more resistive formation such as sand should be encountered.
Swedish Patent 85,932 discloses the use of a suitable number of randomly placed flat bars or straps over the joint between two pilings secured by nails. An internal dowel pin, comprising a central collar portion and a tapered pin portion protruding into each end of the pilings, is apparently relied upon for rigidity. The flat bars are intended to prevent the joint from being pulled apart, but they would not be expected to be able to resist any but small bending moments.
U.S. Pat. No. 4,696,605, “Composite Reinforced Concrete And Timber Pile Section And Method Of Installation”, also to Gillen, employs a means of connecting which apparently relies upon the rigidity of the concrete pile itself to maintain a rigid joint. While technically sound, such a method may often be economically impractical.
U.S. Pat. No. 3,266,255, “Drive-Fit Transition Sleeve”, to Dougherty, employs a pair of flanged pipes telescoped one inside the other and force fitted to each other, much like a plug-and-socket arrangement. Dougherty, however, is obviously limited to connecting metal pilings, and calls for connecting the separate pieces of his connectors to the pilings by welding.
SUMMARY OF THE INVENTION
The present invention involves an improved piling connector which can transfer a bending moment and direct forces across a joint of a composite pile and a unique method of driving composite piles. Unlike pin-type connectors, or connectors which function essentially like a pin-type connector, the connector of the present invention will not allow one pile of a composite pile system to rotate with respect to the other or to induce an eccentricity into the overall, combined column. Further, a lower pile of this system may not be “driven off” the joint while driving the pile assembly, and the connector may be chosen such that it will not be the weakest link in the assembly. Still further, no special preparation or sizing of the ends of the pilings must be done in order to employ the present invention.
A preferred embodiment of the improved connector of the present invention comprises two rigid tubular members joined by a rigid ring or plate with at least one opening permitting fluid communication between the tubular members. Each tubular member preferably has a plurality of holes in the wall thereof, spaced apart both circumferentially and longitudinally, with a deflector attached to the outer wall in alignment with and spaced apart from each hole. When employing one preferred method, a pile is driven in the customary manner until the upper end is at a convenient height above ground level. The battered end is sawn off, as is customary when driving wooden piles. An open end of the connector is then placed on the upper end of the piling, and is rapidly driven onto the piling by the driver hammer. Outer portions of the piling are peeled off by the connector as it is being driven onto the piling, and such peelings are deflected away from the holes in the wall of the connector by the deflectors. The connection is then made rigid, preferably by screwing lag screws, of a size sufficient to permit the transfer of forces between piling and connector, through the wall openings and into the piling. An end of the second piling is then positioned above the upper end of the connector, and that piling is driven into the connector and similarly made rigid, at which point the driving of the composite pile assembly may recommence. If desired, the lag screws may be inserted into both ends of the connector simultaneously.
It is to be noted that no preparatory work has to be done on the piling ends to prepare them for insertion into the connector. Rather, the chambers of the connector are selected so as to accomodate the particular piling ends. While it is preferable to size such chambers so that no voids will exist between the connector walls and the piling, it is not essential to do so inasmuch as the lag screws may be installed in such a manner as to resist bending moments also.
Piling systems of the type contemplated herein are also capable of resisting considerable forces in tension.
A variation of this technique has been found preferable for joining wooden and metal pilings, as in the repair of existing foundations where space for working is extremely limited. This techique is often useful where too few pilings have been employed, where too short pilings have been employed, or where the upper ends of the pilings have dry rotted or are not connected to the foundation they were intended to support. In a preferred application of this technique, a small excavation is made to expose the upper end of the piling to be extended or repaired or to be connected to the foundation. The connector is then positioned on top of such piling and forced into snug engagement therewith, preferably by hydraulic ram. This portion of the connection may then be made rigid as described above. Short sections of wooden or metal pilings may then be employed, sequentially as necessary, until the desired depth is reached or the desired resistance is encountered If metal members have been used, they may be left in place as is, if desired, or a continuous concrete column may be created by pouring cement therein.
In still another variation, new pilings may be driven under an existing foundation by employing a succession of short pilings.
A BRIEF DESCRIPTION OF THE DRAWINGS
A better understanding of the invention can be had when the detailed description of a preferred embodiment, set forth below, is considered in conjunction with the drawings, in which:
FIG. 1 is a sectional view of the connector of the present invention;
FIG. 2 is a plan view of such connector viewed from above;
FIG. 3 is an elevation view of a preferred method of the present invention illustrating the driving of the connector onto a first, unprepared piling end and the insertion of a first rigid connecting means, said connector being ready to receive the remainder of the rigid connecting means and then the upper piling;
FIG. 4 is an elevation view of a preferred method illustrating the driving of the upper wooden piling into the upper end of the connector of the present invention;
FIG. 5 is an elevation view of another preferred method illustrating the employment of the present invention with a metal piling;
FIG. 6 is an elevation view of said other preferred method illustrating said metal piling ready to receive the pouring of a continuous concrete column inside the shell of said metal piling;
FIG. 7 is a plan view of one such metal piling from an end thereof; and
FIG. 8 is a view of another specialized connector.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
It is to be understood that the following detailed description is of preferred embodiments only and is in no way limiting of the generality of the present invention.
FIGS. 1 and 2 illustrate a preferred connector of the present invention. FIGS. 3 and 4 illustrate preferred methods of employing such connector with various composite pile systems, while FIGS. 5 and 6 illustrate the use of a variant of such connector. FIG. 7 and 8 illustrate other preferred connectors.
The connector 10 of FIGS. 1 and 2 may be of any desired shape and size. While several different shapes have been found suitable, it has been found quite economical to fabricate the connector out of tubular members 11 and 12 and a flat plate 13 . It has also been found preferable to have the ends 14 and 15 of members 11 and 12 chamfered to permit easier “biting” when used with wooden pilings. Also, when used with wooden pilings, it has been found preferable in most circumstances to size the members 11 and 12 such that they are slightly smaller than the pilings to be connected, thereby automatically insuring a very tight fit regardless of variations in the pilings. It is to be understood that, if tubular, the diameter may be of whatever dimension is desired.
As may be seen from FIGS. 1 and 2, if a flat plate is used as the connecting element 13 , it is preferable to have at least one opening 16 to permit fluid communication between the interiors of members 11 and 12 . It has also been found preferable, when welding either member 11 or 12 to connecting element 13 , to do so in discontinuous welds 17 so that the fluid may escape from the interior of such members to the exterior. While deflectors 18 are not essential to the present invention, it is a time- and money-saving feature to have some means of deflecting the peelings 34 of the pilings away from wall openings 19 . With a connector so constructed, when using the system in the field one need not bother to cut away the peelings or otherwise bother with them in order to rapidly make the joint rigid.
Deflectors 18 may be of any convenient size and shape. It has been found quite convenient to employ short segments of “angle iron” or “flat bars” for this purpose, as they are easily welded to outer periphery members 11 and 12 .
FIG. 3 illustrates a step in the method of using the connector of the present invention with a wooden piling. If a new piling is being driven, the driving is stopped when the upper end of the piling is at a convenient work height. The connector 10 is then positioned on top of the piling, and at the desired angular orientation, and driven by the pile driver (not shown) onto the end of lower piling 31 . Deflectors 18 have deflected the outer or “excess” portions of piling 31 a distance away from openings 19 sufficient to permit ready access to openings 19 . As shown in FIG. 3, one rigid connector 32 has been inserted into piling 31 ; after all the rigid connections have been made, connector 10 is then ready to receive the upper piling.
If the upper piling 33 is also to be a wooden piling, it is then positioned and aligned as desired and driven into connector 10 as shown in FIG. 4, at which point it too is ready to be made rigid and then driven to the desired depth. Alternatively, all rigid connections may be made after connector 10 has received the upper piling.
If the upper piling is not to be a wooden piling—as frequently is the case when repairing existing construction—a metal piling or structural member 51 may be connected to connector 50 of FIG. 5 . Depending upon the application, one or a series of such members 51 may be employed and left in place, or a continuous concrete column may be created by pouring cement inside such member(s) 51 .
Structural members 51 may conveniently be comprised of short sections of pipe of any desired diameter. As shown in FIGS. 5-7, such segments may be rapidly connected in the tight space under an existing structure by previously welding a plurality of finger-like members 52 to the inside of such members 51 . As shown, the members 52 may be fastened to one end only of members 51 , or, if desired, they could be fastened to both ends of one member and alternated with a member having no members 52 . As shown in FIG. 7, the shape of such members 52 is immaterial, the only requirement being sufficient strength to resist any expected bending moments.
A safer structure will of course result if a continuous concrete column is created upon completion by pouring a cement mixture into the continuous cavity internal to the metal column 60 .
If an entirely new piling is to be constructed under an existing structure, it is convenient to begin by using as the first metal section a member 81 which is not open throughout its length. A most convenient structure is afforded by welding a solid plate 82 inside such member at a distance from the top sufficient to receive the finger-like members 52 . By having such plate spaced away from the bottom of such member, the member may easily penetrate the soil, initially, and become stabilized in direction, while simultaneously preventing the soil or mud from entering the full length of the column. Member 81 may in some circumstances be used in place of member 50 .
Other alternate forms of the present invention will suggest themselves from a consideration of the apparatus and practices hereinbefore discussed. Accordingly, it should be clearly understood that the systems and techniques depicted in the accompanying drawings, and described in the foregoing explanations, are intended as exemplary embodiments of the invention, and not as limitations thereto.
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A method of rapidly installing a composite pile structure of timber pile sections and a pre-selected connector having an opening smaller than a transverse dimension of a working end of a timber pile section. The lower pile section is driven into the ground to a convenient distance, the connector is driven onto the lower pile and the upper pile driven onto the connector, and the connection is rapidly made rigid.
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CROSS-REFERENCE TO RELATED APPLICATION
The present document is based on and claims priority to U.S. Provisional Application Ser. No. 60/889,072, filed Feb. 9, 2007.
BACKGROUND
In many well related operations, a variety of devices and systems are used in performing oilfield services. Some applications utilize the devices and systems in simultaneous operations (SIMOPS) at a given well site. The well site may have multiple wellheads with various operations being performed simultaneously. For example, well stimulation operations can be performed concurrently with perforation operations and drilling operations.
The multiple wellheads at which simultaneous operations are performed often are in close proximity to each other. Additionally, the simultaneous operations can be performed by several different service companies. Because of the concurrent service operations and the close proximity of wellheads, the simultaneous operations potentially can create hazards. For example, breakages, ruptures, or other failures at one wellhead can create detrimental effects at adjacent wellheads. Attempts have been made to create a barrier between operations by erecting panels of steel. However, such panels are heavy, difficult to move from one position or location to another, and the installation of such panels proves labor and time intensive.
SUMMARY
In general, the present invention provides a system and method for use in performing oilfield service operations. A safety shield is formed with a portable stand and at least one lightweight impact panel. The stand and the at least one lightweight impact panel enable easy movement of the safety shield from one well site location to another as needed during well service operations, e.g. during multiple simultaneous operations. The safety shield can be used to provide protection during individual operations and/or to segregate and protect independent operations from each other.
BRIEF DESCRIPTION OF THE DRAWINGS
Certain embodiments of the invention will hereafter be described with reference to the accompanying drawings, wherein like reference numerals denote like elements, and:
FIG. 1 is a perspective front view of one example of a safety shield having a plurality of lightweight impact panels, according to an embodiment of the present invention;
FIG. 2 is a back view of the safety shield, according to an embodiment of the present invention;
FIG. 3 is an overhead schematic view of a well site undergoing simultaneous operations with a safety shield deployed in one example configuration, according to an embodiment of the present invention;
FIG. 4 is an overhead schematic view of a well site undergoing simultaneous operations with a safety shield deployed in another example configuration, according to another embodiment of the present invention; and
FIG. 5 is an overhead schematic view of a well site undergoing simultaneous operations with a safety shield deployed in another example configuration, according to another embodiment of the present invention.
DETAILED DESCRIPTION
In the following description, numerous details are set forth to provide an understanding of the present invention. However, it will be understood by those of ordinary skill in the art that the present invention may be practiced without these details and that numerous variations or modifications from the described embodiments may be possible.
The present invention generally relates to a lightweight portable safety shield useful in oilfield service operations and very well suited for simultaneous operations. The safety shield comprises a portable stand, such as a fabricated stand, fitted with one or more impact panels. The impact panels are made of a lightweight material that is easy to move. In one embodiment, the lightweight impact panels can be hand carried to facilitate quick and easy movement of the safety shield from one well site location to another. Depending on the size of the safety shield, the impact panels can be moved while joined with the portable stand or separated from the portable stand.
The lightweight nature of the portable safety shield enables rapid and inexpensive set up and tear down to facilitate deployment and movement of the portable shield from one location to another. By way of example, the lightweight panels can be constructed from a non-metallic material that is substantially lighter than steel. In one embodiment, the lightweight panels are constructed from a Kevlar® fiber material, such as a sheeted Kevlar® fiber material, available from the DuPont™ corporation, or similar lightweight, impact resistant materials.
The lightweight portable safety shield provides short-term impact protection at the well site to provide well site workers with enough time to get out of harms way in the event of a problem at one of the wells. The safety shield can be used for an individual operation, e.g. a maintenance operation, or it can be used in a simultaneous operations field to segregate and protect the independent operations from each other.
Referring generally to FIG. 1 , one embodiment of a lightweight, portable safety shield 20 is illustrated. In this embodiment, shield 20 comprises a stand or framework 22 , such as a fabricated stand. One or more lightweight impact panels 24 are mounted to the stand 22 . The impact panels 24 can be mounted to stand 22 via a plurality of fasteners 26 which may take a variety of forms depending on the construction of stand 22 and impact panels 24 . For example, fasteners 26 may comprise hooks, pins and corresponding recesses, bolts, and other suitable fasteners. The fasteners 26 can be selected to enable quick connection and disconnection of the impact panels 24 and stand 22 to further facilitate movement, transport, and/or storage.
Additionally, stand 22 can be constructed in sections 28 to enable selective changing or adjustment of the stand configuration and the relative orientation of the lightweight impact panels 24 to accommodate a variety of wellhead and space constraints. The individual sections 28 can be connected together by appropriate connectors 30 . By way of example, connectors 30 may comprise hinges that enable the sections 28 of stand 22 to be pivoted relative to one another. A variety of securing devices 32 , such as bolts, pins, or other fasteners, also can be used to secure stand 22 to a desired surface 34 , such as a surface of the earth or a platform.
The stand 22 can be fabricated in a variety of sizes and configurations depending on the environment and applications in which it is used to provide protection. As illustrated in FIG. 2 , for example, the stand 22 can be fabricated with a variety of vertical elements or legs 36 that are connected by transverse structural members 38 . The transverse structural members 38 may be arranged horizontally or at other angles selected to achieve a desired structural strength.
In FIG. 3 , one embodiment of a well site at which safety shield 20 can be implemented is illustrated. In this embodiment, the safety shield 20 is deployed at a simultaneous operations field 40 . By way of example, field 40 has multiple wellheads 42 , 44 , 46 , 48 , 50 at which various well related operations are being performed concurrently. For example, a well stimulation operation, e.g. a fracturing operation, can be conducted at wellhead 42 while wellhead 44 is in production. Additionally, a perforating operation can be performed at wellhead 46 , and a drilling operation can be conducted from a drilling platform 52 at wellhead 50 .
In this particular example, one embodiment of safety shield 20 is deployed in proximity to wellhead 42 where well stimulation operations are being performed. Safety shield 20 is deployed in a configuration that segregates wellhead 42 from the adjacent wellheads 44 , 46 , 48 , 50 and provides protection for any workers/personnel that are active by these other wellheads. In the event of a problem, such as a failure in treating lines at wellhead 42 , safety shield 20 protects the surrounding area from potentially impacting materials.
It should be noted that the simultaneous operations field 40 is provided as one example. The number of wellheads, placement of the wellheads, type of operations, actual services being conducted simultaneously, and other well related factors can vary from one application to another. Additionally, the configuration and the size of safety shield 20 can vary according to environment, topography, wellhead and operations being conducted. Additional safety shields 20 also can be deployed around other wellheads, or the sequence of service operations can be selected to accommodate movement of one or more safety shields 20 .
Also, the geometry, orientation and number of safety shield sections 28 can be changed according to the environment, operations being performed, and orientation of the wellheads at a particular well site. As illustrated in FIG. 4 , for example, safety shield 20 can be installed around an entire wellhead, such as wellhead 42 . In the illustrated embodiment, safety shield 20 establishes a circumference around the wellhead undergoing fracturing operations. The safety shield also can be used to create a circumference around wellhead 46 undergoing perforation operations or around other wellheads as suited for a given application. In the embodiment illustrated in FIG. 4 , safety shield 20 comprises four sections 28 , however other numbers of sections can be utilized to create the circumference or other shield configuration.
The use of safety shield 20 is not limited to simultaneous operations. As illustrated in FIG. 5 , for example, an embodiment of safety shield 20 is deployed in an individual oilfield service operation. In the example illustrated, safety shield 20 is used in a well stimulation operation at a well stimulation site 54 . The equipment used at site 54 can vary from one service application to another. In this example, however, the well stimulation site may utilize frac tanks 56 , a PCM (precision continuous mixer) 58 , a blender 60 , a chemical tank or hopper 62 , a sand tank or hopper 64 , and multiple frac pumps 66 , 68 , 70 , 72 , 74 , 76 . The frac pumps are connected with high-pressure treating iron 78 .
The safety shield 20 can be set up and/or moved quickly and easily to provide desired protection at a variety of locations throughout well stimulation site 54 . If, for example, one of the frac pumps requires maintenance during the well stimulation operation, personnel generally service the subject frac pump, e.g. frac pump 70 , while well stimulation operations continue. The safety shield 20 provides impact protection for the personnel working on frac pump 70 by segregating them from the neighboring treating iron 78 and the surrounding frac pumps. The safety shield 20 provides protection that gives workers time to move away from potential harm. Additionally, the safety shield 20 is easy to move from one location to another to accommodate, for example, maintenance of other frac pumps. In many applications, the lightweight impact panels 24 and stand 22 enable the safety shield 20 or safety shield components to be hand carried from one location to another. This portability and ease of setup/tear down greatly reduces the cost and improves the efficiency of providing a safety shield at desired locations throughout a given well site.
One or more safety shields 20 can be deployed in a variety of configurations for use at many types of well sites. The actual size and configuration of each safety shield can be selected according to the parameters of a given well site environment or well site application. The one or more safety shields also can be integrated with individual or simultaneous operations and can be used in cooperation with many types of well equipment.
Accordingly, although only a few embodiments of the present invention have been described in detail above, those of ordinary skill in the art will readily appreciate that many modifications are possible without materially departing from the teachings of this invention. Such modifications are intended to be included within the scope of this invention as defined in the claims.
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A technique enables improved performance of oilfield service operations. A protective shield is formed with a portable stand and at least one lightweight impact panel. The one or more lightweight impact panels enable easy movement of the safety shield from one location to another at a given well site or between different well sites, thus affording protection with a minimum of labor and set up time. The safety shield can be used to provide protection during individual operations and/or to segregate and protect independent operations from each other during multiple, simultaneous operations.
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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 novel apparatus for use in the door framing industry. Particularly, the apparatus of the invention is an adjustable device which equips a carpenter engaged in framing doors with an adjustable door spreader capable of spreading virtually all doors, thereby saving time and materials by eliminating the need to build a single-use spreader for each door to be framed.
BACKGROUND OF THE INVENTION
[0002] Carpenters use a wide variety of tools to help them with repetitive tasks. Where the construction of a plurality of doors is concerned, one of the critical tasks is spreading the door bucks to the proper spacing prior to securing the doors' sides and the bottom of the bucks to the floor and other securing members of the frame. Ordinarily, a door spreader is fashioned for each door on each new job from wood or other like material, taking time and using materials.
[0003] In the past, several tools designed to mitigate the need for crafting new spreaders on each job have been disclosed, however, they generally are complicated, clumsy, expensive, or insufficiently adjustable to accommodate the requirements of most door-framing jobs. For example, U.S. Pat. No. 5,340,095 discloses a door spreader with myriad moving parts, connections, and clamps, but it has disadvantages in that it requires tools such as wrenches to adjust the spread width. Likewise, U.S. Pat. No. 3,851,868 discloses a spreader employing bolts, magnets, and sliding members which allows for adjustability, but is limited in its ability to accommodate doors of different sizes, because the largest spread it can accommodate is somewhat less than twice the smallest spread owing to the nature of the sliding members. Further, at wider spreads, the device is insufficiently stable because its sliding members are extended to their fullest and are secured by only a single bolt.
[0004] U.S. Pat. No. 5,775,036 discloses a spreader employing grooves and slots to enable spreading of doors in a range likewise limited by the spread of its sliding members to less than twice the smallest range. Additionally, the lateral ends of the spreader are a single size, such that adaptation to a variety of door buck width sizes is not possible without building additional units.
[0005] The art is therefore in need of a superior door spreading apparatus which is useful on a variety of door spread widths and buck sizes, which may be carried by the carpenter to each job and used on the variety of doors in a repetitive fashion such that each door requires only a simple adjustment of the spreader apparatus.
SUMMARY OF THE INVENTION
[0006] The door spreader of the invention satisfies the needs in the art for a spreader which is reuseable on a variety of door framing jobs, which may be carried by individual carpenters to such jobs, and is both inexpensive and particularly well-adapted to its function.
[0007] In one aspect, the invention comprises an adjustable door spreader having (a) a base member comprising a top surface having two longitudinally opposed notches and two longitudinal rails extending upward from opposing edges of the top surface; and (b) a slideable member slideably affixed to the base member and retained thereon by the rails, wherein at least one end of the slideable member has a notch; wherein the door spreader may be adjusted to accommodate a variety of widths separating a first door buck and a second door buck.
[0008] For door bucks whose width of separation is the same as the width of the base member, the slideable member is unextended; the base member's notches engage the first and second door bucks. However, where the desired door bucks' separation width is greater than that of the base member, the slideable member is extended, wherein one notch of the base member engages the first door buck and the notch of the slideable member engages the second door buck.
[0009] The upper surface of the base member optionally has a spline extending longitudinally along the top surface thereof, while the slideable member has a groove extending longitudinally along a lower surface thereof, such that the groove slides along the spline when the slideable member is extended or retracted.
[0010] In another aspect, the door spreader further comprises means for securing the slideable member to the base member at a desired extension length. The means for securing comprises pairs of recesses at desired locations of the base member, at least one pair of holes at a desired location of the slideable member, and locking pins capable of passing through the holes in the slideable member into the recesses of the base member. The locking pins are generally any means capable of passing through the slideable member and into the recesses on the base member, and may be, for example, dowels, pins, bolts, wingnuts, screws, and spring-bolts. Preferably, the locking pins are spring-bolts.
[0011] The adjustable door spreader optionally has measurement indicators, such as engraved or printed dimensions, along the top surface of the slideable member, the upper edges of the rails, the sides of the base member, or any combination thereof. The measurement indicators are optional because the recesses are spread at precise increments. In use, the door spreader is adjusted to these incremental spread widths.
[0012] In another aspect, then, the door spreader may be locked to at least 2 spread widths found in common door frames, and are generally from 24 to 48 inches in 2 inch increments. Any desired increment may be accomplished by spacing the recesses on the slideable member at the desired distance. Preferably, the door spreader may be locked to a variety of common door frame widths, typically in 2 inch increments. Where the base member is 30 inches in its longest dimension, the spread widths are generally variable from 24 inches (using the slideable member only where the slideable member is 24 inches in its longest dimension), 30 inches (using a 30 inch base member with or without the slideable member affixed to the base member, but unextended therefrom), and from 30 to 48 inches in increments of 2 inches. Again, other increments are easily adapted by designing alternative space increments between the recesses on the slideable member.
[0013] In another aspect, the adjustable door spreader has an additional adjustable extension member adjustably affixed to the upper surface of the slideable member, thereby providing an additional extension and allowing the door spreader to function with larger door buck spread widths. The adjustable extension member is affixed to the slideable member with securing means, such as dowels, pins, bolts, wingnuts, screws, and spring-bolts, which pass through holes in the extension member into recesses in the upper surface of the slideable member. Extension of the adjustable extension member is accomplished through releasing the securing means, repositioning the extension member, and securing the adjustable extension member to the slideable member through a second pair of holes in the extension member and into the recesses of the slideable member. For example, a 9 inch extension member allows for additional extension up to 4 inches.
[0014] In one aspect, an adjustable door spreader with a 30 inch base member, a 24 inch slideable member, and a 9 inch extension member may thus be extended to accommodate spread widths of from 24 to 52 inches in increments of 2 inches, or any combination of at least two of such widths.
[0015] In another aspect, an adjustable door spreader with a 24 inch base member, a 20 inch slideable member, and a 7 inch extension member may thus be extended to accommodate spread widths of from 20 to 44 inches in increments of 2 inches, or any combination of at least two of such widths.
[0016] A suitable handle may optionally be positioned and affixed to the upper surface of the slideable member. The handle may be used to carry the door spreader as well to assist in extending the slideable member.
[0017] In another aspect, the notches of the base member and slideable member are adjustable in width, permitting the door spreader to be employed with a variety of door buck widths, as described more fully below.
[0018] The adjustable door spreader may be fabricated from any suitable material known in the art with sufficient rigidity and the ability to be formed into the required dimensions. For example, the base member, slideable member, extension member, and handle are independently made from wood, fiberglass, plastic, PVC, carbon fiber, aluminum, and the like.
[0019] The invention also includes methods for spreading a door frame using any of the embodiments of the adjustable door spreader of the invention.
[0020] These and other features of the invention are exemplified and further described in the Detailed Description of the Invention below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 is a schematic diagram showing an embodiment of the adjustable door spreader of the invention.
[0022] FIG. 2 is a schematic diagram showing an overhead view of an embodiment of the adjustable door spreader of the invention.
[0023] FIG. 3 is a schematic diagram showing a side view of an embodiment of the slideable member of the invention, with an extension member affixed thereto.
[0024] FIG. 4 is a schematic diagram showing an edge-on view of an embodiment of the adjustable door spreader of the invention.
[0025] FIG. 5 is a schematic diagram showing the base member, the slideable member, and the extension member of an embodiment of the adjustable door spreader of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0026] The door spreader of the invention comprises a base member having a smooth bottom surface, and lateral ends with notches adapted to fit standard door buck widths. The notches may be of a fixed width, or may be adjustable as described below to fit a variety of door buck widths.
[0027] The base member may be used by itself for the smallest door frame sizes, as it is designed to precisely fit the smallest standard door sizes, such as 24 inches or 30 inches. To accommodate larger door spread widths, the base further comprises a longitudinal spline running down the middle of the upper surface, and longitudinal rails running down the sides of the base. These features allow a slideable member having a lower and an upper surface, the lower surface having a groove sized to fit along the spline of the base member, and the slideable member being of width such that it fits within the two rails of the base member. The slideable member has its own set of notches on its longitudinal ends to accommodate the door bucks' width. The carpenter using the spreader simply slides the slideable member along the base member until the desired spread width is achieved.
[0028] The upper surface of the slideable member optionally has an adjustable third member adjustably affixed thereto to allow further extension and additional spreader width.
[0029] Measurement indicators are optionally present on one or more of the upper surface of base member, one or both of the side surfaces of the base member, the upper surface of the slideable member, and the upper surface of the adjustable third member. In one embodiment, the indicators provide markings spaced in intervals of, for example, 2 inches.
[0030] Once the desired spread width is achieved, the width of the spreader is secured by securing means which pass through holes through the entire thickness of the sliding member into recesses in the upper surface of the base member adapted to receive the securing means. Generally, a pair of securing means are used, positioned advantageously in opposition on the slideable member. The securing means may be dowels, pins, bolts, or preferably spring bolts which may be released and secured with a simple twist-and-pull action. The recesses in the upper surface of the base member are positioned such that each will engage a securing means, which have been passed through the holes. In the case of spring bolts, a simple twist-and-pull action recedes the spring bolt from being engaged, allowing the sliding member to slide against the base member, whereupon the desired width is achieved. The spring bolts are then twisted back to reengage the recesses at the desired position, achieving a secure engagement of the sliding and base members at the desired width.
[0031] Thus, in one embodiment of the invention, an adjustable door spreader has (a) a base member comprising a top surface having two longitudinally opposed notches and two longitudinal rails extending upward from opposing edges of the top surface; and (b) a slideable member slideably affixed to the base member and retained thereon by the rails, wherein at least one end of the slideable member has a notch; wherein the door spreader may be adjusted to accommodate a variety of widths separating a first door buck and a second door buck.
[0032] For door bucks whose width of separation is the same as the width of the base member, the slideable member is unextended; the base member's notches engage the first and second door bucks. For example, a base member having a longest dimension of 30 inches accommodates a standard 30 inch door frame, while the slideable member of 24 inches in longest dimension may be used by itself for smaller frames, such as those in smaller closets. However, where the door bucks' separation width is greater than that of the base member, the slideable member is slid within the base member, and extended, wherein one notch of the base member engages the first door buck and the notch of the slideable member engages the second door buck. This allows for spread widths of, for example, 24 inches to 48 inches in desired increments of, for example, 2 inches. In another embodiment, where the base member is 24 inches in width, the door spreader accommodates spreads of 20 to 44 inches.
[0033] The upper surface of the base member optionally has a spline extending longitudinally along the top surface thereof, while the slideable member has a groove extending longitudinally along a lower surface thereof, such that the groove slides along the spline when the slideable member is extended or retracted.
[0034] In one embodiment, the door spreader further comprises means for securing the slideable member to the base member at a desired extension length. The means for securing comprises pairs of recesses at desired locations of the base member, at least one pair of holes at a desired location of the slideable member, and locking pins capable of passing through the holes in the slideable member into the recesses of the base member. The locking pins are generally any means capable of passing through the slideable member and into the recesses on the base member, and may be, for example, dowels, pins, bolts, wingnuts, screws, and spring-bolts. Preferably, the locking pins are spring-bolts, such as those available from McMaster-Carr (e.g., “Pull-Ring” Hand-Retractable Spring Plungers, found in the online catalog at mcmaster.com), and may be made of brass, steel, or the like.
[0035] The adjustable door spreader optionally has measurement indicators, such as engraved or printed dimensions, along the top surface of the slideable member, the upper edges of the rails, the sides of the base member, or any combination thereof.
[0036] In an embodiment of the invention, the door spreader may be locked to at least 2 spread widths found in common door frames, and are generally 24 to 52 inches, in desired increments. Preferably, the door spreader may be locked to all these common door frame widths. Further, the recesses in the base member may be more numerous to allow for locking of the slideable member at additional, less common, widths.
[0037] In another embodiment, the adjustable door spreader has an adjustable extension member adjustably affixed to the upper surface of the slideable member, thereby providing an additional extension and allowing the door spreader to function with larger door buck spread widths. The adjustable extension member is affixed to the slideable member with securing means, such as dowels, pins, bolts, wingnuts, screws, and spring-bolts, which pass through holes in the extension member into recesses in the upper surface of the slideable member. Extension of the adjustable extension member is accomplished through releasing the securing means, repositioning the extension member, and securing the adjustable extension member to the slideable member through a second pair of holes in the extension member and into the recesses of the slideable member. For example, an extension member of 9 inches provides for additional extension of 4 inches.
[0038] In another embodiment, then, the adjustable door spreader with a 30 inch base member may thus be extended to accommodate spread widths of 24 to 52 inches, or any desireable combination of at least two of such widths. Preferably, the door spreader is capable of accommodating all such widths, and may be optionally machined to allow for less common widths in between these standard widths. For example, where a 2 increment is desired, the door spreader accommodates spread widths of 24, 26, 28, 30, 32, 34, 36, 38, 40, 42, 44, 46, 48, 50, and 52 inches. In another embodiment, where the base member is 24 inches long, the door spreader accommodates door buck spread widths of 20 to 44 inches when the slideable member and extension members are utilized. Preferably a 2 inch increment is used, thus allowing for spread widths of 20, 22, 24, 26, 28, 30, 32, 34, 36, 38, 40, 42, and 44 inches.
[0039] A suitable handle may optionally be positioned and affixed to the upper surface of the slideable member. The handle may be used to carry the door spreader as well to assist in extending the slideable member.
[0040] In another aspect, the notches of the base member and slideable member are adjustable in width, permitting the door spreader to be employed with a variety of door buck widths. For example, in one embodiment, the notches, as defined by their protruding sides are 2½ inches wide, but may be adjusted to greater or lesser width by adapting one of the protruding sides defining the notches to be movably adjustable, thereby allowing for door buck widths of from about 1 inch to about 3 inches.
[0041] The adjustable door spreader may be fabricated from any suitable material known in the art with sufficient rigidity and the ability to be formed into the required dimensions. For example, the base member, slideable member, extension member, and handle are independently made from wood, fiberglass, plastic, PVC, carbon fiber, aluminum, and the like. Each of the base member, the slideable member, and the extension member may be constructed from a single piece of material, or may be constructed from separate pieces which, when appropriately joined, formed the respective member. Preferably the door spreader is made of wood or fiberglass.
[0042] The dimensions of the door spreader are chosen for the particular spread of widths intended to be accommodated. Preferably, the door spreader is capable of spreading from 24 inches to 52 inches including a plurality of 2 inch increments thereof, more preferably including a majority of 2 inch increments thereof, more preferably including substantially all 2 inch increments thereof, and most preferably including all 2 inch increments thereof.
[0043] The invention also includes methods for spreading a door frame using any of the embodiments of the adjustable door spreader of the invention. In these methods, the carpenter lays the door spreader between the door bucks and adjusts the door spreader to the desired width, either by using the notches in the base member alone, or by extending the slideable member to a greater width, engaging one of the slideable member's notches with the first door buck and the base member's notch with the other, or by extending the extension member to achieve greater widths than possible with the slideable member alone.
EXAMPLES
[0044] The present invention will be further understood by reference to the following non-limiting examples.
Example 1
Adjustable Door Spreader with 30 Inch Base Member
[0045] With specific reference to the Figures, this Example illustrates an embodiment of the invention wherein the base member is 30 inches in its longest dimension. Made from wood, the door spreader is 30 inches wide, 7 inches across, and 2 inches high (including the height of the rails). The base member ( 1 ) as depicted in FIG. 1 is constructed from ¾ inch thick wood. The rails ( 2 ) are a total of 2 inches high and ½ inch thick, and, as shown in FIG. 4 , at the top ¼ inch of the rails, extend medially 3 /4 inches from the edge of the base member toward the center of the base member to retain the slideable member ( 4 ) in a flange-like manner, thereby providing a 1 /4 inch overhanging retaining portion of the rail.
[0046] The notches on the base member ( 3 ) are defined by tongs extending outward from the base member by ¾ inches, though they may alternatively extend outward by ½ inch to about 1 inch. The tongs are each 1¾ inches across. The notches defined by the tongs extended from the base member are therefore 2½ inches across, accommodating door bucks of up to 2½ inches in width.
[0047] The top surface of the base member has a 2 inch across spline ( 6 ), either side of which are recesses ( 7 ), beginning from between about 4 and 6 inches from either end of the base member, preferably between 5 and 5½ inches, and spaced in an interval of every 2 inches. The recesses ( 7 ) are set about 1 inch from the rails in order to match with the pair of holes ( 9 ) in the slideable member.
[0048] The slideable member ( 4 ) depicted in FIG. 3 is 24 inches in width, 5⅞ inches across, and 11/16 inches thick. The slideable member ( 4 ) has notches ( 3 ) such that the space defined by the tongs thereof are of similar width to those of the base member ( 1 ). The thickness of the notches ( 3 ) shown in FIG. 3 may be less than the full thickness of the slideable member ( 4 ), or the notches ( 3 ) may be fully as thick as the slideable member ( 4 ) itself. In this example, a groove matching the dimensions of the spline ( 6 ) (which in this example is ⅛ inch thick) is provided on the lower surface of the slideable member ( 4 ). As depicted in FIG. 5 , the slideable member ( 4 ) has two pairs of recesses towards one end for adjustably affixing the extension member ( 5 ), only one pair of recesses being utilized at a particular time depending on the desired door buck spread width. The slideable member may have three pairs of recesses, 2 inches apart, to allow for adjusting the extension member to extend by 0, 2, or 4 inches. Towards the opposite end of the slideable member, at a position about 2½ inches from the end of the slideable member, is a pair of holes ( 9 ) through which the locking pins ( 8 ) (shown in FIGS. 2, 3 , and 4 ) are passed, for securing the slideable member ( 4 ) to the base member ( 1 ). The pair of holes ( 9 ) are each set back from the edge of the slideable member by 15/16 inches. The locking pins ( 8 ), after passing through the holes ( 9 ), pass into the recesses ( 7 ) of the base member. A handle ( 10 ) is also provided on the slideable member ( 4 ).
[0049] The extension member ( 5 ) as depicted in FIG. 5 is 9 inches in width, 5½ inches across, and ½ inch thick. It has a notch at only one end, the tongs of which define a space having dimensions as in the notches of the base member and slideable member, although the space defined by the tongs may be less, such as 2¼ inches. Two pairs of holes ( 12 ) are positioned on the extension member ( 5 ) such that it may be affixed to the slideable member ( 4 ) at either an unextended position (see FIG. 2 ), or in an extended position. The affixing is accomplished by means of wingnuts ( 11 ) which pass through the holes ( 12 ) and into the recesses in the slideable member ( 4 ). As shown in the Figures, the extension member ( 5 ) has two pairs of holes for extension purposes, however, if desirable, the extension member ( 5 ) may have additional pairs of holes for additional extension width possibilities. For example, three pairs of holes may be used to accommodate extension by 0, 2, and 4 inches.
[0050] FIG. 1 depicts the fully assembled adjustable door spreader, showing the base member ( 1 ), the slideable member ( 4 ) in unextended position, and the extension member ( 5 ) in unextended position. FIG. 5 depicts the unassembled door spreader, indicating the manner in which it is assembled for use.
[0051] The door spreader is used by placing it between door bucks and adjusting the door spreader so that the notches present in the appropriate member define the desired spread width. For example, a 30 inch spread width is accomplished by merely keeping the slideable member and extension member in unextended positions. A 36 inch spread width is accomplished by releasing the spring-bolts, sliding the slideable member 6 inches, and resecuring the spring-bolts. One notch of the base member abuts one of the door bucks, while one notch of the slideable member abuts (or defines the position) for the other door buck. The door bucks are then affixed to form a door frame of precise desired width. Similarly, a 52 inch spread width may be accomplished by extending the slideable member by 18 inches, and then the extension member to its fully extended position (yielding an additional 4 inches of extension), bringing the total width of the adjusted spreader to 52 inches.
Example 2
Adjustable Door Spreader with 24 Inch Base Member
[0052] This example differs from Example 1 in that the base member ( 1 ) is 24 inches wide, the slideable member is 20 inches wide, and the extension member is 7 inches wide. This example apparatus is capable of spreading from 24 inches to 44 inches.
[0053] It will be apparent to persons skilled in the art that numerous enhancements and modifications can be made to the above described apparatus without departing from the basic inventive concepts. All such modifications and enhancements 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. Furthermore, the preceding Examples are provided for illustrative purposes only, and are not intended to limit the scope of the invention. All references cited herein are expressly incorporated by reference herein.
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The invention relates to an adjustable door spreader apparatus for use in the door framing industry. The apparatus equips a carpenter engaged in framing doors with an adjustable door spreader capable of spreading virtually all common door sizes, thereby saving time and materials by eliminating the need to build a single-use spreader for each door to be framed.
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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 system of closure panels able to divide, isolate or compartmentalize spaces in houses, offices, shops, etc. via a flexible system based on glass and aluminum. For this reason, the invention is directed to the technical area of construction, more precisely in the area of enclosures to divide spaces and to enclose spaces on terraces, balconies, rooms, etc.
2. Description of the Related Art
Within the above described technical area, there are well known systems of enclosure mainly based on a set of panels that hang from upper rails on the ceiling and that move with the help of bearings and other mechanical elements. These devices present several problems and limitations related to not only the reliance on gears and bearings, but also from the fact that the weight of the panels rests on the upper rails and not on the floor. For example, in all of these systems, the bearings and gears wear out over time and use, which makes it necessary to carry out periodic maintenance of them. Moreover, the weight of the panels can result on malformations on the upper rail at the points of contact, in which the weight of these panels rests. Accordingly, the useful life of such enclosure systems is considerably limited. Specific examples of these systems are described on patent WO 90/12128 or in the French document FR2.557.624.
BRIEF SUMMARY OF THE INVENTION
The current invention aims to solve the problems mentioned above by developing an enclosure system in which the weight of the panels rests and moves on the PTFE strips, thus eliminating the need for bearings and gears.
The solution presented below is based in a set of elongated panels that move individually, guided by an top guide and a bottom guide, and in which the weight of each of the panels rests longitudinal and uniformly throughout the lower rail. This structure aims to avoid places in which there is an excessive pressure, as well as mechanical elements vulnerable to suffer failures due to bearings.
The set of elongated panels includes a panel-door and a set of independent panels. Generally, the panel-door is the last panel of the elongated panels and it does not move longitudinally from the pick-up position. The panel-door construction and arrangement is similar to the one of the other elongated panels, though it also includes a system of closure. The independent panels includes are made of toughen glass, between 10 and 30 mm thick. The panels include a set of elements that allow them to move along an upper track and a lower track located one in front of the other, on the ceiling and the floor of a room, terrace, shop, etc. The panels move along these tracks with the help of some guides, and the weight of the whole structure only rests and moves on the PTFE strips. For this reason, the only function of the upper track is to guide the movement of each panel and not to be a weight bearing element. The independent panels can be moved by a person along the tracks. Additionally, they can rotate along an axis by one of the lateral sides of the independent panel in such a way that the independent panel can be placed in a position perpendicular to the tracks. The rotation or opening of the panels in this perpendicular orientation occurs at the end of the tracks. Alternatively, when the panels are extended, the elongated panels act to enclose a desired space.
Between these two extreme positions a variety of intermediary positions may be utilized depending on the needs of a user.
The upper end of the glass is protected by a profile in the form of an aluminum frame that has two outer arms stuck to the glass and a trapezoid structure, the wide side of which is open, while the narrow side of the trapezoid structure connects to the outer arms of the profile. Because of the opening of the wide side of the trapezoid structure, a set made up of three pieces comes out, which make up the upper side of the top flag. These three pieces are:
a) A top flag screw made of, for example, stainless steel and with the shape of a “T”; the head of the “T” screw is oval and has 2 elongated and straight sides. b) A circular section made of, for example, plastic located inside the track. The circular section is a unitary piece made of, for example, polyamide or a similar material and it consists of two cylindrical layers of different diameter. The lower layer of the circular section has a larger diameter and is in touch with the inner walls of the upper track. The upper layer of the circular section has a smaller diameter. The circular section defines a central opening threaded and sized to receive the top flag screw. c) A cylindrical spacer piece made of, for example, plastic that is in touch with the wide side of the trapezoid structure of the profile and the lower layer of the circular section acting as stop between the two of them; this component is centrally bored to accommodate the top flag screw.
A metal sheet is disposed within the hollow trapezoid structure of the profile. The metal sheet defines three threaded holes one of which connects to the top flag screw after it passed through the trapezoid opening in the wide side of the trapezoid structure. The metal sheet is rectangular; three of its sides are straight and the other one is slightly curved. The top flag screw drives into the perforation of the metal sheet which is nearest to the curved side, which is also the nearest side to the prominent end of the panel or the panel-door. This upper metal sheet is located in a determined place along the hollow of the trapezoid structure with the help of two stud screws that drive into the ends of the sides that make up the opening to the hollow of the trapezoid structure, and on the other two threaded hollows of the metal sheet. The upper metal sheet's function is to keep the profile and the upper track together with the help of the set of pieces that make up the top flag. These pieces are not sized to support the weight of the elongated panel, since the panel in the base of the device.
The upper track has a substantially rectangular or squared cross section with its lower side defining an elongated opening through which the top flag passes. The elongated opening is limited by the equidistant sides of the upper track. The upper track is attached to the ceiling via nails, screws or other similar elements that drill a slot in the shape of a channel located in the inner face of an upper side of the upper track.
The lower side of the glass is protected by a lower aluminum profile similar to the upper one. The glass is attached to this profile in the same way that it is attached in the upper side. The upper side of the profile includes the outer arms of the profile, the narrow side of the trapezoid structure and the pair of outer arms defining a recess where the weight of the glass rests. The hollow trapezoid structure has a wide side, a narrow side, and two slanted sides. The wide side of the trapezoid structure defines a trapezoid opening centered between two extensions of the wide side. Within the trapezoid structure a metal sheet similar to the one introduced in the upper side of the panel is placed. A bottom flag screw is driven into the metal sheet and it goes through a component called the bush, made of, for example, polyamide or a similar material, which allows the longitudinal movement along the lower track. The bottom flag screw, the metal sheet, and the bush forms the bottom flag. This bush is a unitary piece and it comprises four cylindrical layers of different diameter:
the first cylindrical layer is at a lowest level of the four layers and has a largest diameter of the four layers. The first cylindrical layer is in contact with the inner walls of the lower track. The second cylindrical layer is constructed and arranged as a step above the first cylindrical layer. The third cylindrical layer is disposed above the second cylindrical floor and has a diameter being equal to a width of a second elongated opening of the lower track. The fourth cylindrical floor is disposed above the third cylindrical floor and has a diameter being slightly larger than the width of the second elongated opening of the lower guide track.
The lower track has a substantially rectangular or squared cross section with its upper side defining an elongated opening through which the bottom flag passes. The elongated opening of the lower track is limited by the equidistant sides of the lower track. It is on these equidistant sides of the lower track that slots of, for example, 4 mm are made in such a way that they are equidistant to a central dividing line of the lower track, and in which PTFE strips interfacing with the lower profile are fitted. In this way, the weight of each elongated panel rests over these PTFE strips. The lower track is attached to the floor similarly to the upper track, with the help of a nail that goes through the longitudinal channel made along the lower side of the lower track.
Inside the trapezoid structure of the lower profile wherein the metal sheet is introduced a worm screw is fitted across the metal sheet; this worm screw includes, at least, two other elements that are introduced within the lower track. These elements, together with the guide component and the worm screw, allow a fine adjustment of the elongated panel in the lower track in order to obtain an optimum assembly between the profile and the PTFE strips over which the weight of the elongated panel rests, thus allowing an adequate movement of the elongated panel.
The structure of the panel-door is slightly different from the rest of the elongated panels, since at first it does not move along the tracks. The upper end of the glass of the panel-door is protected by an aluminum profile; the outer arms of said profile are attached to the glass and have a trapezoid structure, the upper side of which is open and corresponds to the wide side, while the base is the narrow side that attaches to the outer arms of the profile. Inside the trapezoid structure, the metal sheet is attached via a worm screw. A square block made of polyamide or a similar material is attached to the metal sheet via a stop screw. This square block has a section with rounded corners, in order to enable the attachment at a lower and upper part of the square block. The inside part of this square block is hollow and circular, and the heads of two screws, the stop screw and an anchoring screw (the threads of which come out by the lower and upper opening of the square block) are located there. The upper opening in touch with the roof of the upper guide track has a smaller diameter than the head of the anchoring screw that goes through the roof of the upper track and threads in a nut located in the roof of the room. The stop screw comes out through the lower opening of the square block, the circular side of which has a larger diameter than the heads of the anchoring and stop screws; this allows the fitting of the heads of both screws within the square block.
The lower side of the panel-door contains the same elements arranged within the profile (the base of which is trapezoidal-shaped) and the lower track. These lower and upper tracks allow the rotation of the panel-door in both ways and are in touch with the lateral sides of the open edge of the upper track. With the help of the worm screw, the panel-door can be fastened to the upper track. As in the rest of the panels, these components are not sized to support the weight of the panel-door, since the panel-door rests in the base of the device.
On both the panel-door and the independent panels, the upper side of the end that is opposite to the spin axis includes a top guide that is made up by a top guide screw that goes through a cylindrical hollow piece made of, for example, polyamide and located in the hollow part of the upper track. The top guide has a diameter that coincides with the elongated opening of the upper track. The top guide ends on its upper side with a widening of its inner thread in such a way that it coincides with the perimeter of the head of the top guide screw. This screw goes through the hollow of the upper profile trapezoid structure that protects the glass and is driven into a thread of the metal sheet located inside the upper profile trapezoid structure. The metal sheet is rectangular and has two threads equidistantly located along its longitudinal axle. On the other side, in the lower track, the lower sides of the lower profile trapezoid structure that protect the glass rest on the PTFE strips located in the channels of the lower track.
Moreover, a bottom guide, with the shape of an “H”, is partially introduced between the sides that define the hollow part of the lower profile trapezoid structure in such a way that a lower outer cylindrical layer of the bottom guide covers the opening of the lower track, without making the weight of the panel rest over the bottom guide in the inner borders that define the hollow of the lower track. In this way, the bottom guide does not rest over the PTFE strips, but it does cover the opening of the lower track. The washer is attached to the profile with the help of a screw that goes across the threaded hollow through the longitudinal axis to the bottom guide and goes up to the base of the lower profile trapezoid structure.
The central side of the upper track that coincides with the panel-door has a gap in which a turning mechanism based in a series of circular recesses that house the heads of the T-shaped screws is located, so as to enable the rotation and opening of the independent panels when these are picked up in the end of the enclosure system.
In the upper track side that coincides with the end of the panel-door—opposite to the wall—a slot is made, in which a turning arm in the form of an arm-shaped plate is placed. The hollow made in the upper track allows the sheet and their profiles to come out from the plan made up by the upper tracks when these are picked up in the end of the enclosure system. The circular recesses, together with some turning arms that spread perpendicularly to the upper track through the hollow made in said track, enable the panels to rest and avoid them from rotating.
The rotating movement begins when the head of the top flag screw is introduced and fitted within the circular recess of the turning mechanism located at the end of the track, in the vicinity of the panel-door. The sinking within the circular recess establishes and secures the exact point through which the spin axis passes and in which the spin movement of the panel-door or panel will take place. Besides, the looseness of the sinking within the circular recess allows a slight swinging of the panel-door, which eases the opening of the panel or the panel-door. When an elongated panel rotates, it rotates through the spin axis defined by the top flag and bottom flag, and the sheet rotates as well, driving the weight of the glass that the profile receives to the bottom guide. When the bottom guide moves, it is moved above the lower track opening, abandoning it for a notch made in the PTFE. On the other side, the top flag can only abandon the upper track through the hollow made near the wall.
The panel-door includes a handle that allows the opening of the window fitted into the spin arm and that is used, together with the closure of the inner side, to open, close or block the panel-door, thus allowing the system to be completely shut, without making it possible to open it from the outside.
In some arrangements, the system is prepared to support panels up to 3 meters high, in which each sheet can weight up to 50 kg. Moreover, the dimensions of the glass are limited to a width of 10 to 30 mm, because with these conditions and because of the use of the aluminum profiles found of the market, it is possible to obtain the best mechanical behaviors for the system.
The movement and displacement of each panel is manually carried out by a person. The rotation and displacement of each panel will allow an easy cleaning of both faces. Besides, the maintenance of this structure is simple, because no wheels, bearings or drivings that might wear out are used.
The stripes over which each panel rests and moves along the tracks are made up of PTFE, since this material allows an easy movement of the panels, with mechanical properties resistant to abrasion and wear. These strips are fixed to the lower section. The behavior of the PTFE in touch with the aluminum surfaces allows the simple and easy movement of the system.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 represents a set of elongated panels, including the panel-door, spreading along the tracks and defining a space.
FIG. 2 represents the set of elongated panels picked up with a perpendicular positioning to the track.
FIG. 3 represents the section of the independent panel through the first cross section.
FIG. 4 represents the section of the independent panel through the second cross section.
FIG. 5 represents the section of the panel-door of the enclosure system through the third cross section.
FIG. 6 shows a perspective view of the profile.
FIG. 7 shows a perspective view of the lower track.
FIG. 8 shows a perspective view of the upper track.
FIGS. 9 and 10 show an elevation and floor plan view of the top flag screw.
FIGS. 11 and 12 show a section and floor plan view of the circular section of the top flag.
FIGS. 13 and 14 show a section and floor plan view of the cylindrical spacer piece acting as a stop.
FIGS. 15 and 16 show a section and floor plan view of the metal sheet.
FIGS. 17 and 18 show a section and floor plan view of another metal sheet.
FIGS. 19 and 20 show a section and floor plan view of the bush.
FIGS. 21 and 22 show a section and floor plan view of the cylindrical hollow piece of the top guide that comes out through the hollow of the upper track.
FIGS. 23 and 24 show a section and floor plan view of the bottom guide acting as washer.
FIGS. 25 and 26 show a section and floor plan view of the square block located between the panel-door profile and the panel tracks.
FIGS. 27 and 28 show two different views of the turning mechanism.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIGS. 1 and 2 we can see the way in which the set of elongated panels ( 1 , 2 ) are distributed independently along the upper ( 11 ) and lower ( 12 ) tracks. The panel-door ( 1 ) is in the nearest position to the wall, which is the last one to spread. Some of the independent panels ( 2 ) are placed next to the wall perpendicularly and folded, since this is the only position in which it is possible to fold all the panels. Other panels are arranged along the tracks ( 11 and 12 ), thus resulting in the space enclosure.
FIG. 3 shows an independent panel ( 2 ) at a first cross section. The independent panel includes an glass ( 10 ), between 10 and 30 mm wide, and the different devices included to allow the rotation of the independent panel ( 2 ) about a spin axis. The glass upper end ( 10 ) is protected by an aluminum profile ( 3 ), the end outer arms ( 32 ) of which are attached to the glass ( 10 ) and to its base ( 31 ). As shown in more detail in FIG. 6 , the upper side of the profile ( 3 ) is trapezoid-shaped, with a trapezoid opening ( 35 ) located in the wide side of the trapezoid structure and limited by both extensions ( 34 ). The base ( 31 ) is the narrow side and it coincides with the ends of the profile ( 3 ) outer arms ( 32 ). The outer arms ( 32 ) and the base ( 31 ) defines the recesses ( 14 ) that improve the fitting of the glass ( 10 ).
The rotation of the independent panel ( 2 ) is carried out with the help of some pieces partially located in the upper ( 11 ) and lower ( 12 ) guide tracks. Three pieces that make up an upper side of the top flag include:
a) The top flag screw ( 5 ), made up of stainless steel and with the shape of a “T”. In FIGS. 9 and 10 it is shown in detail that the head or upper end ( 42 ) of the top flag screw ( 5 ) has the shape of an oval, with two straight and elongated sides so that, when it spins, it comes into contact with the inner side of the circular recess ( 65 ) of the turning mechanism ( 64 ) as seen in FIG. 28 , which delimits the movement of the top flag screw ( 5 ). The base of the top flag screw is threaded ( 43 ). b) The circular section ( 6 ) is made up of plastic; it has a circular shape and is located inside the track ( 11 ). FIGS. 11 and 12 show that the circular section ( 6 ) is a unitary piece made up of polyamide or a similar material and it consists of two cylindrical layers of different diameter. The lower layer ( 44 ) that is the base of the circular section ( 6 ) has a larger diameter and is in touch with the inner walls of the upper track ( 11 ). The upper layer ( 45 ) has a smaller diameter. Both layers ( 44 , 45 ) have a central first threaded opening ( 46 ) that allows the entrance of the top flag screw ( 5 ), being the diameter of this central first threaded opening ( 46 ) that allows the entrance of the top flag screw ( 46 ). Consequently the diameter of the central first threaded opening ( 46 ) is smaller than the width of the top flag screw ( 5 ) head ( 42 ). c) The cylindrical spacer piece ( 7 ), shown in FIGS. 13 and 14 , is also made up of plastic, and it is the one in touch with the sides extensions ( 34 ) of the profile ( 3 ) and the lower layer ( 44 ) of the circular section ( 6 ), acting as stop between them. The cylindrical spacer piece ( 7 ) is centrally bored ( 47 ) to accommodate the top flag screw ( 5 ) through the central bore ( 47 ).
The circular section ( 6 ) and the cylindrical spacer piece ( 7 ) are crossed by the top flag screw ( 5 ) through the openings ( 46 and 47 , respectively.) The top flag screw ( 5 ) head ( 42 ) is set with the circular section ( 6 ), and the base of this top flag screw ( 5 ) goes through the trapezoid opening ( 35 ) of the trapezoid structure ( 3 ) and is threaded in the upper metal sheet ( 8 ) located along the hollow inside the profile ( 3 ) trapezoid structure.
As it is shown in FIGS. 15 and 16 , the upper metal sheet ( 8 ) is elongated and has three threaded holes ( 37 , 38 and 39 ), of identical diameter, located along the longitudinal axis of the metal sheet ( 8 ). The sides of this metal sheet ( 8 ) are straight, except for the one located at the end of the panel-door or panel ( 2 ), which is curved. In the hole ( 37 ) made nearest to the curved side the T guide ( 5 ) is threaded, fastening the independent panel ( 2 ) to the upper track ( 11 ), with the help of the circular section ( 6 ) and the cylindrical piece ( 7 ). Thus, this upper metal sheet ( 8 ) aims to keep the profile ( 3 ) and the track ( 11 ) stuck together, with the help of the set of pieces ( 5 , 6 and 7 ). The upper metal sheet is placed in a determined place along the trapezoid opening ( 35 ) of the upper profile ( 3 ) with the help of two headless worm screws, not shown in the figures, which are threaded at the edges of the extensions ( 34 ) as well as in the holes ( 38 and 39 ) of the metal sheet ( 8 ). The disposition of all these pieces is set throughout the top guide screw ( 5 ), in relation to the profile ( 3 ) of the independent panel. These components are not sized to support the weight of the independent panel ( 2 ), since it shall rest in the base of the device.
As seen in FIG. 3 , in the vicinity of the head ( 42 ) of the top guide screw ( 5 ), a partial cut of the piece called turning mechanism ( 64 ), which is shown in detail in FIGS. 27 and 28 . The turning mechanism ( 64 ) is a straight and elongated piece, higher than the head ( 42 ) of the top guide screw ( 5 ), and it has a straight side in touch with the wall of the upper track ( 11 ) to which it is attached with the help of some screws (not shown in respective figures) that go through the channels defining the circular recesses ( 65 ). The other side that looks into the track ( 11 ) is made up by a set of curved gaps or valleys defining the circular recesses ( 65 ). The turning mechanism ( 64 ) is located at the end of the track that is in touch with the wall, and from there on it extends out along the upper track ( 11 ). Its length and number of circular recesses ( 65 ) is defined by the number of panels ( 2 ) that make up the enclosure system, since each spoon ( 65 ) shall house the head ( 42 ) of the top guide screw ( 5 ) of each panel and it will help prevent that the panels rotate when they are open. That is, each circular recess ( 65 ) defines one of the points through which the top flag in which each independent panel ( 2 ) rotates passes.
Thus, each turning mechanism ( 64 ) is specifically made for each enclosure, depending on the number of panels that comprise the enclosure system, as well as the geometric characteristics of them, with the aim of establishing the point through which the top flag passes.
As it is shown in detail in FIG. 8 , the upper track ( 11 ) has a rectangular or squared section; one of its sides is partially closed and has a first elongated opening ( 25 ) that allows the entrance of the elements ( 5 , 6 and 7 ) that constitute the upper side of the top flag, which help to rotate the independent panels ( 2 ). The first elongated opening ( 25 ) is defined by the equidistant sides of the track ( 11 ). The upper track ( 11 ) is attached to the roof by means of nails, screws or other similar elements that drill a slot in the shape of a channel ( 23 ) located in the inner face opposite to the opening ( 25 ) of the guide track ( 11 ).
The lower side of the glass ( 10 ) is protected by an aluminum lower profile ( 3 ) similar to the upper one. The glass ( 10 ) is stuck to this profile ( 3 ) in the same way was it is stuck in the upper part. So, the upper side of the profile ( 3 ) includes the profile outer arms ( 32 ), the recess ( 14 ) and the base ( 31 ) in which the weight of the glass rests ( 10 ). From the base ( 31 ) of the profile ( 3 ) some sides ( 33 ) come out; these constitute the trapezoid structure and function as a mounting structure, since they rest on top of a channel ( 9 ) of the lower track profile ( 12 ). The wide side of the trapezoid structure is open and the base ( 31 ) corresponds to the narrow side. Within the trapezoid structure there is a lower metal sheet ( 8 ) as in the upper side of the panel. A bottom flag screw ( 16 ) is driven into this piece ( 8 ), and it goes through the bush ( 15 ), made up of polyamide or a similar material, which allows the longitudinal movement along the lower track ( 12 ). The metal sheet ( 8 ), bottom flag screw ( 16 ), and bush ( 15 ) form the bottom flag. The rotation of the bush ( 15 ) inside the lower track ( 12 ) allows the opening of the independent panels ( 2 ). FIGS. 19 and 20 show that this bush ( 15 ) is a sole unitary piece and that it consists of four cylindrical layers of different diameter, the central portion of which is hollow ( 53 ) so as to allow the entrance of the bottom flag screw ( 16 ). The first cylindrical layer ( 49 ) that makes up the base of the bush ( 15 ) and is at a lowest level of the four layers has the largest diameter and is in touch with the inner walls of the lower track ( 12 ). Subsequently, there is a second cylindrical layer ( 50 ) that functions as step between the first cylindrical layer ( 49 ) and the third cylindrical layer ( 51 ). The third cylindrical layer ( 50 ) and has a diameter being equal to a width of a second elongated opening ( 24 ) of the lower track ( 12 ). Finally, on top of the third cylindrical layer ( 50 ) a fourth cylindrical layer ( 52 ) protrudes, the diameter of which is slightly superior to the second elongated opening of the lower guide track ( 12 ), in order to avoid the bush ( 15 ) from falling into the hollow of the lower track ( 12 ). The third cylindrical layer ( 51 ) is in touch with the end protrusions ( 34 ) that define the trapezoid opening ( 35 ) of the profile ( 3 ) trapezoid structure.
With the screws ( 5 and 16 ) fastened in top and bottom flags, it is possible to make the fine adjustment of the independent panel ( 2 ) between the lower ( 12 ) and the upper ( 11 ) tracks.
As shown in detail in FIG. 7 , the section of the lower track ( 12 ) is rectangular or squared, and its base is closed; the upper side is partially opened ( 24 ) and, through the second elongated opening ( 24 ), the elements of adjustment are introduced. The second elongated opening ( 24 ) of the lower track ( 12 ) is limited by the equidistant sides of the elongated opening ( 24 ) of the lower track ( 12 ). On these sides gaps of, for example, 4 mm are drilled, in such a way that they are equidistant to a central dividing line of the lower track, and in which the PTFE strips ( 4 ) attached to the lower channel ( 9 ) are fitted. In this way, the weight of each panel ( 2 ) rests over these PTFE strips ( 4 ). The lower track is attached to the floor similarly than to the upper track, with the help of a nail ( 19 ) or equivalent piece that goes through the longitudinal channel ( 23 ).
The panel-door ( 1 ) does not move along the lower and upper tracks ( 11 and 12 ), and thus the structure of the panel-door ( 1 ) is slightly different to the rest of the independent panels ( 2 ), as shown in FIG. 5 at a third cross section. The upper end of the glass ( 10 ) is protected by a profile ( 3 ) previously described, in which two end outer arms ( 32 ) are stuck to the glass ( 10 ) and to its base ( 31 ), which is trapezoid-shaped. Inside the trapezoid structure is the metal sheet ( 8 ), also previously described, to which a stop screw ( 27 ) is fastened, the head of which is found within the square block ( 13 ) that, in turn, is located inside the upper track ( 11 ). In FIGS. 25 and 26 this square block ( 13 ) is shown in detail, which is made up of polyamide or a similar material and that contains a rectangular floor plan section with rounded corners, in order to enable the attachment of this component into the lower ( 12 ) and upper ( 11 ) tracks. The inside part of this piece ( 13 ) is hollow and circular, and the heads of stop and anchoring screws ( 27 and 28 ) are located there; the threads of them come out by the lower and upper opening.
The upper opening ( 59 ) of the square block ( 13 ), which is in touch with the roof of the upper track ( 11 ), has a smaller diameter than the head of the anchoring screw ( 28 ) that goes through the roof of the side that makes up the upper track ( 11 ) and is threaded in a nut ( 29 ) located in the roof of the room. The stop screw ( 27 ) comes out through the lower opening ( 60 ), the circular side of which has a larger diameter than the heads of the stop and anchoring screws ( 27 and 28 ), which allows the fitting of the heads of both screws ( 27 and 28 ) within the square block ( 13 ). The lower side of the panel-door contains the same elements arranged between the profile ( 3 ), the base of which is trapezoidal-shaped, and the lower guide track ( 12 ). Inside the lower track ( 12 ), the square block ( 13 ) has rounded corners and is hollow, with an opening ( 59 ) that is in touch with the floor of the track ( 12 ) The opening ( 59 ) has smaller diameter than the head of the anchoring screw ( 28 ) that goes through the lower track ( 12 ) and is threaded in the nut ( 29 ) located in the floor of the room. The diameter of the opening ( 60 ) is larger than the heads of the stop and anchoring screws ( 27 and 28 ). On the other side, the head of the stop screw ( 27 ) is threaded in the metal sheet ( 8 ) located in the hollow of the trapezoid structure ( 3 ).
This set of screws, nuts ( 29 ) and square blocks ( 13 ), together with the metal sheet ( 8 ), enable the rotation of the panel-door in both ways and is in touch with the lateral sides of the open side of the upper track. With the help of the screw, the panel-door can be adjusted to the upper track. As in the rest of the panels, these components are not sized to support the weight of the panel-door, since it shall rest in the lower sides ( 34 ) of the panel-door profile which, in turn, rests on the PTFE strips ( 4 ) located along the channels ( 9 ) in the base of the device.
The panel-door ( 1 ) includes a handle (not shown in the figures), that allows the opening of the panel-door; said handle is used, together with the closure of the inner side, to open, close or block the panel-door ( 1 ), thus allowing the system to be completely shut, without making it possible to open it from the outside.
On the central side of the upper track ( 11 ), that coincides with the end of the panel-door ( 1 ), a gap is made opposite to the wall, and a turning arm ( 40 ) in the form of an arm-shaped plate ( 40 ) is used to guide the exit of the independent panels ( 2 ) and the panel-door ( 1 ). That is, the slot ( 48 ) made in the upper track ( 11 ) allows the sheets ( 10 ) and their profiles ( 3 ) to come out from the plane made up by the upper ( 11 ) and lower ( 12 ) tracks when these are picked up in the end of the enclosure system. The circular recess ( 65 ) defines the axis on which each of the panel rotates, and the turning arm ( 40 ) will help each sheet ( 10 ) to come out, allowing them to rest on it. Thus, when each independent panel ( 2 ) rotates on the spin axle made up by the devices ( 5 , 6 , 7 , 8 , 15 and 16 ) showed in FIG. 3 , the sheet ( 10 ) rotates, coming out of the plane composed by the upper ( 11 ) and lower ( 12 ) tracks, with the help of the devices described below. The same occurs with the panel-door ( 1 ) when it rotates on the spin axle made up by the devices ( 5 , 6 , 7 , 8 , 15 and 16 ), shown in FIG. 5 .
The turning arm ( 40 ) is inserted into the upper track ( 11 ) gap, and it comes out perpendicularly from said upper track ( 11 ) through the gap. On the end of the plate a rope is fastened (not shown in respective figures), which descends in parallel to the sheet ( 2 ) until it is adjusted to the lower track ( 12 ).
As it is shown in FIG. 4 , at a second cross, the glass ( 10 ) is fitted on the profile ( 3 ) previously described of the panel-door ( 1 ) and the independent panels ( 2 ). For both the panel-door ( 1 ) and the independent panels ( 2 ), the upper side of the end which is opposite to the spin axis comprises a top guide having a top guide screw ( 41 ) that goes through a cylindrical hollow piece ( 63 ) made up of polyamide and located in the first elongated opening ( 25 ) of the upper track. This cylindrical guide piece ( 63 ) has a diameter that coincides with the opening of the first elongated opening ( 25 ). The cylindrical hollow piece ( 63 ) is shown in more detail in FIGS. 21 and 22 , showing that the diameter of the inner cylinder allows the entrance of the top guide screw ( 41 ). This hollow widens on the upper part of the cylindrical hollow piece ( 63 ) until it coincides with the perimeter of the top guide screw head ( 41 ), making it fit on the cylindrical hollow piece ( 63 ) in order to enable the entrance of these pieces through the slot ( 48 ) of the upper track. The top guide screw ( 41 ) goes through the trapezoid opening ( 35 ) of the profile ( 3 ) trapezoid structure and is fastened in the thread ( 22 ) of the metal sheet ( 21 ), which is housed inside the profile ( 3 ) trapezoid structure. In FIGS. 17 and 18 you can see in more detail that the metal sheet ( 21 ) is rectangular and that it contains 2 threads ( 22 ) equidistantly located along its longitudinal axle. The metal sheet ( 21 ) is made up of stainless steel or any similar material. In the lower parts of the elongated panels, over the PTFE strip ( 4 ) located in the channels ( 9 ) of the lower track ( 12 ), the lower extensions ( 34 ) of the profile ( 3 ) trapezoid structure rest.
A bottom guide ( 54 ) made up of polyamide and with the shape of an “H”, is partially introduced between the sides ( 34 ) of the profile ( 3 ) trapezoid structure, in such a way that the base of the bottom guide ( 54 ) covers the second elongated opening ( 24 ) of the lower track, but without making the weight of the independent panel ( 2 ) rest over the bottom guide ( 54 ) in the inner borders that define the second elongated opening ( 24 ) of the lower track ( 12 ). In this way, the bottom guide does not rest over the PTFE strips ( 4 ), but it does cover the second elongated opening ( 24 ) of the track ( 12 ). With the help of a bottom guide screw ( 36 ) that goes across the threaded hollow ( 58 ) through the longitudinal center of the washer ( 54 ) and up to the base ( 31 ) of the lower profile ( 3 ) trapezoid structure, the washer ( 54 ) is fastened to the profile ( 3 ).
As it is shown in detail in FIGS. 23 and 24 , the bottom guide ( 54 )—over which the sheet ( 2 ) moves and rotates—has the shape of an “H”, and it is a uniform piece.
The bottom guide is divided into three cylinders: two cylindrical outer layers ( 56 and 57 ) that have equal diameter—and which is larger than the second elongated opening of the lower track ( 12 )—and a cylindrical inner layer ( 55 ), that has a much smaller diameter, which is inserted into the trapezoid opening ( 35 ) of the trapezoid structure of the lower profile ( 3 ).
The rotating movement begins when the head ( 42 ) of the top flag screw is introduced and fitted within the circular recess ( 65 ) of the turning mechanism ( 64 ). The sinking of the spoon circular recess ( 65 ) establishes and secures the exact point through which the spin axis passes and in which the spin movement of the panel-door or panel will take place. Besides, the looseness of the sinking within the circular recess ( 65 ) allows a slight swinging of the panel-door, which eases the opening of the panel ( 2 ) or the panel-door ( 1 ). When an independent panel ( 2 ) or panel-door ( 1 ) rotates, it twists through the spin axis defined by the top flag and bottom flag ( 5 , 6 , 7 , 8 , 15 and 16 ) and the first upper stop and first lower stop ( 8 , 13 , 27 , 28 and 29 ), and the sheet rotates as well, driving the weight of the glass ( 10 ) that the profile ( 3 ) receives to the bottom guide ( 54 ) through its sides ( 33 and 34 ). When the bottom guide moves ( 54 ), it is moved above the lower track ( 12 ) second elongated opening ( 24 ), abandoning it for a notch (not shown in respective figures) made in the PTFE strip ( 4 ). On the other side, the axle top flag and the top guide that comprise the screw pieces ( 41 ) that go through the cylindrical guide piece ( 63 ) and thread into the metal sheet piece ( 21 ), can only abandon the upper track ( 11 ) through the slot ( 48 ). Thus, the screw ( 41 ), the cylindrical piece ( 63 ) and the metal sheet ( 21 ) will be at a different distance on each panel ( 2 ), in such a way that the panels that were last to rotate or be picked up will have the pieces ( 41 , 21 and 63 ) nearest to the spin axle. So, the opposite end to the spin axle made up by the pieces ( 8 , 13 , 27 , 28 and 29 ) of the panel-door ( 1 ) coincides with the axis in which the pieces ( 41 , 21 and 63 ) are located. Other arrangements allow for the size of each elongated panel to be different, so that the edge which is opposite to the spin axis coincides with the place where the guide pieces are placed ( 41 , 21 and 63 ).
A variant to this system consists of welding the top flag screw ( 5 ) to metal sheet ( 8 ) so as to get a higher robustness of the spin system for both the panel-door ( 1 ) and the rest of the independent panels ( 2 ).
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An enclosure system includes a plurality of elongated panels consecutively connected to one another. The plurality of elongated panels includes a plurality of independent panels and a panel-door. The enclosure system also includes an upper track constructed and arranged to receive an upper portion of the plurality of elongated panels and a lower track constructed and arranged to receive a lower portion of the plurality of elongated panels. The lower track includes two polytetrafluoroethylene (PTFE) strips constructed and arranged as a transport system for facilitating movement of the plurality of elongated panels along the upper track and the lower track by achieving a very low coefficient of friction enabling heavy weights to be moved with little effort. Substantially all weight of the plurality of elongated panels is supported evenly across a length of the lower track on the two PTFE strips.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
TECHNICAL FIELD
[0001] The present invention relates generally to an excavating bucket and more specifically to a retention arrangement for a ground engaging tooth and adapter.
BACKGROUND
[0002] Excavating apparatus is commonly equipped with a bucket that serves for accepting and moving a discreet quantity of material, such as soil, rock, and gravel. The bucket is typically controllably and pivotally mounted on one or more arms, enabling an operator to control the bucket. One, or preferably more teeth, extending from the bucket in such a way as to engage and break loose the material as the bucket is driven into the material. Because of the varying characteristics of the materials upon which excavating apparatus is used, it is common to provide these bucket tips as tooth subassemblies.
[0003] These tooth subassemblies, typically are comprised of a tooth mounted upon an adapter that may be selectively secured to the bucket. As the bucket tips are the primary material engaging elements, they are subjected to a high degree of wear. This wear reduces the functionality of the bucket tips over time necessitating their occasional replacement. One of the more successful methods of assembling a bucket tip to the tooth sub-assembly has been to provide a bucket tip having a rearward facing opening designed to cooperatively accept a mounting protrusion from the tooth adapter base. This mounting protrusion typically provides sufficient structural support to ensure that the bucket tip remains generally in the appropriate alignment with respect to the tooth subassembly.
[0004] In order to retain the bucket tip on the tooth adapter base, openings are provided for accepting a securing means through the bucket tip and the adapter. Typically a retaining pin is oriented transversely though the bucket tip the adapter base to secure the tip. Depending on the type of digging operation being performed, the retaining pin may be subject to high shear loads at the intersection between the tip and adapter. During digging operations such as back-dragging, forces tend to pull the tip from the adapter, creating abnormally high shear loads on the pin. Failure of the pin will cause loss of the tip.
[0005] It is desirable to provide a tip and adapter assembly that is capable of overcoming one or more of the above stated problems.
SUMMARY OF THE INVENTION
[0006] A ground engaging tooth having a central axis, a mounting end portion and a ground engaging portion. The tooth includes an outside surface and an inside surface. A retainer opening extends from the outside surface to the inside surface and is oriented substantially parallel to the nose surface. An access bore is defined in the inside surface and configured to lock a secondary retainer with a retainer pin.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] [0007]FIG. 1 is a perspective view of an adapter having a tooth position on and mechanically retention system the present invention.
[0008] [0008]FIG. 2 is an exploded view of the tooth, adapter and retention system as shown in FIG. 1.
[0009] [0009]FIG. 3 is a cross-sectional view of one embodiment of the retention system taken generally along line 3 - 3 of FIG. 1.
[0010] [0010]FIG. 4 is a cross-sectional view of another embodiment of retention system taken generally along line 3 - 3 of FIG. 1.
[0011] [0011]FIG. 5 is a perspective view of an alternative embodiment of a secondary retainer of the present invention.
DETAILED DESCRIPTION
[0012] Referring to FIGS. 1 - 3 , a tooth 14 positioned on an adapter 16 for use with an implement bucket (not shown) is illustrated. The adapter 16 is typically secured to a cutting edge of the bucket by welding. The adapter 16 includes a forward tooth mounting portion or nose 18 , as best illustrated in FIG. 2. The nose 18 extends along a central axis 22 . The tooth 14 is a replaceable ground engaging tool 24 , which in this case is a tooth is removably fastened to the adapter 16 . The tooth 18 retained on the adapter 14 by a mechanical retention system 26 to be more fully described below.
[0013] Referring to FIG. 2, the nose 18 is generally oriented along the normal direction of working forces exerted on the tooth 14 as it is in working engagement with the ground, and is depicted by arrow 28 . The nose 18 includes a blunt abutment surface 30 that is oriented perpendicular to the arrow 28 . The blunt surface 30 is configured to receive the loading forces of the tooth 14 caused by earthworking. A plurality of angled surfaces 32 extend rewardly from the blunt surface 30 and radially outward from the central axis 22 . The plurality of angled surfaces 32 define a somewhat conical member 34 . A retainer pocket 36 is provided in the conical member 34 . The retainer pocket 36 having a shape that substantially one half of a cylinder and is oriented longitudinally. The retainer pocket 36 includes a bottom surface 38 and an end abutment surface 40 . The retainer pocket 36 is preferably positioned along a side of the nose 18 , although may be positioned in any one of the plurality of the angled surfaces 32 .
[0014] The tooth 14 includes a front ground engaging portion 42 and a rear mounting end portion 44 . The ground engaging portion 42 includes a top surface 46 and a bottom surface 48 that are tapered toward the front and converge to define horizontal edge 50 . A pair of side surfaces 48 (one shown) extend between the top 46 and bottom surface 48 . The mounting end portion 46 includes an outside surface 50 and an inside surface 52 defining a wall 54 there between. A cavity 56 is defined by the inside surface 52 and configured to snuggly fit over the nose 18 of the adapter 16 . The cavity 56 includes an abutment surface (not shown) defined at the bottom of cavity 56 . The abutment surface mates with the blunt surface 30 for transferring loads to the adapter 16 . A generally rectangular retainer opening 58 is formed in the wall 54 and extends from the outside surface 50 through to the inside surface 52 . When the tooth 14 is positioned on the adapter 16 the retainer pocket 36 and the retainer opening 58 align. A retainer pin 60 , defining a substantially cylindrical member is inserted into the retainer opening 58 and contacts the bottom surface 38 of the retainer pocket 36 .
[0015] Referring now to FIGS. 2 and 3, a section view of the tooth 14 showing the retainer pin 60 positioned in the retainer pocket 36 . As illustrated the retainer pin 60 includes a first end 62 , a second end 64 and a shoulder portions 66 disposed at each end 62 , 64 . A recess 68 is defined between the shoulder portions 66 . With the pin 60 seated in the retainer pocket 36 a portion of the pin 60 remains in the retainer opening 58 of the tooth 14 . Interference of the pin 60 with the retainer pocket 36 and the retainer opening 58 prevents the tooth 14 from being removed from the adapter 16 . A secondary retainer 70 engages the pin 60 and the tooth 14 or adapter 16 to hold the pin 60 in the retainer pocket 58 .
[0016] One embodiment of the secondary retainer 70 is shown in FIG. 3. The secondary retainer 70 is formed of spring steel or a similar resilient material. The secondary retainer 70 includes a width 72 that is slightly smaller than the recess in the retainer pin 60 . With the pin 60 seated in the retainer pocket 36 the secondary retainer fits into a gap 74 defined between the inside surface of the tooth 14 cavity 56 and the adapter 16 . The secondary retainer 70 includes a hook portion 76 that engages and holds the retainer pin 60 in place and a bore 78 that can be fastened to either the tooth 14 or adapter 16 . An access bore 79 in the tooth 14 aligns with the bore 78 of the secondary retainer 70 . A fastener 80 such as a rivet or bolt engages the bore 78 .
[0017] Referring now to FIG. 5, an alternate embodiment of the present invention is illustrated. In this embodiment the retainer pocket 36 is wider than the diameter of the retainer pin 60 and the retainer opening 58 aligns partially with retainer pocket 36 . The secondary retainer 70 ′ includes a horseshoe shaped portion 82 and a tab portion 84 . The secondary retainer 70 ′ is installed into the prior to inserting the retaining pin 60 . The tab portion 84 of the secondary retainer 70 engages the access bore 79 of the tooth 14 locking the secondary retainer 70 in place. The secondary retainer 70 can be released by depressing the tab portion 84 . As the retainer pin 60 is inserted, the pin 60 engages and compresses the horseshoe portion 82 . Upon being fully inserted into the retainer pocket 36 , the horseshoe portion 82 urges the pin 60 away from the retainer opening 58 , thus locking the pin in engaging contact with the tooth 14 and adapter 16 .
[0018] It should be noted, numerous alternative secondary retainer 70 embodiments might used without deviating from the scope of the invention.
INDUSTRIAL APPLICABILITY
[0019] In operation the tooth 14 and adapter 16 of the present invention function in a typical fashion. As the implement digs or otherwise applies forces in the normal direction, the abutment surface 56 of the tooth 14 pushes on the blunt surface 30 of the adapter 22 . In situations such as back-dragging, forces tend to pull the tooth 24 away from the adapter 16 , the retaining pin 60 is compressed between the retainer pocket 36 and the retainer opening 58 . Because the steel retainer pin 60 can withstand high compressive loading, it may be smaller than a laterally oriented pin.
List of Elements
[0020] Title: Longitudinal Orientation of a Retainer for a Bucket Tip
[0021] File: 01-832
[0022] tooth 14
[0023] adapter 16
[0024] nose (adapter) 18 central axis 22
[0025] ground engaging tool 24
[0026] mechanical retention system 26
[0027] arrow (direction of forces) 28
[0028] blunt surface 30
[0029] plurality of angled surfaces (nose) 32
[0030] conical member 34
[0031] retainer pocket 36
[0032] bottom surface (pocket) 38
[0033] end abutment surface (pocket) 40
[0034] get portion 42
[0035] ground engaging portion 42
[0036] mounting end portion 44
[0037] top surface (get end) 46
[0038] bottom surface (get end) 48
[0039] pair of side surfaces (get end) 48
[0040] outside surface (mounting end 50
[0041] inside surface 52
[0042] wall 54
[0043] cavity 56
[0044] abutment surface (cavity) 58
[0045] retainer opening (tooth surface) 58
[0046] retainer pin 60
[0047] first end (retainer pin) 62
[0048] second end (retainer pin) 64
[0049] shoulder portions (retainer pin) 66
[0050] recess (retainer pin) 68
[0051] secondary retainer 70
[0052] width (retainer) 72
[0053] gap (tooth and adapter) 74
[0054] hook portion 76
[0055] bore (secondary retainer 78
[0056] access bore secondary retainer 79
[0057] fastener (secondary retainer) 80
[0058] horseshoe portion 82
[0059] tab portion 84
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A retainer for removably attaching a ground engaging tooth to an adapter. The retainer comprises a cylindrical steel member adapted to fit into a pocket defined in the outside surface of the adapter and an opening defined in an inside surface of the tooth. The retaining pin is further held in a locking position by a secondary retainer made of spring steel.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
[0001] This U.S. Non-Provisional Patent Application claims the benefit of priority from U.S. Provisional Patent Application Ser. No. 62/205,101, filed Aug. 14, 2015, the entire disclosure of which is incorporated by reference herein.
FIELD
[0002] The present disclosure relates generally to modular building units and structures. More specifically, the present disclosure relates to a pre-fabricated ceiling assembly with a plurality of layered materials or components, and methods of forming the same.
BACKGROUND
[0003] Known ceiling structures for modular building unit structures comprise highly labor-intensive structures and associated methods of forming. Typically, prior art systems comprise cutting or shaping a ceiling panel from multiple pieces of fiber rock or sheet rock. The panel or panels are typically formed by computer-numerical-control systems and devices, but may also be machined or formed by hand or more conventional methods. Steel studs and reinforcing structures are cut and formed to fit a particular ceiling panel, and a stud frame is assembled for each particular ceiling. A jig table is typically used for such assembly processes. The cut fiber rock is then formed into place on the stud frame by known securing methods including fasteners and adhesives. It is also known to provide the assembled ceiling panel on a vertical finishing table and employ a multi-step process to finish the panel to a level five finish, which is desirable or required for areas and rooms where lighting is an important consideration. As used herein, “level five” finishes include, for example, those described in the Gypsum Association published standard GA-214-10.
[0004] Prior art devices are generally labor intensive, expensive, and generally fail to provide a prefabricated ceiling structure that is adapted to and operable to be provided with a prefabricated building unit or structure. Further, these devices generally fail to disclose or provide enhanced safety features including, but not limited to flame retardant features.
SUMMARY
[0005] In view of the limitations present in modular ceiling assemblies, embodiments of the present disclosure provide novel pre-fabricated modular ceiling assemblies which are more efficient to manufacture, more systematic and organized for installation and more versatile in application and operation and more cost effective for mass manufacturing purposes, as shown and described herein.
[0006] U.S. Patent Application Publication No. 2013/0086849 to Clouser et al., which is hereby incorporated by reference in its entirety, discloses modular building structure with a ceiling. Various features and methods of forming a modular room or structure of Clouser are contemplated for use in embodiments of the present disclosure.
[0007] In various aspects of the present invention, a pre-fabricated ceiling assembly for use within a modular building structure (e.g. a pre-fabricated bathroom unit) is provided that increases efficiency during the manufacturing, assembly, and installation processes of the ceiling and the modular structure. In one embodiment, a prefabricated ceiling panel assembly is provided, the panel comprising a plurality of layers comprising a first woven glass layer, a fire retardant layer, and a second woven glass layer, and a surface layer. At least one of the plurality of layers is manufactured from a single sheet of material that is shaped to span an entire ceiling area of a modular structure ceiling space. The at least one of the plurality of layers comprises at least one pre-cut opening for receiving utilities and other features, and at least one of the plurality of layers comprises a flame-retardant material comprising a resistance to fire and/or smoke generation.
[0008] In preferred embodiments, a ceiling assembly is provided with a mono-formed composite ceiling prefinished texture and a fire retardant layer, such as an ASTM E84 polypropylene tri polymer honeycomb, and/or other flame retardant and resistant materials. U.S. Pat. No. 6,443,257 to Wiker et al., which is hereby incorporated by reference in its entirety, discloses a ceiling structure with fire-retardant properties including polyvinyl acetate glue and other halogenated fire suppressants. Such materials are contemplated for use with various embodiments of the present disclosure.
[0009] In various embodiments, a prefabricated ceiling panel and method of forming the same is provided. The panel(s) comprises various built-in features including cable trays, lighting elements, and other features. The panel further comprises a layered structure comprising a plurality of layers to increase the fire resistance, insulation, and/or structural features of the panel.
[0010] In certain embodiments, at least one layer of the ceiling panel is manufactured from a single sheet of material that is shaped to span an entire ceiling area of a modular structure (e.g. a modular bathroom unit) ceiling space. In preferred embodiments, the at least one layer comprises pre-cut openings for utilities, such as electrical components, lighting elements, air ducting, etc. The ceiling panel also preferably comprises at least one layer or material comprising a resistance to smoke generation as well as flame spread.
[0011] In one embodiment, a method of forming a ceiling panel assembly is provided, wherein the plurality of layers are joined or formed using a linear pultrusion impregnation system with unsaturated polyester resin solution at a temperature range of approximately 250-500 degrees Fahrenheit. The method may further comprise cost effective and novel fabrication practices to improve the speed, cost and quality of the product.
[0012] In one embodiment, a prefabricated ceiling panel assembly is provided, the assembly comprising a plurality of layers comprising a first woven glass layer, a fire retardant layer, and a second woven glass layer, and a surface layer. At least one of the plurality of layers is manufactured from a single sheet of material that is shaped to span an entire ceiling area of a modular structure ceiling space. At least one of the plurality of layers comprises at least one pre-cut opening, and at least the fire retardant layer comprises a flame-retardant material comprising a resistance to fire and smoke generation.
[0013] In one embodiment, a prefabricated ceiling panel assembly is provided, the assembly comprising a plurality of layers comprising an upper layer, a fire retardant layer, a woven glass layer, and a lower layer. At least one of the plurality of layers is manufactured from a single sheet of material this is shaped to span an entire ceiling area of a modular structure ceiling space. At least one of the plurality of layers is secured to at least one other layer by an adhesive. At least one of the plurality of layers comprises at least one pre-cut opening. At least the fire retardant layer comprises a flame-retardant material comprising a resistance to fire and smoke generation.
[0014] In one embodiment, a method of forming a ceiling panel assembly and providing the ceiling panel assembly on a modular building structure is provided. The method comprises the steps of forming at least one layer using a linear pultrusion impregnation system with unsaturated polyester resin solution at a temperature range of approximately 250-500 degrees Fahrenheit. The method further comprises the steps of providing a first woven glass layer, a fire retardant layer, and a second woven glass layer, and a surface layer. At least one of the plurality of layers is manufactured from a single sheet of material that is shaped to span an entire ceiling area of a modular structure ceiling space. At least one of pre-cut opening is provided through the plurality of layers to accommodate at least one of a lighting element, an air conduit, and a plumbing structure. At least one of the layers comprises a fire retardant layer comprising a flame-retardant material comprising a resistance to fire and smoke generation. The method further comprises a step of securing or joining the ceiling panel assembly to a modular building unit. In various embodiments, the modular building unit comprises a prefabricated room or component of a building structure.
[0015] In one embodiment, a modular building structure is provided, the structure comprising a plurality of substantially vertical sidewalls at least partially defining an interior volume of the modular building structure. A prefabricated ceiling panel assembly is provided and comprises an upper layer, a fire retardant layer, a woven glass layer, a lower layer, and a plurality of reinforcing members. At least one of the plurality of layers of the ceiling panel assembly is manufactured from a single sheet of material this is shaped to span an entire ceiling area of a modular structure ceiling space. At least one of the plurality of layers of the ceiling panel assembly comprises at least one pre-cut opening, and the fire retardant layer comprises a flame-retardant material comprising a resistance to fire and smoke generation. At least the lower layer of the prefabricated ceiling panel assembly is secured to an upper portion of at least one of the plurality of substantially vertical sidewalls. The modular building structure is operable to be inserted or installed in a larger building unit or project, and wherein the modular building structure comprises a prefabricated unit to increase the ease of construction of a larger building, dwelling, or structure. In various embodiments, modular building structure of the present disclosure comprise prefabricated plumbing and electrical components (for example) that may be connected to and/or integrated with similar components and systems in a larger building structure in which the modular structure is installed.
DESCRIPTION OF THE FIGURES
[0016] FIG. 1 is a top perspective view of a pre-fabricated ceiling structure and a building unit according to one embodiment of the present disclosure.
[0017] FIG. 2 is a top perspective view of a pre-fabricated ceiling structure and a building unit according to one embodiment of the present disclosure.
[0018] FIG. 3 is an exploded, cross-sectional elevation view of components or layers for forming a ceiling structure according to one embodiment of the present disclosure.
DETAILED DESCRIPTION
[0019] The following is a listing of components according to various embodiments of the present disclosure, and as shown in the drawings:
[0020] 2 Ceiling Assembly
[0021] 4 Main Ceiling Panel
[0022] 6 Conduit
[0023] 8 Lifting Element
[0024] 10 Reinforcing Members
[0025] 12 Prefabricated Building Unit
[0026] 14 Apertures
[0027] 20 a, 20 b Finishing Mat
[0028] 22 a, 22 b Structural Mat
[0029] 24 Fire Resistant Layer
[0030] 26 Fire Resistant Veil
[0031] FIG. 1 is a top perspective view of a pre-fabricated ceiling assembly 2 comprising a main ceiling panel 4 , at least one electrical conduit 6 , at least one lighting or fan assembly 8 , a plurality of reinforcing members 10 , and related adhesives and installation fixtures and hardware. In certain embodiments, the main ceiling panel 4 comprises a mono-formed composite ceiling with a prefinished texture including, for example, a polyester surface veil impregnated with unsaturated resin solution.
[0032] In various embodiments, a main ceiling panel is provided and comprises a plurality of layers. In one embodiment, the layers comprise a fiberglass or woven glass layer, such as an 1808 woven roving glass layer; a fire-retardant layer, such as an ASTM E84 polypropylene tripolymer honeycomb layer; an additional glass layer, such as an 1808 woven virgin glass layer; and a surface layer, such as a veil for aesthetic and/or acoustic purposes.
[0033] As shown in FIG. 1 , the main ceiling panel 4 comprises a plurality of reinforcing members 10 , such as steel studs, to provide structural support to the panel 4 and related components and accessories. The number and type of reinforcing members 10 may be varied based on the size, shape, thickness, structure, etc. of an associated ceiling panel 4 . The ceiling panel 4 is preferably shaped, cut, or sized to fit a prefabricated building unit 12 . The prefabricated building unit 12 may comprise any number and type of building units including, but not limited to, modular prefabricated bathroom units.
[0034] FIG. 2 is a partially exploded perspective view of a pre-fabricated ceiling assembly 2 comprising a main ceiling panel 4 . As shown, the main ceiling panel 4 comprises a plurality of pre-formed cut-outs or apertures 14 to accommodate lighting and ducting features, for example.
[0035] FIG. 3 is an exploded, cross-sectional elevation view of components or layers for forming a ceiling structure according to one embodiment of the present disclosure. As shown, a ceiling panel or portion of a ceiling panel in accordance with one embodiment of the present disclosure comprises a first finishing mat 20 a as a lower or base layer of the panel or structure. A first structural fiberglass mat 22 a is provided above the first finishing mat 20 a. A fire resistant layer 24 is provided as an interior layer, the fire resistant layer preferably comprising a honey-comb core layer with at least some fire resistant properties or treatment. The fire resistant layer 24 is provided between the first structural fiberglass mat 22 a and a second structural fiberglass mat 22 b. As shown, a fire resistant veil 26 is provided vertically above the second structural fiberglass mat 22 b. A second finishing mat 20 b is provided as an upper layer of the ceiling panel.
[0036] In various embodiments, including but not limited to the embodiment provided in FIG. 3 , the layers are preferably laminated, joined or formed using a linear pultrusion impregnation system with unsaturated polyester resin solution at a temperature range of approximately 250-500 degrees Fahrenheit, and preferably approximately 325 degrees Fahrenheit. The pultrusion process of the present disclosure comprises a process wherein at least some of the layers provided in FIG. 3 , for example, are bonded under heat and pressure. U.S. Patent Application Publication No. 2001/0048175 to Edwards et al., which is hereby incorporated by reference in its entirety, discloses a process for in-line forming of pultrusion composites. Processes and features of Edwards et al. may be employed in embodiments of the present disclosure. The present disclosure contemplated methods of forming a ceiling panel using pultrusion processes as opposed to convention wet molding of layers. U.S. Pat. No. 8,182,643 to Fanucci et al., which is hereby incorporated by reference in its entirety, provides a process for fabricating structure including a pultrusion process. Such features and methods are contemplated for use in combination with embodiments of the present disclosure. Pultrusion processes contemplated for use in forming ceiling structures according to various embodiments of the present disclosure have provided unforeseen and novel advantages over known construction and formation methods. For example, the use of an in-line pultrusion process in forming ceiling structures of the present disclosure have been shown to reduce or avoid the occurrence of swelling or bulging of the ceiling structure during and after formation. The application of heat and pressure to the various layers shown and described herein provides distinct advantages over known devices and methods. In certain embodiments, the bonding process is accomplished with the addition of a fire-resistant resin and finishing the product with a fire-resistant bonding coat.
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A prefabricated ceiling panel and method of forming the same is provided. The panel comprises various built-in features including cable trays, lighting elements, and other features. The panel further comprises a layered structure comprising a plurality of layers to increase the fire resistance, insulation, and/or structural features of the panel.
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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 door safety devices and more particularly to a safety system in which the door is automatically opened when it strikes an obstruction while being closed.
At the present time the use of safety edge devices on doors, to prevent the door from being closed when it meets an obstruction, is well known, particularly in the doors of automatic elevators. For example, if an elevator door should hit or approach a passenger in its doorway, the elevator door will automatically open.
Various types of systems have been suggested to control such doors. For example, a series of light beams and a series of photoelectric detectors, i.e., "electric eyes," may be used between the door and the door frame. When one of the beams is interrupted, a controlled motor operates and opens the door. Alternatively, the door edge may carry an elongated flexible gas filled bag so that, when the edge strikes an obstruction, the gas pressure rises and operates a motor control mechanism. As another alternative, various types of pressure sensitive electrical switches, such as microswitches, may be used in the door edge. The switches may directly, or indirectly through an amplifying circuit, control a motor which opens the door.
It would be desirable to use a door safety system in other types of doors, particularly in a factory environment. For example, an increased interest has developed in noise control within factories. This has resulted in an increased use of enclosures for noisy machines. Such enclosures require various types of "doors," as that term is used herein, such as vertical sliding portals, horizontal swinging portals, movable hoods and movable windows. These "doors" may be dangerous if closed upon an obstruction, such as a tool or a worker's hand.
However, the door safety systems currently in use present various difficulties, particularly if employed in a factory environment. Certain of those door safety systems are not "fail safe," that is, they will not provide protection if one, or more, of their components should fail. For example, in the case of a direct contact microswitch, the switch contacts may become corroded and fail to make electrical contact when the door hits an obstruction. Other proposed safety door edge systems may be too delicate or complicated for use in factory safety systems.
SUMMARY OF THE INVENTION
In accordance with the present invention, a safety system for a door is provided. The system includes an elongated flexible channel member secured to the free edge of the door. Two normally separated conductive ribbons are positioned within the flexible channel member. When the flexible channel member is compressed by an obstruction, the compressive force is transmitted to the ribbons through a flexible diaphragm and ribs within the channel member. The compressive force brings the ribbons into electrical contact.
The ribbons are part of an active circuit, which active circuit also includes a power source such as a power transformer, a thermal switch, a resistor and an electromagnetic relay having a coil, a spring-loaded moving member (an arm) and electrical contacts.
In operation, the transformer supplies power to the relay coil which energizes a control circuit by pulling the moving member into a closed position. Upon compression of the door channel member, the ribbons touch and shunt the relay coil, causing the moving member to open the control circuit. The control circuit has a solenoid which, when de-energized, causes an air cylinder to open the door. The resistor in the active circuit prevents shorting of the circuit should the ribbons remain in contact. The thermal switch, such as a bimetal lever switch, senses the temperature of the resistor and opens the active circuit when the resistor temperature rises and reaches a selected temperature, thereby preventing over-heating of the resistor.
If any components of the active circuit should fail, or if the power to the active circuit should fail, the power to the relay coil will be lost, allowing the moving member to open the control circuit and de-energize the solenoid causing the door to be opened by the air cylinder. The air cylinder is operated by compressed air stored in a supply tank. The system of the present invention, consequently, presents a "fail safe" system which will open the door upon component or power failure.
OBJECTIVES AND FEATURES OF THE INVENTION
It is an objective of the present invention to provide a safety system for a door edge, which safety system, upon the edge striking an obstruction, will initiate automatic opening of the door.
It is a further objective of the present invention to provide such a safety system which will operate to open the door even though one or more components of its electrical circuit should fail.
It is a further objective of the present invention to provide such a safety system for a door edge which, if the power to its electrical system should fail, will still initiate the automatic opening of the door.
It is a further objective of the present invention to provide such a safety edge which utilizes relatively few components so that it may be relatively readily repaired and may be produced at a relatively low cost.
It is a further objective of the present invention to provide such a safety edge which is especially adapted to be used connected at the edge of the sliding doors of noise enclosures.
It is a feature of the present invention to provide a door safety closing system. The system includes a door frame, a door movably mounted in the door frame and movable into an open and closed position, control means for operating an air cylinder, and an air cylinder to open and close the door upon receiving a control signal from the air cylinder control means. The door has a free edge which is movable against the door frame in the closed position. When the free edge strikes an obstruction, the air cylinder opens the door.
The system also includes an active circuit connected to the air cylinder control means and including a pair of conductive ribbons. Each of the ribbons has a first and a second terminal separated by a length of ribbon. The active circuit also comprises a power source means to provide power to the active circuit and relay means having a coil, contacts, and a movable relay arm which opens and closes the contacts. The relay arm is in closed position energizing the solenoid when the relay is energized. When the solenoid is energized, the door is moved to the closed position. When the relay is de-energized, the relay opens the control circuit and de-energizes the solenoid. When the solenoid is de-energized, the air cylinder moves the door to the open position.
The door has a safety edge means attached to it which provides an electrical change when the safety edge strikes against an obstruction during closing motion of said door. The safety edge means includes the pair of electrically conductive ribbons. The ribbons are normally separated and contact each other when the safety edge strikes an obstruction, the contact of the ribbons shorting the relay coil.
It is a further feature of the present invention that the safety edge means includes an elongated flexible channel member having an open side, an outer wall and an interior cavity. The channel member has its open side attached to the free edge of the door. A diaphragm is attached to the flexible member within said cavity and a plurality of ribs within the cavity extends from the diaphragm to the flexible channel member and moves the diaphragm when the channel member strikes an obstruction. The two conductive ribbons are positioned within the cavity and on the opposite side of the diaphragm from the ribs, so that movement of the diaphragm brings the ribbons into contact and shorts the relay coil.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objectives and features of the present invention may be ascertained from the detailed description provided below, which gives the inventor's best presently known mode of practicing the invention. The detailed description should be taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a schematic diagram of an electrical circuit which is part of the safety system of the present invention;
FIG. 2 is a schematic diagram of the same electrical circuit as in FIG. 1 but showing its relay with its contacts in the closed position;
FIG. 3, a perspective view partly in cross-section, is a representation of a mechanical implementation of the safety system of the present invention in a door edge; and
FIG. 4 is a perspective view of a noise and safety enclosure which is a representation of one embodiment of the present invention, the enclosure including a vertically slidable door.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1, in accordance with the present invention, shows two electrical circuits -- a safety circuit 10 for sensing door obstructions and a solenoid operated air cylinder circuit 11 for raising the door 9 (FIGS. 3 and 4) upon contact with an obstruction.
Circuit 10 uses a magnetic core power transformer 12 for its input voltage supply; for example, it receives 110 volts at its primary and produces 24 volts at its secondary windings. Terminals 33 and 32 of the primary winding of transformer 12 are connected to external power through fuses 13A and 13B, respectively. Output terminal 30 of the secondary winding of transformer 12 is connected in series with a fuse 14, an override switch 15, a thermal switch 16, a resistor 17, and the second terminal 18B of a conductive ribbon 18.
The first terminal 18A of the conductive ribbon 18 is connected to terminal 21A of the coil 22 of an electromagnetic relay 20. Terminal 21B of the coil 22 of relay 20 is connected to the first terminal 19A of the conductive ribbon 19. The opposite and second terminal 19B of ribbon 19 is connected to grounded terminal 31 of transformer 12, thus completing safety circuit 10. The relay 20 has a controlled arm 29 as its movable element.
Resistor 17 of safety circuit 10 has a resistance value equal to, preferably, about 10% of the coil resistance in the coil of relay 20. This resistance value difference allows the relay coil 22 to receive the full circuit voltage without a large voltage drop across the resistor 17. Shorting of the ribbons 18,19 by contacting one ribbon with the other causes the circuit relay 20 to be shunted out of the circuit 10. The coil of the relay 20 is thus placed in a de-energized state. The resistor 17 of circuit 10 then picks up the shunted voltage, preventing a short circuit. The resistance of resistor 17 should be in the range of about 5-20% of the resistance of the relay coil, and preferably about 10% of that resistance. To prevent over-heating of the resistor 17 due to extended shorting or shunting of the coil 22 of the relay 20, the thermal switch 16 in safety circuit 10 will detect an over-heating of the resistor 17 and open, removing power from the resistor 17 and safety circuit 10. This feature is necessary to allow the use of a resistor 17 with a circuit handling (wattage) value within the switching capability of the ribbon switch (ribbons 18 and 19).
The solenoid operated air cylinder of the control circuit 11 of FIG. 1, for raising door 9 (FIGS. 3,4) upon contact with an obstruction, is comprised of a power source 27, shown as a d.c. battery, and a three-way solenoid 25 connected to the controlled switch contacts (terminals 23 and 24) of the relay 20.
The three-way solenoid 25 directs air to an air cylinder 26 which has an air piston 26a disposed therein. When the solenoid 25 is de-energized, a spring-loaded spool in the solenoid causes compressed air entering the solenoid to be directed to one side of the air cylinder 26, causing the door 9 to be moved to the open position. When the solenoid 25 is energized, the spool in the solenoid shifts and directs air to the opposite side of the air cylinder, causing the door to move to the closed position. When the relay 22 is de-energized because of ribbon contact due to an obstruction, or if the relay 22 is de-energized due to power failure, the spring-biased relay arm moves to the open position, thereby de-energizing the solenoid and causing the door to move to the open position. The unconnected terminal 34 of the relay 20 may be connected in series with a light and/or other status indication device to the terminals of power source 27.
FIG. 2 shows the same safety circuit 10 and air cylinder control circuit 11 as shown in FIG. 1, but with the controlled arm (movable element) 29 of relay 20 held in a closed position against relay coil 22. In other words, the relay coil is activated and the switch terminals 23,24 are closed.
FIG. 3 depicts one embodiment of a mechanical implementation utilizing the circuits of FIGS. 1 and 2, which is a perspective view partly in cross-section. The door 9 has as an end projection a flexible and resilient channel member 43, for example, of rubber or synthetic rubber. The open side of channel member 43 is mounted on the free side of the door 9, the free side being the bottom edge in a downwardly closable, vertically slidable door. The flexible channel member 43 is held semi-rigid through the plastic ribs 42 which are attached to a flexible, resilient and movable diaphragm 44. The normally open ribbon switch, comprised of the ribbons 18 and 19, is enclosed within the flexible channel member 43 and positioned between the diaphragm 44 and the edge of the door 9. The ribbons 18 and 19 are separated, for example, 0.015 inch, by either (i) spring-loaded tension along their length, i.e., between their respective first terminals 18A, 19A and the second terminals 18B, 19B; and/or (ii) thin foam washers of a minimal thickness. The minimal spacing 39 is elastic such that the ribbons 18 and 19 may be brought into contact through application of pressure, but will revert to their original position once the pressure is released.
In operation, when the free door edge meets an obstruction, such as a worker's hand or a tool left in the door frame, the flexible channel 43, when it encounters the obstruction, will bend, causing the ribs 42 to push the diaphragm 44 inwardly toward the free edge of the door 9. The inward pressure of diaphragm 44 will cause the ribbons 18 and 19 to contact, thereby shunting relay 20 and thus de-energizing the relay coil 22. The de-energization of the relay coil 22 allows the spring-biased relay arm 29 to move from terminal 23 to terminal 34. This will de-activate air cylinder control circuit 11, de-energizing solenoid 25, causing the air to drive the piston to open the door. However, once door edge 43 has cleared the obstruction, the ribbons 18 and 19 are no longer in contact and the relay 20 is no longer shunted. The relay 20 is again energized; however, a latching circuit prevents the solenoid 25 from being re-energized and closing the door again. A relatching switch must be actuated to again re-energize the solenoid 25 and allow the door to reclose.
The particular fail safe characteristic of the circuit is that, upon de-energizing the solenoid, the door will open. Thus, (i) plant electric power failure, (ii) electrical component failure, (iii) opening of override switch 15, or (iv) safety edge contact with an obstruction, will cause door 9 to open. In situations 1 to 3 the door will be opened until the failure is corrected, i.e., the replacement of the component, the restoring of power, or the closing of the switch 15. There is no danger of door damage as door opening is accomplished through an air driven piston which stops as the door reaches its fully open position. An adequate air supply is maintained to open the door, even though there may be an electrical power failure.
FIG. 4 depicts one embodiment of the mechanical implementation of the system of the present invention as applied to a machine enclosure 50. The interior walls of the enclosure 50 are padded with sound-absorbing material. The enclosure acoustically isolates a machine, located therein, from the plant when its door 51 is closed. The door 51 may be operated either vertically as shown in FIG. 4, or laterally (not shown).
The door 51 has a handle 63, which may be either recessed or surface mounted, a safety edge 53 consisting of a flexible channel attached on its open side to the free side 54 of door 51 and a sound insulated perimeter 57 sufficient to cause the enclosure 50 to be acoustically isolated upon closing of the door 51. The door 51 is vertically slidable in track 56 and closes against jamb 58. The jamb 58 has a safety edge recess 59 which accepts safety edge 53 so that the door 51 may close without compression of the safety edge 53.
A control box 60 containing a door operation switch 61 is located on the exterior of the enclosure 50. FIG. 4 also shows an obstruction 55, placed across the jamb 58 and the safety edge recess 59.
The operation of the preferred and described embodiment of the present invention is as follows: As a result of the obstruction across the jamb 58 and the safety edge recess 59, the door 51 may not be closed but rather is automatically opened. Upon contact with the obstruction the safety edge 53 compresses. As shown in FIG. 3, an inward force is transmitted to the diaphragm 44 through the ribs 42. The diaphragm 44 flexes inwardly, forcing the ribbons 18 and 19, which are normally separated by minimal spacers 39, to come into contact. The contact of ribbons 18,19 shunts relay 20. This causes the coil 22 of the relay 20 to become de-energized, thus allowing controlled switch terminals 23,24 to assume their open position.
The resistor 17 provides a voltage drop path for the shunted voltage, upon closure of the ribbons 18,19, so that the safety circuit 10 is not short-circuited. When the resistor 17 becomes heated, the thermal switch 16 opens, removing power from the resistor 17 -- if the ribbons 18,19 remain in contact for a period of time.
Once the door 9 has cleared the obstruction, the channel member 43 is no longer compressed and is no longer exerting an inward pressure on the diaphragm 44 through ribs 42. The ribbons 18 and 19 are no longer under pressure and will revert to their original spacing, thus removing the shunt to the relay 20. The coil 22 is energized, causing the controlled switch arm to contact terminal 23, closing the circuit 11. However, the latching circuit (not shown) prevents the solenoid 25 from being re-energized and reclosing the door. A relatching switch must be actuated to re-energize the solenoid 25.
The term "door" as used herein is intended broadly to cover various types of portals such as horizontal or vertical slidable hoods.
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A door has a flexible channel along its free edge which flexes upon striking an obstruction and brings together two conductive ribbons within the channel. The ribbons are part of an active circuit which includes a relay coil. Temporary contact of the two conductive ribbons resulting from contact with the obstruction de-energizes the relay coil, fully opening the door. Since door opening results from de-energizing a coil, a power or circuit failure will also cause the door to open.
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FIELD OF THE INVENTION
[0001] The field of the invention is subterranean tools and more particularly tools that release hydraulically with a backup protected shear release that further provides a soft release to avoid damaging components in the shear release alternative.
BACKGROUND OF THE INVENTION
[0002] Frequently an upper string needs to be anchored to a packer to support tools on the string such as an electric submersible pump. Such tools block access below the packer and on some occasions need to be removed from the wellbore for maintenance. Typically the packer has an associated barrier valve that needs to be closed when the upper completion is released from the packer. To hold the upper completion to the packer generally in a polished bore receptacle an anchor or disconnect is used. There are several concerns with such applications that are run in together attached to the packer. There is the concern of an unintentional disconnection such as when setting the packer with internal pressure or when trying to get the assembly to advance to the desired location. In tools that disconnect with an applied force to break a shear pin there is also a concern that the stretch in the string at the time of release would provide a violent ricochet and damage some of the parts such as the actuator attached to the packer barrier valve.
[0003] Tools that release with the breaking of a shear pin or the flattening of a stack of Belleville washers are known for example in U.S. Pat. No. 6,053,262. Some tools replace collets and shear pins in a disconnect to gain full circumferential support in a locked position as in U.S. Pat. No. 7,426,964.
[0004] Devices have been used to reduce shock in the context of dropped tools that have a crushable nose as in U.S. Pat. No. 7,779,907 while others allow a controlled release of parts in a manner to avoid damage to the parts using a multi-dimensional pin in a bore that allows pulling to get a surface signal of landing in a casing collar before sufficient pin movement in the bore to allow a reduction of applied surface force before any release of components. This device is illustrated in US Publication 2011/0056678. U.S. Pat. No. 6,367,552 shows a travel joint that is held together until applied force meters fluid through an orifice to then permit enough relative movement to unlock the travel joint components for relative movement.
[0005] What is lacking in these tools is options for the release that also address in the space limitations of subterranean tools a way to control which release mode is operative at any given time and the ability to minimize damage to associated components when the release would otherwise be violent such as breaking one or more shear pins with a release force applied to a string. The present invention provides hydraulic release or actuation as the primary mode of operation. When operating in this mode the shear release mechanism can be protected from stress from forces applied to the string. Optionally the locking feature that protects the shear device can be disabled for normal operation of the tool with the packer set. If for any reason the manipulation of hydraulic pressure in the control line to the tool does not permit a release by a simple pull on the string a shear device is broken but with travel limited so that disconnection does not occur. Instead a shock absorbing member provides the needed relative movement for defeating the shear member while absorbing the shock of the release. Reversing the relative movement then releases fully two adjacent components so that collets can be undermined for a low force separation that will not harm the barrier valve actuation system that is still engaged to the anchor or disconnect as the upper sting comes out of the hole. While one application is described those skilled in the art will appreciate that other tools can benefit from the described designs in the description of the preferred embodiment and the associated drawings while recognizing that the full scope of the invention is to be determined from the appended claims.
SUMMARY OF THE INVENTION
[0006] A subterranean tool can be actuated with one or more control lines for a hydraulic release. It can further be actuated with a shear release after a lockout feature for the shear release is defeated. The shear release features a lock that limits relative movement so that a shear member can be defeated but without a release. What limits the relative movement is a dog in a wider groove where dog movement in the groove allows a shock absorbing feature to act to cushion the release as the shear member breaks. The shock absorber can be a crushable ring of a soft metal. The relative movement is reversed to let a retaining ring drop out of the way into a groove that comes into alignment with it. The relative movement is reversed again to pull a sleeve out from under gripping collets that have previously failed to release and the tool releases from that point on the same way as the control line actuated release.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1A is a schematic view of the anchor connected to a packer with the packer in the set position;
[0008] FIG. 1B is the view of FIG. 1 showing the upper string with any attached tool coming out as the anchor is released;
[0009] FIG. 2 is a detailed section view of the anchor in the run in position;
[0010] FIG. 3A shows applied control line pressure to the view of FIG. 2 and before parts start moving;
[0011] FIG. 3B is the view of FIG. 3A after the pistons have shifted left to unsupport the locking dogs;
[0012] FIG. 3C is the view of FIG. 3B with the pistons shifted right to disable the primary piston as a result of removal of control line pressure, which fully disables the lockout for the shear ring and positions the secondary piston to allow a release on subsequent pressure applied to the control line;
[0013] FIG. 4A shows the application of hydraulic pressure to unsupport the collets for a normal hydraulic release;
[0014] FIG. 4B is the view of FIG. 4A showing a pulling force applied to get the components to release;
[0015] FIGS. 5A-5C show again the movements in FIGS. 3A-3C but this time the collets are still supported in FIG. 5C and a shear release becomes necessary;
[0016] FIG. 6A shows an applied force after a failure of the hydraulic release as a way of initiating the shear release;
[0017] FIG. 6B shows the shear ring broken due to relative movement but with the collets still supported and the shock absorber taking the shock of the breaking of the shear ring within the limits of travel of a lock ring in a lock ring groove;
[0018] FIG. 6C shows a reversal of relative movement to let the lock ring drop into a groove to free up the latch body from the release sleeve;
[0019] FIG. 6D shows an applied tensile force to start the separation from the polished bore receptacle;
[0020] FIG. 6E shows further movement beyond the position in FIG. 6D toward a separation; and
[0021] FIG. 7 is the view of FIG. 6E showing more of the tool in the same position as the tool is shown in FIG. 6E .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0022] Referring to FIGS. 1 and 2 , a packer 10 is schematically illustrated in the set position against a wellbore wall or surrounding tubular 12 . A barrier valve or formation isolation valve 14 is located below the packer 10 and a polished bore receptacle 16 is above the packer mandrel 18 . A tool such as an electric submersible pump 20 is supported by string 22 . The preferred embodiment of the present invention is an anchor 24 that is secured to the polished bore receptacle 16 and selectively released in one of the described modes below with operation of the hydraulic system shown in this view schematically as a control line 26 . FIG. 2 shows that separation can be accomplished so that the tool 20 can come out with the string 22 while at the same time the formation isolation valve 14 is closed to isolate zone 28 as a result of the polished bore receptacle 16 being open when the tool 20 is removed. Although the invention will be described in the context of the preferred embodiment of an anchor, that is only by way of example as other tools can benefit from the described systems below and the manner that they are assembled and operated.
[0023] The details of the anchor assembly 24 are better seen in FIG. 2 . Mandrel 30 has a through passage 32 and a lower end 34 with an external seal 36 against the polished bore receptacle 16 . An inner sleeve 38 supports one or more dogs 40 that extend into a groove 42 in an outer sleeve 44 . Mandrel 30 has an outer wall that defines an annular space 46 in which sits a collet ring 48 with a series of extending fingers capped by heads 50 that have a grip surface 52 that engages grip surface 54 at the upper end of the polished bore receptacle 16 . For run in a support dog or dogs 56 is axially sandwiched between rings 58 and 60 . Rings 58 and 60 are mechanically connected to mandrel 30 . Ring 58 can slide with inner sleeve 38 and ring 60 is secured to outer sleeve 44 . Outer sleeve 44 is held in position at end 62 by the polished bore receptacle 16 and at end 64 by heads 50 that are held fixed to the grip surface 54 of the polished bore receptacle 16 by virtue of the underlying support collet or ring 56 that is in turn supported by inner sleeve 38 . A shear ring or some other breakable member 66 extends between mandrel 30 and outer sleeve 44 . In the FIG. 2 position mandrel 30 cannot move up in the direction of arrow 68 because the dogs 40 are supported in groove 42 of the outer sleeve 44 by the inner sleeve 38 . Ring 70 sits in groove 72 that is axially wider than ring 70 . A shock absorber 74 is adjacent ring 70 . The purpose of ring 70 in wider groove 72 is to allow enough axial mandrel 30 movement when the dogs 40 are allowed out of groove 42 by initial sliding of inner sleeve 38 and an upward pull on the mandrel 30 in the direction of arrow 68 as will be explained more fully below.
[0024] An upper chamber 76 is separated from annular space 46 by a seal 78 . Primary piston 80 is preferably 1-shaped and has a travel stop surface 82 and opposed seals 84 and 86 . Seal 86 rides in bore 88 and seal 84 rides on inner sleeve 38 to define a sealed sub-chamber 90 with seal 78 . A control line 92 is used to selectively pressurize and to remove pressure from sub-chamber 90 . A secondary piston 94 has seals 96 and 98 in bore 88 . Seal 98 is against the bore 88 and seal 96 is against the inner sleeve 38 . Both pistons 80 and 94 are annular pistons. A return rod 100 is held in the position shown during run in against the force of a spring 104 by a latch 102 . As will be explained below, release of the latch 102 will allow the spring 104 to push the return rod 100 against the primary piston 80 to a point where seal 86 will come out of bore 88 to effectively disable the piston 80 from moving in response to another pressure application in the control line 92 .
[0025] The basic components of the apparatus now having been described the normal hydraulic release feature will now be described in more detail. FIG. 3A shows the parts in the same run in position of FIG. 2 and now in half section for greater clarity. Pressure is applied to control line 92 in FIG. 3B . This makes chamber 90 volume increase as primary and secondary pistons 80 and 98 move in tandem in the direction of arrow 68 . Secondary piston 94 shoulders against the inner sleeve 38 and makes inner sleeve 38 also move in the direction of arrow 68 . Such movement of inner sleeve 38 takes inner sleeve 38 out from under the dogs 40 allowing the dogs to fall into groove 106 now made available to the dogs 40 by the movement of the inner sleeve 38 . This movement is essentially the unlocking of a lock that now frees the mandrel 30 to move relative to the outer sleeve 44 but such movement does not take place merely by adding pressure to control line 92 . Rather a shear release that comprises breaking ring 66 is enabled in FIG. 3B but it does not occur. As long as pressure is held in control line 92 the parts will hold the FIG. 3B position. Included in the FIG. 3B movements is the movement of the latch 102 to a position to allow the spring 104 to move the return rod 100 when pressure in line 92 is relieved from the surface. It is also worth noting that the heads 50 continue to be supported for a grip onto the polished bore receptacle 16 by virtue of the fact that the position of the collet or ring support 56 has not shifted despite the axial movement of the inner sleeve 38 . In FIG. 3C the pressure in the control line 92 is released and the spring 104 takes the rod 100 against surface 82 of piston 80 so that piston 80 bottoms out on stop 106 as seal 86 comes out of bore 88 . The pushing back of piston 80 takes piston 94 with it because the two are liquid locked in bore 88 and move in tandem. Optionally chamber 76 can be open to annulus pressure that can assist in the return motion of pistons 80 and 98 . Again support 56 has not moved in FIG. 3C and the grip to the polished bore receptacle 16 is still maintained.
[0026] Referring now to FIG. 4A the pressure is again applied to control line 92 . This time piston 80 is unaffected by this pressure as one of its seals 86 is out of bore 88 . Now pressure just drives piston 94 that again takes with it the inner sleeve 38 but this time the motion is not curtailed by stop surface 82 now held back by rod 100 using spring 104 . Now piston 94 takes inner sleeve 38 in the direction of arrow 68 a distance great enough to allow the collets or ring support 56 to fall against the mandrel 30 and remove the supports for the heads 50 so that an upward pull on the mandrel 30 in the direction of arrow 68 as shown by FIG. 4B will allow the heads 50 to come away from grip surface 54 and the mandrel 30 will now exit the polished bore receptacle 16 .
[0027] FIGS. 5A-5C are essentially the same as FIGS. 3A-3C except that now when pressure is applied to control line 92 for a second time the piston 94 fails to move the inner sleeve 38 to the point where the support 56 is undermined by the sliding of inner sleeve 38 such as happened in FIG. 4A . This can happen for example if one or both of the seals 96 or 98 on piston 94 fail. As a result a mere pulling on the mandrel 30 in the direction of arrow will not work as the heads 50 continue to be firmly held against grip surface 54 of the polished bore receptacle 16 . When this happens, the release with hydraulic pressure into control line 92 is inoperative and the backup mode of release with a tension force on mandrel 30 has to be deployed.
[0028] Referring to FIG. 6A ring 70 is in groove 72 that is shown as axially longer than ring 70 . At this time the dogs 40 have dropped out of groove 42 due to earlier sliding action of inner sleeve 38 . The shear ring 66 is intact. Because ring 70 is narrower than groove 72 a pull on the mandrel 30 with heads 50 secured to the polished bore receptacle 16 will result in the breaking of the shear ring 66 as ring 70 moves from one side of groove 72 to the other. The placement of the shock absorber 62 is such that the mandrel 30 to keep moving in direction of arrow 106 has to operate the shock absorber. In essence the mandrel 30 continues to be retained in the polished bore receptacle 16 after ring 66 is sheared and as the shock absorber 62 is operating. The shock absorber 62 can be in the form of a soft ring preferably metallic that is crushed with the relative movement of the mandrel 30 with respect to the polished bore receptacle 16 . The shock absorber 62 can be a stack of Belleville washers, a chamber forcing fluid out through an orifice, some other kind of spring, for example and not by way of limitation. The point is that the initial mandrel 30 movement that broke the shear ring 66 and activated the shock absorber 62 will not as yet release mandrel 30 from receptacle 16 because the heads 50 are still supported by support ring or collet 56 , but it will allow the released force from the breaking of the shear ring 66 to be dissipated by the shock absorber 62 so that there is no slingshot effect from the breaking of the shear ring 66 . Note that support 56 is still under the heads 50 in FIG. 6B .
[0029] When the movement of the mandrel 30 is reversed to the direction of arrow 108 as in FIG. 6C the lock ring 70 can fall out of groove 72 and fall into groove 110 that presents itself in alignment due to the setting down weight on mandrel 30 which moved mandrel 30 in the direction of arrow 108 until travel stop 113 is engaged by mandrel 30 . With ring 70 now in groove 110 the mandrel 30 can be picked up again in the direction of arrow 106 . Note that at this time the ring 60 is not retained by outer sleeve 40 because as shown in FIG. 6C groove 42 is over the heads 112 . By friction between the parts the movement of the mandrel 30 and with it inner sleeve 38 will take with it support 56 and rings 58 and 60 so that support 56 is out from under heads 50 by the time the outer sleeve 40 shoulders out at end 62 against the polished bore receptacle 16 . From that point further mandrel 30 movement causes outer sleeve 40 to bump heads 50 and deflect them inwardly now that support 56 has been axially displaced. This is shown in FIG. 6E in close up and the whole assembly in the FIG. 6E position is shown again in FIG. 7 .
[0030] Those skilled in the art will appreciate that what has been described is a tool with dual modes of operation. The first or preferred mode involves hydraulic system actuation. The hydraulic system sequentially moves an inner sleeve 38 in the same direction to initially unlock a lock by letting dogs 42 drop so as to enable a shear release without actually shearing the ring 66 . This sequential movement is accomplished with dual pistons that move together to a travel stop to let the dogs 42 drop and then in another pressure cycle in the hydraulic system which has the effect of disabling the primary piston uses the secondary piston to move the sleeve 38 and even greater distance in the same direction to allow support collet or ring 56 to drop to the mandrel 30 so that a pull on the mandrel 30 results in a flexing of heads 50 and a separation from the polished bore receptacle 16 .
[0031] Dogs 42 are a lock to prevent loading on shear ring 66 during run in and setting of the packer 10 . The shear ring 66 can be used for a backup release in the event the hydraulic system cannot get the support 56 away from the heads 50 for a release from receptacle 16 . Here there is available relative movement between the mandrel 30 and the outer sleeve 40 into which the shear ring 66 extends to allow the ring 66 to break but to prevent the sudden release from the breaking of ring 66 to create a slingshot effect that can for example damage an actuator (not shown) that is connected from mandrel 30 to the barrier valve 14 . Movement of the mandrel in a first direction that breaks the shear ring 66 and actuates the shock absorber 74 does not remove support 56 from heads 50 so that the tool stays attached to the receptacle 16 . Instead the outer sleeve 40 that retains the ring 70 makes the shock absorber 74 actuate until all movement stops. The mandrel 30 has to be moved in the opposite direction to drop the ring 70 out of groove 72 and into mandrel 30 groove 110 so that the mandrel 30 can move up and reposition support 56 away from heads 50 to release from receptacle 16 . Further raising of the mandrel 30 shoulders the outer sleeve 40 and uses sleeve 40 to deflect heads 50 inwardly so that the mandrel 30 will come clear of the receptacle 16 .
[0032] While the invention is described in the form of an anchor with two modes of release the invention is applicable to other downhole tools that operate from a first to a second position and get there in more than one way such as hydraulically and mechanically using a shear release but avoiding the slingshot effect that can damage other parts. The locking feature is enabled for operation and can be defeated to enable a shear release without actually shear releasing. If the hydraulic system fails to release and the locking feature has been earlier disabled then a sequence of opposed mandrel 30 movements will actuate the shear ring breaking and the shock absorber actuating while the tool is still in its initial position. After then setting down weight and picking up there will be a release or a movement of the tool to the second position.
[0033] The above description is illustrative of the preferred embodiment and many modifications may be made by those skilled in the art without departing from the invention whose scope is to be determined from the literal and equivalent scope of the claims below:
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A subterranean tool can be actuated with one or more control lines for a hydraulic release. It can further be actuated with a shear release after a lockout feature for the shear release is defeated. The shear release features a lock that limits relative movement so that a shear member can be defeated but without a release. A dog limits relative movement in a wider groove where dog movement in the groove allows a shock absorbing feature to act to cushion the release as the shear member breaks. The relative movement is reversed to let a retaining ring drop out of the way into a groove that comes into alignment with it. The relative movement is reversed again to pull a sleeve out from under gripping collets that have previously failed to release and the tool releases from that point on the same way as the control line actuated release.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. provisional patent application 61/442,374 filed Feb. 14, 2011 and hereby incorporated by reference.
FIELD OF THE INVENTION
The present invention relates to a method of straightening a foundational wall and in particular for use in the repair and reinforcement of basement walls comprised of blocks or other materials.
BACKGROUND OF THE INVENTION
Below ground walls, such as those which provide for the walls of the basement, must be able to support the weight of a structure resting thereon and to resist lateral forces associated with the surrounding soil and hydrostatic pressure from water in the soil.
Particularly when a basement wall is constructed of masonry block, lateral pressure may cause the wall to deflect inwardly and cracks to appear on the inner surface of the wall as mortar joints yield to a tensile force component. If such deflection continues unabated, the entire wall may buckle and collapse with damage to the supporting structure.
A number of methods of straightening walls experiencing initial stages of deflection employ applying a counterbalancing force on the inner surface of the basement wall by means of cables or a threaded rod passing from a plate on the inner surface of the basement wall through the wall and anchored at a position outside the wall, for example, in a trench. Tightening the cable or threaded rod may then pull the wall back into alignment. A system of this type is taught by U.S. Pat. No. 4,189,891.
In a different approach, U.S. Pat. No. 4,353,194 teaches applying force by means of an ellis jack braced between the floor of the basement and the wall suffering from deflection.
SUMMARY OF THE INVENTION
The present invention provides an improved method of straightening walls that coordinates multiple jacks simultaneously with monitoring of the wall alignment during the jacking operation. In this way, a faster and more uniform straightening process may be obtained, the latter minimizing wall damage. Further, the wall may be straightened substantially immediately, and not over a lengthy period of time as required of other more gradual processes.
Other features and advantages of the invention will become apparent to those skilled in the art upon review of the following detailed description, claims and drawings in which like numerals are used to designate like features.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view of a hydraulic jack mounted on a fixture for attachment to a concrete slab basement floor in one embodiment of the invention;
FIG. 2 is a side elevational view of the hydraulic jack of claim 1 positioned with a bracing system against a foundational wall shown in cross-section;
FIG. 3 is a top plan view of multiple braces of FIG. 2 , each with a hydraulic jack;
FIG. 4 is a fragmentary elevational view showing the interconnection of an electronic level-sensor to a control valve of the hydraulic cylinder of FIG. 1 ;
FIG. 5 is a figure similar to that of FIG. 4 showing an alternative mechanical implementation of the present invention;
FIG. 6 is a plot of data that may be sensed by the level-sensor of FIG. 4 to control hydraulic fluid gated to the cylinders to minimize wall damage;
FIG. 7 is a perspective view of a foot bracket used to prevent push-out of the basement wall near the floor.
Before the embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. The use of “including” and “comprising” and variations thereof is meant to encompass the items listed thereafter and equivalents thereof as well as additional items and equivalents thereof.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 1 , a hydraulic cylinder 10 of the type known in the art may receive hydraulic fluid through electronically controllable valve 12 from hydraulic hose 14 . As is understood in the art, hydraulic cylinders provide for an enclosed chamber that may be pressurized with a hydraulic fluid to apply force to a shaft communicating with the enclosed chamber through a piston or the like.
The hydraulic cylinder 10 may provide for a piston driven shaft 15 having a portion extending from an end of the hydraulic cylinder 10 along an axis 16 tipped at approximately 45 degrees with respect to a plane of the floor 20 on which the hydraulic cylinder 10 rests. The end of the shaft 15 may connect with one end of a diagonal brace 22 also extending along the axis 16 .
A base of a hydraulic cylinder 10 may be attached to and supported by a bracket 24 orienting the shaft 15 along axis 16 , for example, the bracket 24 being fabricated of welded steel plate having a base plate 26 that may rest against the floor 20 with holes receiving anchor screws 28 or the like therethrough to anchor the bracket 24 to the floor 20 . The bracket 24 further provides an angled steel plate against which the base of the hydraulic cylinder 10 may rest so that the piston driven shaft 15 extends along the axis 16 . In an alternative embodiment, (not shown) the bracket 24 may provide a hinge plate allowing flexible adjustment of the angle of the base of the hydraulic cylinder 10 as required.
Referring now to FIG. 2 , the diagonal brace 22 may extend toward a basement wall 30 and be aligned to abut at a hinge 23 an upright brace 32 between the ends of the upright brace 32 . The upright brace 32 may fit against an inner surface of the wall 30 extending approximately vertically by about four feet so that pressure can be directed to a specific spot on the wall 30 . The position of the upright brace 32 is moved up or down the wall 30 depending on where the deflection is. For example, if the wall 30 is bowed at the center then that is where the center of the upright brace is located, if the wall 30 is tipped but essentially flat, then the upright brace is put as high as possible. In the case of severely bowed walls, this fitting against the inner surface may only contact portions of the inner surface. The lower end of the upright brace 32 will generally be above the floor 20 . The diagonal brace 22 and the upright brace 32 may be, for example, rectangular steel pipes or other steel shape including angles, tubes, or I-beams . . . .
Referring now to FIG. 7 , the foot bracket 39 may provide for an L-shaped bracket having a first face that may be attached to the floor 20 with anchor bolts and a second face extending vertically therefrom adjacent to the wall 30 to be anchored thereto. The foot bracket 39 prevents the base of the wall 30 from separating from the floor 20 and moving outward as the wall 30 is straightened. A similar top bracket may be used when it is desired to prevent movement of the top of the wall 30 with respect to the house joists.
Soil 34 outside of the wall 30 may be excavated to provide for a trench 36 on the outside of the wall 30 allowing the wall 30 to be pushed outward into alignment. This trenching operation may be used to replace a drain 33 placed at the bottom of the trench 36 .
A tilt sensor 37 may be attached to the top of the upright brace 32 (or other convenient location) to provide an indication of whether the brace 32 is level and/or to detect movement or acceleration of the top of the upright brace 32 . Typically before the straightening process, the brace 32 will not be vertical but will lean toward the cylinder 10 caused by inward deflection of the wall 30 .
Referring now to FIG. 3 , multiple brace systems comprised each of a cylinder 10 , a diagonal brace 22 , and an upright brace 32 (here shown as cylinders 10 a - d , diagonal braces 22 a - d , and upright braces 32 a - d ) may be simultaneously applied against the wall 30 with the cylinders 10 a - d connected to a common hydraulic pressure source 40 , for example an electric pump.
Referring now to FIG. 4 , in a first embodiment, an electronic control system 42 , for example a microcontroller or programmable logic controller, may receive a signal from tilt sensor 37 , for example a mercury switch, a pendulum and angle sensor (for example a potentiometer) combination, or a solid-state accelerometer, providing an indication of the vertical orientation of the upright brace 32 . In the case of the accelerometer, an angular deviation of a gravitational vector from the axis of the upright brace 32 may be determined as well as acceleration of the top of the upright brace 32 . It will further be appreciated that the indication of vertical orientation of the upright brace may be detected by measuring displacement of the shaft 15 (using a displacement sensor) and trigonometric formulae, for example using known positioning of the bracket 24 with respect to a base of the wall and the height of the hinge 23 .
The electronic control system 42 also provides electrical signals controlling valves 12 , one for each cylinder 10 a - d . Generally, during operation, the electronic control system 42 may, in a first embodiment, allow all valves 12 to be open and the cylinders 10 a - d to extend their shafts 15 outward to press upward on the brace 22 straightening the wall until a signal from the tilt sensor 37 of any upright brace 32 indicates that the upright brace 32 is vertical at which time the electronic control system 42 may shut the valve 12 associated with that upright brace 32 only. In this way each of the brace systems of FIG. 3 may operate simultaneously to bring the wall back into alignment.
Referring now to FIG. 6 , the ability to monitor the orientation of the braces 32 permits more sophisticated control strategies where a most out of alignment section of the wall 30 , indicated by signal 50 a from a tilt sensor 37 , is moved first during time terminating at t 1 and the other sections of the walls indicated by signals 50 b - c from corresponding tilt sensors 37 are moved only after time t 1 is passed. Upon completion of time t 1 , the other sections of the wall may be moved, for example the upright brace 32 associated with signal 50 b being moved after time t 1 , and the upright brace 32 associated with signal 50 c being moved after time t 2 is complete, and the upright brace 32 associated with signal 50 d being moved after time t 3 is complete. Using this technique, the amount of distortion of the wall 30 during this alignment may be significantly reduced thereby reducing additional damage from the alignment process.
Another possible control strategy moves the upright braces 32 at substantially constant angular rates that are different in proportion to the misalignment of the wall associated with that upward brace so that all upward braces move to reach alignment with vertical at substantially the same time.
It will be appreciated that even more sophisticated control algorithms may be developed that look at acceleration to control the valves 12 to reduce or warn of sudden acceleration, or that detect overcenter travel where the wall moves beyond vertical to provide warnings of this situation, or that monitor pressure differentials using pressure gauges (not shown) on each hydraulic hose 14 .
Referring now to FIG. 5 , the present invention contemplates that the sensing of the orientation of the upright braces 32 may be performed mechanically, for example, by attaching a pivot point 60 to the upper end of the upright brace 32 communicating via tie arm 62 to a lever-operated valve 12 ′ with a turnbuckle or other length adjusting mechanism used to cause movement of the upright brace 32 to shut off the valve 12 when the upright brace 32 is in the vertical position. In this case, the tie arm 62 provides a tilt sensor based on a known geometry of the system.
It will also be appreciated that the hydraulic cylinders may be replaced with, for example, electric screw jacks or the like. Further, it will be understood that the present invention is applicable to a wide variety of different types of walls beyond the block walls depicted but also including poured walls.
Certain terminology is used herein for purposes of reference only, and thus is not intended to be limiting. For example, terms such as “upper”, “lower”, “above”, and “below” refer to directions in the drawings to which reference is made. Terms such as “left”, “right”, “front”, “back”, “rear”, “bottom” and “side”, describe the orientation of portions of the component within a consistent but arbitrary frame of reference which is made clear by reference to the text and the associated drawings describing the component under discussion. Such terminology may include the words specifically mentioned above, derivatives thereof, and words of similar import. Similarly, the terms “first”, “second” and other such numerical terms referring to structures do not imply a sequence, or order unless clearly indicated by the context.
References to an electronic control system can be understood to include one or more processors that can communicate in a stand-alone and/or a distributed environment(s), and can thus be configured to communicate via wired or wireless communications with other processors, where such one or more processor can be configured to operate on one or more processor-controlled devices that can be similar or different devices.
When introducing elements or features of the present disclosure and the exemplary embodiments, the articles “a”, “an”, “the” and “said” are intended to mean that there are one or more of such elements or features. The terms “comprising”, “including” and “having” are intended to be inclusive and mean that there may be additional elements or features other than those specifically noted. It is further to be understood that the method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed.
Various features of the invention are set forth in the following claims. It should be understood that the invention is not limited in its application to the details of construction and arrangements of the components set forth herein. The invention is capable of other embodiments and of being practiced or carried out in various ways. Variations and modifications of the foregoing are within the scope of the present invention. It also being understood that the invention disclosed and defined herein extends to all alternative combinations of two or more of the individual features mentioned or evident from the text and/or drawings. All of these different combinations constitute various alternative aspects of the present invention. The embodiments described herein explain the best modes known for practicing the invention and will enable others skilled in the art to utilize the invention.
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A wall straightening apparatus provides multiple independently controllable jacking members pressing outward on diagonal braces to push those braces against the wall to move the wall into a vertical alignment. Feedback control of the jacking members provides coordinated straightening of large wall sections with lessened cracking and distortion.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a valve assembly for use in a wellbore. More particularly, the invention relates to a valve assembly that allows fluid flow to pass through the valve in either direction. More particularly still, the invention relates to a dual purpose valve assembly for controlling the fluid flow during installation of a casing in a wellbore and subsequently for use as float equipment to facilitate the injection of zonal isolation fluids.
2. Description of the Related Art
Hydrocarbon wells are conventionally formed one section at a time. Typically, a first section of wellbore is drilled in the earth to a predetermined depth. Thereafter, that section is lined with a tubular string, or casing, to prevent cave-in. After the first section of the well is completed, another section of well is drilled and subsequently lined with its own string of tubulars, comprised of casing or liner. Each time a section of wellbore is completed and a section of tubulars is installed in the wellbore, the tubular is typically anchored into the wellbore through the use of a wellbore zonal isolation fluid, like cement. Zonal isolation includes the injection of cement into an annular area formed between the exterior of the tubular string and the borehole in the earth therearound. Zonal isolation protects the integrity of the wellbore and is especially useful to prevent migration of hydrocarbons towards the surface of the well via the annulus.
Zonal isolation methods of string are well known in the art. Typically, the cement fluid is pumped down in the tubular and then forced up the annular area toward the surface. By using a different fluid above a column of the cement, the annulus can be completely filed with cement while the wellbore is substantially free of cement. Any cured cement remaining in the wellbore is drillable and is easily destroyed by subsequent drilling to form the next section of wellbore.
Float shoes and float collars facilitate the cementing of tubular strings in a wellbore. In this specification, a float shoe is a valve-containing apparatus disposed at or near the lower end of the tubular string to be cemented into in a wellbore. A float collar is a valve-containing apparatus that is installed at some predetermined location, typically above a shoe within the tubular string. In certain cases, float collars are required rather than float shoes. However, in this specification, the term float shoe and float collar will be used interchangeably.
The main purpose of a float shoe is to facilitate the passage of cement from the tubular to the annulus of the well while preventing the cement from returning or “u-tubing” back into the tubular due to gravity and fluid density of the liquid zonal isolation fluids. In its most basic form, the float shoe includes a one-way valve permitting fluid to flow in one direction through the valve, but preventing fluid from flowing back into the tubular from the opposite direction. The float shoes usually include a cone-shaped nose to prevent binding of the tubular string during run-in.
Typically, wellbores are full of fluid to protect the drilled formation of the borehole and aid in carrying out cuttings created by a drill bit. When a new string of tubulars is inserted into the wellbore, the tubulars must necessarily be filled with fluid to avoid buoyancy and equalize pressures between the inside and the outside of the tubular. For these reasons, a float shoe should have the capability to temporarily permit fluid to flow inwards from the wellbore as the tubular string is run into the wellbore and fills the tubular string with fluid. In one simple example, a springloaded, normally closed, one-way valve in a float shoe is temporarily propped in an open position during run-in of the tubular by a drillable object, which is thereafter destroyed and no longer affects the operation of the valve.
Other, more sophisticated solutions have been the use of a differential fill valve. The differential fill valve allows filling of the tubular and circulation by utilizing the differential pressure between the inner and the outer annulus of the tubular. Typically, the prior art differential fill valve comprises a first and second flapper valve and a sleeve. The flapper valves are bias closed by a spring. The sleeve is secured in place by shear pins and is shiftable from a first to a second position. In operation, the differential fill valve is disposed on the end of the first string of tubular then inserted into the wellbore. During run-in the sleeve is in the first position, which prevents the second flapper valve from operating. As subsequent strings of tubulars are inserted into the wellbore the first flapper valve in the differential flow valve opens and closes based upon the differential pressure, thereby allowing wellbore fluid to enter the tubular string. The volume of wellbore fluid entering the tubular string is predetermined to achieve a differential height between the wellbore fluid inside the tubular annulus and the wellbore fluid outside the tubular. The amount of fluid entering the tubular through the flapper valve is controlled by a spring selected to bias the first flapper valve closed. The process of allowing a predetermined volume to enter the tubular is what is commonly called in the industry as differentially filling the tubular.
After the entire string of tubulars is disposed downhole, the differential fill capability of the valve is deactivated to change the valve into a one-way check valve. Typically, deactivation is accomplished by dropping a weighted ball from the surface down the wellbore either by free-fall or pumped in by a fluid mechanism allowing the ball to land into the sleeve. At a predetermined pressure the pins that secure the sleeve in the first position shear and the sleeve is shifted axially downward to a second position. In the second position, the sleeve closes the first flapper valve and subsequently allows the second flapper valve to operate. The deactivated differential fill valve functions as a standard float valve as described in the above paragraphs.
There are several problems associated with the prior art devices. One problem occurs while dropping the weighted ball to deactivate the differential fill feature in a deviated wellbore (deviations greater than 30 degrees from vertical). Typically, the ball is allowed to drop free-fall or pumped into a ball seat located in a sleeve. After the ball lands in the ball seat, drilling fluid is pressurized to act against the ball seat to shift the sleeve to a second position, thereby allowing a permanent check valve mechanism to engage. The reliability of actuating balls in a deviated wellbore greater than 30 degrees decreases as the deviation increases. Additionally, actuating balls in a horizontal, or near horizontal (70 to 90 degrees) well become ineffective in performing their required function, which leads to an inoperable downhole tool.
Another problem associated with the prior art devices arises when the tool is no longer needed to facilitate the injection of cement and must be removed from the wellbore. Rather than de-actuate the tool and bring it to the surface of the well, the tool is typically destroyed with a rotating milling or drilling device. Generally, the tool is “drilled up” or reduced to small pieces that are either washed out of the wellbore or simply left at the bottom of the wellbore. As in the case with the prior art devices that comprise of many metallic components numerous trips in and out of the wellbore are required to replace worn out mills or drill bits. This process is time consuming and results in lost productivity time.
Another problem with the prior art devices is the inability to operate in high downhole pressures and temperatures. Typically, as the depth of the wellbore increases both downhole pressure and temperature also increase. The prior art devices having a flapper valve design cannot operate effectively in pressures in excess of 3,000 PSI. Additionally, the prior art devices cannot function properly in downhole temperatures in excess of 300° F.
There is a need for a plunger-type check valve that can operate effectively in deviated wells or nearly horizontal wells. There is a further need for a plunger-type check valve that is made of composite components, thereby minimizing milling operation time upon removal of a valve and subsequently reduce the wear and tear on the drill bit. There is yet a further need for a plunger-type check valve that can operate effectively in high downhole pressures and high temperatures.
SUMMARY OF THE INVENTION
The present invention generally relates to a plunger-type valve for use in a wellbore. In one aspect, the plunger type check valve can operate effectively in deviated or nearly horizontal wells. In another aspect, the plunger-type check valve is made out of composite components, thereby minimizing milling operation time upon removal of a valve and subsequently reduce the wear and tear on the drill bit. In yet another aspect, the plunger-type check valve can operate effectively in high downhole pressures and high temperatures.
The plunger-type valve is arranged to selectively allow fluid to enter and exit the valve in both directions. The invention includes a body, at least one locking segment, a locking sleeve, at least one biasing member, a valve seat, and a plunger. In one direction, fluid enters an upper end of the body of the valve and urges the plunger downward, thereby allowing the fluid to exit the bottom of the valve body. In another direction, fluid enters the bottom of the valve body and urges the seat upwards, thereby allowing the fluid to flow to the upper end of the valve body.
In another aspect, the plunger-type valve may be deactivated to selectively allow fluid to flow in only one direction. At a predetermined maximum flow rate, the locking sleeve and the valve seat is urged axially downward. The locking segment moves radially inward to secure the locking sleeve in a fixed position. In turn, the valve seat moves axially downward to a predetermined point in the body. In this manner, both the locking sleeve and valve seat are restricted from axial movement. Consequently, fluid may only enter the top of the valve body and exit the bottom of the valve body by urging the plunger downward.
BRIEF DESCRIPTION OF THE DRAWINGS
So that the manner in which the above recited features and advantages of the present invention are attained and can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to the embodiments thereof which are illustrated in the appended drawings.
It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
FIG. 1 is a longitudinal cross-sectional view of one embodiment of a valve assembly at an end of a tubular in accordance with the present invention.
FIG. 2 is an enlarged cross-sectional view of the valve assembly in FIG. 1 .
FIG. 3 is a cross-sectional view of the valve assembly as the differential pressure moves the valve seat from the plunger to permit fluid to flow from the lower end to the upper end of the valve assembly.
FIG. 4 is a cross-sectional view of a valve assembly pumping fluid through the valve assembly without disengaging the differential fill feature.
FIG. 5 is a cross-sectional view of the valve assembly pumping fluid at a maximum flow rate to deactivate the differential fill feature.
FIG. 6 is a cross-sectional view of a deactivated valve assembly.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 is a longitudinal cross-sectional view of one embodiment of the valve assembly 100 at an end of a tubular 102 in accordance with the present invention. As illustrated, the valve assembly 100 is disposed in a float shoe housing 104 . It should be noted that the valve assembly 100 may also be used in a float collar arrangement, or any other configuration in which a plunger-type check valve is required in a downhole tool.
Typically, the wellbore 103 contains wellbore fluid that has accumulated during the drilling operation. As the tubular 102 is inserted in the wellbore 103 , the fluid is displaced into an annulus 106 created between wellbore 103 and the tubular 102 . As it is lowered into the wellbore, the tubular 102 encounters a buoyancy force that impedes its downward movement. The force increases as the tubular is lowered further. At a predetermined differential pressure between the pressure exerted against the tubular and the internal pressure of the tubular, the valve assembly 100 allows wellbore fluid to enter an interior 108 of the tubular 102 to relieve the buoyancy forces acting on the tubular 102 . The amount of wellbore fluid entering the tubular interior 108 is determined by a pre-selected differential height 109 between the wellbore fluid in the tubular interior 108 and the wellbore fluid in the annulus 106 . The differential height 109 is density dependant, therefore, the heavier the fluid the smaller the differential height 109 and the lighter the fluid the larger the differential height 109 . The valve assembly 100 will differentially fill the tubular 102 by cycling between open and close to maintain the pre-selected differential height 109 .
FIG. 2 is an enlarged cross-sectional view of the valve assembly 100 of FIG. 1 . The assembly 100 includes an upper housing 105 that is threadedly connected to a lower housing 120 . A retaining housing 130 is connected to the lower housing 120 at the lower end of the valve assembly 100 . The valve assembly 100 further includes a plurality of segments 110 radially spaced apart in the upper housing 105 . The upper end of the segment 110 is captured in a groove 107 in the upper housing 105 . The groove 107 is constructed to act as a pivot point for the segments 110 . A biasing member 165 is disposed at the lower end of each segment 110 to provide a means for locking the segments 110 in one position. Preferably, the biasing member 165 is a spring device wrapped radially around segments 110 to bias the segments 110 inward. Although the biasing member 165 is illustrated as an O-ring, it should be noted that the biasing member may include a garter spring, a series of C-rings, or any other device that produces a radial force. A locking shoulder 112 is formed at the lower end of the segment 110 .
A locking sleeve 170 may be disposed inside the segments 110 in the upper housing 105 . The locking sleeve 170 is axially movable between a first position and a lock position and contains a passageway 185 that fluidly connects to a passageway 180 in a valve seat 160 . A surface 172 is provided at the upper end of the locking sleeve 170 that is later used to secure the locking sleeve 170 in place. At the lower end of the locking sleeve 170 is an orifice 175 . The orifice 175 has a smaller inside diameter than the inside diameter of passageway 185 . As fluid flows through the passageway 185 and enters the orifice 175 , a differential pressure is created due to the restricted flow through the smaller inside diameter of the orifice 175 . This differential pressure provides a force required to axially translate the locking sleeve 170 downward. The inside diameter of the orifice 175 is based on the fluid density and flow rate through the orifice 175 .
At the lower end of the locking sleeve 170 are sleeve biasing members 115 . The sleeve biasing members 115 are disposed between the locking sleeve 170 and the valve seat 160 . In the preferred embodiment, the sleeve biasing members 115 are a plurality of disk shaped members such as wave springs or wave washers. However, a sealed volume of compressible fluid/gas or semi-solid compressible material such as an electrometric material, composite or plastic may be employed, so long as it is capable of biasing the locking sleeve 170 . In the preferred embodiment, the sleeve biasing members 115 are an annular member that bias the valve seat 160 and the locking sleeve 170 in opposite directions. Additionally, the sleeve biasing members 115 provide the biasing force (or backpressure force) against the valve seat 160 to control the amount of wellbore fluid entering the valve assembly 100 while differentially filling the tubular (not shown) to maintain a pre-selected differential height. The size and thickness of the sleeve biasing members 115 are selected based upon the desired differential height and the quantity of sleeve biasing members 115 is based upon the desired stroke length of the valve seat 160 .
The valve seat 160 is an annular member that includes passageway 180 at the upper end and an outwardly tapered portion 162 at the lower end. In FIG. 2, the valve seat 160 is shown in a run-in position. In the run-in position a seal member 155 arranged around the valve seat 160 abuts a shoulder 122 in the lower housing 120 . The seal member 155 functions to create a fluid tight seal between the valve seat 160 and the lower housing 120 . The value seal 160 may axially move between a retracted and a final extended position inside the lower housing 120 . While differentially filling a tubular, the valve seat 160 retracts or moves upward to create a fluid passageway between the bottom of the valve assembly 100 and the passageway 180 in the valve seat 160 thereby permitting fluid to enter tubular 102 (not shown) as illustrated in FIG. 3 .
A plunger 150 with a plunger head 190 and a shaft portion 195 is located at the lower end of the valve seat 160 . A sealing relationship is created between the plunger head 190 of the plunger 150 and the tapered portion 162 of the valve seat 160 . A biasing member in the form of a spring 145 is disposed about the plunger shaft 195 to urge the plunger 150 upward into contact with the valve seat 160 while the sleeve biasing members 115 urge the valve seat downward, thereby creating a sealing relationship. The upper end of the spring 145 is adjacent the plunger head 190 and the lower end of the spring 145 abuts a plunger housing 125 . The plunger housing 125 is disposed in the retaining housing 130 at the lower end of the valve assembly 100 . A retainer 140 is attached to the lower end of the plunger shaft 195 by a retainer screw 135 . In the preferred embodiment, the components of the valve assembly 100 are made out of a drillable, composite material.
FIG. 3 is a cross-sectional view of the valve assembly 100 as it is being lowered into the wellbore. In this position, differential pressure resulting from the differential height moves the valve seat 160 away from the plunger 150 to permit fluid to enter from the lower end of the valve assembly 100 . During differential filling of the tubular, wellbore fluid enters the lower portion of the valve assembly 100 and acts against the tapered section 162 of the valve seat 160 . When the differential pressure overcomes the backpressure created by the sleeve biasing members 115 on the valve seat 160 , the sleeve biasing members 115 compress, thereby allowing the valve seat 160 to move axially upward into the retracted position. The upward movement of the valve seat 160 disengages the sealing relationship between the plunger head 190 and the valve seat 160 , thereby creating a fluid passageway around the plunger 150 . Wellbore fluid, as illustrated by arrows 205 , may now enter the lower end of assembly 100 , flow around the plunger head 190 into the passageway 180 created in the valve seat 160 , move through the orifice 175 , and exit the top of the assembly 100 through the passageway 185 . As the differential pressure decreases, the sleeve biasing members 115 return to an un-compressed state, thereby allowing the valve seat 160 to sealingly contact the plunger head 190 as illustrated in FIG. 2 .
FIG. 4 is a cross-sectional view of the valve assembly 100 illustrating the passage of fluid from the tubular, through the assembly and into an annular area between the tubular and a wellborn (not shown). During a completion operation of a well, the wellbore may become clogged with particulates. In this situation, the wellbore needs to be pumped with high pressure fluid to clean out the wellbore prior to inserting another section of tubular. The valve assembly 100 is designed to allow fluid to flow through the valve assembly 100 at a flow rate less than a predetermined maximum flow rate to clean out the wellbore without disengaging the differential fill feature.
In one embodiment, fluid enters the valve assembly 100 at the upper end of the housing 105 as illustrated by arrows 210 . As the fluid 210 flows through the passageways 185 , 180 it acts against the plunger head 190 . When the fluid pressure on the plunger head 190 overcomes the load of the spring 145 , the plunger 150 moves downward compressing spring 145 against the plunger housing 125 . The movement of the plunger 150 disengages the sealing relationship between the plunger head 190 and the valve seat 160 , thereby opening a fluid passageway through the valve 100 . As the fluid pressures increases, the locking sleeve 170 , sleeve biasing members 115 , and the valve seat 160 move axially downward as a unit. As the fluid pressures increases further, the fluid acts on orifice 175 in the locking sleeve 170 . The force exerted by the fluid at the orifice 175 urges the locking sleeve 170 axially downward against the sleeve biasing members 115 . The force exerted on the locking sleeve 170 does not entirely overcome the biasing force of the sleeve biasing members 115 . Thus, the axial movement of locking sleeve 170 only partially exposes segments 110 at the upper end of the locking sleeve 170 . In turn, the sleeve biasing members 115 compress and act upon the valve seat 160 . The valve seat 160 moves axially downward returning to the run-in position wherein the seal member 155 abuts the shoulder in the housing. Alternatively, the locking sleeve 170 can be secured in the upper housing 105 by a shear pin (not shown), which allows the locking sleeve to be retained in the first position and avoid inadvertent movement of the locking sleeve 170 to the locked position. The shear pin is constructed to fail at a predetermined flow rate acting on the orifice 175 , thereby allowing the locking sleeve 170 to move axially downward toward the locked position.
FIG. 5 is a cross-sectional view of a valve assembly 100 pumping fluid at or above a maximum flow rate to deactivate the differential fill feature. The fluid, as illustrated by arrow 215 , initially enters the upper housing 105 in the valve assembly 100 . The fluid flows through the passageway 185 and acts upon the orifice 175 and exerts a force that urges the locking sleeve 170 axially downward. At the maximum flow rate, the locking sleeve 170 is urged sufficiently downward to completely expose segments 110 . Upon exposure of the segments 110 , the biasing member 165 causes the lower end of the segments 110 to move radially inward and the upper end to pivot in the groove 107 . As the segments 110 move radially inward the locking shoulder 112 wedges against surface 172 of the locking sleeve 170 , thereby preventing the locking sleeve 170 from moving axially upward in the valve assembly 100 .
As the locking sleeve 170 moves axially downward, it also compresses the sleeve biasing members 115 against the seat 160 . The force on the seat 160 by the sleeve biasing members 115 causes the seat 160 to move axially downward until the bottom of the seat 160 hits a stop 220 in the lower housing 120 . The fluid, as illustrated by arrow 215 , continues through the passageway 180 and acts upon the plunger head 190 of the plunger 150 thereby causing the plunger 150 to move axially downward. As the plunger 150 moves downward a fluid passageway is created through the valve assembly 100 and the spring 145 is compressed against the plunger housing 125 . The fluid flows around the plunger 150 and exits the retainer housing 130 . The locking sleeve 170 and the seat 160 are secured in a fixed position by the segments 110 at the upper end of the locking sleeve 170 and the stop 120 at the lower end of the valve seat 160 .
FIG. 6 is a cross-sectional view of a deactivated valve assembly 100 . As illustrated, the segments 110 are wedged against the locking sleeve 170 . The locking sleeve compresses the sleeve biasing members 115 against the valve seat 160 , securing the valve seat 160 in a final extended position. While in the final extended position the taper portion 162 of the valve seat 160 creates a sealing relationship with the plunger head 190 .
After the section of tubular is installed in the wellbore, the tubular is typically anchored in the wellbore through a cementing process. The valve assembly 100 is used to facilitate the passage of cement from the tubular to the annulus of the well while preventing cement from returning into the tubular due to gravity and fluid density of the cement. The valve assembly 100 acts as a standard one-way check valve allowing fluid to enter the upper housing 105 into the passageway 185 through the orifice 175 into the passageway 180 and act upon the plunger head 190 . At a predetermined flow rate, the plunger 150 moves axially downward and compresses the spring 145 disposed around the shaft 195 of the plunger 150 . The downward movement of the plunger 150 disengages the seal connection between the plunger head 190 and the valve seat 160 to create a passageway around the plunger 150 . The fluid is allowed to flow through the passageway and exit the bottom of the valve assembly 100 . After the downward flow is stopped, the plunger 150 moves axially upward due to the force of the spring 145 and the plunger head 190 creates a sealing relationship with seat 160 , thereby preventing fluid from returning into the valve assembly 100 from the wellbore.
In another embodiment, a mechanical device, such as a weighted ball (not shown) can be dropped and seated on a ball seat. Pressure application will then slide the locking sleeve 170 to a predetermined distance to deactivate the differential fill feature. In this embodiment, cross-ports are placed above the mechanical device to allow fluid flow pass the device and through the valve.
In operation, the valve assembly 100 is disposed at the lower end of a tubular 102 and then the tubular is run into a wellbore. At a predetermined differential pressure, the valve assembly 100 allows wellbore fluid to enter the tubular. The amount of wellbore fluid allowed to enter the tubular is determined by a pre-selected differential height between the wellbore fluid inside the tubular and the wellbore fluid in the annulus between the tubular and the wellbore. The valve assembly 100 will differentially fill the tubular by cycling between an open and closed position to maintain the pre-selected differential height until the entire section of tubing is disposed in the wellbore.
During differential filling of the tubular, fluid enters the lower portion of the valve assembly 100 and acts against the valve seat 160 . Specifically, the differential pressure overcomes the backpressure created by the sleeve biasing members 115 on the valve seat 160 , thereby allowing the valve seat 160 to move axially upward into the retracted position. The upward movement of the valve seat 160 disengages the sealing relationship between the plunger head 190 and the valve seat 160 . Wellbore fluid may now enter the lower end of assembly 100 , flow around the plunger head 190 into the passageway 180 created in the valve seat 160 , flow through the orifice 175 , and exit the top of the assembly 100 through the passageway 185 . As the differential pressure decreases, the sleeve biasing members 115 return to an un-compressed state, thereby allowing the valve seat 160 to sealingly contact the plunger head 190 .
During a completion operation of a well, the wellbore may become clogged with particulates. In this situation, the wellbore needs to be pumped with high pressure fluid to clean out the wellbore prior to inserting another section of tubular. The valve assembly 100 is designed to allow fluid to flow through the valve assembly 100 at a flow rate less than a predetermined maximum flow rate to clean out the wellbore. Fluid enters the valve assembly 100 at the upper end of the housing 105 . Subsequently, the fluid flows through the passageway 185 and acts against the orifice 175 in the locking sleeve 170 . The force exerted by the fluid at the orifice 175 urges the locking sleeve 170 axially downward against the sleeve biasing members 115 . The sleeve biasing members 115 compress and act upon the valve seat 160 . The valve seat 160 moves axially downward returning to the run-in position. Fluid crossing the orifice enters the passageway 180 it exerts a downward pressure on the plunger head 190 . When the fluid pressure on the plunger head overcomes the load of the spring 145 , the plunger 150 moves downward. The movement of the plunger 150 disengages the sealing relationship between the plunger head 190 and the valve seat 160 , thereby opening a fluid passageway through the valve 100 .
Once the section of tubular is completely placed in the wellbore, fluid is pumped at or above a maximum flow rate to deactivate the differential fill feature. The fluid, initially enters the upper housing 105 in the valve assembly 100 . The fluid flows through the passageway 185 and acts upon the orifice 175 and exerts a force that urges the locking sleeve 170 axially downward. At the maximum flow rate, the locking sleeve 170 is urged sufficiently downward to completely expose segments 110 . Upon exposure of the segments 110 , the biasing member 165 causes the lower end of the segments 110 to move radially inward and the upper ends to pivot in the groove 107 . As the segments 110 move radially inward the locking shoulder 112 wedges against surface 172 of the locking sleeve 170 , thereby preventing the locking sleeve 170 from moving axially upward in the valve assembly 100 .
As the locking sleeve 170 moves axially downward it also compress the sleeve biasing members 115 against the seat 160 . The force on the seat 160 by the sleeve biasing members 115 causes the seat 160 to move axially downward until the bottom of the seat 160 hits a stop 220 in the lower housing 120 . The locking sleeve 170 and the seat 160 are secured in a fixed position by the segments 110 at the upper end of the locking sleeve 170 and the stop 220 at the lower end of the valve seat 160 .
After the section of tubular is installed in the wellbore, the tubular is typically anchored in the wellbore through a cementing process. The valve assembly 100 is used to facilitate the passage of cement from the tubular to the annulus of the well while preventing cement from returning into the tubular due to gravity and fluid density of the cement. The valve assembly 100 acts as a standard one-way check valve allowing fluid to enter the upper housing 105 into the passageway 185 through the orifice 175 into the passageway 180 and act upon the plunger head 190 . At a predetermined flow rate, the plunger 150 moves axially downward and compresses the spring 145 disposed around the shaft 195 of the plunger 150 . The fluid is allowed to flow through the passageway and exit the bottom of the valve assembly 100 . After the downward flow is stopped, the plunger 150 moves axially upward and the plunger head 190 creates a sealing relationship with seat 160 , thereby preventing fluid from returning into the valve assembly 100 from the wellbore.
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 a plunger-type valve for use in a wellbore. The plunger-type valve is arranged to selectively allow fluid flow to enter and exit the valve in both directions. Subsequently, the plunger-type valve can be deactivated to selectively allow fluid flow in only one direction. The valve includes a body, at least one locking segment, a locking sleeve, at least one biasing member, a valve seat and a plunger.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to valves, and more particularly, to bore hole drill string valves for preventing the loss of drilling mud through the drill pipe during the drilling operation.
2. History of the Prior Art
In drilling oil and gas wells or the like by the rotary drilling method, the drill bit is rotated by a string of drill pipe connected to a kelly suspended in a derrick at the earth's surface. Drilling mud, or chemically laden drilling fluid, is pumped through the kelly and string of drill pipe to the drilling bit in a manner well known in the art. During the actual drilling operation, it is repeatedly necessary to disconnect the kelly from the drill string each time additional strands of drill pipe are added to the string. Since the kelly is generally filled with drilling mud or fluid, it is desirable to insert between the kelly and the drill string a valve that will allow mud to flow through the kelly and drill string during drilling, but will automatically close when the mud pumps are deactuated and the kelly is disconnected from the drill string.
The prior art is replete with valve designs for such purposes. These valves are commonly referred to as "mud saver valves" in that the drilling mud is contained rather than lost during this operation. Once disconnected, it is possible to empty the entire contents of drilling fluid in the kelly onto the drilling derrick floor. In drilling a well, it is not unusual for 100-150 barrels of drilling fluid to be lost in this manner. Such an event will result in not only a waste of large quantities of expensive drilling fluid but also the discharge of mud over the adjacent area and workmen to make the derrick floor dangerously wet and slippery. This produces a hazardous situation for personnel working on the derrick floor as well as costing time for maintenance.
Numerous prior art patents have addressed mud saver valve designs. Such valve designs generally incorporate a valve seat, a closure member and means for urging the closure member into engagement with the valve seat. For example U.S. Pat. No. 4,364,407 assigned to the inventor of the present invention discloses a valve having a tubular body connectable between the kelly and the drill string. An annular seat ring having a central opening is mounted within the body. A piston is axially movably disposed with the body for engagement within the seat ring. The piston includes a bore substantially coaxially aligned with the central opening of the seat ring and a flange extending radially outwardly from the piston to slidingly engage the interior of the body. The piston of the aforesaid patent includes a plurality of ports above the piston communicating the exterior of the piston with the bore. A plug is removably mounted in the piston above the ports to normally close the bore. The plug includes a sheer ring removably inserted in the bore and a spear axially movably mounted within the sheer ring and movable between a first position wherein the spear sealingly engages the sheer ring and a second position wherein fluid may flow upwardly between the spear and the sheer ring. A spring is provided to urge the piston into engagement with the seat ring. Other patents showing mud saver valve designs are set forth and shown in the Parker et al., U.S. Pat. No. 4,128,108; Liljestrend, U.S. Pat. No. 3,967,679; Williamson, U.S. Pat. No. 3,965,960; Litchfield et al., U.S. Pat. No. 3,738,436; Garrett, U.S. Pat. No. 3,698,411; and Taylor, U.S. Pat. No. 3,331,385.
The aforesaid patents disclose many advantages and improvements in mud saver valve designs. However, certain disadvantages exist with the prior art designs due to the very nature of the downhole environment. It is well known in the industry that the temperature, pressure and flow conditions of the borehole limit the life expectancy of drilling elements. The same holds true for mud saver valves in that the drilling mud flowing therethrough generally contains abrasive materials under pressure. Such flow can quickly disintegrate sealing surfaces. For this reason, the configuration of the sealing surface as well as the material from which the surfaces are made are integral elements of a reliable system. Moreover, axial and lateral stability of the valve itself is a key element of effective valve operation. Any misalignment in the valve seating can preclude adequate sealing which permits mud flow therefrom. Any flow of the abrasive mud will cause some deterioration in the misaligned area of the valve seat. Likewise, misalignment of mechanical parts in such high torque, high force assemblies can produce unnecessary and damaging wear upon the parts reducing their life span and requiring premature maintenance.
It would be an advantage, therefore, to overcome the disadvantages of the prior art by providing a mud flow valve having sufficient axially and lateral stability to permit effective valve seating and limited abrasive wear therethrough during high pressure mud flow conditions. The mud valve of the present invention provides such an assembly through the utilization of an elongate valve piston incorporating an exfundibular head axially aligned with an infundibular valve seat permitting the mud flow therethrough. The elongate construction reduces the potential eccentricities in valve seat alignment and the arcuate infundibular valve seating configuration facilitates the flow of abrasive mud therethrough without the deteriorating affects conventional in many prior art embodiments. Moreover, the valve seats can be constructed of suitably hard materials to withstand the aforesaid abrasive mud flow without substantial deterioration. Such an embodiment facilitates higher efficiency in operations and reduces requisite maintenance time and cost.
SUMMARY OF THE INVENTION
The present invention pertains to a mud valve for a borehole drill string adapted for enhanced operational reliability. More particularly, the present invention comprises an improved mud saver valve of the type including a tubular body connectable between a kelly and a drill string and a piston axially movable within the tubular body to form a valve seat therein. The valve incorporates a plug movably mounted within the piston to normally close the bore within the piston. The piston is normally biased into engagement with the valve seat for the closure thereof. The improvement comprises the tubular body being formed of upper and lower tubular sections adapted for mating engagement one to the other. An upper valve seat is formed in a lower region of the upper tubular body section and constructed with a curved, outwardly flared, or valve seating recess depending from a cylindrical bore forming an infundibular orifice therethrough. The piston is formed with an upper valve seat member having seat member adapted for matingly engaging the upper body valve seat member and formed with a generally cylindrical curved edge portion atop a cylindrical body portion comprising a generally exfundibular configuration adapted for matingly engaging the infundibular valve seat of the upper body. The piston is formed with a generally cylindrical elongate flange region adapted for axial alignment with and slidable engagement through the lower tubular member for facilitating the axial alignment lateral stability of the upper and lower valve seats.
In another embodiment, the above described mud saver valve further includes the piston having a hollow bore centrally formed therethrough and a valve seat sleeve adapted for receipt therein and securement atop the piston. The valve seat sleeve is formed with an outer curved edge portion adapted for matingly engaging the upper valve seat recess. The piston valve sleeve is further formed with a generally centrally disposed flange member extending outwardly therearound in a downwardly tapering configuration for abuttingly engaging an upper end of the piston and forming a smooth flow surface thereover for mud flowing between the mating valve seats. The piston valve sleeve may further comprise a generally cylindrical member adapted for receiving the plug therein and the axial reciprocation of the plug relative thereto. The piston is also constructed with a plurality of ports formed adjacent the flange in angle relationship relative thereto for facilitating the smooth flow of mud therein and through the bore of the piston.
In yet another aspect, the invention includes a well bore mud saver valve of the type positionable between a kelly and a drill string disposed within a borehole adapted for the flow of drilling mud therethrough. The valve comprises a housing adapted for securement between the kelly and drill string and being formed with an axial bore therethrough. An upper valve seat is formed within the housing bore and constructed with a generally cylindrical, curved valve seating recess therearound. A piston is disposed within the housing bore beneath the upper valve seat and is formed with a lower valve seat in an upper end thereof adapted for matingly engaging the upper valve seat and formed with a generally cylindrical, curved edge portion adapted for matingly engaging the curved recess of the upper valve seat. The piston being axially movable within the housing and is upwardly biased into engagement with the upper valve seat for the closure thereof. The piston is formed of a generally cylindrical, elongate intermediate body portion comprising a flange region adapted for receipt in, axial alignment with, and slidable engagement through the bore of the housing for facilitating the axial alignment and lateral stability of the upper and lower valve seats.
In a further aspect, the above valve includes a plug removably mounted in the piston to normally close the bore with the piston in the upwardly biased position of engagement with the upper valve seat. The piston further comprises a hollow bore centrally formed therethrough and wherein the lower valve seat comprises a valve seat sleeve adapted for receipt within the bore and securement atop the piston, the valve seat sleeve being formed with an outer curved edge portion adapted for matingly engaging the upper valve seat recess. The valve sleeve further comprises a generally centrally disposed flange member extending outwardly therearound in a downwardly tapering configuration adapted for abuttingly engaging an upper end of the piston and forming a smooth the valve seats. The piston valve sleeve comprises a generally cylindrical member adapted for receiving the plug therein and the axial reciprocation of the plug relative thereto. The piston is further constructed with a plurality of ports formed adjacent the flange in an angled relationship relative thereto for facilitating the smooth flow of mud therein and through the bore of the piston. The means biasing the piston upwardly against the upper valve seat comprises a spring axially disposed within the bore disposed around a lower region of the piston and in abutting engagement with the piston for urging the piston upwardly relative to the upper valve seat.
In yet another aspect, the above defined valve includes the housing constructed in a generally cylindrical configuration comprising a tubular body formed with a hollow bore therethrough. The tubular housing is comprised of upper and lower body sections, the upper and lower body sections being adapted for threadable engagement one with the other. The upper valve seat is disposed in the lower end of the upper tubular body portion and comprises a generally cylindrical member secured therein. The generally cylindrical upper valve seat member disposed within the lower end of the upper tubular member is also constructed with an inner lip having a generally infundibular orifice therethrough and an outer lip adapted for engagement with securing means for securing the cylindrical member within the upper tubular housing member. The piston is comprised of a generally hollow tubular member formed with an upper and lower necked regions and an intermediate body portion adapted for slidable engagement within the bore of the lower tubular housing member.
In but another aspect, the invention includes a method of mud saving in a well bore by the utilization of a valve positionable within a drill string disposed within a borehole between a kelly and a drill bit adapted for the flow of drilling mud therethrough. The method comprises the steps of providing a housing having an axial bore formed therethrough and securing the housing between the kelly and the drill string. An upper valve seat is then formed within the housing bore with a curved, infundibular valve seating recess therearound. A piston formed with a lower valve seat in an upper end thereof member is provided and adapted for matingly engaging the upper valve seat and formed with a generally cylindrical exfundibular edge portion adapted for matingly engaging the curved, infundibular recess of the upper valve seat. The piston is then formed with a generally cylindrical, elongate intermediate body portion comprising a flange region adapted for receipt in, axial alignment with, and slidable engagement through the bore of the housing for facilitating the axial alignment and lateral stability of the upper and lower valve seats. The piston is then disposed for axial movement within the housing, the piston is biased into engagement with the upper valve seat for the closure of the valve.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the present invention and for further objects and advantages thereof, reference may now be had to the following description taken in conjunction with the accompanying drawings in which:
FIGS. 1A and 1B comprise an exploded, side-elevational, cross-sectional view of one embodiment of the mud saver valve of the present invention illustrating the assembly thereof;
FIG. 2 is a side-elevational, cross-sectional view of the mud saver valve of FIG. 1 shown in an assembled configuration with all valve members in a closed configuration;
FIG. 3 is a side-elevational, cross-sectional view of the assembly of FIG. 2 with the piston depressed in the downwardly mud flow configuration showing one mode of operation of the mud valve in the present invention; and
FIG. 4 is a side-elevational, cross-sectional view of the assembly 10 of FIG. 2 with the plug disposed in an upward open position to permit mud flow upwardly through the mud valve to illustrate a second mode of operation thereof.
DETAILED DESCRIPTION
Referring first to FIGS. 1A and 1B there is shown an exploded side-elevational, cross-sectional view of one embodiment of the mud saver valve assembly of the present invention. Mud saver valve assembly 10 comprises a top sub 11 and a lower body portion 13 both formed of a generally tubular configuration. The top sub 11 and body 13 are constructed for coupling in a conventional manner wherein body 13 includes a box 14 and wherein top sub 11 includes a pin 15 for threadable engagement with said box. The upper end of the top sub 11 includes a box (not shown) which is connectable to a kelly (not shown) and a pin (not shown). Lower body 13 is machined to form an annular piston recess 16 for receipt of the piston 30 therein. Piston 30 is adapted for engaging a valve seat 20 constructed for mounting within the to sub 11 and described in more detail below. In this manner, the mud saver valve 10 of the present invention affords the reliability, longevity, and repairability necessary for efficiency in drilling operations.
The assembly of the piston 30 of the present invention incorporates the utilization of a conventional spear member 35 urged upwardly by biasing spring 47 as is conventional in the prior art and set forth and shown in U.S. Pat. No. 4,364,407 assigned to the inventor of the present invention. The present invention, however, provides many distinct advantages over the design set forth in the aforesaid patent in that the top sub 11 may be disassembled from the lower body portion 13 for exposing the piston 30 and the upper valve seat 20 therein. Upper valve seat 20 is constructed of a generally cylindrical configuration adapted to be received in upper valve seat recess 17 formed in top sub 11. Valve seat 20 includes a cylindrical central opening 21 with a lower lip area 22 comprising a seating surface adapted for matingly engaging a male seat element upon said piston 30 as described in more detail below. An O-ring 23 is provided around said upper valve seat 20 to form a seal between the exterior of said valve seat and said seat ring recess 17. The upper valve seat 20 is secured within the top sub 11 by a spanner ring 24 having adapted for threadably engaging a threaded recess 25 formed beneath the valve seat recess 17 and top sub 11. In this manner, the valve seat 20 may be easily assembled and disassembled for maintenance. It may further be seen that the valve seat 20 is of integral construction and does not include an elastomeric seat as set forth in certain prior art constructions. Instead, the upper valve seat 20 comprises a seating surface 22 formed of a curved outwardly tapering configuration comprising a generally infundibular orifice in combination with said central aperture 21 that is adapted for matingly engaging a lower diverter valve seat 26. The lower diverter valve seat 26, described in more detail below, incorporates a curved head region 27 with a downwardly tapering configuration defined herein as a generally exfundibular head region adapted for matingly engaging the seating surface 22 of the upper valve seat 20. In this manner all valve closure elements are constructed of a suitably strong material for withstanding the abrasive conditions of mud flow therethrough. Moreover, the elimination of elastomeric materials in the mud flow path adds to the longevity of use between maintenance repairs. Obviously the abrasive mud flow is less deleterious on hard surfaces such as steel or the like of which the valve seating surfaces 22 and 27 may be formed. In accordance with one aspect of the present invention, said seating surfaces may also be formed of ceramics or other suitable hard material that are capable of withstanding the deleterious effect of high pressure mud flow.
One distinct advantage of the mating infundibular/exfundibular valve seat configuration 22-27, is the effective fluid flow sealing therebetween and the provision for reduction in flow turbulence during opening of said valve. The aforesaid prior art U.S. Pat. No. 4,364,407 addressed the fluid flow problem around the flat, abutting seating ring surfaces by providing a downwardly depending annular skirt. Due to the sealing configuration of the valve seats it was found that most of the washing of the interior of the body occurred immediately below the seat ring. This was due mainly to the abutting relationship between the respective valve seats and the indirect non-uniform fluid flow therefrom. The lateral spray of the drilling fluid created great turbulence in the region necessitating a tapered skirt as provided therein. Provision was even made for replacing the skirt along with the sealing ring due to the inherent degeneration of the design thereof. The present invention facilitates directional fluid flow in conjunction with the infundibular tapered orifice between valve seats 22 and 27 and the streamlined inner piston body therebelow as defined hereinafter.
Referring now to FIGS. 1A and 2, the piston 30 is axially movably disposed in body 13 below the upper seating ring 20. Piston 30 incorporates lower, exfundibular seating element 26 having top seating surface 27 adapted for mating engagement with upper seating surface 22. Piston 30 also includes the bore 32 coaxial with central opening 21 of the upper valve seat 20. Bore 32 is normally occluded interior of valve seat 22 by a plug 33, from which upstands a spear 35 axially movably disposed within the lower valve seat 26.
Plug 33 includes an intermediate body portion 37 having a cylindrical upper portion 36 which normally forms a plug within lower valve seat 26. The body portion 37 also includes a lower cylindrical body region 39 with an intermediate slotted region 38 formed therebetween with slotted flow areas 37A therein. It is the slotted areas 37A which permit upward fluid flow as described below. A plurality of flow passages 38 are thus formed for permitting select upwardly flow therethrough. During back flow conditions, spear 35 is driven axially upwardly with respect to lower valve seat 26, such that mud flows through the flow passages 38 and inside upper valve seat 20. The area of the flow passages 38 is substantial and allows significant back flow of mud when the downhole pressure exceeds the head of the kelly. The upward travel of spear 35 during backflow is limited by a plurality of sheer pins 39 which extend radially inwardly to engage the bottom region 39 of plug 33 as shown in more detail below.
The plug 33 is normally retained within the bore 32 by the sheer pins 39. If it is desired to remove plug 33 from bore 32, an overshot may be used to grasp spear 35 and apply an upward force to sheer pins 39 and thereby remove the plug 33 therefrom. Such removal allows full access to bore 32 so that fishing tools may be run down the drill string. An upward force may be applied to spear 35 to sheer pins 39 in a conventional manner. It may be seen that this provision is also provided in U.S. Pat. No. 4,364,407 referred to above although the assembly elements in configuration are substantially different.
Still referring to FIGS. 1A, 1B and 2, piston 30 includes an intermediate flange region 45 which extends radially outwardly into sliding engagement with recess 16 of the body 13. In order to form a seal between the body 13 and flange 45, O-rings 46 may be provided. It may be seen that the intermediate flange region 45 of the present invention is constructed in an elongate configuration to provide axial and lateral stability to the piston 30 within the lower body 13. For this reason, two O-rings 46--46 are provided and disposed in parallel spaced relationship one from the other along flange 45 to maintain axial and lateral stability. Axial and lateral stability are critical elements for valve seat alignment in accordance with the principles of the present invention and plug 33 is likewise constructed with an upper and lower cylindrical body regions 36 and 39, respectively, which allow precise axial alignment of said spear unit 35 within bores 32. As set forth herein said axial alignment facilitates reliability in all operational modes. Piston 30 is next seen to be urged upwardly against valve seat 22 by a spring 47. The spring 47 is positioned and compressed between flange 45 and a lower portion of the bore of body 13. Piston 30 is also centralized within body 13 by the elongate flange region 45. Stabilizing fins and the like previously provided by prior art embodiments are thus not necessary. This design aspect reduces the cost, weight and complexity of the unit and further facilitates reliability in operation.
In order to allow drilling mud to flow into bore 32, a plurality of ports 55 are provided. Unlike many prior art embodiments, the ports 55 of the present invention are angularly formed in the piston body 30 across the upper region of the flange 45. In this region of the flange 45, a tapered configuration is provided as shown in FIG. 1A. The taper of flange 45 facilitates the flow of fluid into ports 55 as the fluid flows from the upper valve seat 22. The pressure of the mud during the drilling first moves lower seating surface 27 away from upper valve seat 22. The pressure then acts on flange 45 to drive piston 30 fully downwardly within the body 13 as shown in FIG. 3, thus allowing the mud to flow smoothly and with the minimum of turbulence through the valve assembly 10. It may also be seen that a flange member 53 is formed outwardly of the lower valve seat 26 to abut against upper surface 55 disposed above flange 45.
The outwardly tapering flange 53 further facilitates smoother fluid flow downwardly from the valve seat 22, directing said fluid flow outwardly and along the body of the piston 30 downwardly to the ports 55 for entry into lower bore region 50. In order to preserve the sealed engagement between the respective elements, lower valve seat 26 is concentrically positioned within the piston body 30 with an O-ring 59 sealed therearound beneath the flange 53. The interior bore 43 of the lower seating element 26 terminates in end portion 60 which rests above the shoulder region 62 formed in central bore 32. A necked bore region 64 is provided below a shoulder region 62 and tapered bore region 66 is provided immediately therebeneath. Taper 66 terminates adjacent the angular outward mud flow ports 55 to comprise a generally infundibular flow orifice through bore 32 in provision for the aforesaid back pressure mud flow conditions. These particular assembly features further facilitate the operation, maintenance, and repairability of the unit as described in more detail below.
Referring particularly now to FIG. 2 there is shown a side elevational, cross-sectional view of the mud valve element set forth in FIGS. 1A and 1B in an assembled configuration. The assembly and interaction of the various valve elements have heretofore been discussed. However, the valve assembly 10 is designed for three distinct positional modes, to wit: "closed", "open down" and "open up". The plug 33 in this particular illustration is in the occluded position with the valve seats 22 and 27 in flush engagement thereacross. In this "closed" mode, the valve assembly 10 is in position for preventing any drilling mud flow therethrough. It may be seen that the spring 47 has thus urged the piston 30 upwardly to force engagement between the lower valve seat 26 and upper valve seat 20. Pressure from fluid in upper bore 32 in top sub 11 maintains the plug 33 and spear 86 in the downward position with the necessary sealing configuration preventing mud flow therethrough.
Referring now to FIG. 3 there is shown the mud valve assembly 10 in a first operational configuration with the piston 30 in the "open down" or depressed position with mud flowing downwardly through bore 32 around spear 35 and between valve seats 22 and 27. The mud flow as indicated by arrow 80 flows downwardly around the annular cavity between body 13 and piston 30 through ports 55 and into the lower bore 52. In this position the plug 33 remains in the closed mode relative to the piston 30.
Referring now to FIG. 4 there is shown the assembly 10 of the present invention in the back flow or "open up" condition. In this position, the piston 47 maintains the piston in the upwardly seated position with valve seats 22 and 27 matingly engaging one another to prevent flow therethrough. Downhole pressure forcing mud through lower bor 52 and upwardly through piston 30 has forced the plug 33 upwardly with spear 35 moving in the direction of arrow 86. The lower body region 39 of the plug 33 is shown to have moved upwardly within the lower valve seat 26 in abutting engagement and retained by pins 39. The flow channels 37A are thus open to flow communication between lower bore 52 and upper bore 21 within upper valve seat 20. This permits the mud flow in the direction of arrow 88 upwardly through the top sub 11 to relieve the downhole pressure. The relative position of the various elements above described may thus be viewed in all operational positions.
It is thus believed that the operation and construction of the present invention will be apparent from the foregoing description. While the method and apparatus shown and described has been characterized as being preferred, it will be obvious that various changes and modifications may be made therein without departing from the spirit and scope of the invention as defined in the following claims.
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A mud saver valve comprising a tubular body connectable between a kelly and a drill string. A piston is mounted therein and includes a bore substantially coaxially aligned with the central opening. A plug is removably mounted in the piston and is movable between a first position wherein a spear sealingly engages the valve seat and a second position that allows fluid to flow upward between the spear and the valve seat. The piston is constructed with an elongate intermediate body section having a plurality of O-rings secured therein and disposed beneath angled ports for enhancing lateral stability of the piston within the body. The valve seat is furthermore secured within the body by a spanner ring with the valve seat being formed with a curved mating surface adapted for flushly engaging a curved valve seat surface of a valve seat disposed upon the piston. Both the upper and lower valve seats are removable for field repair while axially actuatable with lateral stability.
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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 rod-pumped oil wells. More specifically, the invention relates to rod guides that centralize sucker rods within tubing and scrape paraffin from the interior wall of tubing. A rod guide having a high erodible wear volume according to this invention has its by-pass area flow channels placed predominately in the non-erodible portion of the guide.
BACKGROUND OF THE INVENTION
As crude oil is depleted from an underground formation, pressure in the formation decreases to the point that oil must be pumped to the surface. One of several methods for removing crude oil from an underground formation employs a pumpjack located on the surface. The pump-jack is connected via a sucker rod string to a downhole pump at the bottom of the producing oil well. The sucker rod string comprises many sucker rods, each rod connected end-to-end to another rod by a coupling. The entire rod string extends down into a tubing string that is commonly contained within a well casing. The exterior well casing and internal tubing string are permanently installed after drilling the well. The tubing string serves as a conduit for the fluid produced, and the driving force for this production is transmitted to the downhole pump via the sucker rod string positioned within the interior of the tubing string.
The sucker rod string commonly reciprocates inside the tubing string as a result of the upward and downward motion of the pump-jack to which the rod string is fastened. Cyclical upward and downward motion of the pump-jack is thus communicated to a downhole pump located at the lower end of the tubing string. In response, the pump forces the produced fluids collected at the bottom of the well up the tubing string to the surface. In other applications, a progressing cavity (PC) pump is used at the bottom of the well, and in these applications power to the pump is transmitted via a rotating sucker rod string.
The production fluid in the tubing string typically acts as a lubricant for the sucker rod string. Lubrication is derived from the fluid because it is commonly a mixture which includes crude oil, along with water and natural gas. Typically also included in the production fluids are dissolved and undissolved salts, gases and other formation minerals, such as sand. The recovered crude oil is commonly stored in a tank near the well until it is removed for refining. Natural gas is removed in a pipeline. Water is usually reinjected into the production formation or in a disposal well in another formation close to the production formation.
Due to deflections of both the tubing and the rod string, contact may occur between these components. Even though the lubricating bath of the production fluid is present in the tubing, wear is incurred on the rod string and tubing when contact is made. The rod couplings typically have the largest outer diameter of the various components of the rod string and therefore incur, and cause, the most wear. Produced fluids that flow in the rod and tubing annulus also cause wear in the form of abrasion and corrosion. Through time, all these wear factors may lead to parting of the rod string or to the development of holes in the tubing.
When a hole develops in the tubing, pressure is lost inside the tubing. Production will then be pumped into the annulus between the tubing and the casing rather than to the surface for collection and storage. When a sucker rod separates, when a rod coupling breaks, or when holes are created in the tubing, the sucker rods and/or tubing must be pulled from the well and inspected in detail for the extent and nature of the damage. Damaged rods and tubing must be replaced. The resultant down-time as well as the workovers are a great expense to the well owners. Therefore, methods and apparatus for reducing or eliminating costs associated with lost production of hydrocarbons, equipment replacements and workovers are of great benefit to the well owners.
A well known method of preventing wear to the rods and tubing is the use of rod guides, also known as centralizers and paraffin scrapers. In cases involving a reciprocating rod string, paraffin scrapers may also serve as centralizers to reduce wear, in addition to their implied purpose of removing paraffin from the walls of the tubing. Rod guides have a greater outer diameter than other parts of the rod string. As such, the guides are sacrificial and protective. Rod guides retard rod and tubing wear by incurring most of the wear that does occur.
On the average, six rod guides are normally attached at various locations on each sucker rod in the rod string, but as many as ten or more locations per rod or as few as one location per rod may be used. As such, the guides act as a sacrificial and protective buffer between the rod string and the tubing. Wear occurs to the guide as it protects the rod string and the tubing and results in a reduction of the protective thickness of the guide over time.
The wearing effects suffered by the rod guides will eventually cause the guides to have an outer diameter which will approach and become similar to the diameter of the couplings or parts of the rod string larger than the shank or body of the sucker rod. When this happens, the guide will no longer buffer the contact between the rod string and the tubing. The rod guides must then be replaced.
The general state of the art may be gathered by reference to a Rod Guide/Centralizer/Scraper Catalog published in 1997 by Flow Control Equipment (FCE) Inc. This catalog discusses rod guide material selection, paraffin scrapers; classic rod guide designs such as the standard and slant blade; high performance designs such as the NETB, Stealth and Double Plus; rotating rod guides for PC pumps such as the Spin-Thru and the PC Plus; and field installed guides (FIG's) such as the Lotus twist-on, NEPG, Lotus Rubber and Guardian polyguides. Also relevant to the general state of the art are patents to rod rotators and stabilizing bars.
Many of the design considerations applicable to any rod guide for either rotating or reciprocating sucker rod strings are discussed in a 1993 publication by Charles Hart entitled "Development of Rod Guides for Progressing Cavity (PC) Pumps", a 1995 publication by Randall G. Ray entitled "Determination of Rod Guide Erodible Wear Volume," and a 1993 publication by Milton Hoff entitled "Hydraulic Drag Forces on Rod Strings." The general concept of erodible wear volume EWV and specific formulations as "gross" and "net" EWV are used herein in accordance with the use in these publications. In particular, the portion of a rod guide between the largest outer diameter on the rod string (typically the coupling diameter) and the inner diameter of the tubing string is the volume of the guide which can prevent damaging metal-to-metal contact. This protective volume of the rod guide is referred to as EWV. EWV is an important indicator of rod guide performance. The amount of the rod guide outside the outer diameter of the sucker rod couplings is in general referred to a Gross Erodible Wear Volume or Gross EWV. A more refined concept, which is known as Net Erodible Wear Volume, is that amount of the rod guide material that will erode before the sucker rod coupling contacts the tubing. Net EWV is always less than Gross EWV in conventional rod guide designs when the rod string is reciprocated to drive the downhole pump. Even a reciprocating rod string should be slowly rotated during reciprocation to maximize the useful life of the rod guides. An underlying assumption of both of these EWV definitions is that the rod string is continuously rotated and that the rod guides wear evenly. Also, both definitions are based on the assumption that the rod string is in tension and not in compression. In some rod guide designs, the Gross and Net EWV may be almost the same but as they approach equality, then fluid bypass area decreases and the flow resistance or drag around the guide increases to unacceptable levels. It is the primary objective of the invention presented herein to generate more efficient rod guide designs which have Gross EWV approximating Net EWV without sacrificing the necessary bypass area and geometry necessary to achieve desired levels of flow resistance or drag.
For clarity and ease of discussion, a rod guide may be considered to have a radially inner non-erodible zone and a radially outward erodible zone. The boundary line between the two zones, namely the erodible and the non-erodible zones, will be considered to be the projected circumference of the largest outer dimensions of any component anticipated to be on the rod string in the operative region where the respective rod guide is located, which typically will be the rod couplings above and below the respective rod guide. "Operative region" means that section of the rod string close enough to the rod guide so that it may be expected that the rod guide will furnish some protection to the rod and its couplings. It is meant to exclude for definitional purposes couplings or other rod string elements which may be several rod lengths away from the rod guide and which would have no effect on the function or performance of the rod guide, and thus no effect on the guide dimensions at issue. As used herein, the terms "by-pass" and "flow through" are intended to be synonymous and interchangeable.
U.S. Pat. Nos. 586,001 and 1,600,577 are directed to a cleaner for oil well tubing and a paraffin scraper, respectively. Both disclosures have a gross similarity to some of the embodiments of the present invention but differ in intent, function, material and design. The same may also be said of U.S. Pat. No. 2,153,787, which is directed to the shrink fitting of a guard by extraction of a plasticizer. A flexible guide is taught in U.S. Pat. No. 2,651,199. A method of on-site molding of scrapers is disclosed in U.S. Pat. No. 3,251,919.
U.S. Pat. Nos. 2,863,704 and 4,997,039 disclose a combination rod guide and sand purging device. Several of the embodiments referred to in the materials cited above are disclosed in U.S. Pat. Nos. 4,088,185, 5,115,863 and 5,277,254. Recently disclosed variations of a rod guide are found in U.S. Pat. Nos. 5,358,041 and 5,492,174.
None of the above references are directed to the concept of the present invention as set forth and described below. The present invention overcomes the deficiencies of the prior art and achieves its objectives by maximizing EWV while providing adequate flow through paths in and around the guide to both prevent excessive hydraulic drag during movement of the guide with respect to the produced fluid and avoid the creation of an excessive pressure drop as the guide passes through the produced fluid during the downward motion of the sucker rod string.
SUMMARY OF THE INVENTION
The present invention is directed to maximizing the EWV of the guide while at the same time providing for sufficient flow through and around the guide to achieve the necessary or desired low pressure drop for the particular operating conditions in which the rod guide is used. As will be developed further below, the concept of the present invention calls for maximizing the ratios of the EWV to the total volume (TV) of a rod guide as well as the EWV to the flow resistance or drag of a rod guide. Ideally one of the best designs would have a cross section that resembles a bicycle wheel with as few spokes as possible.
The present invention utilizes plastic injection molding technology to secure the rod guide to the sucker rod while also preferably obtaining the formation of the necessary flow passages and open areas in or around the rod guide without resorting to drilling or other subsequent mechanical processes to obtain the desired flow passages.
A suitable rod guide according to the invention is secured to a rod string which is then placed in the tubing, with the guide functioning to centralize the rod string in the tubing while it passes through the tubing to the downhole pump and thereby minimizes wear between the rod string and the tubing. The rod guide has a radially inner non-erodible zone available for flow through and a radially outer erodible zone, as defined above.
An object of the present invention is to maximize the erodible wear volume of a rod guide while maintaining adequate flow through and around the guide to obtain a desired low pressure drop or drag across the guide.
It is an object of the present invention to provide an improved centralizing device which overcomes the deficiencies of the prior art between Gross and Net EWV and at the same time provides for high erodible wear volume consistent with the desired high flow through and low drag characteristics.
It is a feature of the present invention to provide for the molding of centralizers on the rod without having to resort to a drilling or similar operation to produce fluid flow paths in the molded guides resulting in the desired flow through for the guide with a high erodible wear volume.
It is a feature of the present invention to provide an improved and low cost rod guide which averts contact between the sucker rod string and the tubing of a producing oil well.
It is a further feature of the present invention to provide an improved rod guide that may clean mineral scale and paraffin deposits from the interior surface of the tubing when the guide is fixed to a reciprocating rod string.
It is another feature of this invention to achieve the above two features with a provision of an EWV which approaches the maximum obtainable in terms of Gros and Net EWV while providing a desired high flow through and low drag characteristics when the rod guide is in a typical application.
Still another feature of the invention is a rod guide molded around a rod intended to be placed within the tubing, with the rod guide having a high EWV and flow channels or by-pass areas predominately located in the non-erodible zone of the rod guide.
A significant advantage of the present invention is that the rod guide may achieve the above objects and features while the guide remains sturdy, compact, durable, simple, ecologically compatible, reliable, and inexpensive and easy to manufacture and maintain.
Other objects, features and advantages of the present invention, as well as a fuller understanding of this invention, may be had by referring to the following description and claims taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In order to facilitate the understanding of the present invention, reference will now be made to the appended drawings of preferred embodiments of the present invention. The drawings should not be construed as limiting the invention, but are exemplary only.
FIG. 1 is a side view of a typical well having a reciprocating rod string provided with rod guides of the present invention.
FIG. 2 is a side view of one embodiment of a rod guide of the present invention.
FIG. 3 is a top or end view of the rod guide shown in FIG. 2.
FIG. 4 is an isometric view of the molds for the moving and stationary platens of a molding system used to mold the present invention on a rod. The front right of each side mold supports the cavity rods in a cantilevered fashion. These rods are withdrawn before the mold is opened. The upper side mold is mounted to the stationary platen and is shown positioned adjacent the rod for a molding operation. The lower side mold is mounted on the moving platen and away from the rod. In this view, the moving platen is retracted and the molds are in the open position. The cavity rods are shown partially inserted for clarity.
FIG. 5 is an isometric view of the molding apparatus in accordance with the present invention after the separation of the mold from the rod following the molding of a guide on the rod.
FIG. 6 is another embodiment of the present invention with an enlarged flow through area creating a rod guide having a generally Maltese cross configuration which can be achieved by changing the configuration and cross-section of the cavity rods.
FIG. 7 is an end or top view of another embodiment of the present invention in which the rod guide has expanded internal flow through cavities as well as external flow channels, both of which can be obtained by changing the configuration and cross-section of the cavity rods and mold geometry.
FIG. 8 is an end or top view of yet another embodiment of a rod guide in accordance with the present invention in which the generally Maltese cross shaped blades are provided with flow through cavities. The outer surface of the guide is off-set at its center of curvature from the rod center to provide an outer surface conforming to the internal curvature of the tubing. In all cases, the outside diameter of the guide is only slightly less than the inside diameter of the tubing.
FIG. 9 is a side cross-sectional view of an embodiment of a rod guide in accordance with the present invention in which the outermost portions of the guide extend longitudinally parallel to the axis of the rod string and in excess of the portion of the guide molded to and in contact with the rod.
FIG. 10 is a top or end view of another embodiment of a rod guide of the present invention in which the space between the support arms of the rod guide has been enlarged to provide additional flow through capacity.
FIG. 11 is an end or top view of an embodiment of the present invention in which four or more of the two bladed rod guides have been molded on the rod, with each successive guide indexed 45 degrees with respect to the next adjacent rod guide in a nesting approach to concentrate the EWV, which is undesirably low for a single two bladed guide alone but increasingly effective as more two bladed guides are indexed and molded closely together.
FIG. 12 is a side view of a portion of the array shown in FIG. 11, illustrates only two of the two blade rod guides indexed at 90°.
DESCRIPTION OF PREFERRED EMBODIMENTS
The present invention is perhaps best understood by reviewing the first principles upon which the invention is based. As has been noted above, it is desired to maximize the EWV relative to the TV of a rod guide and simultaneously, at least to the extent desired or necessary, maximize the fluid flow channels through and/or around the rod guide to minimize the adverse affects of drag, turbulence or pressure drop across the guide.
The maximum EWV may be obtained by filling the entire area between the rod coupling outside diameter and the inner surface of the tubing with rod guide material like the rim on a bicycle wheel. By maintaining complete circumferential outer contact of the guide with the tubing inside diameter and also providing flow through the guide in the area between the outer diameter of the rod coupling and the outer diameter of the sucker rod should fluid flow through the guide is provided and erodible wear volume is maximized. As additional flow through holes in the guide are provided, usually in the preferred embodiments in a symmetrical pattern, flow is increased to the desired level with a desired low pressure drop and without decreasing the EWV. Preferably at least three through holes are thus provided in the guide. However, the structural integrity of the rod guide is reduced in the process. The present invention balances these factors in a unique manner to provide a moldable rod guide with a high EWV, a desired structural integrity, and flow through the guide to achieve a low pressure drop or low drag.
As holes in the rod guide are enlarged, a Maltese cross configuration such as shown in FIG. 6 may be formed by support arms which interconnect a radially inner substantially sleeve-shaped portion in gripping engagement with the rod with a radially outward sleeve-shaped portion forming a cylindrical outer surface of the rod guide essentially equal to the inside diameter of the tubing. The outer surface may be separated, as shown in FIG. 8 or FIG. 10, to reduce the EWV and provide for greater flow through capacity. Additional flow through capacity (by-pass area) may thus be obtained by increasing the flow through area in the erodible zone of the rod guide. Ideally, the erodible zone of the rod guide is maximized while still providing for high flow through capacity, and the resulting design has a sufficient structural integrity for a molded rod guide. To obtain these objectives, the relatively simple rod guide molding process becomes more complicated. A related concept involves the longitudinal expansion of the radially outer portions of the rod guide as shown in FIG. 9 and will be discussed in greater detail below.
Referring to FIG. 1, a pumping apparatus 100 is shown for pumping fluids from a well 102 and through a string of tubing 106 disposed within well casing 108. Connected to the pumping apparatus 100 is a string of sucker rods 105 connected by coupling, such as typical coupling and pin connector means 104. The pumping apparatus as shown in FIG. 1 drives the rod string in a reciprocating manner to pump fluid to the surface through the well tubing. The rod string 105 may be rotated by a rod rotator 114, if desired, to distribute wear more evenly to both the rod guides 107 and the sucker rods 105.
When the pumping apparatus 100 is on the down stroke of its reciprocating action, the string of rods 105 move axially within the tubing 106 to operate the downhole pump (not shown). A plurality of rod guides 107 of the present invention are fixedly engaged around the sucker rods 105 at selected locations throughout the length of the rod string 105. During this reciprocating movement of the string of sucker rods 105, the well fluids are caused to flow upwardly in the tubing 106 on the upstroke and the rod guides 107 fall through the fluid on the downstroke.
FIG. 2 shows a rod guide 200 molded to a rod 202. The generally cylindrical rod guide body 204 has a circumferential outer surface 210 and is provided with a plurality of cylindrical holes 206 which end at the top and bottom surfaces 208 and 209 of the rod guide, respectively. As a result of the formation of the holes by cantilevered cavity rods as discussed subsequently, the holes 206 may have excess nipple material 212 at one end, as will be made more apparent by considering the molding process described below. This excess material 212 is shown exaggerated in FIG. 2 for clarity.
When seen from a top or end view, the holes 206 appear as holes 306 in FIG. 3 wherein the rod guide 300 is molded about rod 302 and has an outer circumferential surface 304 sized for initial contact (or approximately so) with the internal surface with the tubing (not shown). The outer surface of the couplings in the operative region of the rod 302 is shown in dashed lines and represents the circumferential boundary 308 which defines the inner limit of the erodible wear volume (EWV) 310 which extends to the outer surface 304. The area between the boundary line 308 and the rod 302 thus defines the non-erodible zone of the rod guide. In general, the rod guide may consist of a radially inner non-erodible zone and a radially outward erodible zone. As noted above, the boundary line between the two zones, the erodible and the non-erodible zone, is the projected circumference of the largest outer dimension of any component anticipated to be on the rod string in the operative region of the rod guide. The boundary line which in this example is equal to the outside diameter of the nearest rod coupling is thus the dashed line 308 shown in FIG. 3. The erodible zone contains that material in the region between the boundary line 308 and the outer surface of the rod guide 304 which is only slightly less than the inner diameter of the tubing string. The erodible zone includes that volume of material in the rod guide which may be eroded in use before a component on the rod in the operative region of the rod guide contacts the tubing. It is desired for the rod guide to have the maximum amount of material in the erodible zone and thereby to have the maximum EWV for a given length of guide. At the same time, it is desired to provide for adequate flow through capacity (by-pass area) through the rod guide by providing flow channels, holes 306, through the rod guide. These holes will preferably be located predominately in the non-erodible zone of the rod guide.
As the size of the flow through holes is enlarged to provide for a greater volume of fluid flow through the rod guide without increasing drag and pressure drop, a configuration such as shown in FIG. 6 may result, wherein a rod guide 600 is molded on rod 602. The guide 600 is held in place on the rod by a radially inner substantially cylindrically shaped portion 604 of the non-erodible zone which surrounds the rod 602 and in gripping engagement therewith as a result of the molding process. The enlarged flow through holes 610 form a plurality of support arms 606 in the form of a Maltese cross which connect the radially inner portion 604 with a radially outer cylindrical surface 608 of the crodible zone for complete circumferential contact with the tubing (not shown).
As shown in FIG. 7, a rod guide 700 has support arms which include indentations defined by 704 and erodible wear surfaces 702. Flow through cavities 706 are spaced circumferentially about rod 710, and additional flow capacity is provided by the circumferential spacing between the indentations 704. A similar expansion of the flow through area may result in a Maltese cross of the form as shown in FIG. 8, in which a rod guide 800 has an expanded flow through area bounded by surfaces 804 and flow through holes 806. The outer linear surface 802 has a diameter slightly smaller than the inside diameter of the tubing (not shown). The center 808 of the curved outer surface 802 coincides substantially with the center 110 of the sucker rod 812.
In FIG. 10, a rod guide 1000 is molded about rod 1002 and has flow through areas bounded by 1004 and 1006 which form EWV 1008 bounded on the outside by wear surface 1010. Support arm extensions 1012 may substantially touch to form a substantially complete circumference of wear surface of the EWV to contact the tubing.
The molding operations according to the present invention may be of the type described below in connection with FIGS. 4 and 5. The details of injection molding as employed in the art are well known and, except as expressly noted herein, do not constitute a part of the present invention. A description of the operation and construction of injection molding equipment may be found in a 1962 publication Manufacturing Processes by S.E. Ursunoff, American Technical Society, beginning at page 56. A description of the application of molding processes in connection with molded plastic rod guides, centralizers, scrapers and the like may also be found in U.S. Pat. Nos. 3,251,919 and 4,088,185.
Among the materials suitable for use in accordance with the present invention are polyphenylene sulfide, polyphthalamide, polyamide (nylon), polyethylene, polypropylene, polycarbonate and polyester. All these thermoplastic resins may also be used with glass, arimide fibers and mineral fillers. Ultra-high molecular weight polyethylene may be employed in circumstances which do not involve injection molding. In general, plastics having suitable shrinkage properties and tensile strengths may be employed if not too brittle on molding, if their abrasion and wear characteristics are satisfactory, and if they can withstand the wide range of tempera tures an d c orrosive conditions found in oil well operations. A more extensive listing of suitable materials may be found in U.S. Pat. No. 4,088,185.
It is desirable but not essential according to the present invention to provide the flow through holes in the rod guide without resort to drilling or similar means. The present invention includes the process herein describe of providing such flow through holes as a part of the molding process. As shown in FIG. 4, a two part mold 400 is created or provided consisting of left-side and right-side molds 402 and 404 with a suitably shaped rod guide cavity consisting of left-side and right-side portions 444 and 410, respectively. The cavity in each half of the mold may be filled with plastic material 408 injected into the mold through tube 406. Cantilevered within the cavity may be one or more rods, such as, for example, rods 412 , 414 , 440 and 458 . Th ese rods may each b e cantilevered in the mold cavity 410 and supported by one end of a respective supporting end block member 418. Each mold half also includes an axially opposing end block member 416. The connection face between the rods 412 an d 414 with the mold half 404 i s shown as 462 and 46 4 in FIG. 4.
The two mold halves 402 and 404 are radially closed about the sucker rod 446 and the end blocks 418 are moved axially with respect to mold portions 402 and 404 to a closed or mold position to provide a totally enclosed cavity into which the plastic material 408 is injected through tubing 406. Each mold half includes end blocks with substantially semi-circular ports 424 the rein for receiving the sucker rod 446 when the mold halves are closed. A suitable face seal 428 is provided on the radially inward face of one or both blocks 416, 418 for sealing with the radially opposing block when the mold is closed. Similarly, a seal 430 is provided for sealing e ngagement between the end blocks 418 and the r espective primary left side and right side mold 402 and 404 when the mold is closed. The cantilevered rods 412, 414, 440 and 458, w hich may be of any of many shapes to provide flow through holes of the shape or shapes desired, are further supported in the closed position by insertion of the free or cant levered end of each rod into shallow pockets 420, 422, 432, 434 in the respective opposing end blocks 416 of mold ports 402 and 404 to support the free ends of the rods.
As shown in FIG. 5, after the plastic material 518 has been injected through conduit 520 and through the port 522 in the mold half 516 and into the rod guide cavity 524 formed by the mold halves 515 and 516 which makes up the mold 500, a rod guide 502 having a desired EWV and outer surface 506 will have been formed about rod 508. Rod guide 502 contains axially extending flow through holes 504 formed by the cantilevered rod members 412, 414, 440 and 458. Also, a plurality of outer flow paths 505 are formed about the outer periphery of the guide 502, with these axially extending flow paths 505 being formed by the respective generally semi-cylindrical radially inwardly projections 526 provided in each mold half 514 and 516. The end blocks 509 and 510 are moved longitudinally along the axis of the rod 508, thereby breaking the seals 530 and removing the rods from the holes 504. When end blocks 509 and 510 carrying cantilevered rods 412, 414, 440 and 458 are clear of the guide 502, the mold halves which are attached to the moving and stationary platens of the injection molding machine may then be separated. The substantially sideways U-shaped seal 532 comprising end seal 534 and top and bottom legs 536 and 538 will thus be broken during this separation process. Similarly, the face 521 on the end block 510 may be radially separated from the opposing face on the block 509. In this manner, flow through holes 504 of any desired shape or size may be provided in a single molding operation. The rods 512, 514, 540 and 558 are cantilevered and fixed to end blocks 509 and 510 and sufficient spacing is provided during the molding operation for the blocks 509 and 510 with their supported rods to clear the molded work piece formed on the sucker rod 508. In the above fashion, it is possible to provide flow through holes in various pieces of any molded guide in any size or shape.
In operation, the mold halves and end blocks are closed about the rod and the plastic material is injection molded around the rod. After the guide is formed, the end blocks with cantilevered rods are moved longitudinally along the axis of the rod until clear of the molded workpiece. The major mold halves may then be opened (moved radially with respect to the rod 508) and separated from the molded guide. Those skilled in the art will appreciate that the sucker rods 408 on which the rod guides are molded conventionally have threaded end members 507 as shown in FIG. 5. During the rod guide molding process, these threaded connections 507 are normally broken and the rod guides are molded at preselected axial locations along the length of a single sucker rod. After the rod guide molding operation, the connections 507 on the rods 508 may be threadedly coupled to comprise a rod guide string which is reciprocated in the well.
In a similar fashion to that described above, the dog bone configuration of the centralizer or guide 1100 of FIG. 11 may be molded about rod 1102. Such guides 1100 may be indexed with respect to each other as shown in FIG. 11 to form a nest of rod guides or a helical array of guides effectively providing complete 360 degree coverage and wear contact area with the tubing. As shown in FIG. 11, guides 1100 may be molded about rod 1102 in an indexed fashion of, for example, 45 degrees from the next adjacent guide. The flared area 1104, 1108, etc. may be as extensive as desired consistent with the needed flow through characteristics to provide the desired wear surface and EWV. Holes for the desired flow through 1106 and 1110 may be provided by the molding techniques described herein.
Two of the indexed guides of FIG. 11 are shown in FIG. 12 wherein the array 1200 of guides 1204, and 1208 with the wear surfaces as described above are molded about rod 1202 in an indexed manner of 90 degrees with respect to the next adjacent guide. If desired, flow through holes 1206 and 1210 may be provided by means of the molding process described above.
As shown in FIG. 9, these same techniques may also be applied to mold a guide such as 900 around rod 902 with material in contact with the rod 908 and gripping the rod. The rod guide includes extended longitudinal wings 906 to provide extended wear surface 904 and extended EWV. A multiplicity of flow through holes 910 and 912, for example, may be provided to permit the necessary and desired flow through capacity. The extended longitudinal wings are a further example of a fundamental concept of the present invention in that such a configuration inherently provides for extra outer material for EWV relating to the total volume of the guide and still maintain the necessary flow through capacity in the non-erodible zone of the rod guide.
In most if not all of the configurations shown herein, the circumferential extent of any of the separated arms of the rod guide may be expanded to any extent desired consistent with the desired flow through characteristics or the need for by-pass area up to and including full circumferential contact with the tubing.
While it is preferred to form the flow through channels as described herein, it is within the scope of the claims below describing the present invention to drill some or all of the holes, if desired. The cantilevered rods referred to above may also be suspended by other material supports within the mold cavity.
Further embodiments such as the use of a spiral or helical vane may be employed in accordance with the present invention. In such an embodiment, the EWV may be controlled as a function of the pitch and number of leads provided. The flow through capacity may be controlled by the number and position of the holes in the erodible and the non-erodible zones of the rod guide.
It will be apparent to one of ordinary skill in the art that the present invention may be modified to employ the principles taught within the scope of the present invention. Various changes and modifications may be effected in the illustrated embodiment of the present invention without departing from the scope and spirit of the invention defined in the appended claims. The embodiments shown and described above are exemplary. Various modifications can be made in the construction, material, arrangement, and operation, and still be within the scope of the invention. The limits of the invention and the bounds of the patent protection are measured by and defined in the following claims.
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A rod guide fixedly molded around the shank of a sucker rod string with the rod guide including a radially inner non-erodible zone and a radially outer erodible zone. The non-erodible zone includes a radially inner substantially sleeve-shaped portion having an inner cylindrical surface for gripping engagement with the rod. A plurality of flow through channels are spaced outward of the substantially sleeve-shaped portion. Each flow through channel extends axially along the rod guide and has a maximum circumferential width greater than any gap in the radially outer surface of the erodible zone circumferentially aligned with and radially outward of the respective flow through channel. The radially outer surface of the erodible zone may have a cylindrical outer configuration, such that a radially outward substantially sleeve-shaped portion is provided for engagement with the tubing. The upper and lower surfaces of the rod guide may each be inclined such that the radially outer surface of the rod guide extends longitudinally in excess of the inner cylindrical surface of the sleeve-shaped portion and in engagement with the rod. A guided sucker rod includes an elongate rod having threaded end connectors for mating engagement with an adjoining sucker rod and one or more rod guides fixedly molded thereon. According to the method of the invention, left-side and right-side molds are created each including one or more elongate cavity creating member supported in a cantilevered fashion from a supporting end block. A plastic material is injected into the mold cavity, and the supporting end block is then moved longitudinally along the axis of the rod to remove the one or more channel performing members from the molded rod guide.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority of U.S. Provisional Patent Application No. 61/429,921 filed Jan. 5, 2011, the contents of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The invention relates to the field of road construction.
BACKGROUND OF THE INVENTION
[0003] Asphalt is widely used for paving roads. For reasons including but not limited to cost, asphalt is typically applied in a relatively thin layer above a base course of compacted aggregate. Often, the base course is itself applied upon a compacted sub base course of compacted aggregate, this sub base aggregate having properties that differ from those of the base course aggregate. In a typical road building operation involving both base and sub base layers, elevated areas of the roadway are excavated to the depth of the required sub base. Thereafter, the sub base aggregate is applied in layers, rough graded and compacted, all by heavy equipment. This is followed by application of the base course aggregate which itself is applied in layers, rough graded and compacted, all by heavy equipment. The surface of the base course will then be machine graded, either through blading or compaction, in preparation for application of asphalt. The asphalt itself is usually applied by a self-propelled laydown machine, which receives granular asphalt material, for example, from a dump truck, spreads the asphalt over the base course, and then levels and partially compacts the asphalt with a floating screed. The partially-compacted asphalt is typically thereafter roll-compacted, to achieve a smooth finish and relatively impermeable surface.
[0004] All of the above is conventional, works relatively well and, being substantially mechanized, is relatively economical.
[0005] In some areas of the world it is desirable to include a paved gutter on the outer surface of the roadway for drainage. As the above-described equipment is adapted only for creating substantially planar roadways, it is known to provide paved gutters in a relatively non-mechanized fashion, with the base course and asphalt layers of the gutter area being formed and compacted with hand tools and small mechanized compaction devices. This adds to cost and complexity.
SUMMARY OF THE INVENTION
[0006] A method for constructing an asphalt-paved gutter comprises one aspect of the invention. In this method, the gutter is of the type having a trough-shaped base and an asphalt layer defining the gutter which overlies the base. This method comprises the steps of: screeding a surface with a shaping screed having the shaping profile of said trough-shaped base to form said trough-shaped base; and forming the gutter with an asphalt laydown machine. The laydown machine is of the type used in road construction to spread asphalt over a base course and which screeds and compacts the asphalt using a floating screed. The gutter is formed by providing a protuberance underneath the floating screed, which protuberance is shaped and dimensioned to screed and compact the asphalt layer in use.
[0007] According to another aspect of the invention, the surface can be defined by a layer of aggregate arranged in a strip alongside the base course of a roadway.
[0008] According to another aspect of the invention, the layer of aggregate arranged in a strip and the base course of a roadway can be constructed simultaneously and of identical construction.
[0009] According to another aspect of the invention, as the gutter is formed, the laydown machine can contemporaneously apply a layer of asphalt to the base course of the roadway.
[0010] According to another aspect of the invention, the shaping screed can be secured to the bucket of a front loader.
[0011] According to another aspect of the invention, the shaping screed can be secured to the bucket of a compact skid steer loader.
[0012] According to another aspect of the invention, the shaping screed can extend laterally outwardly and rearwardly from the bucket.
[0013] According to another aspect of the invention, the protuberance can be defined by: a base member having a surface which has a cross-section in the shape of the gutter profile; and a lip rigidly connected to the base member and adapted to be engaged by the floating screed in use to drag the base member with the surface of the base member presenting downwardly for compacting and shaping the asphalt.
[0014] According to another aspect of the invention, the protuberance can be coupled to the laydown machine by a link which is adapted to allow the protuberance to be moved without hand tools between the position underneath the floating screed and a position above the floating screed.
[0015] Other advantages, features and characteristics of the present invention, as well as methods of operation and functions of the related elements of the structure, and the combination of parts and economies of manufacture, will become more apparent upon consideration of the following detailed description and the appended claims with reference to the accompanying figures, the latter being briefly described hereinafter.
BRIEF DESCRIPTION OF THE FIGURES
[0016] FIG. 1 is a side schematic view of a prior art asphalt laydown machine;
[0017] FIG. 2 is a perspective view of an exemplary embodiment of the shaping screed used in the method;
[0018] FIG. 3 is a perspective view of an exemplary embodiment of the packer used in the method;
[0019] FIG. 4 is a view of the apparatus of FIG. 3 from another vantage point;
[0020] FIG. 5 is a view of a structure similar to the structure of FIG. 2 positioned for use; and
[0021] FIG. 6 is a view of the structure of FIG. 3 in use with the structure of FIG. 1 .
DETAILED DESCRIPTION
[0022] Reference is initially made to FIGS. 2-4 , which show apparatus 20 A, 20 B that embody aspects of the invention and which can be used to carry out a road-construction-related method that forms an exemplary embodiment of the invention. For greater certainty, it is hereinafter described that the method of the present invention is carried out, in part, with an asphalt laydown machine, of the general prior art type having a floating screed which is shown by way of example in FIG. 1 and identified with reference numeral 80 , but it should be understood that the laydown machine 80 is illustrated for clarity only. Again, for clarity, only, the floating screed is identified in FIG. 1 with reference numeral 100 .
[0023] FIG. 2 shows a shaping screed 20 A which will be seen to comprise a blade 22 and a bracket 24 . The blade 22 has a protruding tooth 26 . The bracket 24 includes a base 28 arranged in angular relation to the blade 22 , a pair of gussets 30 supporting the junction of the blade 22 and base 28 and a strut 32 rigidly extending between the base 28 and an intermediate portion of the blade 22 . A plurality of apertures 34 are defined through the base 28 .
[0024] A projecting lip 35 extends from the top of the blade 22 and a flag 37 projects upwardly from the blade end.
[0025] FIGS. 3 and 4 shows two sides of a packer 20 B which comprises a base member 36 , a face plate 38 , a pair of chains 40 and a pair of nut and bolt assemblies 42 . The base member 36 is shaped to define a trough 44 . The face plate 38 is rigidly connected to the base member 36 , occludes one end of the trough 44 and extends beyond the trough 44 to define a lip 46 . The chains 40 are coupled to the face plate 38 , with each chain 40 terminating in one of the nut and bolt assemblies 42 .
[0026] Reference is now made to FIG. 5 and FIG. 6 , which show, respectively, an apparatus similar to the apparatus of FIG. 2 and the apparatus of FIG. 3 positioned for use.
[0027] Turning first to FIG. 5 , this shows the base 28 of the bracket 24 bolted (via apertures 34 , not shown) to the bucket 48 of a compact skid steer loader (not shown), such that the blade 22 extends outwardly and rearwardly from the side of the bucket 48 and the tooth 26 projects downwardly. It is notable that the blade 22 , exclusive of the tooth 26 , should not be positioned above the base of the bucket 48 when operatively mounted.
[0028] Turning next to FIG. 6 , this shows the base member 36 positioned beneath the floating screed 100 of the exemplary asphalt laydown machine 80 of FIG. 1 , with the lip 46 projecting upwardly from the base member 36 to engage the screed 100 . The chains 40 and nut and bolt assemblies 42 , only partially shown, secure the packer 20 B to the laydown machine 80 .
[0029] In use, the roadway area is excavated and the base and sub base are prepared in a generally conventional manner, i.e.
the roadway is excavated, as required, to the depth of the base and any required sub base any required sub base is deposited and compacted the base is deposited and compacted and graded as required to receive asphalt
[0033] One notable practical requirement when carrying out the method of the present invention is that the base course be sufficiently wide to accommodate the required driving surface and any required gutter, i.e. a layer of aggregate for faulting the gutter is arranged in a strip alongside the base course of the intended roadway, with both portions being formed effectively simultaneously and of identical construction. [It is conceivable that the method of the present invention could be carried out in isolation, i.e. not as part of a roadway construction, but that would impact upon the economics and may not be advantageous in comparison to other known methods.]
[0034] Once the base course has been prepared, the apparatus 20 A of FIG. 5 is used to screed the base course to form a trough in the base course, i.e. to form a trough-shaped base. To do so, the operator of the loader positions the shaping screed 20 A such that the bottom of the blade 22 , excluding the tooth 26 , is level but slightly above the surface of the base course and drives the loader in a direction along the base course in a direction parallel to but offset from the intended location of the gutter. This causes the tooth 26 of the screed 20 A to excavate the trough, and as the excavated material accumulates, it passes along the length of the blade 22 so as to be deposited to the side of the gutter. The lip 35 (not shown in the screed of FIG. 5 ) if provided as is advantageous, avoids overspill, i.e. it ensures that excavated material is deposited to the side of the gutter, rather than falling behind the blade.
[0035] In regard to excavation, it will be appreciated that the profile of the tooth of the shaping screed is a slightly elongated version of the desired trough; this, coupled with the angular orientation of the blade 22 when coupled to the bucket 48 , provides for the tooth 26 to have a screeding profile, i.e. the profile of the tooth when viewed in the direction of vehicle travel, equivalent to the cross-sectional profile of the desired trough shaped base.
[0036] In this further regard, it is noted that ‘screeding’ often contemplates the preparation of a planar surface, but it is known to screed, for example, wet concrete with an arcuate board, to crown the surface, and thus, in this description and the appended claims, ‘screed’ should be understood to encompass all activities wherein a member is scraped/dragged along a surface to shape/profile the surface to match the scraping member.
[0037] The use of a compact skid steer loader will be understood to be advantageous, in that it is sufficiently lightweight to avoid much in the way of inadvertent dislodgement of the previously-prepared base course material, yet at the same time, is sufficiently powerful to excavate the trough relatively quickly. In order to ensure that the trough is correctly positioned, the operator will be required to drive the loader with some precision, but it will be appreciated that precision driving and bucket placement is a matter of routine to skilled operators and thus this operation is equally a matter of routine. The flag 37 assists in this regard, and also assists the operator in avoiding obstacles.
[0038] Once the trough has been defined in the base material, asphalt is applied using a laydown machine such as that shown in FIG. 1 . The laydown machine operates in a generally conventional fashion, with the notable difference being that, instead of carefully driving the laydown machine to spread asphalt to the edge of the intended roadway, the machine will be operated to spread asphalt to the edge of the intended gutter. As well, the packer 20 B is positioned underneath the screed plate 100 of the laydown machine, with the lip 46 engaged by the screed 100 , as shown in FIG. 6 . Thus, as the screed plate 100 of the laydown machine 80 creates the driving surface, the protuberance (defined by base member 36 and face plate 38 ), which has a cross-section in the shape of the desired gutter, is dragged by the lip 46 and compressed by the screed plate 100 to compact and shape the asphalt to form the desired gutter.
[0039] The chains 40 and nut and bolt assemblies 42 assist in terms of the positioning of the protuberance; without limitation, the chains and nut and bolt assemblies allow the screed plate of the laydown machine to be adjusted upwardly while in operation without disengagement of the protuberance. At the same time, when the protuberance defined by the packer 20 B is not required, the chains allow that portion of the packer 20 B that defines the protuberance to be removed from beneath the screed plate without tools and stowed for subsequent use.
[0040] After the laydown machine has completed its work, the roadway and gutter proper are finished. Run-off channels may be desired at points along the gutter, and these can be constructed and packed with hand tools and small mechanized compaction devices.
[0041] Whereas a single embodiment of the method is described and illustrated, variations are possible.
[0042] Without limitation, the screed 20 A could be carried by a device other than a skid steer loader; other front loaders, for example, could readily be used.
[0043] As well, whereas the screed 20 A has a tooth of a specific profile, other profiles are, of course, possible.
[0044] Further, whereas the packer 20 B has a specific profile and structure, other profiles and structures are possible.
[0045] Additionally, the protuberance can be secured to the underside of the screed plate by means other than chains and nut and bolt assemblies.
[0046] Accordingly, the invention should be understood as limited only by the accompanying claims, purposively construed.
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Disclosed is a method for constructing an asphalt-paved gutter, the gutter being of the type having a trough-shaped base and an asphalt layer defining the gutter which overlies the base. The method comprises screeding a surface with a shaping screed having the shaping profile of said trough-shaped base to form said trough-shaped base. The gutter is formed with an asphalt laydown machine, of the type used in road construction to spread asphalt over a base course and which screeds and compacts the asphalt using a floating screed, by providing a protuberance underneath the floating screed which protuberance is shaped and dimensioned to screed and compact the asphalt layer in use.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a land mine disposal device and a mine disposal method, and especially, relates to an inexpensive device which can dispose antipersonnel mines safely.
2. Prior Art
At present, in every corner of the world, especially in the Third World, a large number of land mines are still laid. Since there are little number of accurate records to show the places where mines are laid, the mine disposal is extremely difficult, and unfortunate and miserable accidents happen repeatedly. In the Third World, there are a large number of lands which cannot be used as a farmland because the mine disposal is incomplete.
The land mines are traditionally detected by a metal detector and then disposed. However, since a lot of antipersonnel mines do not have sufficient metals to which the metal detector can react, there are a large number of cases where the mines cannot be detected by the metal detector. An approach for disposing the antipersonnel mines by running a large-sized automatic guided bulldozer in a land where the personnel mines may be laid has been also attempted. But this approach is not practical because it requires a large sum of costs to revive the land as a farmland after such a disposal has been performed.
SUMMARY OF THE INVENTION
It is, therefore, an object of the present invention to provide an inexpensive mine disposal device which can dispose antipersonnel mines safely.
It is another object of the present invention to provide a safe disposal method of antipersonnel mines.
It is a further object of the present invention to provide a mine disposal device which can reduce cost of reviving the land as a farmland after a mine disposal has been performed.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view showing a tractor with a stabilizer for the mine disposal according to the present invention;
FIG. 2 is a plan view of the tractor;
FIG. 3 is a longitudinal sectional front view of the stabilizer;
FIG. 4 is a longitudinal sectional side view of the stabilizer; and
FIG. 5 is a block circuit diagram.
DESCRIPTION OF THE PREFERRED EMBODIMENT
An embodiment of the present invention will be described by referring to drawings. A tractor 1 has an engine 30 and a crawler or a wheel 31 driven to rotate by the power of the engine 30. Each rear end of supporting arms 2 is rotatably attached to a vehicle body 37 of the tractor 1. To front ends of the supporting arms 2 projecting beyond a front side of the body 37, an attachment or a shank-type stabilizer 3 for mine disposal is rotatably attached with mounting shafts 32. The stabilizer 3 is also connected to the supporting arms 2 through a linkage 33. The stabilizer 3 is substantially vertically moved by the action of hydraulic cylinders 5 mounted between the body 37 and the arms 2, and further, it is rotated about the shafts 32 by the action of hydraulic cylinders 4 mounted between the body 37 and the linkage 33. The tractor 1 with the crawler 31 shows an excellent performance in running on a soft land or a slope land, and can run on almost all lands where mines may be laid.
As shown in FIGS. 3, 4, the stabilizer 3 has a pair of rotational shafts 8, 9 extending in a lateral direction of the body 37 and a plurality of soil pulverizing rotor disks or plates 7 removably attached to the rotational shafts 8, 9. Upper half of the rotor disks 7 are covered by an elongated semi-cylindrical metal cover or shield 6 having side metal plates 34, 35. A plurality of removable bits 10 are attached to a periphery of each of the rotor disks 7. The rotational shaft 8 is connected, through a transmission device 13 fixed to an outer surface of the side plate 34, to a hydraulic motor 11 mounted on an outer surface of the shield 6. And also, the rotational shaft 9 is connected, through a transmission device 14 fixed to an outer surface of the side plate 35, to a hydraulic motor 12 mounted on an outer surface of the shield 6. The width of the stabilizer 3 is equal to or longer than that of the body 37 so that the tractor 1 can advance on the pulverized or cultivated land which is safe from antipersonnel mines as described later.
The tractor 1 is controlled by a control signal from a remote control transmitter 29. The control signal is received at a receiving section 28 equipped on the body 37. The tractor 1 advances, while pulverizing the land 36 by the rotor disks 7. To the outer sides of the transmission devices 13, 14 are fixed sleds 22, 23 which determine the depth of pulverizing soil with the rotor disks 7 by touching the surface of the land 36. The depth of pulverizing soil is preferably 40 to 60 cm. Because almost all the antipersonnel mines had been laid within the said depth.
To the front of the stabilizer 3, a sensor or a metal detector 25 is attached for detecting an antitank mine 24 laid under the ground in the land 36. The sensor 25 is arranged to be able to scan at least the area corresponding to the breadth of the stabilizer 3 (tractor 1). When a detection signal from the sensor 25 is outputted to a control section 38 of the tractor 1, the control section 38 cuts off (i.e. disengages) a main clutch 27 between the engine 30 and the crawler 31 through a relay circuit 26, and stops the advance of the tractor 1, keeping the engine 30 idling. The antitank mine 24 detected by the sensor 25 is disposed by a previous traditional method. When the disposal of the mine 24 has been finished, the tractor 1 is advanced again by the remote control transmitter 29.
Since the antitank mine 24 has a strong explosive power which may give a serious damage to the stabilizer 3, it is removed before the rotor disks 7 touch the antitank mine 24 as described above. However, the explosive power of the antipersonnel mine 15 is relatively weak so that the antipersonnel mine 15 can be disposed by blowing it up by the contact with the rotor disks 7. Therefore, the stabilizer 3 of the present invention is arranged so as to be able to bear the blast of the antipersonnel mine 15. That is, each distance between the rotor disks 7 is made to be a distance sufficient for the blast and the scattered objects to smoothly pass through. Furthermore, movable skirts 16, 18 for lessening the blast of the antipersonnel mine 15 are attached to lower ends of front and rear panels 41, 42 of the shield 6 by shaft 39, 40, respectively. The movable skirts 16, 18 are held at positions shown by solid lines in FIG. 4 with shock absorbers 17, 19. The movable skirts 16, 18 are bent and top portions 43, 44 thereof face the outside. When the antipersonnel mine 15 explodes, the movable skirts 16, 18 are opened outside as shown by dotted lines against resilient forces of the shock absorbers 17, 19 by the blast so as to soften the blast acting on the stabilizer 3. By the above mentioned arrangement, the stabilizer 3 of the present invention comes to be able to bear the blast of the antipersonnel mine 15.
The shield 6 has a front breaking board 20 extending substantially backward from an inner surface of the front panel 41 and a rear breaking board 21 extending substantially forward from an inner surface of the rear panel 42. The cakes of soil or the like raked up by the rotor disks 7 are crushed by colliding with the breaking boards 20, 21 and the diameter of the crushed soil or the like is made to be approximately not more than 30 mm.
OPERATION
When a control signal transmitted to the tractor 1 by the remote control transmitter 29 is received at the receiving section 28, the control section 38 starts the engine 30, rotates the rotor disks 7 by the hydraulic motors 11, 12, and lowers the stabilizer 3 by the hydraulic cylinders 4, 5 so as to pulverize the land 36. When the sleds 22, 23 touch the surface of the land 36, the depth of pulverizing soil is kept constant. In that state, when the main clutch 27 is connected so as to transmit the power of the engine 30 to the crawler 31, the tractor 1 advances, while digging up the land 36 by a depth of approximately 40 to 60 cm, by using the rotor disks 7 and the bits 10. At that time, the relatively large cakes of the soil or the like raked up by the rotor disks 7 collide against the front breaking board 20 to be secondarily broken, and after that, they collide against the rear breaking board 21 to be thirdly broken. Furthermore, most of the thirdly broken cakes are returned to the rotor disks 7 again to be fourthly broken. Thus, even in a large cake, the diameter of the broken soil is made to be approximately not more than 30 mm. Accordingly, the land 36, after the tractor 1 has passed, becomes in a cultivated state and it becomes easy to revive the land 36 as a farmland.
When the stabilizer 3 approaches a position above the antipersonnel mine 15 laid under the ground in the land 36, the antipersonnel mine 15 is exploded by the shock of pulverizing or the contact with the rotor disk 7, and then the blast of the mine 15 and scattered objects smoothly pass through the gaps between the rotor disks 7 to collide with the inner surface of the shield 6, and almost all energy of the blast is absorbed and cut off by the shield 6. If the blast is strong, the movable skirts 16, 18 are opened outside against the resilient forces of the shock absorbers 17, 19 to soften the blast acting on the shield 6. Although the movable skirts 16, 18 are opened outside, the cakes of soil and the broken pieces of the mine collide with the inner surfaces of the bent movable skirts 16, 18, so that they may be prevented from scattering far away.
If the antipersonnel mine 15 is laid in a position of a depth of over 60 cm, the pulverizing depth should be increased.
When the antitank mine 24 with a strong power of explosion is laid in the land 36, before the rotor disks 7 approach the antitank mine 24, the sensor 25 detects the antitank mine 24. Then, the control section 38 operates the relay circuit 26 on the basis of the signal from the sensor 25, and cuts off the main clutch 27, and stops the advance of the tractor 1 so that the antitank mine 24 may not go off, and in that state, the antitank mine 24 is removed by hand.
As mentioned above, in the present invention, the disposal device can be manufactured by attaching the stabilizer 3 to the tractor 1, so that the manufacturing costs can be held low. Further, since the tractor 1 is made to run by a remote control, the disposal of the mine can be safely performed. Moreover, since the antipersonnel mine 15 is sought while pulverizing the land 36 by the rotor disks 7, a sure disposal of the antipersonnel mine 15 can be expected. Furthermore, the sensor 25 for detecting the antitank mine 24 is attached in front of the stabilizer 3, so that the antitank mine 24 can be detected, before the rotor disks 7 touch the antitank mine 24.
Further, in the present invention, since the height and the angle of the stabilizer 3 can freely be adjusted by the hydraulic cylinders 4, 5, the maintenance and repairing of the stabilizer 3 can easily be performed.
Moreover, since movable skirts 16, 18 are attached to the shield 6 of the stabilizer 3, it can be prevented that the stabilizer 3 receives a serious damage by the blast of the antipersonnel mine 15. Furthermore, the movable skirts 16, 18 are bent such that the top portions 43, 44 thereof face the outside, so that it is well prevented that the cakes of soil and the broken pieces of the mine are directly scattered to the outside even if the movable skirts 16, 18 are opened to the outside by the blast.
Furthermore, since the sleds 22, 23 are attached to the shield 6 of the stabilizer 3, the depth of the soil breaking by the rotor disks 7 can be kept to be constant, and the omission of the disposal of the antipersonnel mine 15 can be prevented.
Furthermore, since the breaking boards 20, 21 are attached to the inner surface of the shield 6, the cakes of soil or the like are well broken, and it becomes easy to revive the land as a farmland.
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A mine disposal device comprises an automatically guided tractor with a stabilizer provided in front of the tractor. The stabilizer has a plurality of soil pulverizing rotor disks, and a solid semi-cylindrical shield covering the upper half of the rotor disks. Front and rear movable skirts are rotatably attached the shield. A sled, touching the surface of the land, is attached to the shield and keeps constant the depth of soil pulverized by the rotor disks. The front and rear movable skirts are opened, forward and backward, by the blasts of the antipersonnel mines. The blast force works against the resilient forces of front and rear shock absorbers. Each of the front and rear movable skirts is bent such that a top portion faces outside of the shield.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
[0001] This application claims priority from co-pending U.S. Provisional Application No. 60/424,486, filed Nov. 7th, 2002, the full disclosure of which is hereby incorporated by reference herein.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates generally to the field of oil and gas well services. More specifically the present invention relates to a connector assembly for a perforating gun that is quick, reliable, and simple to use.
[0004] 2. Description of Related Art
[0005] Perforating guns containing shaped charges are used for the purpose, among others, of making hydraulic communication passages, called perforations, in wellbores drilled through earth formations. These perforations hydraulically connect predetermined zones of the earth formations to the wellbore. Perforations are needed because wellbores are typically completed by coaxially inserting a pipe or casing into the wellbore where the casing is retained in the wellbore by pumping cement into the annular space between the wellbore and the casing. The cemented casing is provided in the wellbore for the specific purpose of hydraulically isolating from each other the various earth formations penetrated by the wellbore. Without perforations, the hydrocarbons entrained in the formations surrounding the wellbore could not flow into the wellbore.
[0006] Many different types of perforating guns exist, but most have the same basic components. Those components are, shaped charges, a gun tube, a gun body, a top sub or connector, a detonator, and a bottom sub. Typically the shaped charges are disposed within the gun tube, and the gun tube is inserted into the gun body. The top sub is attached to the upper portion of the gun body and connects the perforating gun to a means for raising and lowering the perforating gun into a wellbore. The bottom sub generally attaches to the lower end of the gun body. Often, the bottom sub houses the detonator within a recess located inside of its body.
[0007] When the perforating gun is situated in the portion of the wellbore where a perforation is desired, the shaped charges within the perforating gun are detonated. This in turn produces perforations through the cemented casing lining the wellbore and into the surrounding formation. As is well known in the art, each time a perforating gun is used to produce perforations inside of a wellbore, some of the components of the perforating gun are either expended or fully destroyed. Thus before perforating guns can be reused, they must be returned to the surface and refurbished to replace the parts destroyed or used up during the previous perforation. During its refurbishment the perforating gun usually must be disassembled and reassembled prior to its next deployment.
[0008] Part of the disassembly and reassembly process of the perforating gun involves disconnecting the perforating gun from its raising/lowering means; which is typically a wireline. The wireline is attachable to a cablehead, which provides the connection between the perforating gun and the wireline. Wirelines can also serve to provide a signal conduit from the surface to the perforating gun to actuate detonation of the shaped charges. Generally the wireline cablehead is affixed to the upper sub of the perforating gun and is detached during refurbishment of the perforating gun. Additionally, the upper sub is disconnected from the gun body when the expended portions of the perforating gun are replaced. Thus to help minimize the time and expense of refurbishing perforating guns between subsequent uses, it is important that disconnecting and reconnecting the upper sub to the gun body be quick, simple, and be capable of being done at or close to the wellbore.
[0009] Often, because of special or uniquely sized components used for a specific perforating application, the perforating gun must be transported to a central processing facility for refurbishment instead of the site where the perforations are performed, i.e. the field. Transportation to and from the field to a central processing facility can be financially expensive as well as costly from a lost time standpoint. On the other hand, if a perforating gun could be refurbished for reuse at a field location, the added expense and time of transportation to a central processing facility could be avoided.
[0010] Some examples of perforating guns having connection means can be found in Hromas et al., U.S. Pat. No. 6,098,716, Burleson et al. U.S. Pat. Nos. 5,778,979, 5,823,266, and 5,992,523, and Huber et al., U.S. Pat. No. 6,059,042. However each of these suffer from the drawbacks that they are complex and the connection mechanisms disclosed therein contain multiple moving parts. Additional components add complexity, which reduces reliability and adds capital and maintenance costs. Further, none of the above noted references appears to have the capability of being refurbished or modified in the field, which limits their application to single uses and reduces their flexibility of use.
[0011] Therefore, there exists a need for a device or system in connection with perforating guns that provides for a fast and simple method of connecting and disconnecting perforating guns from a wireline. Also the system should allow for the perforating guns to be prepared at a field site, provide for multiple gun lengths, minimize the time required to assemble the perforating gun assembly, and include a proven way of sealing the perforating guns from wellbore fluids.
BRIEF SUMMARY OF THE INVENTION
[0012] One embodiment of the present invention discloses a connection system for a perforating gun comprising a top sub formed to receive one end of the gun body of a perforating gun. Disposed on the outer surface of the gun body is a circumferential groove. A collet is securable to the top sub where the collet has at least one finger formed onto its body. The collet finger is produced to engage the gun body groove, which in turn connects the gun body to the top sub. Further included with the present invention is a cover sleeve that circumscribes the finger wedging the finger between the cover sleeve and the groove. Also included with the connection system of the present invention is a seal disposed between the top sub and the perforating gun.
[0013] A fastener, such as threaded bolt, screw, rivet, or pin, can be used to secure the collet and cover sleeve to the top sub. The cover sleeve should be freely slideable along the axis of the perforating gun and formed to simultaneously circumscribe the collet and the perforating gun. The magnitude of the inner diameter of the cover sleeve is substantially uniform along its axis up until it reaches a lip of the cover sleeve. The cover sleeve lip is located on the end opposite where the cover sleeve is attached to the collet. The lip protrudes inward toward the axis of the cover sleeve and axially contacts at least one finger.
[0014] An alternative embodiment of a connection system for a perforating gun comprises a top sub formed to receive one end of a gun body of a perforating gun. A groove is circumferentially disposed on the outer surface of the gun body. Also included is a cover sleeve attachably detachable to the top sub on one end and having an inwardly protruding lip on the other end. Mating threads on the cover sleeve and on the top sub can be used to secure the cover sleeve to the top sub. A ring is disposed within the groove having an outer diameter that is at least equal to the inner diameter of the lip. Thus upon attachment of the cover sleeve to the top sub, the lip engages the ring. The engagement of the lip to the ring secures the gun body to the top sub. The ring is comprised of at least two hemispherical sections.
[0015] One of the many features of the present invention involves providing a fast and simple method of connecting perforating guns. The present invention also provides for perforating guns to be assembled at field locations and allows for random length of gun hardware. Further, the time and expense required to assemble/reassemble perforating guns is reduced by utilization of the present invention.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0016] FIG. 1 illustrates a partial cross-sectional view of a perforating gun connection assembly having a split ring.
[0017] FIG. 2 depicts a cross-sectional view of a perforating gun connection assembly having a collet.
[0018] FIG. 3A illustrates a cross-sectional view of a collet.
[0019] FIG. 3B illustrates an axial view of a collet.
[0020] FIG. 4 illustrates a cross-sectional view of a gun body.
[0021] FIG. 5 illustrates a cross-sectional view of a cover sleeve.
[0022] FIG. 6A illustrates an axial view of a ring.
[0023] FIG. 6B illustrates a cross-sectional view of a ring.
DETAILED DESCRIPTION OF THE INVENTION
[0024] With reference to the drawings herein, a perforating gun quick disconnect system according to one embodiment of the present invention is illustrated in FIG. 1 . For purposes of reference, bottom or lower refers to portions of the perforating gun located closer to the bottom of the wellbore, whereas top or higher refers to portions of the perforating gun situated closer to the wellbore opening. In one embodiment of the invention as shown in FIG. 1 , a top sub 10 is secured to the upper end of a gun body 50 . Seals 16 are provided on the outer radius of the top sub 10 and contact the inner radius of the upper section of the gun body 50 .
[0025] In the embodiments illustrated in FIGS. 1 and 2 , the top sub 10 is substantially cylindrical with a varying diameter, and preferably with its diameter being largest at its mid-section. With regard to the embodiment of FIG. 2 , it is preferred that the diameter of the top sub 10 be substantially equal to the collet base 41 . Just below the top sub 10 mid-section, its diameter reduces to form a shoulder 12 on which the collet base 41 is secured. An annular retainer 25 is attachable to the lower portion of the top sub 10 . It is preferred that the outer radius of the upper section of the retainer 25 be substantially the same as the inner radius of the collet fingers 42 . However, the radius at the lower section of the retainer 25 should be smaller than the radius of the collet fingers 42 . The reduced diameter along the lower section of the retainer 25 creates an annular space between the collet fingers 42 and the retainer 25 . That annular space should be formed such that it is capable of accommodating the upper portion of the gun body 50 along a portion of its lenght.
[0026] In an embodiment of the invention of FIG. 1 , a ring 30 is shown situated inside of a groove formed on the outer radius of the upper section of the gun body 50 . The ring 30 is preferably comprised of at least two hemispherical sections that when placed into the groove on the gun body 50 , the ring 30 can circumscribe substantially the entire diameter of the gun body 50 . Alternatively the ring 30 can be comprised of a single section that is press fit into the groove, or be of three or more sections. A cover sleeve 20 is shown circumscribing a portion of the top sub 10 and a portion of the gun body 50 . A cover sleeve lip 21 is formed on the bottom of the cover sleeve 20 having a radius substantially similar to the radius of the ring 30 . The cover sleeve lip 21 protrudes inward toward the axis of the cover sleeve 20 . The presence of the cover sleeve lip 21 adjacent the ring 30 can prevent the ring 30 from axially moving downward past the cover sleeve lip 21 . Threads 22 on the top of the cover sleeve 20 at its inner diameter are formed to mate with corresponding threads located on the outer diameter of the top sub 10 , thus providing a threaded connection between the cover sleeve lip 21 and the top sub 10 . It is important that the cover sleeve 20 inner radius be formed to allow it to easily axially traverse the gun body 50 , and yet leave only a small clearance between it and the outer diameter of the ring 30 .
[0027] Also included with this embodiment of the invention are a shaped charge 54 , a gun tube 52 , and a detonator 56 . The form and type of the top sub 10 , lower sub 11 , seals 16 , detonating cord 57 , gun body 50 , and detonator 56 can vary from those illustrated here without departing from the spirit of the present invention.
[0028] Assembly of the perforating gun of FIG. 1 generally involves first loading the gun tube 52 with shaped charges 54 using approved ballistic procedures. The detonator cord 57 and associated electrical wire 58 is routed along the path of the ignition points of the charges. The gun tube 52 is then inserted into the gun body 50 . The cover sleeve 20 is slid over the gun body 50 and the top sub 10 is inserted into an opening on the upper portion of the gun body 50 . The ring 30 is placed into the groove 51 on the gun body 50 . The presence of the ring 30 prevents the cover sleeve lip 21 from sliding above the ring 30 . Due to the small clearance between the inner diameter of the cover sleeve 20 and the outer diameter of the ring 30 , the ring 30 is secured in place inside of the groove 51 . It is to be understood that one skilled in the art can determine the clearance between the ring 30 and the cover sleeve 20 necessary to secure the ring 30 within the groove 51 .
[0029] To complete the assembly process, the cover sleeve 20 is slid upwards toward the top sub 10 and screwed onto the top sub 10 by virtue of the threads 22 disposed on the cover sleeve 20 and the top sub 10 . It is important that the sub seals 16 mate up against the inner diameter of the opening of the gun body 50 to prevent fluid leakage from the wellbore to the inside of the gun body 50 . As is well known, if wellbore fluids enter the inside of the gun body 50 , the fluids can either damage the shaped charges 54 before detonation, or cause the gun body 50 to split upon detonation of the shaped charges 54 .
[0030] Another embodiment of the present invention is illustrated in FIG. 2 . In this embodiment, the ring 30 and threads 22 of the embodiment of FIG. 1 , are replaced by a collet 40 and a collet fastener 46 . The collet 40 is formed to fit over a portion of the top sub 10 and is securable to the top sub 10 . The features of the collet 40 include a collet finger 42 with a collet finger insert 44 . The collet finger insert 44 is fashioned to fit within the groove 51 formed on the upper portion of the top sub 10 . Also included with this embodiment is a cover sleeve 20 having inner diameter that is sufficiently large to easily slide over the collet finger 42 . While the present invention can be equipped with one or more collet fingers 42 , it is preferred that the number of collet fingers 42 be six. Further, it is also preferred that the collet fingers 42 be radially displaced around the collet 40 with an equal distance between each adjacent collet finger 42 .
[0031] Assembly of the embodiment of the invention shown in FIG. 2 is much the same as the embodiment of FIG. 1 . The difference lies in how the gun body is secured to the top sub 10 . In the embodiment of the invention illustrated in FIG. 2 , the collet 40 is secured to the top sub 10 before insertion of the gun body 50 into the top sub 10 . Insertion of the gun body 50 into the top sub 10 positions the collet finger insert(s) 44 adjacent the groove 51 on the gun body 50 where the collet finger insert(s) 44 can then fit into the groove 51 . As can readily be seen from FIG. 2 , upon assembly of the present invention, the axis of the collet 40 should be substantially aligned with the axis of the gun body 50 .
[0032] Because the collet finger insert(s) 44 is designed to mate inside of the groove 51 , the distance from the collet axis to the collet finger insert(s) 44 is equal to the distance from the groove 51 to the collet axis. Since the outer radius of the gun body 50 is greater than the distance from the groove 51 to the collet axis, the collet finger insert(s) 44 must be urged axially outward before the gun body 50 is inserted into the top sub 10 . Application of a sufficient upward axial force to the gun body 50 will temporarily bend the collet finger insert(s) 44 outward; thus out of the way of the gun tube 50 . Radial displacement of the collet finger insert(s) 44 allows the gun tub 50 to fit inside of the top sub 10 . To ensure ease of use and a quick turnaround time, the force required to insert the gun body 50 within the collet finger(s) 42 , or retract the gun body 50 from the grasp of the collet finger(s) 42 , should not exceed approximately 50 pounds force. Thus material selection of the collet finger(s) 42 as well as the size of the collet finger(s) 42 is dictated by this requirement. It is believed that one skilled in the art can choose the proper dimensions and material of a collet finger(s) 42 without undue experimentation.
[0033] Once the collet finger insert(s) 44 are within the groove 51 , the cover sleeve 20 can then be slid upward such that the body of the cover sleeve 20 surrounds the collet finger(s) 42 and collet finger insert(s) 44 . The inner diameter of the cover sleeve 20 retains the collet finger insert(s) 44 within the groove 51 on the gun body 50 . The cover sleeve 20 can be secured to the collet 40 by a threaded fastener 46 . However any number of other attachment devices can be employed, such as rivets, pins, or a series of mating threads on the inner diameter of the cover sleeve 20 and the outer diameter of the collet 40 . Firmly securing the collet finger insert(s) 44 inside the groove 51 provides a connection between the top sub 10 and the gun body 52 . This in effect connects the perforating gun to the wireline.
[0034] The present invention could employ a single cover sleeve 20 in conjunction with a single groove 51 formed on the upper or the lower portion of the gun body 50 . This would result in a quick disconnect system for either the top sub 10 or the bottom sub 11 , but not both subs simultaneously. However, a cover sleeve 20 and groove 51 on both ends of the gun body 50 allows for quick and simple removal, as well as attachment, of both the top sub 10 and the bottom sub 11 from the gun body 50 . Thus, it is preferred that the grooves 51 be provided on the gun body 50 at both its upper and its lower end.
[0035] Assembly of a perforating gun could be done with a groove 51 far from either end, but this would require a long collet finger(s) 41 and an elongated cover sleeve 20 . Since a long collet finger(s) 41 or a long cover sleeve 20 can increase the time and effort required to assemble and disassemble the perforating gun, it is preferred that the groove 51 be positioned close to its associated sub.
[0036] One of the many advantages of the present invention is realized during disassembly of the associated perforating gun. Just as the perforating gun having the present invention can be quickly and easily assembled, it can also be quickly and easily disassembled. Once the shaped charges 54 have discharged and the perforating gun is removed from the wellbore, the collet fastener 46 can be removed and the gun body 50 can be detached from the top sub 10 . Detaching the gun body 50 from the top sub 10 of the present invention does not involve the use of tools but instead can be performed manually—simply by pulling the gun body 50 away from the top sub 10 . More importantly, this function can be done in the field, thus eliminating the need to transport the perforating gun to a central processing facility. A loaded perforating gun can then be reattached to the top sub 10 and the perforating process can be repeated immediately.
[0037] The material selection of the gun body 50 , ring 30 , and collet 20 is important. Due to the large impulse forces encountered during use by each of these components, they should be constructed of a material that does not easily yield, either momentarily or permanently. Even small amounts of yield during use can cause the gun body 50 to bond to the collet finger insert(s) 44 . Which is highly undesirable since quick disassembly is important when refurbishing perforating guns. The proper material of the gun body 50 , ring 30 , and collet 20 can be determined by one skilled in the art and without undue experimentation.
[0038] The bottom sub 11 of the embodiment of the present invention of FIG. 2 can be attached to the gun body 50 in much the same fashion as the top sub 10 . However, because of the detonator 56 , safety procedures typically require that the detonator 56 be connected while the detonator 56 is in a blast shield outside of the gun assembly. The detonator 56 is then connected to the detonating cord 57 .
[0039] One of the many advantages of the present invention is the efficient manner in which the perforating gun can be assembled and disassembled, either for its initial use or for subsequent uses. The present invention enables the assembly/disassembly of the perforating guns to be done at either a primary manufacturing site, or in a remote field site. Thus use of the present invention eliminates time wasted to transport perforating guns to a primary manufacturing site for processing, saves money associated with transporting perforating guns, and reduces the time and effort required to assemble/disassemble perforating guns, either in the field, or at a manufacturing facility. For example, the present invention allows the user the flexibility of forming the groove 51 onto the gun body 50 in the field with a lathe or other machining device. The gun body 50 with its newly formed groove 51 can then be attached to the top sub 10 , while still in the field, inserted into a wellbore, and have the shaped charges within the gun body 50 detonated. After the perforating gun is raised up and out of the wellbore, a new gun body 50 , with a newly formed groove 51 can be switched into the present invention and the perforating process repeated. This provides one example of how use of the present invention allows many functions to take place in the field and reduces the need for machining at a manufacturing site, which in turn reduces costs, effort, and time associated with transportation and engineering coordination.
[0040] A further advantage of the present invention is that the top sub 10 can be disconnected from the perforating gun without the need to disconnect the wireline. This not only saves time, but can reduce possible infield anomalies caused by mistakes in the attachment/detachment during use of the perforating gun. In addition to a cost and time savings, the present invention also is flexible in its application. Use of the present invention is not limited to a single perforating gun of a single length. Instead the present invention can be implemented on perforating guns of any length.
[0041] The present invention described herein, therefore, is well adapted to carry out the objects and attain the ends and advantages mentioned, as well as others inherent therein. While a presently preferred embodiment of the invention has been given for purposes of disclosure, numerous changes are possible in the details of procedures for accomplishing the desired results. These and other similar modifications will readily suggest themselves to those skilled in the art, and are intended to be encompassed within the spirit of the present invention disclosed herein and the scope of the appended claims.
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A connection system to be used in conjunction with a perforating gun comprising a top sub formed to receive one end of a gun body of a perforating gun, a circumferential groove disposed on the outer surface of the gun body, and a collet secured to the top sub. The collet has at least one finger that engages the groove. Engaging the groove with the at least one finger of the collect connects the gun body to the top sub. A cover sleeve is included that retains the finger in connective engagement with the groove.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] Not applicable.
STATEMENT OF FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
BACKGROUND OF THE INVENTION
[0003] The present invention relates to plumbing fittings having a groove for accommodating a sealant at an interface between the plumbing fitting and a counter top or wall that the plumbing fitting is to be mounted against. More particularly it relates to a multi-part structure for defining such a putty groove.
[0004] Plumbing fittings such as faucets, spouts and valve control handles are well known. See eg. U.S. Pat. No. 6,345,643. It is common to mount such fittings to a horizontal counter top, or to a vertical wall, through an opening formed therein. This allows the fitting to connect to plumbing lines or other plumbing related controls.
[0005] In a bathroom or other environment water may tend to seep between the downward/inward end of the fitting and the adjacent counter top or wall, and then leak through the opening. It is therefore conventional to surround the opening by preformed gaskets or more commonly a continuous strip of sealant/putty. When using such a sealant, it is desirable to compress the fitting tightly against the surface that it is being mounted on to minimize gaps. However, this can cause the putty to ooze outward if the putty is not confined by the structures involved. This can require some extra labor to clean up the installation, and in some cases may leave the putty slightly visible.
[0006] Thus, it is conventional to provide a confined groove on the underside/innerside of the fitting to receive the putty. This is often provided in an associated putty plate that the valve housing rests on. See e.g. U.S. Pat. No. 5,960,490 where a putty plate was provided with a downwardly opening putty groove just inward of its perimeter.
[0007] Complicating matters is that conventional escutcheons for plumbing fittings are often made of relatively thin material to reduce cost and weight. Hence, providing a putty groove of sufficient depth directly in a thin shell escutcheon can be problematic. Using a separate putty plate for the putty groove helps address this concern. However, when the outer shell/escutcheon sits on the putty plate the less ornamental putty plate may be somewhat visible.
[0008] Another complication is that as the escutcheon of the plumbing fitting is made more and more flared and bell shaped (e.g. for ornamental reasons), there can be difficulties in positioning the putty groove adjacent the outer radius of the escutcheon.
[0009] Hence, a need exists to provide a plumbing fitting with improved putty groove structures, particularly where the escutcheon is bell shaped.
SUMMARY OF THE INVENTION
[0010] The invention provides a plumbing fitting that has a housing (e.g. a decorative escutcheon) defining an outer shell with a hollow interior. There is also a base inserted into the interior of the housing which is connected to the housing. A putty groove is formed at the underside of the fitting in part by the base and in part by an end of the housing. For example, a terminal end of the housing can define an outer side wall of the groove, with a portion of the insert forming the opposed side of the groove.
[0011] While in connection with the disclosure herein the directions up and down (e.g. underside) are referred to, if the fitting is to be mounted on a vertical wall, those terms are to be instead meant to be interpreted so that the upward direction is the direction outward away from the wall, and the downward direction (e.g. underside) is the direction towards the wall.
[0012] Also, when the term “putty groove” is used putty per se does not have to be present or intended to be used. Rather, it is intended that a groove be present which is designed to receive a sealant, regardless of whether specifically putty.
[0013] In a preferred form of the first embodiment of the present invention the end of the housing extends inwardly of a peripheral edge of the base (to thereby trap it in the housing), and the base includes an annular ring that extends axially to define an inner wall of the putty groove. The putty groove is preferably circular, with its side walls being correspondingly circular.
[0014] In another preferred form the putty groove is located radially outward of an opening through the base, and the putty groove is located radially proximate an outer periphery of the base. The housing can then have a flared, generally bell-shaped end receiving the base.
[0015] These structures are most preferably incorporated into a flow control handle assembly. However, they may be incorporated into a variety of other plumbing fittings such as faucets, spouts, shower mixers, etc.
[0016] In another aspect the invention provides a plumbing fitting. There is a housing defining an outer shell with a hollow interior, the housing having a flared lower section with a lower end, the lower section decreasing in height in a radial outward direction, the lower end of the housing providing an outer wall of a putty groove at an underside of the fitting opening in an axially downward direction. There is also an annular base inserted into the interior of the housing at the lower section and decreasing in height in the radial outward direction, the base having an underside defining radially inner wall and also a back wall of the putty groove and cooperating with the lower end of the housing to define the putty groove.
[0017] In yet another aspect the invention provides a plumbing fitting having a first part and a second part. The first and second parts are separately formed and joined thereafter to cooperate to form a putty groove at an underside of the fitting for receiving sealant (e.g. putty). In any event, the first part forms a first side wall of the putty groove, and the second part forms a side wall of the putty groove opposite the first side wall of the putty groove.
[0018] It should be appreciated that the structures of the present invention allow deep putty grooves to be formed with relatively thin material. Further, they can be positioned in designs that are bell-shaped at their base. Moreover, the structure of the present invention facilitates the hiding of the putty or other sealant from view after installation.
[0019] The putty groove will normally have a closed loop configuration, for example a circle, oval, rectangle, square or other such shape. However, this is not absolutely required, albeit it is greatly preferred. Moreover, while the placement of the groove around a countertop opening or shower enclosure wall opening is preferred, the putty groove can be positioned adjacent other structures.
[0020] The housing/escutcheon/outer shell can be formed to capture the base in the interior of the housing. In particular, when the terminal end of the housing extends inwardly of a peripheral edge of the base at an underside of the base, the terminal end doubles as a both groove wall and a connector element. Thus, a solid connection is obtained without the need for separate fasteners being required to join the two components.
[0021] Other advantages of the invention will be apparent from the detailed description which follows and accompanying drawings. What follows is merely a description of preferred embodiments of the present invention. To assess the full scope of the invention the claims should be looked to as the preferred embodiments are not intended to be the only embodiments within the scope of the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIG. 1 is a front elevational view of a first embodiment of the present invention in the form of a water control valve handle assembly;
[0023] FIG. 2 is an exploded assembly view of certain parts thereof;
[0024] FIG. 3 is a vertical sectional view taken along line 3 - 3 of FIG. 1 of certain parts of the assembly, with certain other parts shown therein in phantom;
[0025] FIG. 4 is an enlarged detailed sectional view of the area noted as area 4 - 4 of FIG. 3 ; and
[0026] FIG. 5 is a view similar to FIG. 4 albeit showing an analogous portion of an alternate embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0027] FIGS. 1-4 illustrate a first preferred handle assembly 10 . The assembly/plumbing fitting 10 includes a handle 12 , an elbow 14 , a glide washer 16 , a housing shell or escutcheon 18 , a coupler sleeve 20 , a fastener 22 and a base insert 24 . The handle 12 has a grip area and a threaded end that threads into one end of the elbow 14 . The other end of the elbow 14 has a square stud (not shown) that fits into the square opening of the sleeve 20 and receives the fastener 22 in a threaded opening (not shown) in the stud.
[0028] The sleeve 20 has a splined interior that engages the splined end of a conventional valve stem 26 of a flow control valve 28 (shown in phantom in FIG. 3 ), which are connected to a water inlet line (not shown). The valve 28 can be any conventional valve such as a ¼ turn valve cartridge. Suitable brackets (not shown) secures the valve to the countertop 30 (see FIG. 3 ) and the threaded inner diameter 31 of the base insert 24 threads onto the body of the valve or the brackets to mount the fitting to the countertop 30 .
[0029] As shown in FIG. 3 , the escutcheon 18 forms the ornamental body of the fitting 10 . It can be made of a suitable thin metal in one piece (but possibly two or more pieces). The interior of the escutcheon 18 is hollow and accommodates the sleeve 20 , base insert 24 and valve structure.
[0030] In the embodiment shown in FIG. 3 , the escutcheon 18 has a chess piece shape with a head 32 , narrow body 34 and flared bell end 36 . Like a bell, the end 36 flares radially outward. As it flares outward, the vertical height of the end 36 decreases. Like the end 36 of the escutcheon 18 , the base insert 24 also flares radially outward and decreases in height so that it abuts an inside surface of the escutcheon 18 at its radially widest point.
[0031] As best shown in FIG. 4 , a terminal end 38 of the escutcheon 18 wraps around the base insert 24 and extends radially inward along an underside of the base insert 24 . The edge surface of the terminal end of the escutcheon 18 thus forms a circular, radially outward side wall 40 of a downwardly opening putty groove 42 extending continuously in a circle very near the radial outer periphery of the fitting.
[0032] The inner side wall 44 of the putty groove 42 is formed by a radially outward facing surface of a rib 46 of the base insert 24 . The rib 46 extends axially downward further than the adjacent undersurface 48 of the base insert 24 radially outward of the rib 46 , which forms the upper, back wall of the putty groove 42 .
[0033] In the disclosed FIG. 4 embodiment the surface 48 extends at the same height to essentially the outer periphery of the base insert 24 (other than at the edge radius) such that the terminal end 38 of the escutcheon 18 forms the entire outer side wall of the putty groove 42 . However, this is not necessary, and another downwardly extending portion of the base insert 24 could combine with the terminal end of the escutcheon to form the outer side wall.
[0034] In addition to cooperating with the base insert 24 to create the putty groove, the wrap around configuration of the terminal end 38 of the escutcheon shown in FIG. 4 captures the base insert 24 within the hollow interior of the escutcheon 18 . The escutcheon 18 wraps tightly around the upper and lower surfaces of the periphery of the base insert 24 so that a tight, solid feeling connection is made between the components. Thus, no separate fasteners are required to join the two components.
[0035] As shown in FIG. 5 , in an alternate construction of the fitting, the terminal end 38 A does not wrap around the underside of the base insert. Instead it extends axially straight downward to create the outer side wall of the putty groove. As a result of this configuration, the putty groove is wider and extends nearer the outer periphery of the fitting. However, in this case, the base insert is not captured by the escutcheon such that an additional fastener would be required to connect the escutcheon and the base (e.g. cooperating threads; adhesive; mechanical fastening). Yet, in both cases, the escutcheon 18 can surround the periphery of the base to conceal the base and any other internal structure, and provide the fitting with a clean, finished appearance.
[0036] Because the resulting groove is quite deep, sufficient putty is available to make an effective seal. Yet, the end 36 will prevent putty from oozing out into a visible position.
[0037] While there has been shown and described what is at present considered the preferred embodiments of the invention, various changes and modifications can be made therein without departing from the scope of the invention defined by the appended claims. For example, in certain configurations the outer shell may form the outer side wall and back wall of the putty groove, with the insert forming only an inner side wall. Therefore, various alternatives and revised embodiments are contemplated as being within the scope of the following claims.
INDUSTRIAL APPLICABILITY
[0038] The invention provides a plumbing fitting with an improved putty groove to control leaking by the fitting.
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A plumbing fitting has a putty groove defined between an internal insert and an external decorative shell. In one form, a terminal end of the shell also captures the insert inside the housing. This allows formation of a deep putty groove even in those circumstances where the outer shell is very thin and is flared at the bottom.
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This application is a continuation of application Ser. No. 017,248, filed on Feb. 20, 1987, now abandoned.
FIELD OF THE INVENTION
The present invention relates to a structural assembly for suitably producing walls. More particularly, the invention relates to an assembly which includes elements which jointly or separately define dovetail connection members.
BACKGROUND OF THE INVENTION AND RELATED ART DISCUSSION
Garden walls are produced, for example, from natural stone or from panels resembling natural stone, from planks or sleepers such as those used in the construction of railroads or from concrete slabs which, however, need to be reinforced if they exceed a certain length and which, in consequence, have relatively high manufacturing and production costs. While laying straight wall portions comprised of natural stone and similar materials is relatively simple, of securing of such elements to one another is generally complicated. The configurations of the corners of these types of walls are often aesthetically unpleasing, and their configuration also complicates the task of securing the elements.
Generally, the procedure of securing components of the above-described walls is such that encasement boards are provided behind the wall, so as to face the soil, and the rear surface of the walls is reinforced with concrete. If wooden sleepers are employed, securement may also be achieved by laying such sleepers transversely, but this arrangement complicates the construction of the wall. Moreover, railway sleepers are generally old and do not usually have a particularly attractive appearance. A further complication in the securing of stone or concrete walls arises, because the walls generally have to be partially encased during construction and have to be secured by means of concrete.
Structural elements having dovetailed joints are known, per se, from French publication FR-A-2 376 269, for example. This document describes structural elements which have circumferential grooves and which can be interconnected, through the intermediary of a connecting element having a tongue member at each end. Such structural elements can be used for the composite erection of smooth walls. However, these elements are not suitable for the erection of garden walls which need to be secured.
OBJECT OF THE INVENTION
The present invention seeks to provide a structural assembly for the erection of walls, particularly garden walls, which is easy and economic to produce, permits a simple method of erection to be employed, has a simple means of securement, and has a pleasing appearance.
BRIEF SUMMARY OF THE INVENTION
According to the present invention, there is provided a structural assembly capable of being used for producing walls, comprising a plurality of structural elements, each element including at least one surface defining at least a portion of a dovetail joint. A first one of the elements is a parallelepiped and includes a first longitudinal side, defining a half dovetail groove at each of its ends. A full dovetail groove is disposed at the center of the element, and, a full dovetail tongue or primary protrusion separates the full groove from each half-groove. A second of the elements corresponds one half of the first element and securing element means is also provided, securing element including at least one side, the defining a dovetail tongue member or primary protrusion corresponding to the full groove in the first element. The securing element also includes an aperture.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be further described, by way of example, with reference to the accompanying drawings, in which:
FIG. 1 is a plan view of a portion of a wall erected utilising the structural assembly of the present invention;
FIGS. 2, 3 and 4 are sectional views of three different modifications of elements of the structural assembly;
FIGS. 5 and 6 are sectional views of two different walls of the type shown in FIG. 1; and
FIG. 7 is a side elevational view of a further wall arrangement erected using the structural assembly of the present invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
In FIG. 1, there are shown four different elements belonging to the structural assembly of the present invention. These comprise a first element 1, a second element 2, a third element 3 and a securing element 4. The element 1 has a substantially parallelepiped form and is provided with a dovetailed groove 5 in the centre of one of its longitudinal sides. A dovetail tongue member or primary protrusion 6 is disposed on each side of the groove 5, and half a dovetailed groove 5a and 5b respectively is disposed at each end of the element. The plane coincident with the recessed portion of the grooves 5, 5a, and 5b are referred to as connecting faces of the first element 1. These dovetail joint components are uniformly distributed along the length of the assembly. The second element 2 is exactly half the size of the element 1 and, in consequence, has two dovetail groove halves 5a and 5b between which is defined the dovetail tongue member 6. Again, the plane coincident with the most recessed portion of grooves 5a and 5b are the connecting faces of the second element 2.
The length of the third element 3 corresponds to half that of the first less the width of second element 2-- in the present embodiment, corresponding approximately to one-third of the length of the first element 1. In consequence, the third element 3 has one half of a dovetailed groove 5a at one of its ends. The plane coincident with recessed portion of groove 5a is the connecting face of third element 3. The other end of the third element 3 has a stepped or shoulder portion 7 whose length corresponds to the depth of the groove 5 of the first element 1. As seen in FIG. 1, the length 7 is the dimension running parallel to the connecting face of the third element 3. The depth of shoulder 7 is slightly greater than its length, as is shown in FIG. 1.
The securing element 4 has a substantially square cross-section and is provided with an aperture 8 which extends therethrough. The aperture 8 is, in the present case, rectangular but it may also be round or of any other desired configuration. On one of its sides, the securing element 4 is provided with a tongue member 6a which fits into the groove 5 or into the two half-grooves 5a and 5b provided on adjacent elements. In the center of each of the other three outer surfaces of the securing element 4, there is provided an elongated groove 9 which extends over the entire height of the element and may accommodate plates or panels 10 which may either be encasement boards, if concrete is to be layed behind at least a portion of the wall, or which may serve to establish or form a gravel bed.
On their upper surfaces, each of the three elements 1, 2 and 3 is provided with two longitudinally extending cementing joints 11 which may have a permanently resilient cementing substance inserted therein for the purpose of achieving easier laying and better retention. There do not, of course, need to be two cementing joints and the cementing joints do not necessarily need to extend therethrough. Any type of recess may be provided.
FIGS. 2, 3 and 4 illustrate three possible different profiles for the elements 1, 2 or 3. In FIG. 2, which shows the preferred embodiment, the dovetail tongue member 6 includes a shoulder or stepped portion 12 on its upper surface, so that it is not visible after soil has been filledin, with the result that the wall appears to be continuous and straight when viewed from above. This can be seen in FIGS. 5 and 6. The element shown in FIG. 3 does not have such a stepped portion, while the dovetail tongue member 6 shown in FIG. 4 includes an inclined portion 13 on its upper surface rather than a stepped portion. If a wall is produced utilizing elements shown in FIG. 3, and a straight upper edge is desired, a coping stone 14, of the type shown in FIG. 7 may be used. The stone 14 may have one or two shoulder portions 15 formed on its lower surface to prevent sliding. To improve the appearance of the elements, the longitudinal and vertical edges of the elements 1, 2 and 3 may be chamfered.
The four elements 1, 2, 3, and 4 will generally be produced from concrete, although not necessarily reinforced concrete. However, in order to permit as economic a production as possible by conventional means while producing elements which can be easily carried by one or, at most, two workers, and in order to permit a high degree of flexibility in use, it is desirable if the element 1 has a length of one meter, a width of 15 cm plus an additional 5 cm for the dovetail tongue members, and a height of 15 cm. Accordingly, the elements 2 and 3 will have lengths of 50 cm and 35 cm respectively. The dimensions of the securing element 4, except for the side provided with the dovetail tongue member 6a, are of lesser significance that those of elements 1, 2 and 3. The securing element 4 may, for example, have a surface area of 25 cm×25 cm and a height of 15 cm although the height may also be 30 cm. Such dimensions permit economic production with maximum utilization of space, whereby unit elements may be produced with parting lines or separation joints. Alternatively, elements which are separate from the outset may be cast or moulded. In addition to normal concrete, lightweight concrete may also be used to fabricate the various elements. In particular, lightweight concrete sold under the commercial name of "Lecca", may be used. Other known materials which may, of course, have different colourations as well as treated or untreated surfaces may also be used.
The erection of a back-filled garden wall will be explained hereinafter with particular reference to FIGS. 1, 5 and 6. FIG. 5 shows the wall portion between two securements, while FIG. 6 shows the securement with the securing elements 4. FIG. 5 shows a concrete foundation or base 16 which is erected in the soil and on which a few layers of the elements 1, 2, and 3 are built. In such a case, the elements are sandwiched together by means of a permanently resilient cementing substance which fixedly retains the elements 1, 2, and 3 in their correct position. In FIG. 6, the securing elements 4 are mounted at intervals of 50 cm or one meter simultaneously with the construction of the layers of slabs. Vertical reinforcements 17 are inserted into the openings in securing elements 4. As is particularly apparent from FIG. 6, it is advantageous to offset the securing elements by a distance corresponding to half the height of the slab elements, so as to achieve a better composite arrangement thereby.
After the entire wall has been erected, after the securing elements 4 have been fitted and the vertical reinforcements have been inserted, the whole wall can be checked once more and aligned, prior to the apertures 8 in the securing elements 4 being filled with concrete. A good drainage facility is very important for such walls which are to be back-filled with soil. The present elements are ideally suited therefor, because the rear surface of the elements is not smooth as a result of their being provided with grooves and tongue members. Consequently, the elements allow space for adequate water drainage. It is advantageous for the rear surface of the elements to be coated with a geotextile webbing or non-woven fabric 18 or the like, and for the lower surface of the elements to be provided with drainage material 19 and/or a gravel bed 20, as well as a conventional drainage pipe 21, so that the wall can be subsequently back-filled with soil.
Although assembly comprises only two major elements 1 and 2, a corner element 3, a securing element 4, the number of different applications thereof is very large. Thus, the securing element 4 can also be utilized as a visible feature of the wall. Thus, it can be seen in FIG. 7, for example, that corners may be formed in both directions and in both cases, a neatly-edges corner is produced. As a result of the selected dimension for the framework, especially in the case of the corner elements 3 having a width of approximately 35 cm plus 15 cm, the entire wall can be conveniently secured by the securing elements 4. In FIG. 7, it is further shown that the securing elements 4, if built one above the other, can form a column which may, for example, be used for the securement of a flagpole or for illumination purposes. It is, of course, also possible for the securing elements 4 to be built upwardly along the whole wall or along a portion thereof, and panels or the like may be placed therebetween to form a fence along which, for example, plants or shrubs may be trained. As has already been mentioned, the edge may be formed by means of edge panels and end plates 14.
As is shown in FIG. 1, the securing element 4 may also be used as a corner element or configuration element whereby, for example, the element 1, which is shown in its entirety, is displaced rearwardly and lies behind the thickened portion of the dovetailed tongue member 6a while the slab element, which continues to extend to the left, may form an angle, for example, in such a manner that its lower edge engages in the lower corner of the left-hand longitudinal groove 9 in the securing element 4 or is aligned with the first slab element. This arrangement also produces a co-operation between the slab elements and the securing element. It is self-evident that, by so doing, a better securing can be provided in those cases where mounting is particularly associated with a risk of slippage. The slippage risk is reduced because, for example, two securing elements 4 are used which are disposed one behind the other and which, in addition, are horizontally interconnected by reinforcement rods.
As is further apparent from FIG. 1, the slab elements may also be interconnected in such a manner that the dovetail tongue members 6 and dovetail grooves 5 engage in one another, thereby forming a double row with a side intended to be seen facing outwardly on both sides.
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A structural assembly is used for producing walls. The assembly includes a plurality of structural elements, each element having at least one surface defining at least a portion of a dovetail joint. A first one of the elements is parallelepiped in shape and includes a first longitudinal side, the longitudinal side defining a half dovetail groove at each of its ends. The first element also includes a centrally disposed full dovetail groove and a full dovetail tongue separating the full groove from each half-groove. A second element of the assembly corresponds to one half of the first element. A securing element is also provided which includes at least one side defining a dovetail tongue member corresponding to the full groove in the first element. The securing element also includes an aperture extending therethrough. The structural assembly can be manufactured very economically on conventional machines and permits garden walls and the like to be easily produced and also to be secured firmly in position.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND
[0001] The present invention relates generally to operations performed and equipment utilized in conjunction with subterranean wells and, in an embodiment described herein, more particularly provides a reduced debris milled multilateral window.
[0002] In multilateral wells it is common practice to drill a branch or lateral wellbore extending laterally from an intersection with a main or parent wellbore. A casing string is typically installed in the parent wellbore, a whipstock is positioned in the casing string at the desired intersection, and then one or more mills are deflected laterally off of the whipstock to form a window through the casing sidewall.
[0003] Unfortunately, this milling process usually produces a large amount of debris, such as small pieces of the metal casing, which accumulate in the parent wellbore. This debris may make the whipstock difficult to retrieve after the milling process is completed. Even after the whipstock is retrieved, the debris may cause other problems, such as plugging flow control devices, damaging seals, obstructing seal bores, interfering with passage of equipment past the intersection, etc.
[0004] One proposed solution is to pre-mill the window in the casing, that is, form the window through the casing sidewall prior to installing the casing in the parent wellbore. However, if the casing is to be cemented in the main wellbore, the window should be closed during the cementing operation, such as by using an internal or external sleeve. Typically, the sleeve is made of an easily milled material, such as aluminum or a composite material, or is made so that it can be retrieved after the cementing operation.
[0005] Although such sleeves have achieved some success, they also have their problems. For example, the sleeve material may be incompatible with fluids used in the well. The use of an external sleeve increases the casing outer diameter, requiring either a smaller casing size to be used, or a larger wellbore to be drilled. The use of an internal sleeve reduces the casing inner diameter, restricting the passage of fluids and equipment through the casing. The use of a shiftable or retrievable inner sleeve requires another operation in the well and increases the complexity of the equipment and the procedure.
[0006] From the foregoing, it can be seen that it would be quite desirable to provide improved apparatus, systems and methods for forming windows in casing.
SUMMARY
[0007] In carrying out the principles of the present invention, in accordance with an embodiment thereof, a window joint is provided for interconnection in a casing string. The use of the window joint reduces the debris created when a window is milled through the window joint.
[0008] In one aspect of the invention, a window joint is provided which includes a generally tubular body having a sidewall. A window portion of the sidewall is configured for forming a window therethrough. A thickness of the sidewall is reduced in the window portion using a variety of techniques.
[0009] In another aspect of the invention, a window joint system is provided which includes a window joint interconnected in a casing string and positioned in a parent wellbore. The window joint includes a sidewall having a window portion through which a window is formed to drill a branch wellbore. The window portion has a reduced thickness of the sidewall prior to forming the window through the window portion.
[0010] In yet another aspect of the invention, a method of drilling a branch wellbore extending laterally from an intersection with a parent wellbore is provided. The method includes the steps of: interconnecting a window joint in a casing string, the window joint including a sidewall having a window portion with a reduced thickness of the sidewall; positioning the casing string in the parent wellbore; aligning the window joint with the window portion facing toward the desired branch wellbore; cutting through the window portion of the window joint, thereby forming a window through the sidewall; and drilling the branch wellbore through the window.
[0011] These and other features, advantages, benefits and objects of the present invention will become apparent to one of ordinary skill in the art upon careful consideration of the detailed description of representative embodiments of the invention hereinbelow and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] [0012]FIG. 1 is a schematic partially cross-sectional view of a method embodying principles of the present invention;
[0013] [0013]FIG. 2 is a schematic cross-sectional view of a first window joint embodying principles of the invention;
[0014] [0014]FIG. 3 is a cross-sectional view of the first window joint, taken along line 3 - 3 of FIG. 2;
[0015] [0015]FIG. 4 is a schematic cross-sectional view of a second window joint embodying principles of the invention;
[0016] [0016]FIG. 5 is a cross-sectional view of the second window joint, taken along line 5 - 5 of FIG. 4;
[0017] [0017]FIG. 6 is a schematic cross-sectional view of a third window joint embodying principles of the invention;
[0018] [0018]FIGS. 7A & B are alternate cross-sectional views of the third window joint, taken along line 7 - 7 of FIG. 6; and
[0019] [0019]FIG. 8 is an elevational side view of a fourth window joint embodying principles of the invention.
DETAILED DESCRIPTION
[0020] Representatively and schematically illustrated in FIG. 1 is a method 10 which embodies principles of the present invention. In the following description of the method 10 and other apparatus and methods described herein, directional terms, such as “above”, “below”, “upper”, “lower”, etc., are used only for convenience in referring to the accompanying drawings. Additionally, it is to be understood that the various embodiments of the present invention described herein may be utilized in various orientations, such as inclined, inverted, horizontal, vertical, etc., and in various configurations, without departing from the principles of the present invention.
[0021] In the method 10 , a main or parent wellbore 12 is drilled and a casing string 14 is installed and cemented in the wellbore. The terms “parent” and “main” wellbore are used herein to designate a wellbore from which another wellbore is drilled. A parent or main wellbore does not necessarily extend directly to the earth's surface, but could instead be a branch of yet another wellbore.
[0022] The term “casing” is used herein to designate a tubular string used to line a wellbore. Casing may actually be of the type known to those skilled in the art as “liner”, and may be made of any material, such as steel or composite material, and may be segmented or continuous, such as coiled tubing.
[0023] The casing string 14 in the method 10 includes a window joint 16 interconnected therein. An internal orienting profile 18 may be formed directly on the window joint, or it may be separately attached thereto as depicted in FIG. 1. The window joint 16 is positioned at a desired intersection 22 between the parent wellbore 12 and a branch or lateral wellbore 20 to be drilled later.
[0024] The terms “branch” and “lateral” wellbore are used herein to designate a wellbore which is drilled outwardly from its intersection with another wellbore, such as a parent or main wellbore. A branch or lateral wellbore may have another branch or lateral wellbore drilled outwardly therefrom.
[0025] The window joint 16 and orienting profile 18 are rotationally oriented relative to the branch wellbore 20 using techniques known to those skilled in the art, such as by using a gyroscope engaged with the orienting profile.
[0026] The parent wellbore 12 below the intersection 22 may be completed before or after the branch wellbore 20 is drilled (or not at all). As depicted in FIG. 1, the lower parent wellbore 12 has been completed and has a packer 24 installed therein. The packer 24 includes an internal seal bore or PBR 26 .
[0027] When it is desired to drill the branch wellbore 20 , a whipstock or deflector 28 is positioned in the casing string 14 below the intersection 22 . Keys or dogs 30 carried on the whipstock cooperatively engage the orienting profile 18 . This engagement anchors the whipstock 28 to the casing string 14 and rotationally orients an inclined deflector surface 32 so that it faces toward the desired branch wellbore 20 .
[0028] One or more cutting tools, such as mills and drills, are then lowered through the casing string 14 and deflected laterally off of the deflector surface 32 to form a window 34 through the casing and to drill the branch wellbore 20 . In prior art methods, this process of forming the window 34 has resulted in a large quantity of debris accumulating in the parent wellbore 12 at and below the intersection 22 . Although the whipstock 28 might have been equipped with a debris barrier 36 in these prior art methods, the debris could still hamper retrieval of the whipstock from the well, interfere with passage of equipment through the intersection 22 , cut seals (such as packing elements on the packer 24 ), prevent sealing in seal bores (such as the seal bore 26 ), or cause other difficulties.
[0029] The present invention, however, substantially reduces the debris created in milling the window 34 , which reduces or eliminates the problems described above. These advantages are achieved in the method 10 without requiring the use of an internal or external sleeve. Nevertheless, a sleeve could be used in the method 10 , if desired, without departing from the principles of the invention.
[0030] To achieve these benefits, the window joint 16 used in the method 10 has a reduced thickness sidewall in a window portion of the window joint. This reduced thickness results in less debris being created when the window 34 is milled. Although reduced, the sidewall thickness in the window portion is still sufficient to prevent cement, or other fluids or gases, from flowing therethrough when the casing string 14 is installed and cemented in the parent wellbore 12 .
[0031] The reduced thickness of the window portion of the window joint 16 makes the sidewall lighter in the window portion, and so the opposite side of the window joint is influenced by gravitational force to seek the lower side of the wellbore 12 when the casing string 14 is installed. The parent wellbore 12 is depicted in FIG. 1 as being substantially vertical, but those skilled in the art understand that this situation is very rare, since most wellbores are actually deviated at least somewhat from true vertical.
[0032] Preferably, the branch wellbore 20 is drilled so that it extends at least partially upwardly from the parent wellbore 12 . Therefore it is a significant benefit for the side of the window joint 16 opposite the window portion to seek the lower side of the wellbore 12 when the casing string 14 is installed.
[0033] Representatively and schematically illustrated in FIGS. 2-8 are various window joints which may be used for the window joint 16 in the method 10 . These various specific examples of window joints are described herein to show how the principles of the invention may be incorporated into the construction of window joints, but it is to be clearly understood that the principles of the invention are not limited to the details of these specific examples. Instead, the principles of the invention permit a wide variety of window joint constructions.
[0034] In addition, it should be clearly understood that the principles of the invention may be incorporated into methods other than the method 10 , such as methods wherein a whipstock is not used. The window joint examples described below, and other window joints embodying principles of the invention, may be used in these other methods, as well.
[0035] In FIGS. 2 & 3 a window joint 40 having an internal orienting profile 42 formed in a tubular body 38 of the window joint is depicted. Preferably, the orienting profile 42 is formed directly on the window joint 40 , so that the separate steps of connecting the orienting profile to the window joint and rotationally aligning the profile with the window joint are avoided. However, the orienting profile 42 could be formed in a separate element, such as a collar, if desired.
[0036] The window joint 40 has a sidewall 46 that is a consistent thickness at upper and lower end connections 48 of the window joint. The end connections 48 may be provided with conventional threads, seals, seal bores, or welds, etc. (not shown) for interconnection in a tubular string. However, between the end connections 48 , the window joint 40 includes a window portion 44 having a reduced sidewall 46 thickness.
[0037] This reduced sidewall 46 thickness is formed by laterally offsetting an inner diameter 50 in the window portion 44 relative to inner diameters 52 at the end connections 48 . That is, a longitudinal centerline 54 of the window portion 44 is laterally offset relative to a longitudinal centerline 56 of the end connections 48 . However, note that the window joint 40 has the same outer diameter 58 at the window portion 44 and at the end connections 48 , resulting in the inner diameter 50 being also laterally offset relative to the outer diameter 58 .
[0038] The offset inner diameter 50 may be formed in the window joint 40 using various methods. For example, the inner diameter 50 may be cut using a lathe, or the window joint could be cast, forged or drawn with the offset inner diameter.
[0039] In FIGS. 4 & 5 another window joint 60 is depicted. A sidewall 62 of the window joint 60 has a reduced thickness in a window portion 64 . The reduced thickness is due to a recess 66 formed internally on the sidewall 62 . The recess 66 may be formed by milling, casting, forging, or any other method.
[0040] One advantage of using an internally formed recess is that the recess may be used for additional purposes. For example, a whipstock or deflector 68 may carry a member 70 which engages the recess 66 to position and rotationally align a deflector face 72 relative to the window portion 64 .
[0041] In FIGS. 6, 7A & B another window joint 80 is depicted. The window joint 80 has a sidewall 82 with a reduced thickness in a window portion 84 between end connections 86 . The window joint 80 can also include an orienting profile, such as the profile 42 described above, and can also include one or more internal recesses, such as the recess 66 described above, formed on the window portion 84 .
[0042] The cross-sectional views in FIGS. 7A & B depict alternate methods of forming the reduced sidewall thickness in the window portion 84 . In FIG. 7A, the reduced thickness is formed by cutting (or casting, forging, drawing, etc.) a laterally offset, but larger radius 88 on an outer radius go of the window joint 80 . The radius go has a longitudinal centerline 92 , which also corresponds to inner and outer diameters 94 , 96 of the window joint 80 . However, a centerline 98 of the radius 88 is laterally offset relative to the centerline 92 .
[0043] Thus, the window portion 84 includes multiple intersecting external radii 88 , go. One benefit of this construction is that the sidewall thickness of the window portion 84 gradually increases to either side between the radius 88 and the inner diameter 94 in the window portion, providing increased support against collapse of the window portion.
[0044] Although the window joint 80 as depicted in FIG. 7A has the radius 88 greater than the radius go, it should be understood that the radii could be the same, or the radius 88 could be smaller than the radius go.
[0045] In FIG. 7B the window joint 80 is depicted with the reduced sidewall thickness being due to a recess 100 formed externally on the window portion 84 . The recess 100 may be formed by milling, casting, forging, or any other method. Note that any shape of the recess 100 may be used in keeping with the principles of the invention.
[0046] For example, instead of the recess 100 being curved about the circumference of the sidewall 82 , as depicted in FIG. 7B, the recess could be straight, etc. Although the recess 100 is depicted in FIG. 7B as extending only a portion of the length of the window joint 80 , the recess could extend the entire length of the window joint.
[0047] In FIG. 8 another window joint 110 is depicted which is similar to the window joint 80 . However, the window joint 110 includes a window portion 116 having multiple recesses 112 formed externally thereon. Between the recesses 112 , circumferentially extending ribs 114 are disposed to support the reduced sidewall thickness resulting from the recesses.
[0048] The window joint 110 may alternatively, or in addition, have one or more recesses formed internally thereon, such as the recess 66 described above, and if multiple internal recesses are used, supporting ribs may be formed between the internal recesses.
[0049] Of course, a person skilled in the art would, upon a careful consideration of the above description of representative embodiments of the invention, readily appreciate that many modifications, additions, substitutions, deletions, and other changes may be made to these specific embodiments, and such changes are contemplated by the principles of the present invention. Accordingly, the foregoing detailed description is to be clearly understood as being given by way of illustration and example only, the spirit and scope of the present invention being limited solely by the appended claims and their equivalents.
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A reduced debris milled multilateral window. In a described embodiment, a window joint is constructed in a manner which reduces debris created when a window is milled therethrough. The window joint includes a generally tubular body having a sidewall, a window portion of the sidewall being configured for forming a window therethrough, and a thickness of the sidewall being reduced in the window portion.
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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 generally relates to a seismic load transmitting system for multi-span continuous bridges, and more particularly, to a seismic load transmitting system based on impact mechanism for multi-span continuous bridges, which can improve earthquake resistance capacity of a bridge by transmitting seismic load from the superstructure not only to fixed support piers of the bridge, but also to movable support piers of the bridge.
[0003] 2. Description of the Related Art
[0004] Recently, multi-span continuous bridges are widely used. In general, such a multi-span continuous bridge is designed to have a single fixed point in the longitudinal direction of the bridge. FIG. 6 a shows an example of the conventional multi-span continuous bridge. In the conventional 4-span continuous bridge, a fixed support 121 is installed on a fixed support pier 120 , which is located in the middle of the 4-span continuous bridge, to restrict the longitudinal movement of the superstructure 100 of the bridge. Movable supports 122 are installed on movable support piers 110 and 130 to permit free longitudinal movement of the superstructure 100 of the bridge. FIG. 6 b is a schematic view illustrating the deformation of the 4-span continuous bridge of FIG. 6 a when a seismic load is imparted thereto. Referring to FIG. 6 b , the seismic load is applied to the superstructure 100 of the bridge in the arrow direction “b” by an earthquake ground motion expressed in the arrow direction “a”. The superstructure 100 of the bridge moves in the longitudinal direction of the bridge due to the seismic load. With no frictional force of the movable supports, the seismic load imparted to the superstructure 100 of the bridge would be transmitted only to the fixed support pier 120 through the fixed support 121 . The fixed support pier 120 provided with the fixed support 121 would withstand the whole seismic load transmitted from the superstructure 100 of the bridge, and finally be forced to deform as shown FIG. 6 b . If an excessive seismic load is applied to the fixed support pier 120 , the bridge itself as well as the fixed support 121 of the fixed support pier 120 would be seriously damaged, maybe resulting in the failure of the fixed support pier 120 .
[0005] Seismic isolators, i.e., lead rubber bearings, friction pendulum seismic isolation bearings, etc., are conventionally employed to reduce the seismic load transmitted from the superstructure of the bridge to the piers. It is most convenient if the conventional seismic isolators are installed between the piers and the superstructure from the beginning of the construction of the bridge.
[0006] Meanwhile, shock transmitters have been developed to transmit the seismic load not only to the fixed support piers but also to the movable support piers by the aid of high viscosity fluid. To be specific, the apparatus is characterized by a cylinder and rods connecting both ends of the cylinder to the superstructure of the bridge and to the piers. In general the cylinder is divided into two chambers by a sliding piston. The chambers are filled with fluid and connected through an orifice. It allows slow displacement under static load such temperature load. But it provides temporary restraint under the suddenly applied dynamic load such as earthquakes. This apparatus using viscous fluid, however, should always be kept sealed so as to prevent the fluid from leaking out and the function thereof from deteriorating due to the leakage. For this, the apparatus may need measures for continuous monitoring, maintenance and repair. Further, there may happen deterioration in the viscosity of the fluid with the passage of time, possibly inducing loss in efficiency of the impact transmitting apparatus and in earthquake resistance capacity of the bridge.
SUMMARY OF THE INVENTION
[0007] It is, therefore, an object of the present invention to provide a seismic load transmitting system based on impact mechanism for a multi-span continuous bridge, which can overcome the disadvantages of the conventional shock transmitters in a mechanical manner in contrast to the conventional seismic isolator.
[0008] To achieve the above object, there is provided a seismic load transmitting system based on impact mechanism for a multi-span continuous bridge, which improves its resistance capacity against earthquakes by converting the seismic load transmitted from a superstructure of the bridge into a compressive force and transmitting the same not only to fixed support piers but also to movable support piers.
[0009] To be specific, the seismic load transmitting system comprises impact assemblies (or impactors) that are connected to a superstructure of the bridge for colliding with the movable support piers according to longitudinal displacement of the superstructure of the bridge caused by the seismic load and that transmit the seismic load from the superstructure of the bridge to the movable support piers; and impact receiving assemblies (or targets) that are installed in the movable support piers for receiving impact forces generated when the movable support piers collide with the impact assemblies (or impactors) and that transmit the seismic load from the superstructure of the bridge through the impact assemblies to the movable support piers, whereby the seismic load transmitting system can improve the earthquake resistance capacity of the bridge by converting the seismic load generated in the superstructure due to the earthquake into compressive forces due to the collision between the impact assemblies and impact receiving assemblies and transmitting the seismic load to the fixed support piers but also to the movable support piers.
[0010] The seismic load transmitting system according to the present invention has also functions of distributing and transmitting impact forces generated at expansion joints of bridge superstructures owing to the causes other than earthquakes.
[0011] According to the present invention, the impact assembly includes a main body, said main body being fixed to the superstructure of the bridge at one end thereof and extending toward the impact receiving assembly at the other end thereof, an impact plate being installed at an end of the main body and facing the impact receiving assembly with a predetermined gap therebetween; and a buffer plate made of an elastic material, the buffer plate being provided in front of the end of the impact plate, for reducing impact load generated when the impact assembly is collided with the impact receiving assembly.
[0012] The impact receiving assembly may include a base plate attached to the movable support piers for fixing the impact receiving assembly to the movable support piers, a contact plate being in contact with the buffer plate during the collision between the impact assembly and the impact receiving assembly, and an impact absorbing plate being installed between the contact plate and the base pate to absorb the impact force generated during the collision between the impact assembly and the impact receiving assembly.
[0013] The impact assembly may further include a plurality of supplemental intermediate metal plates of a predetermined thickness between the impact plate and the rear of the buffer plate, and the contact plate of the impact receiving assembly has a curved surface of predetermined single or double curvature. The surface of double curvature means a curved surface that is defined by horizontal curvature and vertical curvature that can be different from each other.
[0014] In the other embodiment, the impact plate, intermediate plates and buffer plate of the impact assembly have curved surfaces of predetermined single or double curvature.
[0015] The impact receiving assembly may further comprise an impact absorbing plate being installed between the contact plate and the base plate to absorb the impact force generated during the collision between the impact assembly and impact receiving assembly.
[0016] The contact plate in the impact receiving assembly and the buffer plate in the impact assembly may have, respectively, a curved surface of single or double curvature.
[0017] The structures of the impact assembly and the impact receiving assembly can be interchanged each other to achieve the functions intended by the seismic load transmitting system of the present invention.
[0018] The impact assembly and the impact receiving assembly may be enclosed by a flexible protection hood, respectively. A shear key may be installed at the upper part of the movable support piers, and the impact receiving assemblies may be installed at both sides of the shear key.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] The above and other objects, features and advantages of the present invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings, in which:
[0020] [0020]FIG. 1 a is a schematic view illustrating a 4-span continuous bridge provided with the seismic load transmitting system according to the present invention;
[0021] [0021]FIGS. 1 b and 1 c are, respectively, a schematic view illustrating a deformation of the 4-span continuous bridge provided with the seismic load transmitting system of FIG. 1 a when a seismic load is imparted thereto;
[0022] [0022]FIG. 1 d is an enlarged view illustrating a portion indicated at A in FIG. 1 a;
[0023] [0023]FIG. 2 a is a schematic side-sectional view illustrating an impact assembly according to a preferred embodiment of the present invention;
[0024] [0024]FIG. 2 b is a schematic view illustrating a front of the impact assembly drawn in FIG. 2 a;
[0025] [0025]FIG. 3 a is a schematic view illustrating an impact receiving assembly according to the preferred embodiment of the present invention;
[0026] [0026]FIG. 3 b is a schematic side-sectional view illustrating the impact receiving assembly drawn in FIG. 3 a;
[0027] [0027]FIG. 3 c is a plan-sectional view illustrating the impact receiving assembly of FIG. 3 a eyed from the top of a pier;
[0028] [0028]FIG. 4 is a schematic view illustrating a shape of the seismic load transmitting systems provided with protection hoods;
[0029] [0029]FIG. 5 a and FIG. 5 b are, respectively, a schematic view illustrating another installation of the seismic load transmitting system according to the present invention;
[0030] [0030]FIG. 6 a is a schematic view illustrating a conventional 4-span continuous bridge; and
[0031] [0031]FIG. 6 b and FIG. 6 c are, respectively, a schematic view illustrating a deformation of the conventional continuous bridge of FIG. 6 a when a seismic load is applied thereto.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0032] A preferred embodiment of the present invention will be described herein below with reference to the accompanying drawings. In the following description, well-known functions or constructions are not described in detail since they would obscure the invention in unnecessary detail.
[0033] [0033]FIG. 1 a is a schematic view illustrating a 4-span continuous bridge provided with the seismic load transmitting system according to the present invention. A fixed support 13 is installed at the fixed support pier 10 , which is located in the middle of the bridge, to restraint the longitudinal movement of the superstructure 1 of the bridge. Respective movable supports 14 are installed at the first movable support pier 11 and the second movable support pier 12 to permit free longitudinal movement of the superstructure 1 of the bridge.
[0034] The seismic load transmitting system 20 according to the present invention comprises impact assemblies 21 for applying impact forces to the piers due to the longitudinal displacement of the superstructure 1 of the bridge caused by a seismic load; and impact receiving assemblies 31 for receiving the impact force imparted by the impact assemblies 21 and transmitting the seismic load transferred from the superstructure 1 of the bridge in the form of a compressive force through the impacting assemblies 21 to the piers.
[0035] [0035]FIG. 1 d is an enlarged view illustrating a portion indicated at A in FIG. 1 a . Referring to FIG. 1 d , the impact assemblies 21 are connected firmly to the superstructure 1 of the bridge and arranged at both sides of the respective movable support piers 11 and 12 . The impact receiving assemblies 31 are attached to both side surfaces of the respective movable support piers 11 and 12 .
[0036] [0036]FIG. 1 b and FIG. 1 c are schematic views illustrating the deformation of the 4-span continuous bridge provided with the seismic load transmitting system of FIG. 1 a when the seismic load is applied thereto. In the state where the seismic load is not applied to the superstructure 1 of the bridge, a predetermined gap (G) is maintained between the end surfaces of the impact assembly 21 and the corresponding impact receiving assembly 31 at one side of the respective movable support piers as shown in FIG. 1 a . In contrast, once the seismic load is applied to the superstructure 1 of the bridge, the superstructure 1 of the bridge moves in the longitudinal direction. If the longitudinal displacement of the superstructure 1 exceeds the predetermined gap (G) between the impact assembly 21 and the impact receiving assembly 31 , a collision takes place between the impact assembly 21 and impact receiving assembly 31 , so that the end surface of the impact assembly 21 is forced to be in contact with the impact receiving assembly 31 as drawn in FIG. 1 b . Untill the time when the impact assembly 21 and impact receiving assembly 31 begin to collide with each other, the fixed support pier 11 withstands the total force caused by the displacement of the superstructure 1 of the bridge. If the superstructure 1 of the bridge moves further in the longitudinal direction even after the collision of the impact assembly 21 with the impact receiving assembly 31 , the seismic load is being transmitted from the superstructure 1 of the bridge in the form of a compressive force through the impact assembly 21 and the impact receiving assembly 31 to the movable support piers 11 and 12 . In this case, the bridge will deform in such a way as shown in FIG. 1 c that the movable support piers 11 and 12 as well as the fixed support pier 10 accommodate the seismic load. Meanwhile, if the superstructure 1 of the bridge moves in the opposite direction, the impact assembly and impact receiving assembly installed in the other side of the respective movable support piers are operative to transmit the seismic load to the movable support piers 11 and 12 in the same way as described early.
[0037] In this regard, the seismic load transmitting system according to the present invention is capable of transmitting the seismic load imparted to the superstructure of the bridge due to the earthquake to the movable support piers as well as to the fixed support piers, thereby drastically increasing the earthquake resistance capacity of the bridge.
[0038] Abutments and ground, not shown in FIG. 1 a to FIG. 1 d , are indicated generally as 2 and 3 , respectively.
[0039] A construction of the impact assembly 21 and impact receiving assembly 31 according to the preferred embodiment of the present invention will be described herein below with reference to FIG. 2 a to FIG. 3 c.
[0040] [0040]FIG. 2 a is a schematic side-sectional view illustrating the impact assembly 21 according to the preferred embodiment of the present invention, whereas FIG. 2 b is a schematic view illustrating the structure of the impact assembly 21 . The impact assembly 21 includes a main body 27 , which is fixed to the superstructure 1 of the bridge at one end thereof by a bolt fastening, welding, etc. and extends toward the impact receiving assembly 31 at the other end thereof, and an impact plate 22 , which is installed at the other end of the main body 27 . The impact plate 22 is provided with a buffer plate 25 made of an elastic material at the front thereof to reduce the impact load generated when the impact assembly 21 collides with the impact receiving assembly 31 . For instance, an elastic plate materialized of rubber may be used for the buffer plate 25 , which is mounted in such a way to be easily replaceable.
[0041] Referring to FIG. 2 b , an intermediate plate 28 of a predetermined thickness is attached to the rear end of the buffer plate 25 . The intermediate metal plates 28 is connected to the impact plate 22 by fastening means 26 . Depressed grooves are formed in the intermediate metal plate 28 , so that the head of the fastening means 26 , including bolts, is not projected out of the surface when the intermediate metal plates 28 is connected to the impact plate 22 by the fastening means. Perforations 29 are formed in the buffer plate 25 to pass the fastening means therethrough. The buffer plate 25 is attached integrally to the intermediate layer of metal plates 28 by means of adhesives or the like.
[0042] A plurality of supplemental intermediate metal plates 24 having a predetermined thickness can be installed between the impact plate 22 and the intermediate metal plate 28 . The gap (G) (as seen in FIG. 1 d ) between the impact assembly 21 and the impact receiving assembly 31 is easily adjustable by controlling the number of the supplemental intermediate metal plates 24 , and further, the stress and deformation applied to the impact plate 22 are easily maintainable within a predetermined range by controlling the number of the supplemental intermediate metal plates 24 . Referring to FIG. 2 a , the supplemental intermediate metal plates 24 are preferably installed by the aid of the fastening means 26 , such as bolts, so as to be easily replaced, added, or removed, but they are not limited to this installation method.
[0043] An envelop 23 may be formed around the impact plate 22 and have a predetermined size large enough to envelop the intermediate metal plate 28 or the supplemental intermediate metal plates 24 .
[0044] [0044]FIG. 3 a is a schematic view illustrating the impact receiving assembly 31 according to the preferred embodiment of the present invention, while FIG. 3 b is a schematic side-sectional view illustrating the impact receiving assembly 31 . Furthermore, FIG. 3 c is a schematic plan-sectional view illustrating the impact receiving assembly 31 eyed from the superstructure of the bridge. The impact receiving assembly 31 includes a contact plate 32 with which the buffer plate 25 of the impact assembly 21 is directly in contact during the collision between the impact assembly 21 and the impact receiving assembly 31 , and a base plate 33 for fixing the impact receiving assembly 31 to the movable support piers 11 and 12 . An impact absorbing plate 34 is preferably installed between the contact plate 32 and the base plate 33 to absorb the impact force generated due to the collision between the impact assembly 21 and the impact receiving assembly 31 . The impact absorbing plate 34 is preferably materialized of a metal having a high impact absorbing capacity and a predetermined thickness.
[0045] As drawn in FIG. 3 b , the base plate 33 is integrally fixed to a side of the movable support pier 12 by means of anchor bolts 35 , etc., and the contact plate 32 and the impact absorbing plate 34 are fixed to the base plate 33 by the fastening means 36 including bolts. In particular, if the end of the fastening means 36 for connecting the contact plate 32 and impact absorbing plate 34 protrudes out of the surface of the contact plate 32 , the buffer plate 25 of the impact assembly 21 and the fastening means 36 itself may be damaged because of the protruded end of the fastening means 36 during the collision with the impact assembly 21 . Hence, the end of the fastening means 36 is preferably kept within the contact plate 32 .
[0046] In the event that the contact plate 32 in the impact receiving assembly 31 and the buffer plate 25 in the impact assembly 21 are all of flat surfaces, it is possible that both surfaces of the contact plate 32 and the buffer plate 25 are not accurately opposite to each other due to construction errors, thermal changes, deflection of the bridge, etc. In this case, if the impact assembly 21 collides with the impact receiving assembly 31 , the buffer plate 25 or contact plate 32 would suffer a local stress concentration, increasing the possibility of damage thereto and failing to efficiently transmit the seismic load from the superstructure of the bridge to the piers.
[0047] To solve the problems, the surface of the contact plate 32 in accordance with the present invention is designed to have predetermined single or double curvatures. Specifically, it is more desirable in consideration of diverse effects including the construction errors, thermal changes, etc. that the surface of the contact plate 32 has predetermined double curvatures. That is, the surface of the contact plate 32 has two different curvatures, namely, a vertical curvature (R y ) in FIG. 3 b and a horizontal curvature (R z ) in FIG. 3 c.
[0048] Accordingly, even if there exists a slight variation in the position of the contact plate 32 or buffer plate 25 owing to the construction errors, thermal changes, etc., the collision of the impact assembly 21 with the impact receiving assembly 31 does not build up the local stress and the seismic load can be efficiently transmitted from the superstructure of the bridge to the piers.
[0049] According to another embodiment of the present invention, the buffer plate 25 of the impact assembly 21 is formed to have a curved surface with double curvatures like the above, but the contact plate 32 of the impact receiving assembly 31 may have a level surface.
[0050] In the meantime, the impact assembly 21 and the impact receiving assembly 31 are preferably enclosed by a flexible protection hood 37 to be protected from the adverse environmental effects as shown in FIG. 4.
[0051] In the above preferred embodiments of the present invention, the impact receiving assemblies 31 are installed at both sides of the respective movable piers 11 and 12 . Still another preferred embodiment of the present invention herein below is also available to be used. That is, a shear key 40 having a predetermined height is fixed at the center of the upper part of the respective movable piers 11 and 12 , and the impact receiving assemblies 31 may be installed at both sides of the shear key 40 as shown in FIG. 5 a . Further, individual shear keys 50 are fixed to the movable piers 11 and 12 and the impact receiving assemblies 31 may be installed at the individual shear keys 50 as shown in FIG. 5 b . Fastening means including anchor bolts indicated generally as 51 in FIG. 5 a and FIG. 5 b is used to integrate the separately built shear keys 40 and 50 with the movable piers 11 and 12 .
[0052] In addition, if the system according to the present invention is installed between the superstructure 1 of the bridge and the abutment 2 , it can function as a system for preventing falling down of the bridge superstructure.
[0053] In the case that the fixed support does not have sufficient lateral load carrying capacity, then a premature failure will be resulted. To prevent such a problem, the seismic load transmitting system of the present invention can be installed at the fixed support pier. But the impact assemblies and the impact receiving assemblies should be arranged in such a way to prevent the failure of the fixed supports during the deformation of the fixed support pier.
[0054] In the similar way, the present invention can be used to transmit the seismic load acting in transverse direction from the super structure to the piers of the bridge. The transverse direction means the horizontal direction perpendicular to the longitudinal direction of the bridge. In this case, the seismic load transmitting systems will be installed at the sides of the piers perpendicular to the transverse direction of the bridge.
[0055] The structures of the impact assembly and the impact receiving assembly can be interchanged each other to achieve the functions intended by the seismic load transmitting system of the present invention.
[0056] While the invention has been shown and described with reference to certain preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined by the appended claims.
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Disclosed is a seismic load transmitting system based on impact mechanism for a multi-span continuous bridge, comprising impact assemblies connected to a superstructure of the bridge for colliding with movable support piers according to a longitudinal displacement of the superstructure of the bridge caused by a seismic load and transmitting the seismic load from the superstructure of the bridge to the movable support piers; and impact receiving assemblies installed in the movable support piers for receiving an impact force generated when the movable support piers become collided with the impact assemblies and transmitting the seismic load transferred from the superstructure of the bridge through the impact assemblies to the movable support piers, wherein the seismic load generated in the superstructure of the bridge is transmitted not only to the fixed support piers but also to the moving support piers due to the collision between the impact assemblies and the impact receiving assemblies; and wherein the contact plate of the impact receiving assembly has a curved surface of a predetermined curvature.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
INTRODUCTION
This invention relates to an improved roof control system for underground mines and, more particularly, to a system where load applied during installation of a roof bolt in a borehole is adjusted to provide a pre-selected and optimum tension/torque ratio of the bolt for rock in the particular strata that happens to surround the borehole in which the bolt is installed. This allows an "Optimum Beaming Effect" (OBE) to be achieved by an array of bolts for supporting a mine roof under a given set of conditions.
BACKGROUND OF THE INVENTION
For many years roof bolts have been used for supporting rock strata above the roofs in underground mines. Roof bolts are typically formed of elongated rods of steel anchored in boreholes by (1) various types of mechanical shells or (2) resin which extends along all or part of the length of the bolt. More recently, bolts which are both mechanically anchored in the borehole and reinforced by resin have proved advantageous by preventing loss of tension (e.g., bleed-off) in the bolt over time which had previously been caused by deterioration of surrounding strata, creep, improper hole size or bolt damage during installation.
Within the past 10 years, significant advances in bolt technology have contributed to faster installation speeds, greater anchoring effectiveness, and more favorable economics in the use of roof bolts. One example is a roof bolt such as the one known as the INSTAL bolt made by Jennmar Corporation which operates to mix a two-part resin and then tension the bolt by continuous rotation in a single direction immediately after the bolt is inserted into the borehole. See, for example, U.S. Pat. Nos. 4,413,930 and 4,419,805. Another advance was the use of an effective compression ring for compacting resin into a solid, void-free column which surrounds and extends below an expansion shell which provides better anchorage with less resin. See U.S. Pat. No. 4,865,489.
Another advance was a technique for reducing internal friction between various component parts of a roof bolt, for example, a low friction washer formed of plastic or lubricated components, located between the bearing plate, which is adjacent to the mine roof, and the hardened washer which is positioned adjacent to the forged head on a roof bolt.
These latter devices are particularly effective in reducing internal friction and frictional torque loss during bolt installation since the interface between the bearing plate and hardened washer is believed to be the greatest single source of internal friction in a roof bolt. Other developments include adjusting angles and the surface areas between the camming plug portion of an expansion shell and the adjacent expansion fingers and to provide low friction materials between those adjacent surfaces.
Such efforts to reduce internal friction are known to increase the tension/torque ratio from about 50:1 in a bolt where the hardened steel washer engages the bearing plate, to as high as 120:1. While the installed load of a roof bolt is generally not recommended to exceed 70 percent of the yield strength of the bolt material, higher tension/torque ratios can be obtained by upgrading bolt specifications. Although the reduction of internal friction in various components of a roof bolt was generally considered advantageous, the effect of increasing the installed load and consequentially the tension/torque ratio for various types of roof strata was not understood.
SUMMARY OF THE PRESENT INVENTION
The invention is directed to providing a bolt system where the installed load and consequently the tension/torque ratio of a roof bolt is pre-selected and adjusted to provide maximum performance for a particular rock strata. After the rock strata is analyzed and its mechanical properties determined, a generally acceptable tension/torque ratio is pre-selected, being known from experience. For example, where there is a weak, thinly laminated strata, a higher tension/torque ratio is preferred, as opposed to a more competent strata with a high percentage of coarse or fine grained sandstone where a lower tension/torque ratio provides more desirable results.
Since different types of roof bolts have internal frictional characteristics depending on size, configuration, and materials from which the various components are formed, tests are conducted to determine the tension/torque ratio for a particular bolt under various conditions depending on the bolts specified by a particular mine. After tests determine the tension/torque ratio for these bolts, the installed load is adjusted by, for example, varying the internal frictional characteristics of the component parts. A preferred way of varying the frictional interplay is by providing a selection of plastic washers with varying volumes or displacements, preferably formed of polyethylene, which can be placed between the bearing plate of the bolt and the normally hardened steel washer located above the forged head. By providing a plurality of such washers with different displacements, the frictional losses can be pre-selected and adjusted to optimize the installed load of the bolt and consequently the tension/torque ratio.
In this way, the bolt can be custom designed for a particular rock strata for a maximum performance.
BRIEF DESCRIPTION OF THE DRAWINGS
For a better understanding of the invention, reference should be made to the detailed description of explanatory embodiments set forth below, considered in conjunction with the accompanying drawings which include:
FIG. 1 is a plan view of a mine roof bolt with a bail-type shell which can be used with the present invention;
FIGS. 2-4 are schematic views of a bolt similar to the bolt of FIG. 1, but with a conventional expansion shell with a support nut instead of a bail-type shell, being installed;
FIG. 5 is a chart showing the deflection of elongation of bolts installed with different low-friction washers; and
FIG. 6 is a chart showing the deflection of elongation of bolts using an optimum low-friction washer under a given set of conditions.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows a mine roof bolt of the type to which the present invention can be applied. The bolt is formed of an elongated length of steel rod 16 which can either be smooth on its outer surface or with projections as shown which are typical of using lengths of rebar or J-bar for the rod 16. A head 22 is forged on one end of the rod, with the other end (the end which is inserted into the borehole) being formed with threads 18. An expansion shell, which in this case is formed of a camming plug 38, expansion fingers 40 and a bail 42 for holding the plug and fingers on the threads 18, is mounted on the threads 18 as shown.
An adjustable resin compression ring 26 is mounted on an adjustable wire clamp 28 which ears 30 on the rod 16 for compacting resin in a resin cartridge 32, which is inserted into a borehole 14 drilled in surrounding rock strata 34, prior to insertion of the bolt as described in greater detail below. The bolt shown in FIG. 1 also includes a bearing plate 24 which is positioned adjacent to the mine roof 12. A hardened steel washer 23 is typically located between the bearing plate and the forged head 22. As shown, a low-friction washer 25, discussed in detail below, is located between the steel washer 23 and bearing plate 24.
Another type of bolt 48 which can be used with the invention is shown in FIGS. 2-4, where a standard shell 54 formed with expansion fingers 52 and a camming plug 50 with a shear pin 58, is mounted on the bolt threads above a support nut 56, as described in greater detail in U.S. Pat. Nos. 4,413,930 and 4,419,805 mentioned above. Instead of using the clamp for holding the compression ring 26 in place, a rubberlike washer 48 is used.
In a typical installation of the bolts described, a cartridge of two-component resin is inserted into the borehole, which is then followed by the bolt as shown in FIGS. 1 and 2. The bolt is then pushed upwardly into the borehole as shown in FIG. 3 which causes the upper end of the bolt and shell assembly to puncture the resin cartridge and travel through it to a position several inches away from the end of the borehole. The bolt is then rotated by a bolting machine which engages the forged head 14 and operates to rotate the expansion shell, camming plug and support nut to mix the resin.
The camming plug can be formed with a shear pin, as shown in U.S. Pat. Nos. 4,413,930 and 4,419,805, which maintains the plug fixed relative to the rotating bolt until the resin hardens enough to cause sufficient drag on the shell assembly so that advancement of the bolt breaks the shear pin and causes it to move along the threads. When the support nut reaches the end of the threads, the camming plug is caused to move downwardly along the expansion fingers to expand them for anchoring the bolt into adjacent rock.
In another embodiment of the invention, the camming plug does not include a shear pin. The internal frictional forces between adjacent surfaces of the shell assembly and the threads on the bolt provide frictional interaction which causes the shell assembly to rotate with the bolt and mix the resin before the expansion shell expands into contact with the borehole wall.
Once the shell assembly has been expanded into engagement with the walls of the borehole, as shown in FIG. 4, continued rotation of the bolt relative to the camming plug creates a tension in the bolt. The bolt is rotated and advanced until the bolting machine reaches a predetermined load limit and stalls out, at which time installation is complete.
During installation of the bolt, the bolting machine applies a turning force to the bolt. The amount of load actually translated to the rock strata by the expansion fingers through the bolt is significantly less than the load applied directly to the bolt because of internal frictional losses due to engagement of adjacent surfaces of the bolt. These surfaces include the interfaces between the forged head 22 and the hardened steel washer 23, the washer 23 and the bearing plate 24, the inner surfaces of the expansion assembly, and the expansion assembly and the threads on the end of the rod. Because the surface area between the hardened steel washer 23 and the bearing plate 24 is greater than any of the other adjacent surface areas, it absorbs much of the thrust of the bolter. It has been determined that this interface experiences the greatest frictional loss in the bolting system.
Over the years, bolts such as the one shown in FIGS. 1 and 2 have been used in mine roof control plans with little regard to the effect that an installed load might have on the effectiveness of the roof bolt. It has also been determined that various types of roof bolts work better under certain conditions such as, for example, that resin anchored bolts without mechanical shells work better in wet conditions with what is known as a "bad roof," while mechanical bolts with or without resin work better with dry, more stable roof conditions. Accepted procedures have been developed for the spacing and configuration of roof bolts in a mine to provide maximum benefit for the roof bolts under various conditions.
The ratio between the tension placed on a bolt and the torque applied by the bolting machine is measurable. It has been determined that for a typical hardened steel washer there is generally a tension/torque ratio of about 50:1. Recent developments such as the use of a low-friction washer between the bearing plate and hardened steel washer are known to increase the tension/torque ratio because the washer allows an increase of installed load through the reduction of friction between these two adjacent surfaces.
In accordance with the invention, it was determined that installed load and consequently the tension/torque ratio can effect the performance of a roof bolt under certain roof conditions. For example, where there is a weak, thinly laminated strata, a higher tension/torque ratio is preferred because where there is a higher installed load applied quickly through the strata, increased frictional resistance along the bedding planes of the rock would make them more resistent to lateral movement. On the other hand, where there is more competent strata such as, for example, a high percentage of coarse or fine grained sandstone, optimum anchorage is obtained with a lower installed load and tension/torque ratio.
In accordance with the invention, a series of different sized anti-friction washers have been developed in order to accommodate varying types of strata and customize roof bolts to a particular roof condition. It has been determined that most mine roof conditions can be accommodated through five different sizes of washers formed of polyethylene (called numbers 1-5, respectively). The outer diameter, inner diameter and thickness of these washers are (1) 1.75"×0.82"×0.10"; (2) 1.625"×0.82"×0.125"; (3) 1.650"×1.020"× 0.160"; (4) 2"×1.175"×0.160" and (5) 2.5"×1.5"×0.1875". These same number designations are used below when referring to the washers.
The smaller washers reduce friction less than the larger washers because of the lesser volume and surface area of the smaller washers between the bearing plate and hardened steel washer of the bolt, as shown in FIGS. 1-4, where a polyethylene washer 25 is located between the hardened steel washer 23 and roof plate 24.
In order to adapt these washers to particular roof bolts and particular strata in the mine, the following procedure is used. First, the strata of the mine must be examined to determine the characteristics of the rock. Factors which must be considered are:
1. Overburden depth.
2. Strata composition.
3. Fineness and number of laminations.
4. Number of changes in the type of rock comprised in the laminations.
5. Rock physical properties--compressive strength, Young's modulus, Poisson's ration, density, moisture content, etc.
From these data, an understanding of the rock strata can be obtained to determine a general range of tension/torque ratios along with the generally accepted type of bolt for that particular strata. Next, tests are conducted at various locations in the mine with a bolt selected for use to determine the anchorage capacity and tension/torque ratio and whether it generally matches the rock strata at the mine. The tension/torque ratio is then adjusted by testing various ones of the low-friction washers mentioned above and measuring installed load by using a load cell on the bolt in a known procedure.
The optimum anti-friction washer for a particular roof condition is one where pull tests determine the lowest deflection or lengthening of the bolt when pulled to the yield strength of the bolt material after the bolt has been installed. It has been found that the greater the installed load, the lesser the deflection under a given set of conditions. However, once a minimum deflection is determined then the tension/torque ratio should be adjusted for the particular rock condition.
By matching the tension/torque ratio to the strata, what is called the "Optimum Beaming Effect (OBE) can be achieved. What this means, is that given a particular type of strata, by proper bolt spacing and installed load on the bolt, the summation of the resultant upward compressive forces can in effect produce a beaming effect that could support any amount of strata, at any depth.
For the roof to begin to fail, the vertical downward pressure would have to exceed the summation of the upward forces created by the installed load for each roof bolt. This information can be obtained through the use of a stratascope to examine the inside of boreholes drilled at various locations in the mine and from core drilling data that most mines have available.
The effect of different sized anti-friction washers is shown in the chart of FIG. 5, where the "Y" axis shows the deflection in inches of 19 different bolts installed with various sized low-friction washers, the "X" axis showing the pull exerted on the bolts. Deflection is the distance the bolt is stretched or elongated as it was pulled up to the yield strength of the steel used in the bolt. FIG. 5 shows that under the same conditions and in a number of tests where the same bolt was used, which was a bail-type shell known as the Jennmar J3BM, different deflections resulted from tension/torque ratios adjusted by using different low-friction washers. For example, for tests 1, 2, 10, 11, 14, 15, 16, 17 and 18, a number 1 low-friction washer was used, and in tests 3 and 4 a number 2, tests 5 and 6 a number 3, tests 12 and 13 a number 4, and test 19 is a test showing no resin used with the bolt.
These tests illustrate the respective deflections caused by the different tension/torque ratios resulting from the use of low-friction washers of various sizes, with the tests with a number 2 washer showing the greatest consistency in producing a relatively low deflection. A higher tension/torque ratio consequently produces a higher amount of installed load of initial bolt tension. During a pull test, bolt head deflection readings are lower on bolts with high installed loads. The installed load must be exceeded by the applied load before large deflections can occur. In mine roof control, this fact is very important. Before the roof can begin to fail, the installed load of the roof bolt would also have to be exceeded by the vertical downward load applied by the roof.
In the chart shown in FIG. 6, ten pull tests were conducted with the same J3BM shell mentioned above with a low-friction washer matched to the strata for the mine where the tests in FIG. 5 were conducted, which was a number 2 polyethylene washer. This washer was determined to be the proper sized one for the strata involved which was thinly laminated, weak shale with a low percentage of sandstone or sandy shale. This result was determined because under these conditions and for the bolt selected there was a relatively low deflection with relatively consistent results.
Thus, in accordance with the invention, it has been determined that by adjusting the size of low-friction washer located between the bearing plate and hardened steel washer, the installed load and consequently the tension/torque ratio can be adjusted to optimize the bolt to particular roof conditions. It should be understood that the importance of an anti-friction washer is to reduce internal friction in the bolt and that other friction-reducing members can be used, such as, for example, a plastic sheet located between the surface of the camming plug and expansion fingers, and lubricating or otherwise making smoother adjacent surfaces. The invention contemplates reducing internal friction to optimize bolt performance and is not limited to use of an anti-friction washer for accomplishing these results.
It should also be understood that the invention can be improved or modified and still incorporate the primary features of the invention, which are set forth in the appended claims:
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A roof control system for underground strata has an elongated bolt adapted for insertion into a hole bored into the underground strata. The bolt is securely anchored in the hole at a location where a significant length of the bolt remains between the opening of the borehole and the anchor. A significant length of the bolt is placed in tension by rotating the bolt at a predetermined torque, with a plate mounted on the bolt and located adjacent to the outer surface of the strata and a nut on the end of the bolt for engaging the plate. The friction between adjacent surfaces which rub against each other when the bolt is rotated is selectively adjusted so that the tension/torque ratio of the bolt is selected to match the desired level for a particular type of strata. A array of friction reducing washers with different contact surface areas are provided so that one can be selected for location between the nut and plate.
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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 a dozer blade assembly and more particularly relates to a blade mounting and a blade actuating means which cooperate for selective angling and tilting of the blade.
Dozer blade assemblies are commonly constructed so as to include a blade connected to a central front part of a C-frame by means of a universal connection located midway between opposite ends of the blade. A pair of hydraulic angling actuators are often respectively connected between opposite legs of the C-frame and the blade and are actuatable to angle the blade about a vertical axis passing through the universal connection, and a hydraulic tilting actuator is connected between the front part of the frame and the blade and is actuatable to tilt the blade about a fore-and-aft axis passing through the universal connection.
These known dozer blade assemblies fail to operate in a satisfactory manner since either no provision at all is made for compensating for the changes in location of the points of connection of the angling actuators with the blade during tilting of the latter resulting in high forces being induced in the angling actuators which sometimes cause the blade to bind at its points of connection with the C-frame, or the blade is connected to the frame such that it will undergo a pitch change to compensate for the changes in location of the points of connection of the angling actuators with the blade during tilting of the latter, such a pitch change sometimes being unsuited for the work being performed. Further, the angling actuator of these known assemblies are sometimes hydraulically connected such that high pressures are generated therein when working loads are imposed on the corner of the blade.
SUMMARY OF THE INVENTION
According to the present invention there is provided a novel blade assembly structured such that mounting means and actuating means of and for the blade cooperate for efficient and effective tilting and angling of the blade.
A broad object of the invention is to provide a mounting means and actuating means which cooperate such that loads which might tend to bind tilting movement of the blade are prevented from being developed in the blade assembly.
A more specific object is to provide a mounting means and an actuating means, as described in the foregoing paragraph, wherein the actuating means includes pressure relief circuitry embodying valve means automatically operated to exhaust fluid from the angling actuators so as to allow angling of the blade during tilting of the latter so as to compensate for the change of the positions of the points of connection of the angling actuators with the blade when the latter is tilted.
Still a more specific object is to provide a normally closed relief valve which is actuated in response to a predetermined pressured being developed in the angling actuators by operation of the tilt actuator but is connected to the angling actuators so as not to be affected by pressure developed in the angling actuators by working loads imposed on the blade.
Another object is to provide valve means in the pistons of the angling actuators for interconnecting opposite ends of each of the actuators together so as to prevent a pressure build-up therein during tilting of the blade when the angling actuators are in respective bottomed conditions.
Yet another object of the invention is to provide a mounting means and an actuating means which cooperate to maintain the blade at a constant pitch during angling and tilting of the blade.
Another object is to provide angling actuators which are hydraulically coupled so as to minimize circuit pressures induced by working loads imposed on one corner of the blade.
These and other objects will become apparent from a reading of the ensuing description in conjunction with the appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a somewhat schematic side elevational view of the dozer blade assembly of the present invention with a part of the stabilizer connection broken away to expose other parts thereof.
FIG. 2 is a sectional view taken along the line 2--2 of FIG. 1.
FIG. 3 is a sectional view taken along the line 3--3 of FIG. 1.
FIG. 4 is a schematic representation of the hydraulic actuators and circuitry therefor for controlling the blade assembly.
FIG. 5 is a schematic top plan view of the angling actuators, the tilting actuator and the dozer blade with the right and left angling actuators being respectively retracted and extended within an inch of the ends of their strokes and holding the blade in a rightwardly angled position and with the tilting actuator being retracted and holding the blade in a counterclockwise tilted position.
FIG. 6 is a rear elevational view of the blade and actuator shown in FIG. 5 but with the angling actuators removed so as to expose their connection points with the blade.
FIG. 7 is a view similar to FIG. 5 but showing the tilting actuator extended and holding the blade in a clockwise tilted position.
FIG. 8 is a rear elevational view of the blade and actuators shown in FIG. 7 but with the angling actuators removed so as to expose their connection points with the blade.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIGS. 1-3, therein is shown a dozer blade assembly indicated in its entirety by the reference numeral 10. The blade assembly 10 includes a support frame 12 of a type commonly called a C-frame and defined by right and left side members 14 and 16 (FIG. 3), respectively, having their forward ends joined by a transverse member 18 and having their rearward ends pivotally connected to tractor framework schematically shown at 20. Conventionally, the frame 12 would be disposed with its sides 14 and 16 along opposite sides of and with the member 18 just forwardly of a forward end portion (not shown) of a tractor. The frame 12 is swung vertically about its connection with the framework 20 through selective actuation of right and left hydraulic lift actuators 22 and 24, respectively, connected between the framework 20 and right and left upstanding members 26 and 28 respectively fixed to the tops of the sides 14 and 16 of the support frame 12.
A dozer blade 30 is joined to the transverse member 18 of the frame 12 through means including a lower ball joint connection 32 and an upper stabilizing connection 34. The ball joint connection 32 includes a ball receptacle 36 fixed to a lower central backside portion of the blade 30 and receiving a ball 38, which is fixed to the transverse member 18 at a central location thereof. The stabilizing connection 34 includes a member 40 fixed to the backside of the blade 30 at an upper central location thereof and defining an inverted U-shaped guide channel or track 42 which is curved arcuately at a fixed radius about a horizontal axis X extending longitudinally in the direction of travel of the blade 30 and passing centrally through the ball 38 of the connection 32. Disposed in the channel 42 is a slide block 44 swivelly mounted on one end of a vertical pin 46 fixed in a forwardly projecting portion 48 of an upstanding support post 50 fixed to a central topside portion of the transverse member 18. The pin 46 is located along a vertical axis Y which passes centrally through the ball 38 of the connection 32. Thus, it will be appreciated that the blade 30 is mounted for respectively tilting and angling about the axes X and Y.
It is here noted that the forward projecting portion 48 of the support post 50 could be made telescopic for the purpose of adjusting the pitch of the blade 30 with bolts or a hydraulic pitch actuator or the like being provided for fixing the portion 48 in a fixed adjusted length.
In FIGS. 1-3, the blade 30 is shown in an unangled condition wherein it extends perpendicular to the axis X and an untilted condition wherein it is horizontally disposed. For the purpose of selectively tilting the blade 30 about the axis X, there is provided a hydraulic tilting actuator 52 having its head end connected to the portion 48 of the support post 50 by the pin 46 and having its rod end connected to an ear 54 fixed to the backside of the blade 30.
For the purpose of selectively angling the blade 30 about the axis Y, there are provided right and left hydraulic angling actuators 55 and 56, respectively, having their respctive head ends coupled to the upstanding members 26 and 28, as at 57 and 58, and their respective rod ends pivotally connected to the backside of the blade 30 at connections 60 and 62.
Referring now to FIG. 4, therein is shown the hydraulic circuitry in which the blade actuators are embodied. Specifically, the hydraulic circuitry includes three manually operable open center direction control valves 64, 66 and 68 connected in parallel in a pressure line 70 having one end connected to a pump 72 and having another end connected to a return line 74. The pump 72 and the return line 74 are both in fluid communication with a sump or reservoir 76. The rod ends of both lift actuators 22 and 24 are connected to the control valve 64 by a control line 78 and the head ends of both left actuators 22 and 24 are connected to the valve 64 by a control line 80. The rod and head ends of the tilting actuator 52 are connected to the control valve 66 respectively through means of control lines 82 and 84. The head end of the angling actuator 55 and the rod end of the angling actuator 56 are connected to the control valve 68 by a control line 86 while the rod end of the actuator 55 and the head end of the actuator 56 are connected to the valve 68 by a control line 88. This cross connection of the head and rod ends of the actuators 55 and 56 has the advantage that only about one-half as much pressure is developed in the circuitry due to loads imposed on one end of the blade 30 as would be developed if the rod ends of the actuators 55 and 56 were connected together and the head ends of the actuators 55 and 56 were connected together.
The connections 60 and 62 which join the rod ends of the angling actuators 55 and 56 to the blade 30 move with the blade 30 when the latter is tilted about the axis X and it will be appreciated that provision must be made to compensate for this movement of the connections 60 and 62 if the blade 30 is to tilt without binding at the connections 32 and 34 and for without undue pressure being developed in the actuators 55 and 56. Such provision is made according to the present invention by incorporating features in the angling actuators 55 and 56 and in the circuitry just described.
Specifically, the angling actuators 55 and 56 respectively include pistons 90 and 92 fixed to respective first ends of piston rods 94 and 96. The piston 90 of the actuator 55 divides the cylinder thereof into rod and head end chambers 98 and 100 and the piston 92 of the actuator 56 divides the cylinder thereof into rod and head end chambers 102 and 104. Extending through the pistons 90 and 92 are respective passages 106 and 108. A coil compression spring 110 is located in the passage 106 and acts oppositely against poppet valve elements 112 and 114 to maintain the valve elements 112 and 114 in normally seated conditions wherein respective stem portions 116 and 118 thereof extend into the rod and head end chambers 98 and 100 for engagement with the opposite ends of the cylinder of the actuator 55 for unseating the valve elements 112 and 114 respectively when the actuator 55 becomes fully retracted and extended. Similarly, a coil compression spring 120 is located in the passage 108 and bears against poppet valve elements 122 and 124 at its opposite ends to maintain the valve elements 122 and 124 in normally seated conditions wherein respective stem portions 126 and 128 thereof extend into the rod and head end chambers 102 and 104 for engagement with the opposite ends of the cylinder of the actuator 56 for unseating the valve elements 122 and 124 respectively when the actuator 56 becomes fully retracted and extended. The purpose for the valve elements 112 and 114, and 122 and 124 will be presently described.
Returning now to the circuitry shown in FIG. 4, there is shown a pressure relief circuit including a relief line 130 which connects the control line 88 to the sump 76 and contains a normally closed, pressure relief valve 132 which is pilot operated in response to a predetermined pressure in the control line 86, the latter being connected to the valve 132 by a pilot pressure line 134. The sump 76 is respectively connected to the relief line 130, upstream from the valve 132 and to the pilot pressure line 134 by make-up fluid line 136 and 138 which respectively contain check valves 140 and 142 for permitting flow only from the sump 76.
The operation of the dozer blade assembly 10 is as follows: Assuming the blade 30 to be disposed as illustrated in FIGS. 5 and 6, the tilting actuator 52 will be retracted and the angling actuators 55 and 56 will be in respective retracted and extended conditions wherein the respective pistons thereof are approximately one inch from stroke extremes.
If it is then desired to tilt the blade 30 clockwise about the axis X, as viewed in FIG. 6, towards the position shown in FIG. 8, the control valve 66 is shifted rightwardly from its neutral position shown in FIG. 4 so as to connect the pump 72 and sump 76 respectively to the head and rod ends of the tilting actuator 52 to effect extension of the latter. As the blade 30 begins to tilt, the connections 60 and 62 of the angling actuation 55 and 56 with the blade 30 will respectively begin to move with the blade 30 downwardly and outwardly and upwardly and inwardly relative to the axis X. However, since the angling actuators 55 and 56 are at this point pressure locked in a fixed length, the movement of the blade 30 will act in a direction tending to forcibly contract or collapse the actuators 55 and 56. This results in an increase in the pressure in the respective head end and rod end chambers of each of the actuators 55 and 56. When the pressure, developed in the line 86 by the blade tending to collapse the right actuator 55, reaches the predetermined level necessary to operate the pressure relief valve 132, the valve 132 will open permitting pressurized fluid from the head end chamber 104 of the left actuator 56 to go to the sump 76 via the control line 88 and relief line 130. As the fluid from the chamber 104 is relieved to sump, the left actuator 56 will contract to thus allow the fluid from the head end chamber 100 of the right actuator 55 to flow into the rod end chamber 102 of the actuator 56 and allow the actuator 55 to contract. In this manner the actuators 55 and 56 are forcibly contracted.
It will be appreciated then that when the blade 30 is tilted from its FIG. 8 position to its FIG. 6 position the actuators 55 and 56 will be forcibly extended. This will induce a vacuum in the head end of actuators 55 and 56. Makeup fluid will then enter the head ends of actuators 55 and 56 through the check valves 140 and 142, thus eliminating hydraulic cavitation in actuators 55 and 56.
Assuming the blade 30 to be in a fully rightwardly angled position just beyond that shown in FIG. 5, the angling actuators 55 and 56 will respectively be fully retracted and fully extended and the poppet valve element 114 of the actuator 55 and the poppet valve element 124 of the actuator 56 will be unseated due to their respective stem portions 118 and 126 being respectively engaged with the head end of the actuator 55 and the rod end of the actuator 56.
If it is then desired to tilt the blade 30 clockwise about the axis X, as view in FIG. 5, the tilting actuator 52 is actuated, in the manner previously described, to cause it to extend. As the blade 30 begins to tilt, the connections 60 and 62 of the actuators 55 and 56 with the blade 30 will respectively begin to move downwardly and outwardly and upwardly and inwardly with the blade 30. As described before, the tilting movement of the blade 30 will cause an increase in the pressure in the respective head end chamber 104 of the actuator 56 and rod end chamber 98 of actuator 55. This pressure rises to a predetermined point where poppet valves 116 and 128 are hydraulically unseated allowing fluid to pass by the mechanically unseated poppet valves 118 and 126, thus interconnecting hydraulically the head and rod ends of actuators 55 and 56.
As the pressure rises sufficiently to operate the relief valve 132, as occasioned by further tilting of the blade, pressure fluid will flow from the head end chamber 104 of actuator 56 to the return line 130 either via a path through the line 88, poppets 116 and 114, line 86 and the relief valve 132 or via a path through the poppets 124 and 126, the line 86 and the relief valve 132. In either case, the actuator 56 is forcibly contracted as occasioned by the tilting actuator 52.
It is to be noted that during operation pressure developed in the angling actuators 55 and 56 due to engaging the blade 30 with an item or substance to be dozed will not be effective to cause extension or retraction of the actuators 55 and 56. For example, if the force resisting movement of the blade 30 is distributed evenly over the length of the blade, no pressure will be developed in the actuators 55 and 56 due to the control lines 86 and 88 being cross connected between the opposite ends of the actuators 55 and 56. If the blade is for example, loaded more to the left than it is to the right of the axis Y, the pressure in the rod and head ends respectively of the actuators 55 and 56 might raise to that sufficient to open the relief valve 132 but no fluid would pass therethrough since no pressure would be developed in the head and rod ends respectively of the actuators 55 and 56.
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Mounted between a frame and a dozer blade at opposite sides of vertically spaced stabilizing and ball joint connections joining the frame and blade are a pair of hydraulic angling actuators which are operative to angle the blade about a vertical axis defined by the connections. A hydraulic tilt actuator is connected between the frame and blade in the vicinity of the stabilizing connection and is operative to tilt the blade about a fore-and-aft axis passing through the ball joint connection. Pressure relief circuitry including a normally closed relief valve is connected to the angling actuator and the relief valve is opened in response to a predetermined pressure build-up in the angling actuators, as occasioned by changes in the location of the points of connection of the angling actuators with the blade during tilting of the latter, to exhaust fluid from the angling actuators to permit extension or retraction thereof. Poppet valving is provided in the pistons of the angling actuators for interconnecting opposite ends of each of the angling actuators when the latter are at the ends of their respective strokes so as to prevent the pressure from building up in the angling actuators when the blade is tilted.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a Division of pending application Ser. No. 10/700,221, filed Nov. 3, 2003. Said application Ser. No. 10/700,221 is a Division of application Ser. No. 10/017,116 filed Dec. 14, 2001 and Issued as U.S. Pat. No. 6,644,099 on Nov. 11, 2003.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] The present invention relates to shaped charge tools for cutting pipe and tubing. More particularly, the invention is directed to methods and apparatus for improving the performance and cutting reliability of shaped charge tubing cutters.
[0005] 2. Description of Related Art
[0006] The capacity to quickly, reliably and cleanly sever a joint of tubing or casing deeply within a wellbore is an essential maintenance and salvage operation in the petroleum drilling and exploration industry. Generally, the industry relies upon mechanical, chemical or pyrotechnic devices for such cutting. Among the available options, explosive shaped charge (SC) cutters are often the simplest, fastest and least expensive tools for cutting pipe in a well. The devices are typically conveyed into a well for detonation on a wireline or length of coiled tubing.
[0007] Although simple, fast and inexpensive, SC cutters are reputedly not the most reliable means for cutting tubing downhole. State-of-the-art SC cutters are typically tested and rated for cutting capacity at surface ambient conditions. In field use, however, downhole well conditions may exceed 10,000 psi and 400° F. The impact of such elevated pressure and temperature has upon SC performance, generally, is not well understood. High pressure/temperature test environments for SC tubing cutters is not a norm of the industry. Industrial standards for SC cutter performance provide only for cutting capacity at standard atmospheric conditions.
[0008] Physical testing under simulated well conditions has revealed two primary influence factors affecting the cutting capacity of SC cutters:
(1) The spacial clearance between the cutter perimeter and the inside wall of the tubing; and, (2) Hydrostatic well pressure.
[0011] Asymmetric alignment of the SC cutter within the flow bore of the tubular subject of a cut may reduce the SC cutting capacity up to 35% under atmospheric conditions. At 15,000 psi, SC cutting capacity is reduced an additional 20-25%.
[0012] The graph of FIG. 1 illustrates the performance of a typical, 1 11/16″ state-of-the-art SC tubing/casing cutter operating upon an L-80 grade, 4.7 lb./ft., 2⅜″ production tube. The abscissa axis of this graph plots the dimension of radial separation between the SC perimeter and the proximate tubing wall surface. When the SC cutter is aligned substantially coaxial with the tube, the clearance will be a uniform 0.15 in. around the SC perimeter as indicated by the dashed line coordinate that intersects the abscissa at the 0.15 in. value. The ordinate axis of the graph represents the wall penetration depth of an SC cutting jet. The dashed line coordinate from the ordinate axis represents the wall thickness of the tested tubing. The locus of curve “A” plots the SC performance at atmospheric pressure. The locus of curve “B” plots the SC performance at 15,000 psi.
[0013] To be noted from FIG. 1 is that even when the SC cutter is centrally aligned within the tube flow bore, the SC penetration capacity is marginal for completely severing the tube thickness at atmospheric pressure (curve A). When the pressure of the operational environment is raised to 15,000 psi, (curve B) the SC wall penetration capacity is substantially reduced. Similarly, when the SC is eccentrically misaligned with the tube axis whereby one portion of the SC perimeter is in contact with the tube wall and the diametrically opposite portion of the SC perimeter has a 0.30 in. clearance, at atmospheric pressure the SC cutting capacity is reduced by 35%. Under 15,000 psi pressure, the cutting capacity is reduced by another 25% for a total of 60%.
[0014] Although SC cutter manufacturers offer centralizers for their tools and recommend their use, in field practice most cutters are operated without the use of a centralizer. However, such prior art centralizers are constructed of plastic or other low abrasion resistive material. Hence, such prior art centralizers are frequently damaged while running into a well by abrasion or by various restriction elements within the tubing bore. Consequently, a partial cut is the common result. As the data of FIG. 1 indicates, the penetration capacity of most cutters is marginal under optimum conditions and substantially lacking under severe conditions.
[0015] Another finding from test experiences is that SC cutters frequently lose penetrating capability when the cutter is mounted rigidly against the top sub of the tubing assembly or against the bottom of the SC cutter housing. The loss of cutting capacity is most severe when the SC is tightly coupled only on one side of the SC cutter. It would appear that the cutting jet generated by such a SC is asymmetrically formed due to such confinement. Such disruption of the normal jet formation also increases an undesirable flared distortion of the severed tubing wall at the separation plane and an undesirable deformation to the end face of the top sub.
[0016] In principle, the explosive assemblies of SC tubing cutters comprise a pair of truncated cones. The cones are formed as compressed powdered explosive material and joined along a common axis of revolution at a common apex truncation plane. The respective conical surfaces are faced or clad by a dense liner material; usually metallic. An aperture along the common conical axis accommodates a detonation booster.
[0017] In theory, ignition of the detonation booster initiates the SC explosive along the cone axis. Explosive detonation propagates a rapidly moving pressure wave radially from the axis through the two explosive material cones. Traveling radially from the cone axis, the pressure wave first encounters the charge liner at the truncated apex plane and progresses toward the conical base. As the two liners erupt from the conical surface into the proximate window space, heavy molecular material from the respective charge liners collide with substantially equal impulse along the common juncture plane. Since there is an included angle between the liners, the resulting vector of this collision is a substantially planar jet force issuing radially from the cone axis.
[0018] In sequence, the explosive material decomposes more rapidly than the liner material. Hence, the explosive material is transformed into a high pressure gaseous mass confined behind the liner barrier. I have discovered that if a portion of that gas escapes into the jet cavity between the conical liners in advance of the liner material merger, the intensity and direction of the cutting jet is compromised.
[0019] It is an object of the present invention, therefore, to provide the industry with tubing cutters having a substantially known downhole, high pressure cutting capacity.
[0020] Also an object of the present invention is to disclose a test method for quickly and inexpensively determining the cutting capacity of a cutter assembly under downhole conditions.
[0021] A further object of the invention is a cutter assembly design that reliably confines the decomposing SC explosive behind the SC liner to prevent distortion of the cutting jet development.
[0022] Another object of the invention is a reliable centralizer assembly.
[0023] Also an object of the invention is a new detonator booster design that ignites the SC booster substantially along the cone axis of the charges and at the common plane of apex truncation.
[0024] A further object of the invention is provision of an SC tube cutter explosive liner having deeper and more effective cutting capacity.
SUMMARY OF THE INVENTION
[0025] These and other objects of the invention as will become apparent from the following detailed description are provided by an SC assembly wherein the explosive unit of the assembly is substantially isolated between the end wall of the assembly top sub and the inside end-face of the housing by respective spaces of about 0.100″ or more. A plurality of metallic dowel pins protruding from the end face of the top sub engage the adjacent face of the SC thrust plate. Preferably, the thrust plate is brass or other non-ferrous material whereas the spacer pins may be steel. At the housing end, the SC end plate may be ferrous but separated from the housing end wall by a non-conductive elastomer washer that resiliently biases the SC explosive against the top sub dowel pins.
[0026] The invention housing is a generally cylindrical element of hardened, high-strength steel having structural weakness or failure lines formed about the housing perimeter above and below the cutting jet window. Internally of the housing, a cutting jet window is defined about the inside perimeter of the housing by concentric channeling. An outer channel having substantially radial walls spans an inner channel, also having substantially radial walls. The axial span between the outer radial window walls is coordinated to the axial span between the conical base perimeters of the SC explosive unit liners whereby the edge thickness of the liner base is intersected by the radially projected plane of the outer window wall.
[0027] Externally, the SC housing is formed to an axially projecting salient for secure attachment of a centralizer having spring steel centralizing blades whereby the blades have significant abrasion resistance and are free to flex without exceeding material yield limits.
[0028] The SC explosive unit is lined with a pressure formed powdered metal mixture comprising about 80% or greater (80≧%) tungsten with the remainder comprising a mixture of about 80% copper and about 20% lead powders. The liner cladding is formed to an approximate 0.050″ thickness.
[0029] A cylindrical aperture is formed along the explosive unit axis to receive a detonation booster comprising a substantially cylindrical brass casement having an elongated, small diameter axial primer channel into a large diameter main cavity. High explosive powder in the primer channel is packed to a density of about 1.1 to about 1.2 g/cc whereas the main cavity explosive is packed to about 1.5 to about 1.6 g/cc. Axially opposite of the primer channel entry into the main cavity, the main cavity is volume defined by a brass plug insert. The detonation booster casement is positioned along the axial aperture to locate the juncture plane of the apex truncations across the approximate center of the booster main cavity. The booster casement wall thickness along the length of the primer channel is sized to prevent detonation of the SC explosive by the primer decomposition.
[0030] Also within the scope of the present invention is a highly simplified test procedure for testing cutter performance within a pressure vessel and for determination of an associated relationship between the cutting performance of a tool at atmospheric pressure and the cutting capacity of the same tool at some designated downhole pressure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] The advantages and further aspects of the invention will be readily appreciated by those of ordinary skill in the art as the same becomes better understood by reference to the following detailed description when considered in conjunction with the accompanying drawings in which like reference characters designate like or similar elements throughout the several figures of the drawing and wherein:
[0032] FIG. 1 is a graph of cutting performance data observed from tests of prior art SC cutters.
[0033] FIG. 2 is a cross-section of one embodiment of the invention.
[0034] FIG. 3 is a plan view of the present invention centralizer.
[0035] FIG. 4 is a detailed section of cutter perimeter and jet window
[0036] FIG. 5 is a cross-section of an additional embodiment of the invention.
[0037] FIG. 6 is an end view of the assembly top sub.
[0038] FIG. 7 is an axial cross-section of the present invention detonation booster.
[0039] FIG. 8 is a sectioned plan view of the FIG. 9 test apparatus.
[0040] FIG. 9 is a sectioned view of the present test apparatus.
[0041] FIG. 10 is a sectioned view of a simplified alternative test apparatus.
[0042] FIG. 11 is a plan view of the FIG. 10 test apparatus.
[0043] FIG. 12 is a graph of SC performance under various conditions.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0044] Referring initially to the invention embodiment of FIG. 2 , the cutter assembly 10 comprises a top sub 12 having a threaded internal socket 14 for secure assembly with an appropriate wire line or tubing suspension. In general, the cutter assembly has a substantially circular cross-section. Consequentially, the outer configuration of the cutter assembly is substantially cylindrical. The opposite end of the top sub includes a substantially flat end face 15 having dowel sockets 17 for receipt of spacer pins 19 . The end face perimeter is delineated by a housing assembly thread 16 and an O-ring seal 18 . The axial center of the top sub is bored between the assembly socket 14 and the end face 15 to provide a detonator socket 30 .
[0045] Occasionally, when operating tubing cutters, the detonator socket 30 becomes plugged with debris from the detonator, its holder and debris from the well. Resultantly, pressure is trapped within the top sub which presents a personnel hazard when disassembling the tool upon recovery from the well. Responsively, the present invention provides a pair of supplementary vents 31 as illustrated by FIG. 6 alongside the detonator socket 30 as pressure bleed-off vents.
[0046] Referring again to FIG. 2 , the present invention cutter housing 20 is secured to the top sub 12 by an internally threaded sleeve 22 . An O-ring 18 seals the interface from fluid invasion of the interior housing volume. A jet window section 24 of the housing interior may be axially delineated above and below by exterior “break-up grooves” 26 and 28 . The break-up grooves are lines of weakness in the housing 20 cross-section and may be formed within the housing interior as well as exterior as illustrated. The jet window 24 is that inside wall portion of the housing 20 that bounds the jet cavity 25 around the SC between the liner faces 58 .
[0047] Below the lower break-up groove 28 is an end-closure 32 having a conical outer end face 34 around a central end boss 36 . A hardened steel centralizer 38 is secured to the end boss by an assembly bolt 39 , A spacer 37 may be placed between the centralizer and the face of the end boss 36 as required by the specific task.
[0048] Preferably, the shaped charge housing 20 is a frangible steel material of approximately 55-60 Rockwell “C” hardness. Prior art common steel cutter housings usually break up adequately so that debris will fall harmlessly to the bottom of the well when fired at low hydrostatic pressures. However, when fired at elevated pressures, the prior art material may fail to fragment satisfactorily, thus plugging the tubing bore in which it is fired. More seriously, the threaded sleeve section of a mild steel cutter housing may simply flare to a larger diameter when the SC is discharged. If the diameter increase is excessive, the top sub of the cutter housing cannot be retrieved through some restrictions that are commonly installed in the tubing string above the cut, thereby resulting in an expensive and time consuming fishing operation to recover the tool remainder. By utilizing a hard, frangible steel material for the housing fabrication, fragmentation of the housing 20 is encouraged and flaring is minimized or eliminated.
[0049] The flaring consequence of a cutter discharge may also visit the end face of the top sub 12 . The detonation forces may radially curl or flare the intersecting corner between the end face 15 and the top sub OD surface. Such added radial dimension to the top sub may also prevent recovery of the tool following the tubing cut thereby requiring a fishing operation. As shown by the FIG. 5 embodiment of the invention, a relatively narrow shear shoulder 50 is formed in the top sub body to seat the end face of the cutter housing sleeve 20 . The shear shoulder base is sized to accommodate the normal static loads on the housing sleeve but to separate under the shear loads imposed by detonation.
[0050] Prior art tool centralizers are often damaged when running into a well by being forced past certain tubing restrictions without accommodation for sufficient flexure within the yield limits of the centralizer material. The present invention centralizer 38 shown in plan by FIG. 3 comprises 3 or more, in this case 4, centralizing arms 52 radiating from a central body 54 . Preferably, the centralizer 38 is fabricated from thin, spring-steel stock. Returning to FIG. 2 , the centralizer is firmly secured to a projecting end of the cutter housing 20 by a machine screw 39 , for example. This projecting end mount permits the centralizer arms 52 to pass through the restrictions before engaging the cutter housing 20 . The conical surface relief of the housing end face 34 coupled with the projection from the outer perimeter of the end-closure 32 provided by the end boss 36 and the thickness of the spacer 37 allows the centralizer arms sufficient free deflection space to pass the tubing restrictions without exceeding deformation stress by forcing the arms to pass between the outer perimeter edges and internal tubing restrictions.
[0051] The shaped charge assembly 40 is preferably spaced between the top sub end face 15 and the inside bottom face 33 of the end closure 32 by spacers. An air space of at least 0.100″ between the top sub end face 15 and the adjacent face of the cutter assembly thrust disc 44 is preferred. Similarly, it is preferred to have an air space of at least 0.100″ between the inside bottom face 33 and the adjacent cutter assembly end plate 46 . The FIG. 2 invention embodiment provides a plurality of steel (for example) positioning pins 42 inserted into dowel sockets 17 . The pins 42 project from the end face 15 for a stand-off compression engagement of the brass (for example) thrust disc 44 top face. An elastomer compression washer 47 spaces the adjacent faces 33 and 46 . The material composition of these components is addressed to a non-sparking environment. Other materials may be used that are functionally relevant to the invention operation.
[0052] State-of-the-art tubing cutters have been provided with a steel compression spring bias against the shaped charge assembly. However, such arrangements represent substantial safety compromises when bearing upon a steel or ferrous metal thrust disc 44 and/or end plate 45 or 46 due to the difficulty in maintaining the cutter housing interior free of loose particles of explosive. Loose explosive particles can be ignited by impact or friction in handling, bumping or dropping the assembly. Ignition that is capable of propagating an explosion may occur at contact points between a steel thrust disc 44 or ferrous metal end plates 45 or 46 and a steel housing 20 . To minimize such ignition opportunities, the thrust disc 44 and end plates 45 and/or 46 , for the present invention, are preferably fabricated of non-sparking brass. Assuming the thrust disc 44 is brass, the positioning pins 19 may consequently be formed from steel or other ferrous material. If the compression washer 47 is an elastomeric or other non-ferrous material, the end plate 46 may be a ferrous material. Conversely, if the resilient bias on the assembly is provided by a ferrous spring such as a bellville washer type not shown, the end plate 46 material should be non-ferrous.
[0053] As a further alignment control means, the outside perimeter diameter of the brass thrust disc 44 may be only slightly less than the inside diameter of the housing 20 to assure centralized alignment of the explosive assembly within the housing 20 . The end plates 45 and/or 46 , on the other hand, which may be formed of a ferrous material, should have an outside perimeter diameter less than the inside diameter of the steel housing to avoid a steel-to-steel contact.
[0054] The shaped explosive charge 56 that is characteristic of shaped charge tubing cutters comprises a precisely measured quantity of powdered form explosive material such as RDX or HMX that is formed into a truncated cone against the conical faces respective to a pair of end plates 45 or 46 . An axial bore space 59 through the thrust disc 44 , end plates 45 and 46 and explosive material 56 is provided to accommodate a detonation booster 57 . The taper face explosive cones of the present invention are clad with a high density, pressed, powdered metal liner 58 comprising about 80% or greater (80≧%) tungsten and an approximate 80/20% mixture of copper and lead powders. A representative liner thickness may be about 0.050″. As understood by those skilled in the art, shaped charge penetration capability increases with (a) an increase in liner density and (b) a pressed powder liner material. A pair of such conical units are assembled in peak-to-peak opposition along a common apex truncation plane P J .
[0055] With respect to FIG. 4 , the axial span 60 of the charge between the liner base perimeters 68 adjacent the inside wall of the housing 20 is closely correlated to the axial span 62 of the jet window 24 between the opening walls 64 . See FIG. 4 . Preferably, the window wall 64 will be aligned about midway of liner 58 thickness at the perimeter base 68 . Cutting jet formation may be disrupted due to explosive forces spilling prematurely past the liner base 68 into the jet cavity 25 . As a consequence, jet penetration may be reduced to fractional levels or to none at all. This disfunction is reduced by providing a jet window span 62 about 0.050″ greater than the liner span 60 to align the outer jet window wall 64 within the thickness of the liner base perimeter 68 . Apparently, the proximity of the liner base perimeter 68 to the inside wall of the housing 20 shields explosive forces from entering the jet cavity 25 .
[0056] If the span 60 of the liner base perimeter 68 significantly exceeds the span 62 between the window walls 64 , however, collapsing liner elements 58 may strike the window wall 64 corner thereby wiping off the rear portion of the jet. As a consequence, jet penetration is reduced. Referring to FIG. 4 , an efficient compromise of these critical parameters could place the outer window walls 64 as coinciding with the SC liner bases 68 at about mid-thickness.
[0057] The second “step” of the jet window 24 is delineated within the outer walls 64 and between the inner walls 66 . This second step has been found to deflect reflected shock waves that disrupt jet formation and reduce jet penetration.
[0058] Following the traditional operating sequence and returning the descriptive reference to FIG. 2 , the SC detonator 51 is ignited by an electrical discharge carried by conduits 55 from the surface. Ignition of the detonator 51 triggers the ignition of the booster 57 . The booster 57 explosive decomposes with a greater shock pulse than the detonator 51 explosive but requires the moderately explosive shock provided by detonator 51 for initiation. Ignition of the booster 57 detonates the shaped charge explosive 56 resulting in enormously high explosion pressures (2 to 4×10 6 psi) on the powdered metal liner 58 . The resulting high pressures collapse the liner inwardly thereby merging the liner elements along the common geometric plane P J thereby resulting in a high speed jet of liner material which is propelled radially outward at velocities in excess of 15,000 ft/sec. The high velocity of the jet cuts through the housing 20 and continues outwardly to cut through the wall of the tubing or casing surrounding the SC.
[0059] It is a generally accepted axiom of the art that to extract maximum cutting effectiveness, the cutter charges 56 must be initiated on the geometric plane of juncture P J between the two conical forms. Initiation at this point releases balanced forces within the charge and generates a coherent jet radially outward along the juncture plane substantially normal to the cutter axis.
[0060] With respect to FIGS. 2 and 7 , the present invention detonation booster 57 is configured to shield the explosive charges 56 from a detonation energy level except within an immediate proximity of the charge juncture plane P J . The booster casement body is preferably turned from an intermediate to high density material that is relatively strong such as brass. The primer section 70 (see FIG. 7 ) includes an annular wall 71 with a thickness of about 0.080″ to about 0.100″ or sufficiently thick to prevent cross-initiation by such low energy levels as 2 and above. The primer section wall surrounds an axial bore 72 having an inside diameter of about 0.045″ to about 0.080″ that is large enough to sustain a high order initiation and set off explosive in the main cavity 75 but at the same time, is small enough to contain a quantity of explosive (about 10 to about 20 grains/ft. of RDX) that is inadequate to initiate the explosive charges 56 prior to the main cavity detonation. A representative primer explosive density may be about 1.1 to about 1.2 g/cc.
[0061] Typically, the main cavity 75 is about 0.156″ long ( FIG. 7 ). The inside diameter of the main cavity may be maximized for confining a maximum quantity of RDX explosive at the juncture plane P J ( FIG. 2 ). The main cavity explosive is packed more densely than in the primer train. For example, the main cavity explosive may be packed to about 1.5 to about 1.6 g/cc. The casement wall around the main cavity is about 0.010 in. thick or as thin as practicable ( FIG. 7 ).
[0062] The main cavity bore of the booster casement is closed by a pressed plug 78 having sufficient mass (density/weight/length) to terminate the explosive initiation and to direct the explosive energy laterally.
[0063] When fired in the usual fashion, the booster primer section 70 ( FIG. 7 ) detonates along the small diameter bore 72 to initiate the larger main detonation cavity 75 . Explosive energy from the main cavity 75 ignites the SC explosive 56 on the juncture plane. The primer section construction prevents cross-firing of the SC charge because of the low explosive weight in the primer bore 72 combined with a thick, energy absorbing wall 71 . Premature ignition of the explosive in the main detonation cavity 75 is arrested by a high density and strong energy absorbing plug 78 . This plug 78 prevents cross-firing of the charge on the opposite side of the charge juncture plane from the detonator. When the detonation front impacts the plug 78 , initiating energy is prevented from progressing downward. Moreover, detonation pressure is increased due to impact with the solid boundary of the plug. That elevated pressure is reflected laterally to the SC explosive thereby significantly enhancing initiation efficiency at the desired initiation aperture.
[0064] The current state-of-the-art quality control test for well tubing cutters is to place a cutter into piece of “standard” field tubing such as 2⅜″ OD, 4.7 lb/ft., J-55 pipe or 2⅞″ OD, 6.5 lb/ft, J-55 pipe and fire the cutter. The cutter is usually centralized, in water and at atmospheric conditions for firing. If the tubing is severed, the test is considered successful.
[0065] As explained previously, however, cutter performance is influenced by two major factors: a) clearance between the cutter and the wall of the tubing (up to 35% penetration reduction) and b) hydrostatic pressure in the well (up to 25% reduction at pressure levels of 15,000 psi and greater). Consequently, the present invention has devised a simple but effective test procedure to monitor the actual penetration value of a cutter configuration under simulated extreme conditions.
[0066] To this end, the cutter 10 is inserted centrally within a test assembly such as that illustrated by FIGS. 8 and 9 and fired. The test assembly may comprise a representative section of tubing 80 having 4, for example, steel “coupons” 82 secured as by welding, for example, within longitudinal slots in the sample tube wall. The coupons 82 are preferably, of the same alloy as the tubing 80 . The radial depth of the coupons, dimension “W” in FIG. 9 , is preferably greater than the deepest possible penetration of the cutting jet. The assembly may be immersed in a desired fluid atmosphere and enclosed by a pressure vessel. The pressure vessel is charged to the anticipated operating pressure such as a bottomhole well depth pressure and fired.
[0067] After firing, penetration of the coupons 82 and tubing wall 80 is measured at different points radially (along dimension W) around the test assembly, checking for radial integrity in the coupons as well as in the pipe. At the same time, the character of the cut is noted. The penetration values are then compared with minimum penetration requirements established by taking into account the factors defined previously.
[0068] A simplified and less expensive alternative to the foregoing test procedure is represented by FIGS. 10 and 11 which utilizes the same coupons 82 secured (as by welding, for example) to a base plate 84 as radial elements about a circle. The SC, independent of a housing 20 enclosure, is positioned within the interior circle at a substantially concentric stand-off (dimension S.O.) from the interior edge of the coupons 82 and discharged.
[0069] The graph of FIG. 12 illustrates an actual application of the two procedures described above. The tubing 80 object of the test was an L-80 alloy having a mid-range strength and standard wall thickness as specified by the API for perforator testing. Radial penetration dimension is represented linearly along the ordinate axis. Environmental pressure on the test shot is represented in units of 1000 lbs/in (ksi) along the abscissa. The solid line “T” represents the tube wall thickness dimension of 0.190″. The test included two basic sets of environmental conditions: a) at ambient temperature and pressure and b) at the rated downhole temperature and pressure. The shot point designated on the graph as QC 1 results from a FIG. 10 test apparatus. The graph point QC 1 reports the average coupon penetration by the 1 11/16″ shaped charge test subject without the housing 20 and with no (zero) clearance between the SC perimeter and the coupon 82 edge. The shot point designated as QC 2 also results from a FIG. 10 test method and reports the average coupon penetration by a 1 11/16″ shaped charge test subject in assembly with a stand-off dimension S.O. corresponding to the average radial distance between the perimeter of the SC thrust disc 44 perimeter and the inside wall of a tubing 80 . The shot points designated as IT 1 and IT 2 on the FIG. 12 graph report the SC penetration of coupons 82 set in the manner illustrated by FIGS. 8 and 9 . Shot point IT 1 was made under atmospheric P/T conditions whereas shot IT 2 was made under 15 kps pressure.
[0070] From an analysis of the FIG. 12 graph, it is readily seen that a 1 11/16″ cutter requires a 0.380″ penetration of L-80 steel at atmospheric conditions to reliably cut the same 0.190″ tubing wall thickness at 15,000 psi.
[0071] Other data points on the FIG. 12 graph represent shots made under the charted conditions by prior art assemblies. Notably, the shots designated by a “diamond”+resulted in a severed tubing. However, the tubing separation was not entirely due to SC jet. A portion of the cut was due to spalling.
[0072] Although our invention has been described in terms of specified embodiments which are set forth in detail, it should be understood that this is by illustration only and that the invention is not necessarily limited thereto. Alternative embodiments and operating techniques will become apparent to those of ordinary skill in the art in view of the present disclosure. Accordingly, modifications of the invention are contemplated which may be made without departing from the spirit of the claimed invention.
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A shaped charge tubing cutter includes a minimal contact suspension to isolate the cutter explosive from the housing and sub structure. A charge detonation booster main-cavity is located on the juncture of the charge truncation planes. Explosive in the booster main-cavity is detonated by a shielded primer path. Explosive density in the primer path is less than the main-cavity density. A dense, powdered metal SC liner and an abruptly stepped jet window in the tubing cutter housing improve performance. The axial span of the jet window is preferably aligned with the axial span between the liner bases. A testing apparatus and procedure inexpensively verifies downhole performance.
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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 the field of waste disposal and, more specifically, to an apparatus (comprising a frame and a bag) and to a preferred bag for packaging waste for disposal.
Under the so-called "pooper scooper" laws, those responsible for a dog (usually, the owner) must promptly remove any solid or semi-solid waste material left by the dog on sidewalks, etc. Thus, a person wishing to obey such a law has the problems of removing the offending material and then of its disposal.
There have been various attempts to deal with those problems. For example, those who can reason with their dogs often ask the dogs to consider using a circumscribed area on the ground upon which a substrate such as newspaper has been placed. If there are no mishaps, the newspaper may be folded to wrap the waste and the entire package thereafter disposed of. Those who cannot reason with their dogs as to the location but have quick reflexes sometimes attempt to place the substrate/wrapping material into position on the ground before the waste hits the ground.
For those with slower reflexes who still wish to comply with the law, a shovel may be employed to remove the waste material from the ground after the fact. The waste can then be put into a bag or placed on a substrate for wrapping and disposal. Some individuals have been known to place one of their hands inside a bag made of flexible material as if it were a glove, pick up the waste material using the "gloved" hand, and pull the end of the bag off the hand in a manner so as to invert the bag and package the waste material inside the bag for later disposal.
One device that has been used for attempting to scoop up waste after it is on the ground consists of a framework having a rectangular opening at its front end and a bag that is attached to the framework with the opening of the bag congruent with the rectangular front opening of the framework. The framework with the bag attached is placed on the ground with one side of the rectangular opening touching the ground. The device is pushed forward towards the waste material on the ground to scoop up the waste and have it pass through the rectangular opening into the rest of the attached bag. The bag is removed from the framework for disposal.
Each of those methods and devices has drawbacks. One problem with the apparatus just described is that the opening of the bag and the frame become contaminated with waste material. That is because the opening of the bag is at the leading edge of the framework and contacts the waste on the ground during the scooping maneuver. This makes closing the bag and disposal somewhat tricky. Other drawbacks of the various apparatus and methods used are obvious. Shovels become contaminated; the "gloved hand" method is aesthetically unpleasing, not to mention the problems encountered if the "glove" (i.e., bag) breaks at an inopportune moment.
SUMMARY OF THE INVENTION
A new apparatus that avoids the above-noted problems and has numerous other advantages has now been developed. Broadly, the device facilitates the disposal of the waste by packaging it in a rapid and reliable manner and with a minimum of handling and comprises:
(a) a bag having an open end, a periphery, a central portion, an inner surface, and an outer surface; and
(b) a frame having sides and having an inversion point, the frame being at least partially within the bag thereby to support it and having an open area located near the central portion of the bag; the bag being larger than the frame to provide sufficient slack so that after waste is placed on the outer surface of the central portion of the bag, the waste and that portion of the bag nearest the waste are pulled down by gravity at least partially into the open area of the frame and sections of the bag are drawn snug towards the frame, the frame and bag thereafter cooperating so that as a portion of the open end of the bag is moved towards the inversion point to remove the bag from the frame, the portion of the bag lying near the inversion point becomes inverted and further movement of the end of the bag in a direction to remove the bag from the frame results in inverting the rest of the bag, thereby placing the outer surface of the bag on the inside and packaging the waste inside the bag.
In other aspects of the invention, the frame comprises at least two members (and preferably three in the approximate shape of a triangle), and/or the bag carries closure or locking means so that it may be tied shut after the waste material is inside, and/or a plurality of bags may be stacked or nested one inside the other on the frame, and/or a handle portion is attached to the frame and the handle has grippers or other securing means for preventing the bag or bags from sliding off or otherwise being removed from the frame until such removal is required. Sticks or other disposable members may be carried within the handle and the sticks employed to help position the waste material on the device.
Another aspect of the invention concerns a preferred bag having integral flaps for tying the bag closed. The two major faces of the bag are attached directly or indirectly (i.e., through an intervening edge panel) to each other at their corresponding edges.
The frame itself need not be rigid and may be comprised of pieces that can rotate with respect to one another. Accordingly, in one embodiment the frame is collapsible and may be collapsed and retracted into or around or about the handle of the device to provide a small readily portable device. In another embodiment, the frame members may be rotated with respect to one another to form a "V" shape to provide an inversion point at what becomes the lowest vertical point of the "V" frame rather than at the lateral sides of the flat (unrotated) frame.
Devices of this invention may be used to efficiently and effectively scoop waste material off a variety of substrates (for example, concrete, carpeting, sand, grass, snow, leaves) or the device may be used to catch the waste in mid-air, before it hits the ground. The frame of the device remains clean because it is covered by the bag, and the open end of the bag is not contaminated with waste either during the scooping procedure or later. The leading edge of the bag, which does become contaminated during the scooping procedure, is placed inside by the inversion procedure. Thus, what becomes the outer surface of the bag after packaging is complete and the open end of the bag remain free of waste. Other advantages, aspects, and embodiments of the invention will be described below.
BRIEF DESCRIPTION OF THE DRAWINGS
To facilitate further description of the invention, the following drawings are provided in which:
FIG. 1 is a perspective view of the device being held in a position to scoop up waste material on the ground;
FIG. 2 is a cross-sectional view taken along line 2--2 of FIG. 1;
FIG. 3 is a side elevational view of the device of FIG. 1 before waste material is on the device;
FIG. 4 is a detail view of FIG. 3 after the waste material has been placed on the device;
FIG. 5 is a perspective view showing the first stage in removing the bag from the frame of the device of FIG. 4 to package the waste material;
FIG. 6 is a perspective view of the device showing a further stage in the removal of the bag from the device;
FIG. 7 is a cross-sectional view of the device of FIG. 6 taken along line 7--7 of FIG. 6;
FIG. 8 is a perspective view showing a later stage in the removal of the bag from the frame of the device;
FIGS. 9 and 10 are detail views showing subsequent steps in the removal of the bag from the frame;
FIG. 11 shows the waste material in the bag after the bag has been completely inverted and is no longer supported by the frame;
FIG. 12 is a view showing the two integral strips on the bag tied together to securely close the bag;
FIG. 13 is a plan view of the preferred bag of the invention;
FIG. 14 is a plan schematic view of the preferred frame and handle of the invention;
FIG. 15 is a perspective view of another embodiment of the invention in which the two frame members are rotatably connected to one another;
FIG. 16 is a view of the device of FIG. 15 after the two frame members have been rotated up towards one another;
FIG. 17 is a view of a third embodiment of the device in which the frame members are rotatably connected to one another to permit the frame to be collapsed for storage and portability;
FIG. 18 is a view of the device of FIG. 17 showing the frame being collapsed for storage within the handle of the device; and
FIG. 19 is a view of the device of FIGS. 17 and 18 in which the frame has been collapsed and is being retracted into the handle of the device.
These drawings are provided for illustrative purposes only and should not be construed to limit the scope of the invention.
DETAILED DESCRIPTION OF THE INVENTION
In FIG. 1, handle 40 of device 20 is being held in left hand 22. The device comprises frame 24 and bag 26 having periphery 28 and two integral flaps 38 at open end 168 (or rear extent) of the bag. Frame 24 comprises side 32, side 34, and side 36, which is located at the leading or front edge of the device. The three sides lie substantially in the same plane and in substantially the shape of a triangle. Optional securing means 44 prevents bag 26 from sliding down and off the frame while the device is downwardly disposed towards waste 30, which is on the ground. The device need not have securing means 44. In that case, left hand 22 could hold the rear portion of the bag against handle 40 to prevent the bag from sliding off the frame. Central portion 42 of bag 26 is located in gap (or space or void) 84 between frame members (or sides) 32, 34, and 36.
In the cross-sectional view of FIG. 2, central portion 42 of bag 26 lies below the plane of frame members 32 and 34. Bag 26 has two major faces, upper face 50 and lower face 52, each of which has an inner surface 54 and an outer surface 56. Bag 26 may be thought of as having one continuous inner surface (or inside) 54 and one continuous outer surface (or outside) 56. Pressure pad 64, which is attached to front end 72 of securing means 44 (as more clearly shown in FIG. 3), temporarily secures bag 26 in place. The pad may be of any material that provides the required friction, such as rubber or flexible foam.
In FIG. 3, the device has been positioned with its leading edge on ground 74 so that it can be moved in the direction indicated by arrow 70 to scoop up waste material 30, which is also on the ground. Handle 40 has front end 46 and rear end 48. The frame is attached to the front end of the handle, and cylindrical cavity 66 terminates at rear end 48. Elongate sticks 68 (for example, ice cream sticks or tongue depressors) are stored within cavity 66. A stick 68 may be removed from cavity 66 and used to help push and position waste 30 on central portion 42 of the bag (see FIGS. 1 and 2).
Each of the two securing means 44 is rotatably connected to the handle, here by a pivot pin 62 in ears 60. The two securing means 44 are biased (spring biasing means not shown) so that pressure pads 64 connected to front ends 72 frictionally retain reinforced areas 88 of bag 26 against the outer portion of front end 46 of handle 40. (Reinforced areas 88 on bag 26 are better seen in FIG. 13.)
In FIG. 4, waste 30 is positioned adjacent central portion 42, both of which have been pulled down by gravity so that much of waste material 30 lies below the plane defined by the frame members. Arrow 78 indicates the direction of travel of the front end of the device for subsequent use.
As best seen by comparing FIGS. 1 and 2 with FIGS. 4 and 5, before waste 30 is positioned on central portion 42 of bag 26, the bag fits somewhat loosely on the frame because the bag is larger than the frame, that is, there is some slack. In FIG. 2 periphery 28 is seen to extend beyond frame members 32 and 34. In contrast, in FIGS. 4 and 5, the weight of waste 30 has pulled central portion 42 of the bag downward so as to take up the slack by pulling various portions of periphery 28 of the bag against the frame. For example, a portion of the front or leading edge of the bag has been drawn snug against a corresponding portion of leading side 36 of the frame and sections of the periphery of the bag have been drawn snug against corners (or shoulders) 80, which are located at the approximate places where lateral side members 32 and 34 meet front side member 36. In FIG. 5, left hand 22 is holding the device and right hand 76 is commencing the bag-removal and wrapping (or packaging) procedure.
During the removal procedure, the bag is inverted so that the outside of the bag becomes the inside and the waste material thereby becomes packaged inside the bag. Inversion of the bag may be facilitated by the frame increasing in transverse size from the rear of the frame to the front. For example, the device of FIG. 5 increases in lateral width from near handle 40 to a maximum at the imaginary line connecting the two corners 80. Inversion is also made possible in the embodiments shown by the periphery of the bag or at least certain sections of the periphery of the bag being pulled or drawn snug towards the inversion point and at least one other point on the frame. Usually, the weight of the waste material will pull the central portion of the bag down sufficiently to take up the slack in the bag provided the bag is sufficiently flexible and is not too big.
In FIG. 5, right hand 76 is grasping a portion of the open end of the bag towards the rear of the device. Right hand 76 then moves in a direction towards the front side 36 of the frame. The bag is usually manipulated at or near the beginning of this procedure to partially invert the small section of the opening of the bag between the thumb and forefinger of hand 76. That part of the bag is then drawn forward (i.e., towards front side 36 of the frame). Whether or not such preliminary inversion is carried out, at some point along the frame at or before corner 80, the bag will not be able to slide off the frame (because the bag lies so tightly against the frame) and the outer surface of the bag immediately adjacent to that point will be forced to fold over on itself as the open end of the bag continues to be pulled forward. Alternatively, gripping means (for example, adhesive) may be placed on a small section of the side portion of the frame to prevent the bag from sliding off the frame and thereby to cause inversion to occur at that point as the opening of the bag is being pulled forward. In that case, the lateral sides of the frame need not be diverging and may be parallel or converging.
In FIG. 6, arrow 82 indicates the direction in which the end of bag 26 is pulled to continue the removal procedure. Left hand 22 is holding the device by handle 40 and at the same time it is pushing release mechanism handles 58 towards main handle 40 to move pressure pads 64 away from the bag, thereby to release the bag and allow the inversion and removal procedure to continue. In many cases it will not be necessary to push release handles 58 because the act of pulling inverted portion 170 of the bag forward will pull the temporarily secured portions of the bag out from under pressure pads 64.
At some point during the inversion/removal procedure, the part of the opening of the bag lying at the bottom of the bag-frame combination must pass below the lowest point of central portion 42. If that does not occur, the edge of the already inverted portion of the opening of the bag will not clear the waste material and central portion of he bag that are located below the plane of the frame, and the inversion and removal procedure will not be able to continue. Thus, FIG. 7 shows a section of inverted portion 170 of the bag positioned below the bottom most part of central portion 42 and waste material 30 to enable the opening of the bag to clear (pass below) them at their lowest point. The top section of inverted portion 170 must pass above waste 30, and FIG. 7 shows this too. Finally, FIG. 7 shows that the weight of waste material 30 on central portion 42 has drawn part of periphery 28 of the bag against frame sides 32 and 34.
In FIG. 8 the bag has cleared corner 80 between frame members 34 and 36 and the inversion process is essentially complete: outer surface 56 is now the inside of the bag in contact with waste material 30. Void (or space or gap) 84 between the three frame members is no longer completely covered by the bag. The full completion of the inversion/removal procedure is then accomplished as leading edge 168 of the inverting bag clears the remaining shoulder between frame members 32 and 36. This occurs with continued travel along the direction of arrow 166.
FIGS. 9 and 10 show further stages of removing the bag from the frame. Arrow 86 indicates the direction of travel of the bag to complete removal.
FIG. 11 shows the completely inverted bag containing the waste material situated freely within void 84 of the frame at the conclusion of the removal/inversion procedure. Inner edge 164 of integral flaps 38 define U-shaped cutout 90. Two reinforced areas 88 (only one of which is shown) are located at the bottom of the U-shaped cutout. It is those two portions of the bag that securing means 44 contacts to temporarily secure the bag to the frame. Reinforced areas 88 are optional; any non-reinforced area of the bag may serve as the contact area of the bag for the gripping means.
FIG. 12 shows integral flaps 38 tied together so as to close and secure the opening of the bag to prevent waste material from leaving the bag.
FIG. 13 is a plan view of the preferred bag. The dimensions of the bag will depend principally on the dimensions of the frame: the bag must be larger than the frame so that the bag can fit onto the frame but should not be so large that too much slack is provided. FIG. 14 is a schematic diagram of a preferred frame and handle of the invention in which the frame is generally triangular in shape. Various combinations of bag and frame shapes and sizes may be used. For the shapes shown in FIGS. 13 and 14, three preferred size combinations are shown below.
______________________________________Dimension Approximate Size In InchesLine Set I Set II Set III______________________________________A 20 16 12B 12.5 10.5 8.5C 12.5 10.5 8.5D 10.5 8.5 5.5E 8.25 6.5 5F 10.5 8.5 6.5G 9.5 7.5 5.5______________________________________
The bag may be made of any material that has the required physical properties. Important physical properties include abrasion resistance, drapability, deformability, resilience, and strength. Preferred bags are of thin (about 0.5-2.5 mils in thickness) plastic film. Any size and shape bag and any bag material may be used so long as the bag in combination with the frame and rest of the device is capable of performing the desired function. Shapes and features other than that shown in FIG. 13 may be used, for example, the bag may be square or rectangular or have no U-shaped cutout or have no reinforced areas.
Similarly, the frame and handle may be made of any materials that have the required properties such as strength and resilience. Usually, the frame and handle will be made of metal and/or plastic. The particular size and shape of the frame are not important so long as the frame can interact with the bag to perform the desired function. Thus, the frame will generally have one or more frame members that provide a point along the frame at which inversion of the bag can take place (usually because of the bag being pulled taut in a transverse direction by a transverse frame size that increases towards the front of the device). Desirably, the frame will have a leading side to facilitate scooping up waste material that is on the ground and the leading member will be thin and not easily bent or deformed. The leading side may be straight or concave in, concave out (as shown in FIG. 14) being preferred. The bag must be sufficiently abrasion resistant so that the integrity of the bag is not compromised by the bag's being pushed along the ground (see FIGS. 3 and 4).
The location of the inversion point for a given bag/frame combination will vary depending on what means are used to retard the forward motion of the bag and hinder its sliding on the frame, e.g., adhesive on a lateral side of the frame, the bag's being pulled taut against the frame by the weight of the waste, etc. If the bag is pulled taut by the frame (as in the embodiments of FIGS. 1-19), the location of the inversion point will depend on the sizes of the bag and the frame, the physical characteristics of the bag employed (for example, the resistance of the bag to stretching, its tensile strength, and its flexibility and resilience), and on how tightly the bag's periphery is pulled against the frame and where. The increase in the lateral size of the frame of FIG. 14 towards the front of the frame and use of a bag not too much larger than the frame insures that inversion will occur at or before corner 80. If the bag is too large, inversion will not occur, regardless of the weight of waste material 30.
Two or more bags may be nested within one another and the frame placed within the innermost bag of the nested stack. In that case, the user would employ only the outermost bag, thereby leaving the rest of the stack of bags on the frame for subsequent use.
Other shapes may be employed for the frame. For example, the frame may be a polygon of more than three sides or the frame may be circular. The particular shape is not important so long as the device is able to perform the desired function. A frame with parallel or even converging sides may be used if adhesive or other such means is located on one section of a side for causing the inversion.
The frame need not lie in only one plane. For example, the front or leading edge of the frame and the forward sections of the two side frame members of the device of FIG. 1 may be bent upwards. Even if the frame members lie in a single plane at the start of the scooping and disposal operation, the frame need not remain in that one plane. For example, FIGS. 15 and 16 illustrate frame members that can rotate with respect to one another. The frame comprises side pieces 92 and 96, front piece 94 (which itself is comprised of segments 94a and 94b) and pivot 100. Corners 98 are located between the side pieces and the front pieces. Side pieces 92 and 96 are connected to straight portions 102 and 104, which are rotatably mounted in block 132. Extensions 102 and 104 terminate in bent portions 106 and 108, which prevent the frame from being pulled out of block 132.
FIG. 16 shows the two halves of the frame rotated up out of the plane they define when they are in their normal (or down) position. In FIG. 16, corners 98 have been rotated up out of the plane and towards one another.
To use this device, waste material is again positioned on the central portion of the bag (not shown), which is within gap (or void) 84 between the frame members. The two frame members are then rotated u into the position shown in FIG. 16 either manually or by spring-loaded or other means (not shown). At this point, most or all of the waste material hangs down below the two corners 98. To remove and invert the bag of this device, the bottom portion of the bag near its opening, which is pointed towards the rear of the handle, is grasped and pulled forward. That portion of the bag must be low enough to clear the bottom of the waste material and the central portion of the bag adjacent to it at their lowest point while they are hanging from the frame. Pivot point 100, which as shown in FIG. 16 is a low point for the frame, may help invert the bag. However, inversion may start before the lower open end of the bag is brought forward enough to meet pivot point 100. The top of the open end of the bag must also pass over the high points of the frame, corners 98 in FIG. 16.
FIGS. 17, 18, and 19 illustrate another embodiment of the invention, namely, a collapsible device. This device may be used in the same manner as the devices previously described except that it has the advantage that the frame can be collapsed. All of the frame or a substantial portion of it can be stored inside or around or about the handle so that the device may be carried in, for example, a pocket or pocketbook.
The frame comprises side piece 110, front piece 112 (which comprises portions 112a and 112b), side piece 114, corners 116, straight extension portions 124 and 126 (which are slidably mounted within block 134), and bent portions 128 and 130 (which prevent the frame from being pulled forward out of slidable block 136). The frame pieces are rotatably connected to one another at pivot points 120, 118, and 158. Extension or tab 122 on frame member 112b prevents sections 112a and 112b from rotating with respect to one another to move pivot point 120 forward beyond its forwardmost location shown in FIG. 17. Sliding block 136 is slidably mounted in path 138 of handle 40. Block 136 is biased towards the rear of the handle by spring 140, which is attached at its forward end to block 136 and at its rear end to fixed point 142.
Release mechanism 144 is rotatably mounted to handle 40 on ears 150. The forward end of release mechanism 144 carries pin 146, which passes through the outer surface of handle 40 into hole 148 located at the top of sliding block 136. As long as pin 146 lies within hole 148, block 136 is prevented from moving back under the force of spring 140. When trigger 152 of release 144 is pushed down in the direction shown by arrow 160, pin 146 is withdrawn from hole 148 and spring 140 pulls block 136 back in the direction shown by arrow 162. Prior to depressing trigger 152, pivot 120 is moved towards the rear of the device in the direction shown by arrow 154. That in turn causes rotation of the frame members with respect to one another and movement of side pieces 110 and 114 towards one another in the directions shown by arrows 156. When trigger 152 is depressed, the collapsed frame will be drawn into the front hollow storage section of handle 40. (A similar type of spring-powered mechanism may be used to rotate the two frame halves of the device of FIG. 15 when a trigger is depressed.)
To use this device, the front end of the collapsed frame is pulled forward and pivot 120 is moved to its forwardmost position (FIG. 17). A spring (not shown) biases trigger 152 up, thereby pushing pin 146 down into hole 148 when the hole is brought into registration with the pin. That prevents the frame from collapsing and being moved inward by spring 140. A bag may be stored in a rear hollow section of handle 40. Regardless of where the bag is stored, it is placed on the frame and the device is used in the same manner the device of FIG. 1 is used. After disposal of the waste, the device may be collapsed and stored again in a pocket or pocketbook.
The collapsible frame and bag may have any shapes and be of any materials that allow them to perform the desired function. The frame may be circular, oval, rectangular, etc. so long as it can be collapsed or folded into or around or about the handle. Means may be present to push out or unfold or erect the collapsed frame. For example, spring-biased means similar to those in FIGS. 17-19 may be used to push the collapsed frame out of the handle when a trigger is depressed. Other means dissimilar to those of FIGS. 17-19 may also be used. The frame need not fold only but could also have telescoping members.
Other variations and modifications may be made in this and all other embodiments shown herein, and the claims are intended to cover all variations and modifications that fall within the true spirit and scope of the invention.
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Apparatus (including a frame and a bag), a preferred bag, and a method for packaging waste for disposal are disclosed. The frame fits into the bag at the open end of the bag. The frame has a central open area, and when waste material is placed on the outside of the bag corresponding to the open area of the frame, the waste material and the adjacent portion of the bag are pulled by gravity down through the open area of the frame. That pulls the bag tightly around the frame, which in turn facilitates the inversion of the bag as the bag is removed from the frame. Inversion of the bag results in the waste being trapped inside the bag, which may then be securely closed for disposal of the waste. The sizes and shapes of the frame and bag are not critical. The device finds particular use as a so-called "pooper scooper" for dogs.
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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 rock drill boom structure and more particularly to such a structure which provides a simple and inexpensive mounting and rotation device for the boom.
Prior art drilling rigs with a boom structure of the above mentioned kind are very cumbersome in transport because of the overhanging length and weight of the boom structure. This is true even when the actual boom itself is telescopically extensible as is common in the art.
A boom structure according to the invention can, when mounted on a mobile carrier, be retracted into a transport position on the carrier. In the transport position it adds a comparatively short length to the carrier, and its center of gravity can be comparatively close to its mounting. This ensures easier and faster transport of the rig. One particular advantage is that the rig can be designed to fit within a mine shaft conveyance, such as a cage, without being dismounted. As a consequence, the transport of the rig into and down the mine and between the levels in the mine can be considerably facilitated.
The invention also provides a simple and inexpensive mounting and rotation device for the boom. The mounting device also permits for a simple drawing of the power lines through the boom.
An embodiment of the invention will now be described by way of example with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of a rock drilling rig that is equipped with a drill boom structure according to the invention.
FIG. 2 is an enlarged side view of the mounting of the drill boom structure shown in FIG. 1.
FIG. 3 is a view as indicated by arrows 3--3 in FIG. 2, the view being partly in section.
FIG. 4 is a section taken along line 4--4 in FIG. 3.
FIG. 5 is a section taken along line 5--5 in FIG. 3.
FIG. 6 is a section taken along line 6--6 in FIG. 3.
FIG. 7 is a diagram showing the hydraulic system for rotating a disc in the mounting shown in FIG. 2.
FIG. 8 shows the rock drilling rig shown in FIG. 1 in its transport position.
DETAILED DESCRIPTION
The rock drilling rig shown in FIG. 1 comprises a chassis 11 on wheels 12. It has an upstanding bracket 13 on which a rock drill boom structure 14, an operator's control panel 15, and a power pack 16 are mounted. The boom structure comprises a support or mounting 17 that comprises a housing 18. The housing 18 is bolted to the bracket 13 and it carries within it a rotatable disc 19 in a way to be described later. A square section guide bushing 20 has a pair of trunnions 21 (FIG. 2) by which it is pivotably mounted to two lugs 22 on the disc 19. Two double acting hydraulic cylinders 23, 24 are pivotably coupled between the disc 19 and the guide bushing 20 to pivot the latter about the axis of the trunnions 21. The axis of the pair of trunnions 21 is parallel with the disc 19, i.e. it is perpendicular to the axis of rotation of the disc. A square section boom 26 is received within the guide bushing 20 and locked against axial movement by means of two locking bolts 27, 28. The disc 19 has a rectangular opening 29 so as to permit the boom to extend through the disc.
A hollow cross beam 32 of rectangular section is mounted on the outer end of the boom 26 to be pivotable on pivot 33 that is parallel with the pair of trunnions 21. In FIG. 1 the cross beam 32 is cut so that its interior is shown. Inside the cross beam 32 there is a hydraulic cylinder 34 that is coupled between the boom 26 and the cross beam 32 to tilt the latter about the pivot 33. A holder 35 is mounted on the outer end of the cross beam so as to be pivotable on a pivot 36 that is parallel with the pivot 33. The holder 35 is tiltable by means of a hydraulic cylinder 37 that is pivotably coupled between the holder 35 and the cross beam 32 and located inside the cross beam.
A feed beam 38 for a rock drill 40 is axially slidably mounted in the holder 35 and two long slender single acting hydraulic cylinders 41, 42 are mounted on the feed beam and they have their piston rods coupled to the holder 35 so that the feed beam can be axially displaced in the holder by means of these hydraulic cylinders. The feed beam 38 incorporates non-illustrated power means for axially displacing the rock drill along the feed beam, and the rock drill 40 can be a hydraulic or pneumatic percussion drill that rotates and hits a drill steel 43. The feed beam is not illustrated in detail. It can preferably be of the kind shown in U.S. patent application Ser. No. 904,214 and German Patent Publication DT OS 28 20 325.
The hydraulic hoses for the hydraulic cylinders 34, 37, 41, 42 for the non-illustrated feed motor of the feed beam and for the rock drill--if it is hydraulically operated--are conveniently drawn through the hollow boom 26. The hoses are only shown as a bundle of hoses 44 on the chassis.
The housing 18 of the mounting 17 is bolted to the bracket 13. In FIG. 3 the housing 18 is partly cut away so that the interior of the housing can be seen. The housing 18 carries two waisted rollers 50, 51 that are journalled in roller bearings 52, 53 (FIG. 5). The rollers 50, 51 carry and guide the large diameter disc 19. The disc 19 is also guided by slots 54 in two bolts 55, 56. The bolts 55, 56 form part of two identical clamping units 57, 58. FIG. 4 shows the clamping unit 57 to which bolt 55 belongs. Each clamping unit 57, 58 comprises a housing 59 affixed to the housing 18. A stack of disc springs 60 is arranged to pull the bolt 55 inwardly so that the bolt clamps the disc 19 against the housing 59 of the clamping units. The housings 59 of the clamping units 57, 58 have passages 61 connected to a hose that is illustrated in FIG. 7 and has been given the same reference numeral 61.
When high pressure hydraulic fluid is supplied through the passages 61 to act upon the bolts 55, 56 counteracting the disc springs 60, the clamping units 57, 58 release their firm grip. The disc springs 60 should be stronger than the opposed hydraulic force so that they are not compressed. The bolts 55, 56 will now guide the disc 19 while permitting rotation thereof, although they still apply a braking force.
The lower end of the disc 19 is surrounded by a clamping unit 63 that comprises a U-formed arcuate member 64 that has four blind bores 66-69 extending through the slot 65 in the member. The bores 66-69 form cylinders for hydraulically actuated pistons 70. The clamping unit 63 is carried by the disc 19 by means of pins 71 that extend into a circular groove 72 in the disc 19. The pins 71 are carried by end plates 73 that are secured in the bores by snap-rings 74 in grooves in the bores. A passage 76 in the arcuate member 64 opens into the bottom of each blind bore and the passage 76 is connected to a hydraulic hose that has been given the same reference numeral 76 in FIG. 7. When the passage 76 is pressurized, the four pistons 70 clamp the clamping unit 63 to the disc 19. A double-acting hydraulic cylinder 77 is mounted in the housing 18 and its piston rod 78 is coupled to a reciprocable member 79 that is guided in guides 80 in the housing 18. The clamping unit 63 and the reciprocable member 79 are interconnected by means of a link 81 that is pivotably connected to both so that the cylinder 77 can be operated to move the arcuate member 65 along the guides 80.
The hydraulic cylinder 77, the clamping unit 63 and the two clamping units 57, 58 can be operated to rotate the disc 19 as will be described with reference to FIG. 7. The two clamping units 57, 58 and the clamping unit 63 are coupled to a common line 83. A selector valve 84 is operable to connect this line 83 selectively to one or the other of two lines 85, 86 that are controlled by a valve 87. The cylinder chamber 88 with the larger piston area is connected to the line 85 by means of a one-way valve 89 and a restriction 90 and the cylinder chamber 91 with the annular piston area is connected to the line 86 by means of a one-way valve 92 and a restriction 93. The control valve 87 is connected to pump and to tank on the power pack 16 by two lines 94 and 95 respectively. When the selector valve 84 is in its illustrated position the two clamping units 57, 58, the clamping unit 63, and the cylinder chamber 88 are connected in parallel to the line 85. When the selector valve 84 is in its other position the three clamping units 57, 58, 63 are instead connected in parallel with the cylinder chamber 91 to the line 86.
When the selector valve 84 is in its illustrated position, and the valve 87 is changed over to pressurize the line 85 and to drain the line 86, the clamping unit 63 grips at the same time as the two clamping units 57, 58 release their grip. The piston rod 78 moves to the right to move the clamping unit 63 to the right so that the disc 19 is turned counter-clock wise in FIG. 7. The restrictions 90, 93 delay the action of the cylinder so that the piston rod will not move before the clamping units have shifted their grips. Further, the restriction slows down the rotation of the disc 19.
When the valve 87 is instead changed over to pressurize the line 86 and drain the line 85, the two clamping units 57, 58 grip due to their springs and the clamping unit 63 releases its grip. The piston 78 moves to its withdrawn position to the left in FIG. 7 without turning the disc 19. When the control valve 87 is again changed over to pressurize the line 85 the disc 19 is again turned counter-clock wise. When the control valve 87 is in its illustrated normal middle position into which it is biased by springs, both lines 85, 86 are drained and the disc 19 is thus firmly arrested by the two clamping units 58, 59. It is appreciated that the disc is arrested also in the event of failure of the hydraulic system. When the selector valve 84 is in its non-illustrated position, operation of the valve 87 effects clockwise turning of the disc 19.
When drilling a tunnel face, the feed beam 38 is normally maintained in its illustrated position transverse to the cross beam 32. The parallelism of the feed beam is maintained by means of the cylinder 34 for tilting the cross beam 32 when the boom 26 is swung by the two cylinders 23, 24. When it is desired to drill holes transverse to the tunnel, i.e. roof bolt holes, the cylinder 37 is operated to tilt the feed beam into parallelity with the cross beam 32. The hydraulic system is such that the cylinder 34 can be operated to tilt the cross beam independently of the operation of the boom swinging cylinders 23, 24, and by switching a non-illustrated valve, one of the boom swing cylinders 23, 24 and the tilt cylinder 34 can instead be coupled in a masterslave relationship so as to make the feed beam move in parallelism when the boom is swung.
In the geometrical configuration shown the feed beam 38 does not move perfectly in parallelism. It will have a tendency to look out at the extreme swing positions of the boom. In order to provide for a perfect parallelism, the master and the slave cylinders should form similar triangels with the respective axes of swinging, and the master and slave cylinders should extend and shorten simultaneously to maintain the similarity in all positions. In the illustrated embodiment one of the cylinders extends when the other shortens and vice versa.
In FIG. 8, the rig is shown in its transport position. The boom 26 is horizontal and has been moved into its rearmost position in its guide bushing 20, the feed beam 38 has been moved to its rearmost position in its holder 35, and the rock drill 40 has been moved to its rearmost position on the feed beam 38. The disc 19 has been rotated to locate the feed beam 38 as close to the chassis as possible. In this position, the cross beam 32 will for example be inclined 45 degrees from the vertical. Because of the length of the cross beam 32, the feed beam and the boom can be parallel in the transport position. Another advantage with a long cross beam is that it makes the coverage area large although the boom 26 is comparatively short. The cross beam should preferably have a length that is at least one fourth of the length of the boom.
It may be advantageous to have the boom 26 in its fully withdrawn position or in a partly withdrawn position not only during transport but also during rock bolting when the feed beam 38 is parallel with the cross beam 32. For rock bolting purposes it may also be advantageous to make the cross beam in two parts; a base part in which the hydraulic cylinder 34 is located and an outer part in which the hydraulic cylinder 37 is located, the outer part being turnable relative to the base part about a longitudinal axis. Then the operator will be able to see the rock drill while standing at the panel 15 and drilling bolt holes.
The boom 26 is arranged to be manually displaced in its guide bushing 20. To facilitate the axial displacement, the operator may incline the boom to take advantage of its weight. Alternatively, power means can be provided to move the boom in its bushing. The boom can for instance be provided with a rack along its entire length and a motor with a pinion that engages with the rack can be mounted on the guide bushing. The possibility of displacing the feed beam 38 axially in its holder 35 is also used for thrusting the feed beam against the rock face before drilling of a hole starts.
The upper part of the bracket 13 has a U-form or any other suitable form that permits the boom 26 to extend backwardly past the bracket. If the chassis is railbound, the bracket 13 should preferably be turnable relative to the chassis about a vertical axis in order to facilitate driving a tunnel in a curve. The bracket 13 may additionally or alternatively be mounted on a transverse guide member on the chassis so that it can be laterally displaced relative to the chassis. If the chassis is carried by tyred wheels, the bracket need not be adjustably mounted on the chassis. Then, however, it will be advantageous to have power actuated support legs on the chassis in order to stabilize the rig during drilling.
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A rock drill boom structure comprises a support means, an elongated boom swingably carried by the support means and a feed beam on which a rock drill is mountable so as to be power displaceable therealong, the feed beam being carried by one end of the boom. The support means includes an elongated hollow guide means of substantially less longitudinal length than the boom and in which the boom is slidably received to project through both ends of the guide means, the boom being arrestable in the guide means, a rotatable member on which the guide means is pivotably mounted for pivotable movement about an axis transverse to the axis of rotation of the rotatable member, first power means for pivoting the guide means and second power means for rotating the rotatable member. The rotatable member 19 is preferably disc-shaped and has an aperture therein through which the power lines of the rock drill are drawn.
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CLAIM OF PRIORITY
This application is a U.S. National Stage of International Application No. PCT/US2013/078011, filed Dec. 27, 2013.
TECHNICAL FIELD
The present disclosure relates to systems, apparatus, and methods relating to tool string braking in a downhole drilling environment.
BACKGROUND
Where downhole tools are used to accomplish stationary tasks (e.g., well-logging or well-completion tasks) via suspension lines (e.g., wirelines or slicklines) in a wellbore, the depth of the suspended tool string is of considerable importance. For example, in well-logging processes, it is often necessary to take corresponding measurements over multiple runs at the same depth position within the wellbore. Additionally, logs from different wellbores may be depth-matched for comparison. Thus, errors in depth measurement of the tool string are detrimental to data interpretation. Moreover, performing completion processes at the wrong depth can result in excessive fluid production in the wellbore and/or entirely bypassing a particular zone of interest in the wellbore.
To locate the tool string in a substantially vertical wellbore, one conventional process is to initially drop the tool string below the intended depth and subsequently pull the tool string up to the target depth by a winch, so that the cable is held in tension. Yet, when the winch is stopped at the target depth, the tool string continues to move on the suspension line upward out of the wellbore. This phenomenon is known as “creep.” Failure to account for creep causes downhole tool operations to be conducted at an incorrect depth.
DESCRIPTION OF DRAWINGS
FIG. 1 is a schematic diagram of a tool conveyance system for use in a downhole environment of a wellbore.
FIG. 2 is a side view of a tool string for a downhole tool conveyance system.
FIG. 3A is a cross-sectional side view of the braking apparatus of FIG. 2 with the spring casing in a lowered position.
FIG. 3B is an enlarged view of a side slot of the braking apparatus of FIG. 2 .
FIG. 3C is a cross-sectional side view of the braking apparatus of FIG. 2 with the spring casing in a raised position.
DETAILED DESCRIPTION
FIG. 1 is schematic diagram of an exemplary tool conveyance system 10 for use in a downhole environment of a wellbore 12 . The tool conveyance system 10 includes a tool string 14 , a suspension line 15 , and a hoisting mechanism 16 . As shown, the tool string 14 is supported in the wellbore 12 by the suspension line 15 . In some examples, the suspension line 15 is an electrically conductive wireline that physically supports the tool string 14 and conveys electricity to the tool string. In other examples, however, the suspension line 15 is non-electrically conductive slickline that only provides physical support to the tool string 14 . The hoisting mechanism 16 provides motive force for moving the suspension line 15 , and thus the tool string 14 , through the wellbore 12 . In this example, the hoisting mechanism 16 is anchored to a ground surface 17 at the head of the wellbore 12 . However, other implementations may employ the hoisting mechanism 16 on a drilling rig, offshore platform, heavy-duty vehicle, etc. The hoisting mechanism 16 may include a motorized winch, crank, pulley or any other device suitable for anchoring and/or providing motive force to the suspension line 15 .
The tool string 14 includes a cable head 18 , a downhole tool 20 , and a braking apparatus 100 . The cable head 18 securely couples the tool string 14 to the suspension line 15 . If the suspension line 15 is an electrical wireline, the cable head provides an electrical connection between the wireline and the downhole tool 20 . The downhole tool 20 may include one or more various types of downhole tools. The downhole tool(s) can be designed to accomplish well-logging tasks, such as measuring rock and fluid properties in a new wellbore and/or measuring pressures or flow rates in the wellbore. The downhole tool(s) can also be designed to accomplish well-completion tasks, such as perforating the wellbore casing to allow the inflow of gas and liquids. Downhole tools suitable for various other well-logging and/or well-completion operations can also be used. In some examples, the downhole tool 20 can include at least one well-logging tool and at least one well-completion tool.
In the foregoing description of the tool conveyance system 10 , various items of conventional equipment may have been omitted to simplify the description. However, those skilled in the art will realize that such conventional equipment can be employed as desired. Those skilled in the art will further appreciate that various components described are recited as illustrative for contextual purposes and do not limit the scope of this disclosure. Further, while the tool conveyance system 10 is shown in an arrangement that facilitates deployment in a substantially vertical or straight wellbore, it will be appreciated that arrangements are also contemplated in a horizontal or highly deviated wellbore environment where the tool string may experience involuntary movement and therefore are within the scope of the present disclosure. The tool conveyance system 10 and other arrangements may also be used in wellbores drilled at an angle greater than 90 degrees to inhibit tool string movement due to gravitational forces.
FIG. 2 is a side view of a tool string 14 that can, for example, be incorporated in the tool conveyance system 10 depicted in FIG. 1 . In this example, the downhole tool 20 includes a casing collar locator 20 a and a perforating gun 20 b . The casing collar locator 20 a is an electrical well-logging tool used for depth correlation. The perforating gun 20 b is a well-completion tool designed to create perforations (e.g., punched holes) in the casing of the wellbore, allowing oil and/or gas to flow through the casing into the wellbore.
While the casing collar locator 20 a and the perforating gun 20 b are common downhole tools, their illustration in this example is not intended to be limiting. As discussed above, any suitable downhole tools are embraced by the present disclosure. Further, while in this example, the braking apparatus 100 is located between the casing collar locator 20 a and the perforating gun 20 b , other arrangements are also contemplated. For example, the braking apparatus 100 can be located at the leading or trailing end of the tool string 14 without departing from the scope of this disclosure.
Referring next to FIGS. 3A-3C , the braking apparatus 100 includes a housing 102 , an actuating mechanism 104 , and a pair of braking arms 106 . As shown, components of the braking apparatus 100 are arranged about a central longitudinal axis 101 . The housing 102 is a hollow tubular body having an external cylindrical side wall outlining an internal cavity. The actuating mechanism 104 includes a wedge member 108 located at the floor 109 of the housing 102 . As shown, the wedge member 108 includes a cylindrical pedestal 110 projecting to a frustoconical tip 112 defined by a sloping outer conical surface 114 .
The actuating mechanism 104 further includes a push-pull device 116 coupled to the housing 102 . The push-pull device 116 includes a biasing member casing 118 to house a biasing member (further discussed below) and a linkage member 120 attached to the upper end 119 of the biasing member casing. The linkage member 120 is connectable directly to the suspension line 15 or indirectly via other tool string elements to the suspension line. Similar to the housing 102 , the biasing member casing 118 is a hollow tubular body having a cylindrical side wall outlining an internal cavity. A guide rod 122 extends through the internal cavity of the biasing member casing 118 and through the floor 121 of the biasing member casing to reach the frustoconical tip 112 of the wedge member 108 . The distal end of the guide rod is attached to the tip 112 of the wedge member 108 . A biasing member 124 is disposed coaxially about the guide rod 122 . The biasing member 124 urges the biasing member casing 118 downward towards the wedge member 108 . The biasing member 124 is biasing to provide a downward biasing force at least as great as the weight of the tool string. In this example, the biasing member is an axial coil spring, in which the context of the casing 118 may alternatively be referred to as a spring casing 118 ; However, other types of biasing members (and corresponding casing for the biasing member) may also be employed as an alternative or supplementing biasing member (e.g., a disk spring, a resilient sleeve, and/or a compressible gas or fluid).
The linkage member 120 is coupled, directly or indirectly, to the suspension line 15 . In either case, the coupling between the linkage member 120 and the suspension line 15 is such that at least a portion of the pulling force imparted on the suspension line by the hoisting mechanism 16 is conveyed to the linkage member 120 . So, when the hoisting mechanism 16 exerts a pulling force on the suspension line 15 , the spring casing 118 is pulled (e.g., with substantially equal pulling force) via its attachment to the linkage member 120 . When the pulling force on the linkage member 120 exceeds the biasing force of the biasing member 124 , the biasing member collapses, allowing the spring casing 118 to be moved upward in the housing 102 , away from the wedge member 108 . When the pulling force is reduced, or ceases, the biasing member 124 urges the spring casing back downward towards the wedge member 108 .
The braking arms 106 are pivotally coupled to the floor 121 of the spring casing 118 and extend downward towards the wedge member 108 . As shown in FIG. 3A , when the spring casing 118 is in the lowered position (e.g., when the pulling force exerted on the linkage member 120 is less than the biasing force of the biasing member 124 ), the braking arms 106 bear against the sloping conical surface 114 of the wedge member 108 , forcing the braking arms 106 to pivot radially outward. In this position, the braking arms 106 protrude through arm-bay openings 126 formed radially along a lower portion of the housing 102 (see FIG. 3B ). With the braking arms 106 deployed through the arm-bay openings 126 , brake pads 128 formed on the distal ends of the braking arms 106 are designed to engage a casing wall of the wellbore 12 . Friction between the casing of the wellbore 12 and the brake pads 128 produce a braking force to hold the tool string 14 in place. Thus, the hoisting mechanism 16 is stopped when it is determined that the tool string 14 is at the target depth within the wellbore 12 , thereby eliminating the pulling force, the braking force from the deployed braking arms 106 counteracts the creep phenomenon.
FIG. 3C shows the spring casing 118 in a raised position (e.g., when the pulling force on the linkage member 120 is greater than the biasing force of the biasing member 124 ). In the raised position, the braking arms 106 pivot radially inward toward the central longitudinal axis 101 of the braking apparatus 100 . The inward pivoting motion of the braking arms 106 pulls the brake pads 128 away from the wellbore casing, lessening the friction braking force and allowing the pulling force of the hoisting mechanism 16 to move the tool string 14 upward through the wellbore 12 .
In some embodiments, to reduce frictional drag as the tool string 14 is being lowered through the wellbore 12 , an electrical or mechanical device can be employed to hold the braking arms 106 in a retracted state until the lowest tool depth is reached. For example, a band can be used to hold the arms closed until a small charge is set off that would break a link in the band. The braking arms would then expand to the point allowed by the mechanism. As yet another example, a small motor could be used to hold the braking arms in place while the tool string is being lowered through the wellbore.
A number of embodiments of the invention have been described. Nevertheless, it will be understood that various additions and modifications may be made without departing from the spirit and scope of the inventions.
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A braking apparatus for a tool string positionable in a wellbore and a method of braking a tool string in a wellbore is disclosed. The braking apparatus includes: a tubular housing having at least one radial arm-bay opening; an actuating mechanism including: a wedge member mounted in an internal cavity of the housing; an axial guide rod coupled at one end to the wedge member; and a push-pull device. The push pull device includes: a biasing member casing through which the guide rod extends to contact the wedge member, a biasing member; and at least one braking arm pivotably mounted to a lower portion of the biasing member casing, wherein when the biasing member casing of the push-pull device in in a lowered position, the braking arm bears on a sloped surface of the wedge member to project the braking arm into contact with a wellbore wall.
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CROSS-REFERENCE OF RELATED CASES
This application claims the benefit under 35 U.S.C. §119 to U.S. Provisional Patent Application Ser. No. 60/225,439, entitled WELL HAVING A SELF-CONTAINED INTERVENTION SYSTEM, U.S. Provisional Patent Application Ser. No. 60/225,440, entitled “SUBSEA INTERVENTION SYSTEM” and U.S. Provisional Application Ser. No. 60/225,230, entitled “SUBSEA INTERVENTION,” all of which were filed on Aug. 14, 2000.
BACKGROUND
The invention generally relates to a well having a self-contained intervention system.
Subsea wells are typically completed in generally the same manner as conventional land wells. Therefore, subsea wells are subject to the same service requirements as land wells. Further, services performed by intervention can often increase the production from the well. However, intervention into a subsea well to perform the required service is extremely costly. Typically, to complete such an intervention, the operator must deploy a rig, such as a semi-submersible rig, using tensioned risers. Thus, to avoid the costs of such intervention, some form of “light” intervention (one in which a rig is not required) is desirable.
Often, an operator will observe a drop in production or some other problem, but will not know the cause. To determine the cause, the operator must perform an intervention. In some cases the problem may be remedied while in others it may not. Also, the degree of the problem may only be determinable by intervention. Therefore, one level of light intervention is to ascertain the cause of the problem to determine whether an intervention is warranted and economical.
A higher level of light intervention is to perform some intervention service without the use of a rig. Shutting in a zone and pumping a well treatment into a well are two examples of many possible intervention services that may be performed via light intervention.
Although some developments in the field, such as intelligent completions, may facilitate the determination of whether to perform a rig intervention, they do not offer a complete range of desired light intervention solutions. In addition, not all wells are equipped with the technology. Similarly, previous efforts to provide light intervention do not offer the economical range of services sought.
A conventional subsea intervention may involve use a surface vessel to supply equipment for the intervention and serve as a platform for the intervention. The vessel typically has a global positioning satellite system (GPS) and side thrusters that allow the vessel to precisely position itself over the subsea well to be serviced. While the vessel holds its position, a remotely operated vehicle (ROV) may then be lowered from the vessel to find a wellhead of the subsea well and initiate the intervention. The ROV typically is used in depths where divers cannot be used. The ROV has a tethered cable connection to the vessel, a connection that communicates power to the ROV; communicates video signals from the ROV to the vessel; and communicates signals from the vessel to the ROV to control the ROV.
A typical ROV intervention may include using the ROV to find and attach guide wires to the wellhead. These guidewires extend to the surface vessel so that the surface vessel may then deploy a downhole tool or equipment for the well. In this manner, the deployed tool or equipment follows the guide wires from the vessel down to the subsea wellhead. The ROV typically provides images of the intervention and assists in attaching equipment to the wellhead so that tools may be lowered downhole into the well.
The surface vessel for performing the above-described intervention may be quite expensive due to the positioning capability of the vessel and the weight and size of the equipment that must be carried on the vessel. Thus, there is a continuing need for an arrangement that addresses one or more of the problems that are stated above.
SUMMARY
In an embodiment of the invention, a system includes a subsea well and a carousel of tools. The carousel of tools is adapted to automatically and selectively deploy the tools in the well to perform an intervention in the well.
In another embodiment of the invention, a method includes halting the flow of fluid in a well and deploying a tool from within the well while the fluid is halted. The tool is allowed to free fall while the fluid is halted. The flow is resumed to retrieve the tool.
In yet another embodiment of the invention, a method includes injecting sensors into a fluid of a well and using the sensors to measure a property of the well. Data is retrieved from the sensors, and this data indicates the measured properties.
Advantages and other features of the invention will become apparent from the following description, drawing and claims.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a schematic diagram of a subsea production system according to an embodiment of the invention.
FIG. 2 is a schematic diagram of a wellhead assembly according to an embodiment of the invention.
FIG. 3 is a schematic diagram of a tool carousel assembly according to an embodiment of the invention.
FIG. 4 is a flow diagram depicting a technique to deploy and use a tool from within the well according to an embodiment of the invention.
FIGS. 5 , 6 , 7 and 8 are schematic diagrams depicting deployment and retrieval of tools according to different embodiments of the invention.
FIG. 9 is an electrical schematic diagram of a free flowing sensor according to an embodiment of the invention.
FIG. 10 is a schematic diagram of a system that includes a tractor deployed permanently inside a well according to an embodiment of the invention.
FIG. 11 is a schematic diagram depicting use of the tractor according to an embodiment of the invention.
FIG. 12 is a schematic diagram of a well depicting the tractor in a collapsed state and the release of a buoyant member to indicate the collapsed state according to an embodiment of the invention.
FIGS. 13 and 14 are schematic diagrams of sensors according to different embodiments of the invention.
DETAILED DESCRIPTION
Referring to FIG. 1 , an embodiment of a subsea production system 12 in accordance with an embodiment of the invention includes a subsea field 8 of wells 10 (wells 10 A, 10 B, 10 C, 10 D and 10 E depicted as examples). Each well 10 includes a wellbore that extends into the sea floor and may be lined with a casing or liner. Each well 10 also includes a subsea wellhead assembly 22 (wellhead assemblies 22 A, 22 B, 22 C, 22 D and 22 E, depicted as examples) that is located at the well surface, which is the sea floor 15 .
Each wellhead assembly 22 may be connected to a conduit 26 (e.g., hydraulic control lines, electrical control lines, production pipes, etc.) that runs to a subsea manifold assembly 28 . Conduits 26 A, 26 B, 26 C, 26 D, and 26 E connect respective wellhead assemblies 22 A, 22 B, 22 C, 22 D and 22 E to the manifold 28 . In turn, various conduits 30 are run to a host platform 32 (which can be located at the sea surface, or alternatively, on land). The platform 32 collects production fluids and sends appropriate control (electrical or hydraulic) signals or actuating pressures to the wells 10 A- 10 E to perform various operations and may also communicate chemicals to chemical injection ports of the wellhead assemblies 22 . During normal operation, well fluids are delivered through the production tubing of each well and through the conduits 26 , manifold 28 , and conduits 30 to the platform 32 .
In some embodiments of the invention, the wellhead assembly 22 may include at least part of a system to perform light intervention, an intervention that includes self diagnosis of the associated well 10 and/or to remedy a diagnosed problem in the well. For example, as described below in some embodiments of the invention, the system that is described herein may test the well 10 at various depths, for example, to determine a composition of the well fluids that are being produced by the well. The results of this test may indicate, for example, that a particular zone of the well 10 should be plugged off to prevent production of an undesirable fluid. Thus, in this manner, the system may plug off the affected zone of the well. The testing of well fluid composition and the above-described setting of the plug intervention are just a few examples of the activities that may be performed inside the well 10 without requiring intervention that is initiated outside of the well 10 , as described below.
Referring to FIG. 2 , in some embodiments of the invention, each wellhead assembly 22 may include a wellhead tree 52 that controls the flow of well fluids out of the well 10 and a blowout preventer (BOP) 36 that is connected to the wellhead tree 52 for maintaining a seal in the well 10 when tools are introduced into and retrieved from the well 10 . The wellhead assembly 22 also includes electronics 50 to, as described below, generally control the interventions inside the well 10 . In this manner, the electronics 50 may, for example, cause (as described below) a tool to be run downhole to perform a diagnosis of the well 10 for any potential problems. Based on the results of this diagnosis, the electronics 50 may then cause (as described below) another tool to be run downhole to take corrective action, or remedy the problem.
Referring also to FIG. 3 , for purposes of making those tools available, the wellhead assembly 22 may include a tool carousel assembly 40 that is connected to the BOP 36 , for example. The carousel assembly 40 includes a carousel 63 that holds various tools 65 , such as tools to diagnosis the well 10 and tools to remedy problems in the well 10 . In this manner, the assembly 40 includes a motor 62 that rotates the carousel 63 to selectively align tubes 64 of the carousel 40 with a tubing 66 that is aligned with the BOP 36 . Each of the tubes 64 may be associated with a particular tool (also called a “dart”), such as a plug setting tool, a pressure and temperature sensing tool, etc. Thus, because the carousel assembly 40 is sealed into the well head assembly 22 , self diagnosis and light intervention may be performed within the well 10 without requiring intervention that is initiated outside of the well 10 .
In some embodiments of the invention, the electronics 50 , well tree 52 and tool carousel assembly 40 may perform a technique 70 to run a tool downhole to perform either tests on the well 10 or some form of corrective action. The initiation of the technique may be triggered, for example, by a periodic timer, by a command sent from the sea surface, or by a previous measurement that indicates intervention is needed.
In the technique 70 , the electronics 50 first stops (block 72 ) flow of well fluid from the well 10 by, for example, interacting with the well tree 52 to shut off the flow of fluids from the well 10 . Next, the electronics 50 selects (block 74 ) the appropriate tool 65 from the carousel assembly 40 . For example, this may include interacting with the motor 62 to rotate the carousel 63 to place the appropriate tool 65 in line with the tubing 66 . Thus, when this alignment occurs, the tool 65 is deployed (block 76 ) downhole.
Referring also to FIGS. 5 and 6 , as an example, the electronics 50 may select a tool 65 a to set a plug 94 downhole. Thus, as depicted in FIG. 5 , once deployed, the tool 65 a descends down a production tubing 90 of the well until the tool 65 a reaches a predetermined depth, a depth that the electronics 50 programs into the tool 65 a prior to its release. During this descent, the electronics 50 delays for a predetermined time to allow the tool to descend to the predetermined depth and perform its function, as depicted in block 78 of FIG. 4 . Therefore, for the plug setting tool 65 a , when the tool 65 a reaches the predetermined depth, the tool 65 a sets the plug 94 , as depicted in FIG. 6 .
After the expiration of the predetermined delay, the electronics 50 interacts with the well tree 52 to resume the flow of well fluids through the production tubing 90 , as depicted in block 80 of FIG. 4 . Referring to both FIGS. 4 and 6 , the flow of the fluids pushes the tool 65 a back uphole. The tool 65 a then enters the appropriate tubing 64 of the carousel 63 , and the carousel 63 rotates (under control of the electronics 50 ). The electronics 50 may then interact with the tool 65 a to retrieve (block 82 of FIG. 4 ) information from the tool 65 a , such as information that indicates whether the tool 65 successfully set the plug 94 , for example.
Besides indicating whether a run was successful, the tool 65 may be dropped downhole to test conditions downhole and provide information about these conditions when the tool returns to the carousel. For example, FIG. 7 depicts a tool 65 b that may be deployed downhole to measure downhole conditions at one or more predetermined depths, such as a composition of well fluid, a pressure and a temperature. The tool 65 b includes a pressure sensor to 103 to measure the pressure that is exerted by well fluid as the tool 65 bs descends downhole. In this manner, from the pressure reading, electronics 102 (a microcontroller, an analog-to-digital converter (ADC) and a memory, for example) of the tool 65 b determines the depth of the tool 65 b . At a predetermined depth, the electronics 102 obtains a measurement from one or more sensors 103 (one sensor 103 being depicted in FIG. 7 ) of the tool 65 b . As examples, the sensor 103 may sense the composition of the well fluids or sense a temperature. The results of this measurement are stored in a memory of the electronics 102 . Additional measurements may be taken and stored at other predetermined depths. Thus, when the tool 65 b is at a position 108 a , the tool 65 b takes one or more measurements and may take other measurements at other depths.
Eventually, the electronics 50 (see FIG. 2 ) interacts with the well tree 52 to reestablish a flow to cause the tool 65 b to flow uphole until reaching the position indicated by reference numeral 108 b in FIG. 7 . As the tool 65 b travels past the position 108 b , a transmitter 104 of the tool 65 b passes a receiver 106 that is located on the production tubing 90 . When the transmitter 104 approaches into close proximity of the receiver 106 , the transmitter 104 communicates indications of the measured data to the receiver 106 . As an example, the receiver 106 may be coupled to the electronics 50 to communicate the measurements to the electronics 50 . Based on these measurements, the electronics 50 may take further action, such as communicating indications of these measurements to a surface platform or sending a plug setting tool downhole to block off a particular zone, as just a few examples.
FIG. 8 depicts a tool 65 c that represents another possible variation in that the tool 65 c releases microchip sensors 124 to flow uphole to log temperatures and/or fluid compositions at several depths. In this manner, the tool 65 c may travel downhole until the tool 65 c reaches a particular depth. At this point, the tool 65 c opens a valve 130 to release the sensors 124 into the passageway of the tubing 90 . The sensors 124 may be stored in a cavity 122 of the tool 65 c and released into the tubing 90 via the valve 130 .
In some embodiments of the invention, the chamber 122 is pressurized at atmospheric pressure. In this manner, as each sensor 124 is released, the sensor 124 detects the change in pressure between the atmospheric pressure of the chamber 122 and the pressure at the tool 65 c where the sensor 124 is released. This detected pressure change activates the sensor 124 , and the sensor 124 may then measure some property immediately or thereafter when the sensor 124 reaches a predetermined depth, such as a depth indicated by reference number 127 . As the sensors 124 rise upwardly reach the sea floor 15 , the sensors 124 pass a receiver 125 . In this manner, transmitters of the sensors 124 communicate the measured properties to the receiver 125 as the sensors 124 pass by the receiver 125 . The electronics 50 may then take the appropriate actions based on the measurements. Alternatively, the sensors 124 may flow through the conduits 26 to the platform 32 (see FIG. 1 ) where the sensors 124 may be collected and inserted into equipment to read the measurements that are taken by the sensors.
In some embodiments, the sensors 124 may not be released by a tool. Instead, the sensors 124 may be introduced via a chemical injection line (for example) that extends to the surface platform. Once injected into the well, the sensors 124 return via the production line flowpath to the platform wherein the sensors 124 may be gathered and the measurement data may be extracted. Other variations are possible.
FIG. 9 depicts one of many possible embodiments of the sensor 124 . The sensor 124 may include a microcontroller 300 that is coupled to a bus 301 , along with a random access memory (RAM) 302 and a nonvolatile memory (a read only memory) 304 . As an example, the RAM 302 may store data that indicates the measured properties, and the nonvolatile memory 304 may store a copy of a program that the microcontroller 300 executes to cause the sensor 124 to perform the functions that are described herein. The RAM 302 , nonvolatile memory 304 and microcontroller 300 may be fabricated on the same semiconductor die, in some embodiments of the invention.
The sensor 124 also may also include a pressure sensor 316 and a temperature sensor 314 , both of which are coupled to sample and hold (S/H) circuitry 312 that, in turn, is coupled to an analog-to-digital converter 310 (ADC) that is coupled to the bus 301 . The sensor 124 may also include a transmitter 318 that is coupled to the bus 301 to transmit indications of the measured data to a receiver. Furthermore, the sensor 124 may include a battery 320 that is coupled to a voltage regulator 330 that is coupled to voltage supply lines 314 to provide power to the components of the sensor 124 .
In some embodiments of the invention, the components of the sensor 124 may contain surface mount components that are mounted to a printed circuit board. The populated circuit board may be encapsulated via an encapsulant (an epoxy encapsulant, for example) that has properties to withstand the pressures and temperatures that are encountered downhole. In some embodiments of the invention, the pressure sensor 316 is not covered with a sufficiently resilient encapsulant to permit the sensor 316 to sense the pressure. In some embodiments of the invention, the sensor 316 may reside on the outside surface of the encapsulant for the other components of the sensor 124 . Other variations are possible.
In other embodiments of the invention, the sensor may not contain any circuitry but may change in response to a detected pressure or temperature. For example, FIG. 13 depicts a sensor 500 that may be formed from an encapsulant 503 that has a cavity 505 formed therein. In response to the pressure exceeding some predetermined threshold, the encapsulant 503 “pops” or collapses inwardly into the cavity 505 , thereby indicating the predetermined threshold was exceeded. The pressure threshold sensed by the sensor 500 may be controlled by varying the thickness of the encapsulant 503 , size of the cavity 505 , composition of the encapsulant 503 , gas content inside the cavity 505 , etc.
Another embodiment for a sensor 550 is depicted in FIG. 14 . The sensor 550 may be used to detect a predetermined temperature. The sensor 550 may be formed from an encapsulant 553 that has a metal 551 , for example, contained therein. In response to the temperature of the sensor 550 exceeding some predetermined threshold, the metal 551 melts, thereby indicating the predetermined threshold was exceeded. The temperature sensed by the sensor 550 may be controlled by varying the thickness of the encapsulant 503 , composition of the metal 551 , composition of the encapsulant 553 , use of substitute materials for the metal 551 , etc.
Other variations for the sensor are possible.
In some embodiments of the invention, an arrangement that is depicted FIG. 10 may be used inside the subsea well 10 . In this manner, a robot, such as a tractor 150 , may be located inside the production tubing of the well 10 to carry tools (such as a tool 152 ) about the well for purposes of diagnosing problems in the well and performing intervention in the well. The tractor 150 is permanently sealed inside the well 10 .
The tractor 150 may be tethered from a cable 154 that is in communication with the electronics 50 and/or an operator at the platform. The tool 152 that is moved by the tractor 150 may be a tool that is designated for use by the tractor 150 or a tool that is selected from the carousel assembly 40 , as just a few examples. As depicted in FIG. 10 , the tractor 150 may be used to carry the tool 152 into a horizontal 95 tubing that lines a lateral well bore, for example.
Referring to FIG. 11 , besides carrying a tool to a specific location, the tractor 150 may also be used to perform other tasks within the well 10 . For example, the tractor 150 may include a robotic arm 160 that the tractor 150 may use to move the sleeve on a valve 164 , for example. The tractor 150 may be used for other purposes.
Other variations are possible. For example, the tractor 150 , in some embodiments of the invention, is self-guided and self-powered by its own battery. In this manner, the tractor 150 may receive commands and power to recharge its battery when stationed at a docking station in the well. The tractor 150 may be dispatched to perform a particular task from the docking station without being connected to the docking station. After performing the function, the tractor 150 returns to the docking station.
It is possible that the tractor 150 may become lodged inside the production tubing during the performance of a given task. Should the tractor 150 become lodged to the point that it is not possible or feasible to dislodge the tractor 150 , the tractor 150 may collapse, as depicted in FIG. 12 and fall to the bottom of the well bore. For the case where the tractor 150 becomes lodged and does not have a tethered cable connection, the tractor 150 may communicate by releasing a buoyant member 204 that propagates through the production tubing to the platform to indicate that the tractor 150 has become lodged and has assumed the collapsed position.
While the invention has been disclosed 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 system includes a subsea well and a carousel of tools. The carousel of tools is adapted to automatically and selectively deploy the tools in the well to perform an intervention in the well. The flow of fluid in a well is halted, and a tool is deployed from within the well while the fluid is halted. The tool is allowed to free fall while the fluid is halted. The flow is resumed to retrieve the tool.
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This is a continuation-in-part of application Ser. No. 701,180 filed June 30, 1976 now U.S. Pat. No. 4,071,992.
SUMMARY OF THE INVENTION
The invention relates to composite wall elements for walls, ceilings, and the like, and in particular for structural work above the surface and below ground level, bridges, tunnels, vehicles, cold storage houses and cold storage rooms, means of transportation, or the like.
An object of the invention is to provide a wall element having a resistance to bending so as to be capable of carrying high loads as well as having high acoustic and thermal insulation properties.
More than two wall elements can be successively connected to each other in order to satisfy various functions, in particular the bending strength or, respectively, the load-carrying capacity and the thermal and acoustic insulation. For this purpose the invention provides special connecting means by which the resistance to bending and thus the load-carrying capacity can be increased up to the limit of the strength of the material and, if necessary, sound insulating functions can be achieved by elastic tensioning and embedding on all sides in elastic seals.
The acoustic and thermal insulation can preferably be achieved by a smaller insulating wall element provided in the interior of a composite wall element and consisting of a casing which air-tightly and vapor-tightly, seals the wall element, said casing consisting, for instance, of synthetic resin material, plastic, or metal capable of carrying load. Within the hollow space, there are arranged insulating elements, preferably reflective foils, which can be aluminum, plastic with vapor-deposited aluminum or sheet metal plates capable of carrying load.
Flat and corrugated metal plates and/or plastic panels with reflecting coatings, and deformable closed-pore plastic foam plates or the like which are arranged therebetween, can also be provided, combined in groups. In particular these casings and their inserts can be tensioned in combination with outer shells or, respectively, wall elements, or parts thereof.
The inner wall element and also, if required, the hollow spaces of the outer wall element can be connected by pipes extending thereinto and having provided thereon valves with air drying devices, volume equalizing elements, air-filtering devices and especially with evacuating devices or pressure pumps and, if desired, with hydraulic pumps. In this manner it is possible to provide the interior of the wall element with dry air and/or other dry gases of any desired pressure, for instance, of a high negative or positive pressure to maintain a desired condition for an unlimited period of time. In this manner water condensation is prevented from forming on the reflecting foils upon a decrease in temperature. The vapor-tight sealing of the inner wall element by seals or the like enhances this. In order to render vapor-proof the flexible or rigid envelopes, which envelop the inner wall element, they may be multi-layer in form, or may comprise boxes. If they consist of synthetic resin foils or plastic panels or sheet metal, they can be bonded to each other in several layers, welded, pressed together, or otherwise connected to each other in a flat or profiled manner, in which case they can be provided with metallic, vapor-tight layers or they can have metal foils therebetween.
The envelopes or boxes of the inner element, if of porous material can be immersed after completion into liquid plastic material to which preferably metal powder has been added in order to achieve vapor-tight sealing. Also, metal foils or sheets can be arranged around the inner wall element in a vapor-tight manner overlapping each other. If the inner wall element is then cast into an outer wall element, any admission of air and vapor is prevented. It is advantageous to provide vapor barriers also in the outer wall element, especially towards its front wall side. For this purpose the inner sides of the outer envelopes or the outer wall shells can be connected vapor-tightly with metal foils or sheets and can be sealed hermetically.
The envelopes and outer shells can consist of several parts and can have interposed sheet metals. Such shells can be made, for instance, of concrete by pouring around such sheet metals in a mold established for this purpose. Such shells of concrete can be reinforced in order to further increase their strength and load-carrying capacity. Thus, concavely bent reinforcing irons can be cast into vertical wall parts, such reinforcement excluding an outward bulging of the wall element. In addition, the reinforcements can extend throughout the casting around the wall element, and can be interconnected in such a manner to ensure the concave bending and consequently the increased load-bearing capacity.
In order to connect the opposite surfaces of the wall element in an increased load-carrying manner, there can be arranged tensioning or anchoring screws which pass in an air- and vapor-tight manner through the inner wall element. They cause a concave bending of the surfaces of the envelopes or the shells and plates. These screws can be of several parts and screwed into each other. The heads can be adjustable and capable of being fixed in any position. Different threads can be cut on the screw spindles depending on the requirements.
Pressure differences within the housing can serve to effect movement for producing compressive or tensile stresses and for achieving support of load-carrying parts, for instance, of the wall shells or of the fixed envelopes and the inner and outer supporting elements.
Also, load-bearing supporting elements can be advantageously pre-stressed, which is counteracted by loading. Since laterally or horizontally applied pressure, due at least partially to the pre-stressing, increases with the load more than proportionately, pressures up to the limit of elasticity can be absorbed. The load-carrying parts can be kept accordingly lighter. This partial conversion of the vertical forces acting as load into the horizontal forces which increase more than proportionately with respect to the bulging component is the decisive factor.
For casting the inner composite wall element, different cast materials can be employed and connected with each other. The nature of the material depends upon the function of the wall part, for instance, the required load-carrying strength, flexible elasticity, compressibility, and acoustic and thermal insulating power. The casting in place can be effected layer-wise in time sequence with different materials and solid re-inforcing inserts, for instance, iron bars, pipes, square pipes, perforated metal sheets, perforated plastic boards, and adhesives, in such a manner that, after hardening, elements of different composite layers are formed as a whole or partially as groups or as individual elements.
The outer wall element can be cast in advance on all sides, for instance, with th exception of the surface directed towards the inside of the building. This casting can have any shape, for instance, in combination with an outer frame which encloses intermediate cavities which can also be separated hermetically from each other and can hermetically define toward the inside the hollow space for the inner insulating element. These possibilities of different shapings and developments are unlimited.
In order to receive the inner wall element or elements, corresponding recesses or hollow spaces are provided in which the wall elements are inserted.
By means of the intermediate spaces which remain, the wall elements can be arranged or cast hermetically in an air-tight and vapor-tight manner in these cavities. The casting material can be selected suitably of various types and can also consist of mixed working materials, for example, a metal alloy. In particular, it can form additional vapor-proof envelopes around the inner wall elements. The insulating properties can also be further increased, for instance, by foaming plastic foams into the insulating element. With such pre-fabricated outer wall shells the cavity surfaces on their inner side can be profiled, in particular developed in corrugated shape. They can be coated in a vapor-tight manner with reflective foils and thus can form additional radiation spaces with respect to the inner wall elements and can serve at the same time to apply linear pressure to the inner supporting elements, for instance, via anchoring bolts and atmospheric pressure.
Within these intermediate spaces horizontally and/or vertically corrugated flexible plates can be arranged. If necessary, there can be interposed on one or both sides of the corrugated plates elastic foam plates which can be pressed in a cushion-like manner into the corrugations so as to take up pressures.
The surface of the inner wall element located towards the inner side of the building can, after appropriate sealing of the edges of the inner wall element, be cast or also foamed in place. Instead of casting, a load-carrying cover plate with an outer layer of plaster can be provided, having towards the inner element a polished, reflecting, and vapor-proof surface, for instance, a corrugated plate, trapezoidal plate, a flat metal plate or a plastic plate, provided if desired with additional coatings.
The cavity of the outer wall element is provided with a vapor-tight aluminum lining on all sides and, after introduction of the load-carrying insulating element, is preferably also provided with a vapor-proof rigid or flexible or stiff envelope. The cavity can be sealed in a vapor-tight manner, e.g. filled with a dry gas under a suitable pressure, that is, positive or negative pressure or a vacuum. A positive pressure can be exerted also by a liquid. Radiation spaces, for instance, horizontal radiation chambers, can be formed by spacer strips. The introduction of the insulating element into the evacuated cavity of the outer wall element makes possible a completely pressure-free arrangement of the insulating element, by which the heat conduction through the invidivdual parts of the insulating element which are in contact with each other can be substantially reduced.
If the vapor-tight closure is assured for an unlimited period of time by the covering or the box of the inner wall element and in addition by the outer wall element and its cavity, the wall element, before it is closed, can be filled with a dry gas of predetermined negative or positive pressure or be completely evacuated, and the closing can be effected in a pressure or evacuation space. In order to avoid the oxidation of reflective metal surfaces, it is advantageous to provide them with a layer of polyethylene of a thickness of less than 0.1 mm.
The building element is preferably formed with at least one disk which is formed of cap bolts, the heads of which rest against the outer walls of the buidling element and the inner ends of which are connected by a thread arranged within the interior of the insulating elements. In this connection, the length of thread is such, and flanges are so arranged on the cap bolts, that, upon the tightening of the two spindle parts, the anchor bolt or its flange rest against the covering or the walls of the insulating elements. By means of the anchor bolts, an increased compressive strength of the building element is obtained transverse to the longitudinal axis of the anchoring bolt. At the same time, the walls of the insulating element are maintained an exact distance apart from each other.
BRIEF DESCRIPTION OF THE APPLICATION DRAWINGS
FIG. 1 is a fragmented vertical cross-sectional view through one of the forms of the invention;
FIG. 2 is a fragmentary, perpsective view of a modified wall element form;
FIG. 3 is a perspective, fragmentary view of a composite building block;
FIG. 4 is a perspective view, fragmentary and partially cross-sectioned, of a still further modified form of the invention;
FIG. 5 is a vertical cross-sectional view of yet a further wall element modification;
FIG. 6 is a fragmentary, front elevational view of a screw assembly used in accordance with the invention, and
FIG. 7 is a modification of the screw assembly of FIG. 6.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 is a cross section through an upper part of a composite wall element consisting of the combination of an inner smaller wall element which serves for thermal insulation and which is enclosed on all sides in air-tight and vapor-tight manner by a covering 10 of synthetic resin or plastic material. An outer wall element 15, for load-bearing and compressive strength, is cast around the inner wall element 10 and consists of any suitable maerial, for instance, concrete, cement or plastic.
The covering 10 is made reflective on its inner side or is coated, for instance, with a foil 4 of plastic with aluminum vapor deposited on both sides thereof, in order to assure the vapor-tight closure. For the shaping and stiffening of the covering for load-bearing purposes, plates 1, 2, 3, for instance, of metal, wood, plastic, rigid foam, cardboard, or the like, are arranged around all the inner sides of the covering 10, the plates being reflective towards the hollow space of the wall element thus formed as a result of reflective foils 4 or coatings applied to them. These reflective foils may be, for instance, aluminum foils or plastic foils with aluminum coatings vapor-deposited thereon.
The coverings 10 themselves may consist of any flexible or rigid material, depending on function. In particular, they may consist of a composite with other materials, which are combined with each other, for instance, by bonding. The shaping may be multipartite, for instance, with intermediate sealings, as described below.
The structural element is traversed by at least one two part anchor bolt 11, 12, the two parts 11, 12 of the anchor bolt being connected with each other by a tapered thread 13 on the part 12 which can be screwed into an inner mating thread 13a of the part 11.
On the outer wall of the covering 10, flanges 14a are arranged on the anchor bolt 11 and also on the anchor bolt 12, and flanges 14b on the inside of the covering 10. The outer flanges 14a, resting against the covering 10 form at the same time the bolt heads for the spindles which pass through the inner wall element.
The outer flanges 14a can be arranged firmly on the bolts 11 and 12 so as not to be displaceable in a given position, for instance, by welding. Another possibility consists in providing bore holes 140 in the screw spindles 11 and 12, into which holepins or protruding head bolts can be placed which prevent the flanges from being shifted, at least in the direction towards the anchor heads 11a and 12a. Instead of or in addition to this, annular grooves can be cut into the spindles 11, 12 at predetermined places and the flanges can be inserted therein, for instance, by means of radial cuts in the flanges. If the hole in the flanges 14 corresponds to the diameter of the spindle, protruding resilient split rings can then be inserted into the grooves on both sides of the flanges. The intermediate flanges are prevented from any shift in position by the rings which limit then on both sides and act as stops. Thread cuts are made on the screw spindles and can extend in the same direction or in opposite directions for the moveable arrangement, if desired, of the flanges 14a, 14b which in each case bear corresponding mating threads. It is also advantageous to arrange the anchor heads 11a, 12a of the anchor bolts in detachable manner, for instance, with internal threads such as nuts, but nevertheless in lockable fashion, so that they can be screwed on and off and fixed in the desired end position, for instance, by means of small radial screws 11s, 12s. These small screws can extend through bore holes provided at small distances apart from each other.
The spindle flanges 14a, 14b can be arranged at a desired distance apart, so that in the end position they rest firmly against the outer walls of the covering or wall. Thus they assure a very specific distance between the coverings 10 or covering walls 10 against which they rest. For this purpose, for instance, the fixing of a given thread length can also be used. In this way the inner wall element is protected from an excess of pressure or static stress being pressed inwardly in the direction of the longitudinal axis of the anchor bolt. On the other hand, it is also possible, if necessary, to exert a predetermined pressure on the inner wall element and its inserts by the screwing together of the anchors 11, 12 by means of their threads 13, 13a.
It may be sufficient to provide a thread for the screwing on of the flanges 14a only on the spindle parts which are located outside of the covering. From the length of the thread the possibility results of use for wall elements of different depth dimensions which are to be pressed against each other by the flanges 14a.
As shown by FIG. 1, there are loosely arranged on the inner sides of the covering 10 on threads directed in the same direction, i.e. on the extended threads from the anchor heads, opposing flanges 14b. The flanges 14b are stopped at their end position on the spindles towards the inside of the covering by screws 14s which are tightened against the spindles 11, 12, and thus, by the pressure which they exert, connect the flanges 14b firmly at the intended place to the spindle. For this purpose, there can also be provided corresponding bore holes 140 on the spindle into which these screws engage with their ends. Grooves can also be cut at successive places in the corresponding regions of the spindles and the flanges 14b can thus be fastened in longitudinal direction by engagement of the screws into these grooves.
FIG. 1 shows another possibility for positioning the flanges. For the right-hand flange 14b there are arranged resilient triangular locking elements 14p which have an oblique plane in the direction towards the screwable spindle end part 13. If the flange 14b is pushed, coming from the thread 13, onto the spindle 12, these triangularly broadening oblique elements 14p will be pressed down elastically against springs within this spindle so that the flange 14b can be pushed over it. Since the triangular locking elements have a flat triangular base which is developed perpendicular to the surface of the spindle and against which the flange 14b can lie flat, the flange 14b is prevented from changing its position back against this locking element. This is of importance when the wall element or its cavities are to be widened by displacement of its wall parts in such a manner that it is possible jointly to evacuate all chambers, cells, and other cavities from one point. If the spindle parts 11, 12 are screwed apart, the cover parts 10 are pressed outwardly by the flanges 14b. In this way there is produced the necessary evacuation slot. Such locking stop elements 14p can be arranged at all places on the spindles, particularly in the case of building elements having a plurality of partition walls, coverings, and the like, the movement of which is required. This may also be necessary in order to compress an intermediate space by widening the spaces arranged on both sides thereof.
A blocking of the flanges 14b is necessary with an arrangement of the thread in opposite direction. With the countercurrent arrangement of the thread, the two flanges 14a, 14b move further and further apart upon the reverse movement, i.e. upon the partial turning outwardly of the connecting thread 13. This is not possible, however, if the inner flange 14b is stopped either by such elastic blocking means, or by pins which engage in bore holes, or by screws which extend radially through the flanges. In such a case, the flange would have to turn with the spindle and not axially relative thereto.
If the flange 14b has a thread and if it is firmly fastened to the covering 10 or the partition wall, then the wall must move or bend either inwardly or outwardly corresponding to the direction of the thread or the direction of the actuation of the spindle.
The provision of the locking elements 14p has the advantage that, with the rotation of the flange 14b on the thread, the locking takes place automatically in the intended position which is to be assumed upon the termination of the rotation of the flange 14b. For reasons of assembly, this may then be particularly advantageous if it is not possible to insert locking pins or to provide screws.
The coverings can bear horizontally firmly arranged pins or the like vertically on their surfaces directed towards the flanges 14b by means of which they can engage into corresponding perforations in the flanges. In this way, depending on the length of these pins a connection is produced during a certain rotation of the spindle between covering and flange. Then the flange must move in the longitudinal direction of the spindle corresponding to the rotation thereof. This displacement may serve either for evacuating the air or for other purposes, for instance, for the production of pressure by adjacent load-bearing supporting elements or the like.
There may also be instances in which a different pitch can advantageously be employed on the thread 13 with respect to the pitch of the flanges 14a, 14b. The flatter the thread, the stronger the pressure which can be exerted by the flanges. Different thread pitches in the different regions make it possible to move with the same number of revolutions over different lengths of paths of the walls and, temporarily or in final manner, to change the distances from the adjacent partition walls and shells which are also simultaneously moved.
The advantage of the arrangement of the flanges on threads within given regions of movement is a precise possibility of adjustment, as desired, of the distance from the other opposite flanges 14a, 14b and thus the assuring of the intended functions. The coverings can bear, around the holes through which the spindles are pushed, guides which can widen as desired on both sides, consisting of correspondingly thick rubber disks, rings, pipe lengths, or the like which are glued thereon. In this way in case of contrarotating threads there is obtained a correspondingly hermetically sealed play for the variability of the final position of the flanges. The same anchor bolts can in this way be used for differently dimensioned inner wall elements. Between the inner flanges 14b there can preferably be provided fixed spacer sleeves 14d, for instance, of insulating material such as plastic, the ends of which press themselves into highly elastic seals, for instance, of rubber, which may be arranged on the flanges 14b, or in case of larger diameter, on the covering 10. When the spindles 11 and 12 are screwed together, the bolt passage is closed off towards the rest of the cavity of the inner building element. By the dimensioning of said sleeves 14d a predetermined spacing of all flanges 14b can be maintained and thus the corresponding depth direction of the inner wall element in the end positions can be kept uniformly flat. Furthermore, these sleeves 14d serve as additional pressure-resistant supports in the direction of the spindle axis. If the sleeves are made of rubber, they can also contribute to the acoustic insulation.
An air-drying device 7, 7a, 8, 9 can be provided in the upper part of the inner wall element. The venting and pressure regulating of the inner wall element can be achieved by a drying device 16, 17, 18, with valve 19. In this way, the inner structural element can enter into communication with the outer atmosphere or a pump unit, without water vapor being able to penetrate into the inner element. The pipe 18 can also be connected with, for instance, a volume equalization device so that the same pressure is always present within the wall element as outside of it. The valve 19 can be adjustable so that a given pressure, positive or negative, can be maintained in the interior. In particular, the pipe 18 can be connected to an evacuation unit and by suitable adjustment of the anchor bolts, for instance, by providing an appropriate length of the thread 13 and of the spacing of the flanges 14, the evacuation of all hollow spaces can be effected from a single point.
The wall element itself and all parts which lead into the inner wall element, are sealed off in air- and vapor-tight manner by corresponding sealing means, and all walls of cells, chambers, and other hollow spaces are preferably insulated in vapor-tight manner on all sides by a reflective development or coating.
FIG. 1 shows in the outer cast layer, in order to provide an increased load-bearing function, a vertical reinforcement 15k and a horizontal reinforcement 15'k. These reinforcements are bent concavely toward the inner wall element. They are directed opposite the preferably similar concave reinforcements present on the other side of the wall element. This applies both for the vertical as well as the horizontal reinforcement. Even in the case of extremely high pressures, the outer cast layers can thus not bulge outwardly.
Additional reinforcements 15k", 15l, 15l' and 15l" are also cast into the outer layer 15, positioned so that the curved ends of reinforcements 15k and 15l either extend over or engage around certain of these reinforcements so as to achieve the prestressing desired.
The anchor bolts can be made of any suitable material, depending on the requirements. The same applies also to the flanges, as well as to the sleeves 14d. Thus they can consist, for instance, of a metal alloy which is of poor heat conductivity, such as of iron with an about 30% to 40% addition of nickel, or of plastic or of some other material resistant to pressure or to tension.
Instead of dry air, another gas of poor heat conductivity, for instance, dichloro difluoro methane or sulfur hexafluoride, can be introduced in the wall element in dried condition at a negative pressure. A negative pressure or vacuum results in a favorable pressure action by the atmosphere on the outer cast structural parts 15. These parts are thereby pressed concavely from both sides towards each other or towards the intermediate inner wall element. Due thereto the lateral supporting of load-bearing elements arranged in between is increased.
If such a structural element is pressed together in part by the atmospheric pressure and in part also by firmly tightening the screwable anchor bolts 11a, 12a after the casting has solidified, then the vertical actions can increase the stresses only in a direction concavely towards each other. As a result of the increased concave bending towards each other, an increased horizontal opposing force, acting laterally on the load-bearing supporting elements, is produced that corresponds to the increase in the bulging components. By the reinforcement described above with vertical and horizontal reinforcement members directed concavely towards each other or, for instance, with reinforcement sheets, such wall elements can compensate over-proportionately in horizontal direction, upon increasing load in vertical direction, in a rupture-proof manner for the horizontal bulging component which develops. For protection during the casting, the outer spindle parts are covered with protective coverings, for instance, with sleeves 14d, lengths of pipe, or parts of hose, which are arranged permanently or can be removed subsequently and replaced by other means.
The supporting opposing forces increase to a greater extent than the bending component which is formed from the increasing load. If metal sheets are used for the reinforcement, they should preferably be perforated in order to make possible the coherence of the concrete layers. Such reinforcements or reinforcement sheets can be strengthened, for instance, by square iron bars or they can be profiled.
FIG. 1 also shows honeycomb plates 5 and 6 with interposed reflector means 4 which can be load-bearing supporting elements as, for instance, plates 1 and 2, which, as shown, extend to the upper horizontal bearing plae 3. These supporting elements can be composite elements consisting, for instance, of a plurality of pipes arranged spaced alongside of each other, particularly square pipes which are surrounded in an air- and vapor-tight manner on both sides by metal sheets and can be fastened to said sheets, for instance, by welding, cementing, riveting, or the like.
Other supporting means can also be provided, for instance, square or round pipe lengths arranged horizontally between the vertical square pipes by which the distance of the vertical pipes from each other is assured and a lateral bending of the pipes is precluded, even in case of great load on the vertical pipes. The metal sheets arranged on both sides of the vertical pipes are supported by the honeycomb plates 5 and 6. This can be effected not only by the anchor bolts 11, 12 and/or the atmospheric pressure, but also from both sides by a concave prestressing of the vertical outer walls of the wall element by means of stressed cast-in-place reinforcements 15k, 15'k. For this purpose, the reinforcements, prior to the casting, are introduced not only bent into the casting mold but also by special tensioning means which may possibly also be cast in place. Thus, for instance, the concave curved reinforcements 15k, 15'k may be cast in flatter position, stressed elastically by tensioning means. Thus they have an increased opposing force as soon as a force attempts to deform them in convex direction.
The honeycombs should advantageously be selected in such a size that their webs bridge over the distances between the pipes. The space between the metal sheets in which the pipes are located can be evacuated and in this manner, if an atmospheric pressure or a positive pressure prevails in the inner wall element, an additional higher pressure or tension can be exerted on the sheet metal walls and intermediate pipes in order to increase their resistance to bending and their load-bearing capacity.
The horizontally arranged pipe lengths mentioned can be arranged laterally to the vertical pipes, and disks cemented or welded to the vertical pipes laterally, corresponding to the inner diameter of the horizontal pipes. The disks then enter in air-tight manner into the pipes which are arranged in between and thus fix their position.
Instead of square pipes there can also be arranged between such composite sheets vertical corrugated plates, for instance, trapezoidal sheets or corrugated sheets. Instead of pressing by honeycombs the surrounding composite sheets from the outside, this can be done, for instance, by horizontally corrugated plates, particularly corrugated metal sheets. This has the advantage that under the pressure which acts on them, deformation of the undulations by flattening takes place or, if this is not possible, an increased tensioning takes place whereby a stretching of such horizontally corrugated sheets occurs. In this way, the bending strength and the load-bearing capacity are further increased. These horizontal corrugations which are placed under tension by the lateral pressure provide increased support, for instance, horizontally, for the interposed load-bearing supporting elements.
These stresses can be increased and act horizontally on the adjacent supporting elemnts, concentrated at individual lines of contact, so that in this way a further opposing force is developed against a pressure which increases with increasing load. Gases, rather than liquids, can also be used for exerting the pressure.
In addition to the stress forces exerted on the load-bearing supporting elements horizontally and vertically over the horizontally corrugated intermediate plates, a high hydraulic pressure can be exerted on all sides upon all walls in the hermetically closed hollow space in which the vertically corrugated plate is located, and in this way not only are the vertically load-bearing supporting elements additionally supported against bending in order to take up even higher loads, but, at the same time, a high pressure action is exerted on the upper cover which, by corresponding connection by bolts with the vertical load-bearing parts of the wall element, produces a tensile stress on the latter in vertical direction and results in a stretching, which additionally counteracts lateral bulging upon the action of this stress.
The bending strength is thus produced in two ways, on the one hand by horizontal pressure and on the other hand by vertical tension.
The increased resistance to bending by stretching the supporting elements, e.g., the load-supporting square pipes, can be produced in advance by the production of a tension of any desired value in vertical direction in pipes whose function is to produce the load-bearing capacity of the wall element.
FIG. 2 shows a wall element, preferably as a building block, consisting of at least two shells 61a, 61b, spaced from each other and consisting of load-bearing material, e.g. slabs of cement, concrete, clay, plastic, and/or suitable materials combined with each other in composite character. The load-bearing materials are formed jointly with side walls 69a, 69b which are preferably of material of poor heat conductivity, for instance, plates, covers of plastic, synthetic resin, foamed materials, and the like, which vertically surround a hollow space which can be closed off in air-tight and preferably vapor-tight manner on top and on the bottom by cover plates 64a, 64b of material of poor thermal conductivity, such as plastic slabs.
The side walls 69a, 69b have the function of limiting the heat conduction from the outer wall 61 to the inner wall 61b to a minimum. For this purpose, the thickness of the material of poor heat conductivity can also correspondingly be determined. The vertical walls of the element can be connected to each other directly or by seals.
For fastening the different parts to each other, screws, bolts, pins, clamps, and the like may be used which extend, for instance, through correspondingly provided holes and the like. All walls of the hollow space are coated or otherwise developed in a hermetically insulating and particularly reflecting manner. For insulation, foam plates can be arranged, for instance, on the inner surfaces of the hollow space, for instance, by bonding. Reflective foils, of aluminum, or plastic with vapor-deposited aluminum, can be arranged on such insulated plates, for instance bonded thereon and/or clamped in whole or in part thereon. In this way the hollow space can be sealed off in a reflective manner on all sides. The cover plates 64a, 64b also are provided on the inner side of their cavity with correspondingly suitable insulating and/or reflective layers. In the hollow space itself, there is preferably elastically resilient, upright or stressed reflective foils, panels, or metal sheets or swingable plates provided with a reflective coating, for instance, of plastic or synthetic resin. Such foils, and in particular thin plates, can be tensioned as a whole or can be subdivided in a manifold tensioned manner by interposed springs or by other elastic tensioning means in order to absorb sound. By a hanging or vertically tensioned arrangement, there are imparted to the foils natural frequencies which enable them to absorb resonance vibrations. The arrangement is highly elastic on all sides and permits a considerably broader resonance spectrum than a rigid attachment of the edges. The foils or panels can be arranged in a multiple staggered arrangement one behind the other and, in accordance with the stresses imparted to them, achieve the absorption in predetermined regions of the acoustic spectrum. In this way, low-frequency vibrations can also be taken up as membrane vibrations. In combination with associated additional sound-absorbing means, for instance, with interposed closed-pore foam layers which can be completely surrounded with, for instance, stretched foils, the oscillations are converted into irregular molecular thermal movement. The interposed foam layers can be arranged under elastic tension, for instance, over the foils surrounding them. Foils, panels, and metal sheets capable of vibration can be arranged vertically upright on highly elastic, for instance, ribbed bottom supports.
In order to maintain their vertical position they can be deformed in suitable manner vertically and/or horizontally and can be stiffened. Accordingly, the vertical edge parts can be bent, for instance, in zigzag shape, whereby a uniform development of the surface in vertical direction is effected. By elastic spacer means arranged especially on the upper and lower edge parts, for instance, by interposed foam strips, a uniform parallel development of the surface with respect to the following foils can be achieved in horizontal direction. It may be advantageous to provide the edge portions of the foils with reinforcing means.
The outer parts of such a structural element can advantageously be connected with each other by the cover plates 64a, 64b which lie on the upper and lower horizontal edge surfaces of the plates 61a, 61b, and 69a, 69b and are connected to these vertical wall parts. Furthermore, they can hold said parts in their position and reinforce them at least on two sides, preferably on the sides 69a, 69b which shall close them off in insulating fashion, by means of vertical bends. By a suitable inward bending there is achieved a U-shaped embracing. In the same manner, the front and rear plates 61a, 61b can also be embraced so that the two cover plates 64a, 64b cover the structural element in its entirety, embrace it, seal it off in vapor-tight manner, and uniformly distribute the pressure acting thereon. For connecting the front and rear structural panels 61a, 61b and for exterting pressure, anchor bolts 61c are passed through the hollow space or through the side walls 69a, 69b in suitable number.
For air-tightly closing off the holes, corresponding sealing means, for instance, sealing disks, are provided for the screws between nuts and the inner and outer flanges and shells. The same applies in particular to screws or bolts which extend into the hollow space of the wall element, for instance, through the lateral load-bearing walls 69a, 69b. It is possible to provide the inner hollow space with a negative pressure or vacuum by which it is possible to improve the bending strength and acoustic insulation.
As shown in FIG. 2, the upper and lower cover plates 64a, 64b of the wall element have depressions. These depressions serve not only for the U-shaped embracing and connecting of the vertical structural parts but also for the insertion of insulating connecting plates, for instance, of rigid foam plastic, which are preferably enveloped by vapor-proof foils. In this way, the exact position of the building blocks to be placed one above the other is assured. Continuous holes from the top to the bottom can be provided in the vertical walls through which bars are inserted, for instance, bars of plastic material. In this way the building blocks which are stacked one above the other are accurately and firmly connected with each other to form flat inner and outer overall walls.
The arrangement of the cover plates 64a, 64b in connection with wall elements or building blocks makes it possible to connect the superimposed hollow spaces of the building blocks. It is then possible to insert larger foils in tensioned condition, for instance, arranged on suitable frames, in a larger total hollow space formed in this manner.
In the preceding and succeeding hollow spaces enclosed by further building shells, pressure differences can be produced. The variation of such pressures is advantageous for the bending strength and thus the load-carrying capacity of such building elements and their combinations. For this purpose the lengthened anchor bolts 61c can extend through further head and end parts, and also through the associated wider hollow spaces and additional outer walls and can bear further flanges, nuts, and sealing means, for instance, spacing and sealing sleeves.
FIG. 2 shows a pipe length 65 for evacuating the building block. In this way communication can also be achieved with adjacent building blocks for ventilating with dry air or dry gases.
FIG. 3 shows, in perspective view, a similar wall element in the form of a composite building block. This composite building block consists of a front block 71, a gap 72 in which insulating inserts are arranged, and block part 74. The gap 72 is provided in the full height and width of the building block parts so that the insulation provided therein thermally and acoustically separates the blocks from each other. This gap is closed in air- and vapor-tight manner at its upper and lower openings by profiled cover plates 75a, 75b of insulating material. Such cover plates can consist, for instance of plastic. The corner parts can be closed also in vapor-tight manner by adhesive strips, for instance, of aluminum foils. In this way the gap is closed off hermetically in vapor-tight manner on all sides.
What has already been stated with regard to the insulating inserts 62, 63 in FIG. 2 applies also to the insulating insert designated by the reference numeral 51 in FIG. 3. The inner walls of the gap 72 are also covered on all sides with insulating and reflecting layers. A layer of closed-pore plastic foam can be bonded to the inner surfaces and can bear aluminum foils which reflect towards the free space of the gap. The bonding of insulating means to the block surfaces of the parts 71 and 74 can be effected at individual points or over the entire surface, depending on whether the ability of vibration of such parts is to contribute to the acoustic insulation.
The parts 71 and 74 are profiled similar to the cover plates 64a of FIG. 2 to make possible the positioning of intermediate layers of insulating plates between the upper and lower surfaces of the blocks.
The front block part 71 is connected with the rear inner block part 74 by the upper and lower cover plates 75a, 75b and by means of screws 75c. As a result of these and correspondingly profiled lateral vertical cover plates (not shown), such a building block forms a firm unit.
Anchor bolts 74a are preferably provided extending through the entire building block. By the pressure which they are able to exert in predetermined manner, seals, for instance, rubber plates, can seal off the gap 72.
Vertical holes or recesses can also be provided in the outer block surfaces 71 and 74 permitting a connection of the stacked blocks by the passage therethrough of corresponding round bars of metal or plastic or the like, in order to secure the arrangement of the blocks one above the other.
The air gaps can be in communication with gaps arranged alongside of and/or above each other by pipe lengths 76 or openings.
FIG. 4 shows another wall element consisting of an outer shell 50a, preferably of pressure-proof, load-bearing, inorganic building material, for instance, cement, concrete, clay, or the like, and also a compression-resistant, load-bearing shell 50b of approximately similar type, arranged at a distance therefrom.
In the space between these two shells there is arranged a box-like, bipartite body preferably of insulating material, for instance, synthetic resin, plastic, aluminum sheet, or the like. The horizontal flanges 52c, 52d of the vertical box parts 52a and 52b, respectively, are arranged displaceably in one another against seals 52e and intermediate seals 52f, as well as inner sealing inserts. In the hollow space between parts 52a and 52b there are arranged thermal and acoustic insulating elements, particularly ones with reflective surfaces. For this purpose, reference is had to the insulating inserts as they have already been described in the preceding examples of embodiments. Panels 53 and 54 are arranged with or without tension in load-bearing manner, for instance, by means of edge bends or zigzag edge profilings between elastic, insulating, vibratable sealing strips 52g. This can be done in such a manner that the width of the plates is maintained larger in a predetermined amount corresponding to the desired difference in degree of tension, than the width of the space. In this way, there are produced predeterminable natural frequencies. Between these flat reflector plates 53, 54 there are arranged horizontally and vertically corrugated plates, panels, foils, or the like 55, 56, which are upright and standing, with or without tension. In particular, vertically corrugated plates can thus be inserted. The outer block parts 50a, 50b are connected with each other at a predetermined pressure and spacing, by means of anchor bolts 50c which pass through the box-like body. For this purpose the spindles bear, in the inner boxes 52a, 52b or covering, threads, preferably opposing. The flanges secure the distance apart so that the inner element cannot be changed even under a higher pressure of the outer anchor heads or of the tensioning bolts. The predetermined pressure exerts an intentional deformation on the corrugated reflector plates, which deformation, insofar as it cannot act through the upper and lower as well as lateral limitations, achieves a static condition of stress in vertical as well as in horizontal direction of the corrugated intermediate plates 55. In this way, the block is made of increased load-bearing capacity. These stresses are at the same time of advantage for acoustic insulation by the formation of natural frequencies. In order to be able to reflect vibrations at the edge parts as elastically as possible in the same phase, circumferential, highly elastic sealing strips 52g are preferably provided.
Between the flat plates 53, 54 and the corrugated plates 55, 56 there can be provided further insulating means, for instance, profiled and particularly cross-wise ribbed plastic foam plates (not shown), the ribs being so arranged with respect to the corrugated plates that they intersect the same.
By the stacking of the flat and corrugated plates one behind the other and by the stress imparted to them, for instance, via the anchor bolts 50c, the closed-pore plastic foam layers are pressed in cushion-like fashion into the chambers formed by the corrugations. These cushions are preferably coated on all sides with reflective foils, for instance, aluminum foils, so that these foils also are tensioned in the same manner as the foam foils or plates and have natural frequencies to take up resonant oscillations. The plastic foam plates may be of different thickness and different density and thus elasticity. By these different embodiments, predetermined ranges of the acoustic spectrum can be covered and the corresponding frequencies absorbed as body vibration and then converted into molecular heat movement.
Thus a high acoustic insulation can be achieved with such building blocks as well as with wall elements. For heat insulation, all hollow spaces and the closed-pore foam plates are reflectively enveloped on all sides. For a further increase in the reflection, thin wrinkled foils of aluminum can be introduced into the hollow spaces formed by the corrugations, particularly in large chambers and cells, by means of which air convection is impeded and the infrared rays are diffused in all directions with the formation of interference. Plastic foam beads of special plastic which can be coated in a vacuum with aluminum, may also be put in. Glass fibers or glass wool, preferably coated with aluminum in a vacuum, can also be introduced into large chambers, the direction of the reflecting glass fibers being preferably the same as that of the flat plates. As a result, the glass fibers extend transversely to the passage of sound and heat so that the absorbed energy is deflected in transverse direction to the direction of passage. The insulating element between the block parts can be provided with a negative pressure or a vacuum, whereby the strength of the composite unit and the acoustic insulation is improved.
The load-bearing capacity of the building block is also increased by incorporating into the inner element corrugated plates. The inner stresses in horizontally and vertically corrugated plates result in an increased lateral as well as increased vertical support. The embodiments described hereinbefore can also be employed in the other illustrative examples of embodiments.
FIG. 5 shows an inner wall element surrounded in air- and vapor-tight manner by a covering 51. The wall element is suitable for composite wall elements as well as for building blocks as the inner element thereof. It consists of two preferably load-bearing insulating supporting elements 41 which are arranged spaced from each other. The inside vertical surfaces 42 thereof are profiled in undulated shape and reflectively coated, for instance, with reflective foils 43. Between the two supporting elements is arranged a composite supporting element consisting, for instance, of pipes 44 or bars, preferably square pipes, arranged at pre-determined distances apart in a row (one behind the other in cross-section), preferably with cylindrical bores which are surrounded on both sides by reflective, pressure-resistant, load-bearing metal sheets 44b to which they are fastened. Round pipes which are inserted into square pipes can also advantageously be employed. This composite supporting element of pipes and lateral cover sheets is preferably closed in air- and vapor-tight manner on all sides.
On the side of the cover sheets 44b there are arranged corrugated reflective sheets 46a which contact both the cover sheets 44b and the vertical profilings of the supporting plates 41. Through this inner element 41, 46a, 44, 46a, 41 there are extended anchor bolts 11, 12 (shown schematically by line 11, 12) which exert a pre-determined pressure or tension on the supporting elements 41, as a result of which the latter are pressed against the horizontally corrugated plates 46a, thereby producing therein both a vertical load-bearing as well as a horizontal supporting stress. In this way, the composite supporting element 44 is supported in bending-resistant manner from two sides. In lateral direction the pipes can be supported, for instance, by anchor bolts extending through the pipe spacings or by spacer means in the form of horizontal transverse pipes.
If the space in which the perpendicular corrugations 44a are located is evacuated, atmospheric pressure bears on the cover surfaces 51 and effects a concave inward bending of the inner wall element from both sides. Above the outer supporting elements 41 there are arranged elastic circumferential sealing strips 41a above which there is arranged a pressure plate 48e and a circumferential plate 48 in the center of which is mounted a preferably elastic seal 48b. Bolts 51s extend through plates 48, 48e, and 41a into the supporting elements 41. The bolts are surrounded in the plates 48, 48e, and 41a in air-tight manner by sleeves 51h. By tightening the bolts, the supporting elements 41 are stretched and placed in tensile stress. This is made possible by the elasticity of the circumferential seals 41a which can be pressed together upon the stretching and by the supporting of the pressure which the bolt heads of the bolts 51s exert on the load-bearing composite supporting elements 44 by their counteracting stress. The stretching of the outer supporting elements 41 with simultaneous compression in a horizontal direction by the anchor bolts 11, 12 against the corrugated plates 46a and the composite supporting element 44, 44b produces a high resistance to bending as well as a high load-bearing capacity of the inner wall element. The stretching tension counteracts a bulging. The anchor bolts impart a predetermined concave bend to the wall element. The load pressure, therefore, produces an increased concave tensioning of the supporting elements 41 directed against each other and thus a more than proportional supporting of the composite supporting element 44, 44b. The structural shells of the outer wall element act likewise. The cover 51 may consist of flexible, firm or stiff material. The joints can be closed off towards the outside in advance by adhesive sealing strips 48a. For better distribution of the load a pressure joint 48c is arranged above the composite supporting element 44, 44b and the elastic seal 48b.
FIG. 6 shows a screw spindle 111 having a foot 111a and a locking ring 120 fastened thereon, which is encased detachably by a corresponding housing 121 by screw 122 and cover plate 123 positioned in the composite wall 101. The spindle 111 can therefore not shift in the longitudinal direction. The partition walls 102, 103 have accompanying disks 104 welded around the passage openings or reinforcement strips with mating threads are applied to the spindle. The spindles, depending on the direction of the thread cuts, can be screwed into said mating threads after complete evacuation of the intermediate hollow spaces. This is done by simple turning, by means of which the shells 102, 103 are simultaneously moved. For this purpose, the spindles may have, within the regions entering into consideration, different and preferably increasing diameters and bear threads of different pitch and direction of thread. This can precisely be determined in advance, and thus all functions to be performed by the shells in their permanent end position can be achieved simultaneously and jointly by means of the corresponding screw movement.
Instead of the stepwise increase in the diameters of the threads, pipe lengths of correspondingly larger diameter can also be fastened on the spindle. Such pipe lengths can be placed one behind the other on a smooth spindle and, by the nature of their attachment, for instance, by slots which push themselves onto pins which extend transversely through the spindle, can rotate with the spindle. The threads can be provided on these pipe lengths so that the shells, partition walls, or the like arranged thereon carry out the intended movements in the manner necessary. Thus, by a greater thread pitch the movements of the one shell can amount, with respect to the other shell, to twice the path at the same rotation or, in the case of counterrotating threads, the building shells can be moved against each other. Thus all possibilities are afforded. As many pipe sleeves as desired can be put on such a spindle with driving pins which are insertable into the spindles and which engage in longitudinal slots of the pipe lengths. A spindle with partition walls arranged thereon can also be provided on the opposite left-hand side of the shell 101 in the same manner by lengthening the foot 111a. In this way, any desired number of partition walls and shells can be brought into the predetermined arrangement and their parallel position with respect to each other assured.
FIG. 7 shows a variant of FIG. 6. In this form the foot 211a of the spindle 211 is mounted rotatable with a ring 220 in a housing 221 in a shell 201, with the ring being detachably fastened by a transverse screw 222. The spindle 211 bears threads with different pitches. On the thread, there is arranged a pipe length 130 with internal mating threads, having four driving disks 241, 242, 243, 244, and two partition walls 202, 203 arranged between. These driving disks can be fastened detachably on the transverse screws which engage in grooves on the pipe lengths or are otherwise attached in the intended position after arrangement of the partition walls 202, 203. If it is necessary to widen the intermediate space from the building shell 202 to the building shell 201 by 5 mm., e.g., in order to effect the evacuation of the air, the building shell 203 must be displaced by 10 mm. in order to obtain a change in position of 5 mm. with respect to the building shell 202. The building shell 203 must in addition, for the widening of its own hollow space, be removed by a further 5 mm., for a total of 15 mm. from its original position. Accordingly, the driver disk 241 in its starting position is at a distance of 10 mm. from the position of the building shell 202 on the screwed-on pipe length 130, and a return disk 242 is fastened on the pipe length 130 at a distance of 15 mm. from said driver disk 241. The driver disk 243, on the other hand, is in its basic position only 5 mm. from the partition wall 203 and the corresponding return disk 244 rests against the partition wall 203. If the pipe length 130 is moved from left to right by the movement of the "endless screw", then, after passing over a distance of 5 mm. the disk 243 will contact the partition wall 203 and will shift the same by 10 mm.
The driver disk 241, on the other hand, comes into contact with the partition wall 202 only after a path of 10 mm. of the pipe length and can shift the partition wall only by 5 mm. There is thus obtained the required widening of the hollow spaces. The return disk 244 in this displaced position is only at a distance of 5 mm. from the partition wall. On the other hand, the return disk 242 is at a distance of 10 mm. from the partition wall 202. The original starting positions of the partition walls 202 and 203 are again assumed after the evacuation is completed. The outer shell 204, on the other hand, is not arranged on the pipe length but on the spindle 211, the shell having a counter-thread of its own. This thread within the range of movement of the shell 204 is cut with such a different pitch that, with the same number of revolutions of the spindle for displacement of the partition walls 202, 203, the outer shell 204 changes its position by a total of 15 mm. and thereby widens also by 5 mm. the hollow space between it and the partition wall 203 arranged in front of it for the purpose of evacuation.
Sleeves 231 are arranged around the spindle passages between highly elastic rubber rings 232 and assure an air- and vapor-tight closure of the spindle openings in addition to the other sealing disks and rings which are arranged directly on the perforations.
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A wall unit having a vapor-proof evacuatable envelope and a supporting core in the envelope. Wall shells form the outer sides of the element, and screw means extend through and rigidly interconnect the wall shells and thus the element, the screw means having flanges which can be adjusted toward or away from each other to adjust the pressure applied to the wall element by the screw means. Horizontal and vertical reinforcement means are pre-stressed and cast in the outer wall shell.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
This is a continuation of co-pending application Ser. No. 205,677, filed on June 13, 1988, now abandoned.
SUMMARY OF THE INVENTION
The invention disclosed herein comprises a shield, manufactured of plastic in two sections, which protects a storm drain outlet pipe. The shield is set down into the storm drain and secured to the storm drain walls. The placement of the shield stops damage caused by mechanical devices inserted into the drain. The placement of the shield also prevents destructive particles from entering the intake area of the storm drain.
BRIEF DESCRIPTION OF THE DRAWINGS
Further details are explained below with the help of the example(s) illustrated in the attached drawings in which:
FIG. 1 is a front elevational view of the shield according to the present invention; and
FIG. 2 is a top plan view of the shield shown in FIG. 1 positioned in a storm drain.
DESCRIPTION OF THE PREFERRED EMBODIMENT
There is shown in FIG. 1. a drain pipe shield 10 comprising a first section 12 and a second section 14. The two sections 12 and 14 are generally arched, rectangular in configuration and may be formed of polypropylene or a similar substance. In an engaged position, sections 12 and 14 form a convex shape providing a barrier between an intake area 2 within which an outlet pipe 36 is positioned and a discharge area 4 of a shield 10 protects the outlet pipe 36 from elements such as cleaning clam shells which are inserted into the drain 30. The first section 12 contains a first side edge 16, a second side edge 18, and a fifth side edge 32. The second section 14 includes a third side edge 19, a fourth side edge 17, and a sixth side edge 34. The first and fourth side edges 16 and 17 are in apposed, substantially parallel relation.
The two sections 12 and 14 fit together in a hinged relationship the elements of which are positioned on the second and third side edges 18 and 19 as shown in FIG. 1. The side edges 18 and 19 each are provided with a series of interlocking knuckles. The knuckles are coaxially aligned in a vertical relation. Each knuckle has a through hole 13 through which a pull pin 37 can be placed to hold the sections 12 and 14 in a substantially fixed position. Side edge 32 is in integral angular relationship with side edge 18 and side edge 34 is in integral relation with side edge 19. When the pull pin 37 is engaged the side edges 32 and 34 form a substantially U-shaped configuration allowing access to a first opening 45 without the necessity of opening the shield. This U-shaped configuration allows approximately 98% fluid discharge 4 from the discharge area over the shield to the intake area 2.
The first section 12 has an inner surface 20 and an outer surface 22. The second section 14 has an inner surface 21 and an outer surface 23. The inner surface areas of sections 12 and 14 can be ribbed for added strength. The top edge of the shield 10 and side edge 16 define a first corner. A first pintle hinge 24 is secured to the outer surface 22 adjacent the first corner. The first section 12 and second section 14 contain bottom edges 38 and 40 respectively. A second pintle hinge 26 is secured to the outer surface 22 at a second corner defined by the bottom edge 38 and the side edge 16. A third pintle hinge 25 is secured to a third corner defined by the top edge of the shield 10 and side edge 17. A fourth pintle hinge 27 is secured to a fourth corner defined by the bottom edge 40 and the side edge 17. The pintle hinges 24, 25, 26, and 27 are welded into position on the shield in a manner known in the art.
A continuous wall 28 forms the interior surface of the storm drain 30. The pintle hinges 24 and 26 are aligned and secured to the continuous circumferential wall 28 supporting first section 12 in a right angle relationship with a base portion 42 of the drain 30. The second set of pintle hinges 25 and 27 are aligned and support section 14 in a manner similar to section 12. The pintle hinges 24, 25, 26, and 27 can be attached to the surface 28 by inserting screws or similar fasteners through apertures set in the hinges and into anchors set into the cement of the wall 28.
The pintle hinges 24, 25, 26, 27, may be designed to lock in two positions, the upper position allows the bottom edges 38 and 40 to be positioned approximately 2" above the base portion 42 of the storm drain 30. When the pintle hinges are set into their lower position the shield rests just above the base portion 42. Single position hinges can also be used, in this embodiment the bottom edges 38 and 40 would rest on the base portion 42. In the case of the single position hinges, because the upper surface of the base portion 42 is irregular, sand and fine grit could wash through openings under the sides 38, 40 into the intake area 2.
It is also possible to have the shield 10 unitary in configuration. Side edges 18 and 19 would be eliminated, along with the need for the pull pin 37 and through hole 13. All other aspects of design would be essentially the same.
In a locked position the drain pipe shield 10 acts as a buffer protecting the outlet pipe 36 from objects entering the discharge area 4 of the storm drain 30. When a maintenance crew is conducting regular maintenance of the drain a mechanical cleaning device or a suction hose is inserted through the top of the drain 30 down into the storm drain chamber to remove grit and debris from the base portion 42. In many instances the mechanical device or hose will swing within the chamber area, if unportected the drain pipe can be severely damaged by blows from the mechanical device. By placing the shield 10 in front of the outlet drain 36, the damage can be averted.
An additional function of the drain pipe shield is as a grit sieve. The action of the water against the shield would allow only a minor amount of smaller particles to pass under or over the shield while keeping large destructive particles in the discharge area 4. These destructive particles of sand and grit can then be removed by the mechanical claw or vacuum.
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A plastic shield which is generally rectangular and convex in shape is inserted into a storm drain to provide protection to a storm drain outlet from cleaning tools. The shield is constructed in two sections and is moveably connected to the storm drain to allow workman easy access to the storm drain outlet.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
FIELD OF THE INVENTION
The invention relates to methods of performing seabed excavation and to a tool for performing the method.
SUMMARY OF THE INVENTION
The method is particularly suitable, for example, for excavating the seabed beneath a frame to enable isolation valves to be installed or in a coffer dam in order to expose a buried pipeline. In these instances the seabed is more or less horizontal. However, the method has other applications including those in which the seabed in non-horizontal, so that the array of water jet nozzles has to be operated in a plane other than horizontal. For that reason, the term `depth of cutting` as used herein is not to be limited to a vertical direction.
According to the invention, a method of performing seabed excavation comprises rotating an array of a minimum of three water nozzles about a axis of rotation and moving said axis parallel to itself in at least one direction, the effect of the jet from a first nozzle which lies nearer to said axis intersecting at a first depth of cutting the effect of the jet from a second nozzle, which lies further from the axis, the third nozzle being further from said axis than said first nozzle and the effect of its jet intersecting at a second depth of cutting less than said first depth, the effect of the jet from said first nozzle, and removing debris from the result of action of said jets.
According to the invention, a tool for performing the method comprises a rotatable assembly comprising a generally planar member supported by a hub, the plane of the member being at right angles to the rotational axis of the rotatable assembly and the hub forming an inlet for debris, the tool being movable parallel to the said axis in at least one direction, and an array of a minimum of three water nozzles mounted on said planar member, the effect of the jet from a first nozzle which lies nearer to said axis intersecting the effect of the jet from a second nozzle, which lies further said axis, at a first depth of cutting, the third nozzle being further from said axis than said first nozzle and the effect of its jet intersecting the effect of the jet from the first nozzle at a second depth of cutting less than said first depth, and a jet pump in a conduit for removing debris through said inlet from the result of action of said jets.
BRIEF DESCRIPTION OF THE DRAWINGS
An example of the method and an example of a tool for use in performing the method will now be described with reference to the accompanying drawings in which:
FIGS. 1 to 3 show modes of cutting the seabed using the tool in the course of excavating the seabed using the method,
FIG. 4 is a scrap vertical section through an array of nozzles and part of a disc supported on a hub on which the array is mounted,
FIG. 5 is a vertical diametric section through the tool showing the disc and hub shown in FIG. 4 but not showing the array of nozzles,
FIG. 6 is a view, looking upwards, of the tool shown in FIG. 5, and
FIG. 7 is a schematic plan view of the operation of the present invention within a coffer dam.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1-3 show modes of operation of the tool 10 shown in FIGS. 4-6. The tool 10 consists of an array of three nozzles mounted on a circular disc 12. The disc 12 is rotatable about an axis 14 normal to the disc 12. The tool 10 is movable from right to left as shown in the FIGS. (and back from left to right). The tool 10 is also movable in both directions transversely to the plane of the FIGS. and can also move up and down in the plane of the FIGS. as shown.
Each nozzle emits a jet of high pressure (eg 3000 pounds per square inch) water and the effects of these jets are shown by three lines 16, 17, 18 in the figures. The tool 10 is designed to cut and excavate a seabed consisting of clay, for example the boulder clay encountered in the Morecambe Bay zone of the North Sea. Such excavation is required to enable buried pipelines to be exposed, for example, within a coffer dam.
FIG. 1 shows the mode of operation when the tool 10 advances at a constant height above the seabed 20. A shallow trench 22 is cut out. The sides of the trench are vertical owing to the effect 16, together with the effect 17, which enables the segment of clay to be detached. The nozzle producing the effect 16 is angled very slightly to point outside the periphery of the disc 12 as described below.
If the array consisted of only the nozzle producing the effect 18, the sides of the trench would be sloping, at the angle of the effect 18. The forward motion of the disc 12 would repeatedly strip off sections of clay at that angle thus producing the trench 22.
By adding the two nozzles producing the effects 16 and 17 the disc 12 has the ability to cut downwardly until it is obstructed by the base of the trench 22 as shown in FIGS. 3. FIG. 2 shows an intermediate stage.
The disc 12 can thus cut clay right up to a vertical boundary in any plane. Further progress in cutting, now at the new depth of cutting shown in FIG. 3, can be made by advancing the disc 12 from left to right back along the route of the trench 22, if desired. Of course, the whole of an area (for example the rectangular area within a coffer dam) can be cut at the depth of cutting shown in FIG. 1 before any sinking of the disc 12 is attempted. Then, a new first trench is cut from the position shown in FIG. 3 and, using cuts at the same depth, the whole area is again cut. Thus, progressively, the whole area may be excavated to any depth.
FIG. 4 shows the three nozzles 24, 26, 28 producing the effects 16, 17, 18 just referred to. The nozzles 24, 26 28 form an array mounted on the disc 12 supported by a hub 30, part of which is shown in FIG. 4 but which is better shown in FIG. 5. The disc 12 has a downwardly extending peripheral circular flange 32. The angle of inclination of the nozzle 24 produces an effect 16 which intersects with the effect 17 from the nozzle 26 at a point close to or on the notional cylinder, the continuation downwardly of the flange 32. This means the effect 16 excavates a vertical wall which just clears the flange 32.
FIGS. 1 to 4 shown the lines 16-18 or the three nozzles 24, 26 and 28 in an idealised manner, all lying in the same vertical plane. In fact, the three nozzles are distributed about the centre of the disc 12 at 120 degree spacing, as shown in FIG. 6. Each nozzle 24, 28 is mounted in its own manifold 40, 42, respectively, and is fed by tubes 44, 46, respectively, from a water distribution annulus 48 (FIG. 5). The nozzle 26 is mounted on the hub 30 and communicates directly with the water distribution annulus 48 (FIG. 4). The effect of rotation of the disc 12 makes the effects of the nozzles as explained with respect to FIGS. 1 to 4.
The water distribution annulus 48 is fed by a plurality of drillings 50 which extend longitudinally within the wall of the hub 30, which with the disc 12 forms the rotatable assembly 51 of the tool. The drillings 50 are fed from a water feed annulus 52 machined in the non-rotatable assembly 54. High pressure water seals 56, 58 are positioned in the non-rotatably assembly 54 on each side of the water feed annulus 52. The water reaches the feed annulus 52 through three cross-drillings 60 in the non-rotatable assembly 54, three water transfer tubes 62 and three hoses 64 extending downwardly within a tubular mast 66. The water fed to the nozzles 24, 26, 28 is supplied from a point remote from the vicinity of cutting effected by the nozzles 24, 26, 28.
The hub 30 is rotatably mounted in two sets of ball bearings 68, 70 and carries a gear 72 which meshes with another gear 74 driven by a hydraulic motor 76.
A brush seal 78 engages the upper end of the hub 30. A lip seal 80 engages the hub 30 beneath the high pressure seals 56, 58. A lip seal 82 and a brush seal 84 are also provided.
Debris is removed from the seabed, resulting from the effects of the jets 16, 17, 18 upwards through the inlet 90 formed by the bore of the hub 30. The entrance to the inlet has a coarse mesh grid 92 placed over it. Upflow through the inlet 90 is produced by a jet pump located at 94 and the debris is ejected through a conduit 95 leading to a remote point of disposal. Water flow hoses for the jet pum are connected at 96.
A supply of hydraulic fluid (and a return path not shown) for the hydraulic motor 76 is fed by a hose through the centre of the mast 66 to the bulkhead connector 100. From there another hose connects with the motor 76.
In this example, the tool is part of an arrangement for excavating the seabed within a coffer dam 110 (FIG. 7). The apparatus shown in FIG. 5 includes the lower end of a mast 66 which is mounted on a gantry 112 movable along the coffer dam 110 on a pair of rails 114. The mast 66 is mounted so as to be traversable along the gantry 112 and also so as to be movable towards and away from the seabed.
Although in this example the seabed is considered to be horizontal, in other applications the array of nozzles 24, 26 and 28 may be operated in a plane which is other than horizontal, for example where a sloping seabed is being excavated or where a vertical wall is to be excavated. The depth of cutting is not limited to a vertical direction, for that reason.
Further nozzles can be used in modifications. For example, further nozzles on the same pitch circle as the nozzle 28 can be used. This will have the effect of deepening the trench 22 but reducing the rate of advance. Further nozzles corresponding to the nozzles 24 and 26 can be used but in all cases more water power must be provided or else, or in addition, some control of the period during which the nozzles are `on` will be needed.
The mast 66 described above may, in a modification, be mounted on a frame instead of being mounted in a coffer dam. Such an arrangement is suitable for digging foundations for sub-sea isolation valves. The mast would be movable along the frame and also movable across the frame as well as being movable vertically. In another modification the tool may be mounted on a tracked sub-sea vehicle. For example, the vehicle may have a plunge arm on which the tool is mounted.
In all such modifications and in the example described above with reference to the drawings the tool can be remotely operable from a surface vessel or platform.
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For excavation of a clay seabed, particularly in a coffer dam to expose a buried pipeline, a minimum of three water nozzles producing water jets and the associated effects 16, 17 and 18 are used. The nozzles are mounted on a disc 12 which can move horizontally and vertically and which rotates in a horizontal plane. The effect 18 (if operated alone) would produce a trench 22 having sloping sides. The two effects 16, 17 enable a trench having vertical sides to be cut and enable the disc 12 to be moved downwardly until obstructed by the base of the trench. The three nozzles are equiangularly spaced about the axis. The rotation of the disc 12 makes the effect of the nozzles possible.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND
1. Field of the Invention
The present invention generally relates to improvements for guardrail terminal installations and, in particular aspects, the invention relates to improved support posts and support systems for guardrail terminal systems that have safety end treatments.
2. Description of the Related Art
An important aspect of guardrail design is the ability of the guardrail to resist rupture and prevent penetration of the rail by a vehicle that impacts the guardrail end. For that reason, conventional guardrail installations are provided along their lengths with “strong” support posts that provide very little give when impacted by a vehicle. “Strong” support posts include 7″ diameter wood posts, W6×9 steel section posts and 6″ by 8″ wood posts.
Recently, it has also become important that a guardrail installation not present a hazard to a vehicle during an “end-on” impact where the guardrail installation is impacted from its end by a vehicle. As a result, a number of solutions have been proposed and used for eliminating the upraised end of the guardrail for making it safer.
The guardrail extruder terminal (GET) and slotted rail terminal (SRT) are known safety end treatments for a guardrail assembly that permit the guardrail assembly to safely absorb some or all of the vehicle's kinetic energy during an end-on collision, thereby eliminating the hazard associated with the upraised end. These end treatments are desirable because they absorb the energy of an end-on collision in a controlled manner to help bring an impacting vehicle to a safe stop or they allow the vehicle to safely “gate” through the terminal after absorbing some of the vehicle's energy. The GET is described in U.S. Pat. Nos. 5,078,366 and 4,928,928. The SRT is described in U.S. Pat. Nos. 5,547,309 and 5,407,298. Those patents are incorporated herein by reference. These end treatments were originally designed so that the support posts of the terminal would be readily frangible, “breakaway” posts made of wood. Holes were usually drilled through the post near the ground line in order to weaken the post at that point. Guardrail support posts downstream from the terminal are typically solid wooden posts used to securely anchor the midportion of the guardrail assembly to the ground. As the guardrail collapsed or became flattened by the end treatment, the breakaway posts would be broken at or around the ground line.
There are, however, drawbacks to using strong posts along the length of the end-treatment terminal. The strong posts must be weakened in some manner to accommodate end on impacts to the terminal. These modifications are costly and time consuming and, if done improperly or forgotten, can result in a significant safety hazard for motorists.
The inventors believe that, to date, guardrail terminals have used entirely strong support posts that have been modified by drilling holes or using other means to cause the post to breakaway. An improved guardrail installation would be desirable.
SUMMARY OF THE INVENTION
The present invention provides new and innovative devices and methods for supporting guardrail in guardrail terminals that incorporate safety end treatments such as the GET and the SRT. Preferred embodiments are described wherein the guardrail in a terminal is primarily supported above the ground using weak support posts that are preferably made of metal. The ends of the terminal installation are secured to the ground using breakaway posts and other accessories.
In operation, the weak posts in the downstream portion of the guardrail installation help to contain and redirect a vehicle during a lateral collision to the rail member. The anchorage in part provided by the breakaway end posts helps prevent excessive guardrail displacements that will allow the impacting vehicle to pass over to the opposite side of the guardrail during side or lateral impacts along the length of the terminal.
In other aspects, the invention provides an alternative to use of post weakening mechanisms which results in savings of costs. In operation, terminal assemblies constructed in accordance with the present invention provide an improved support system for the rail member which is more forgiving than conventional strong post support systems, thereby providing an improvement in safety.
At the present time, the invention has particular application in some non-U.S. countries, where it is required or highly preferred that metal support posts be used either completely or primarily within guardrail installations. However, the invention is also applicable to installation within the United States.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an overall plan view of an exemplary guardrail system constructed in accordance with the present invention having a guardrail extruder terminal-type end treatment.
FIG. 2 is a perspective view of the upstream end of the exemplary guardrail system illustrated in FIG. 1 .
FIG. 3 is a cutaway detail illustrating interconnection of the rail member to a support post.
FIG. 4 is a plan view illustrating disconnection of a weak support post from the rail member during an end-on collision.
FIG. 5 illustrates an exemplary S3×5.7 steel section post supporting a rail.
FIG. 6 depicts an alternative guardrail installation constructed in accordance with the present invention and having a slotted rail terminal-type end treatment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring initially to FIGS. 1 and 2 , there is shown an exemplary guardrail assembly 10 that is constructed in accordance with the present invention. The guardrail assembly 10 runs longitudinally along a section of roadway 12 and has a first, upstream end 14 and a second, downstream end 16 . Although the guardrail installation 10 is depicted as being disposed along a straight line, it will be understood that it may be curved as well to conform to the shape of the roadway 12 and may be made of any desired length. The guardrail installation 10 has a central standard guardrail section 11 with guardrail safety end terminals 13 located on either end of the standard section 11 . The boundaries between the terminals 13 and the standard guardrail section 11 are illustrated by lines 15 in FIG. 1 . The standard section 11 includes a corrugated rail 17 that is supported, in most instances, by strong posts 19 .
Each of the guardrail terminals 13 include a substantially continuous, corrugated rail 18 that is supported at its end 14 or 16 by a pair of support posts 20 . The rail 18 is supported in each terminal 13 by support posts 22 .
FIG. 2 depicts the upstream end 14 of one of the guardrail terminals 13 in greater detail. It is noted that the construction and operation described for the upstream end 14 is representative of both the upstream and downstream ends 14 , 16 . FIG. 2 illustrates that the rail 18 is made up of corrugated rail members 24 , 26 that are interconnected, or spliced, to one another using nut and bolt assemblies 27 .
Each terminal 13 of the rail installation 10 includes a safety device, generally depicted at 28 in FIG. 2 which is used to reduce the hazard associated with an upraised guardrail end. In this embodiment, the safety device 28 provides a guardrail extruder terminal impact head 30 . The structure and operation of these type of terminal heads 30 is generally described in U.S. Pat. Nos. 5,078,366 and 4,928,928. FIGS. 2 and 4 illustrate the fact that the traffic side 32 of the head 30 has reduced profile as compared to the non-traffic side 34 of the head 30 . The head 30 is composed of an impact portion 36 and a feeder chute 38 that fits over the end of the rail 18 . As FIG. 4 shows, the head 30 encloses a throat 40 that receives the rail 18 and helps flatten the corrugations in the rail 18 . Additionally, the head 30 includes a curved bending plate 42 that bends and further flattens the rail portion 18 , displacing it laterally away from the head 30 . FIG. 4 illustrates a flattened portion 44 of the rail 18 being displaced laterally away from the head 30 .
Preferably, up to three types of support posts, 20 , 22 , and 19 may be used to support the rails 17 and 18 . Moving downstream from the impact head 30 along the terminal 13 , the first two support posts 20 (only one shown in FIG. 2 ) are breakaway post members that provide secure anchorage of the rail 18 to the ground 46 . The anchorage provided by the support posts 20 is required for redirection of vehicles that might impact the rail assembly 10 from the side proximate the end 14 .
A tension cable assembly 48 (shown in FIG. 2 ) is disposed through the lead breakaway post 20 . Tension cable assemblies such as assembly 48 are well known in the art and operate to transmit tensile forces applied longitudinally to the rail 18 to the lower end of the lead support post 20 . As a result, the force from lateral impacts to the rail 18 are, in part, transmitted to the lower end of the support posts 20 at either end 14 , 16 of the installation 10 . This helps to securely anchor the rail 18 during such lateral impacts.
The support posts 20 , which are the one or two most extreme posts at either end 14 or 16 of the installation are, as noted, frangible or breakaway in nature. During an end-on impact, then, the supports posts 20 will easily breakaway near the ground line of the post 20 to release the cable 48 and the rail 18 from their anchorage. With when the lead post broken away, the cable assembly 48 will also be released from its attachment to the post 20 . There are a number of post structures that are suitable for use as breakaway posts 20 . In certain, non-U.S. countries, for example, it is desirable and sometimes required to use non-wooden posts for guardrail installations. Thus, a breakaway steel post assembly would be particularly desirable. One example of a suitable steel breakaway post is described in U.S. Pat. No. 5,988,598. Another suitable steel breakaway post is the HBA post, which is Marketed commercially by Trinity Industries of Dallas, Tex. In other instances, a wooden breakaway post may be used, although this is not preferred, particularly in many non-U.S. countries where the use of wooden support posts must be minimized or eliminated. The structure and operation of wooden breakaway posts is known and described in U.S. Pat. No. 5,547,309.
Posts 22 located along the length of each terminal 13 downstream from posts 20 along assembly 10 , are unmodified yielding, or “weak,” support posts. The term “unmodified,” as used herein, refers to a post that has not been subjected to any weakening mechanisms, whether by mechanical, chemical or other means, such as by drilling holes in the post, by notching the post, by incorporating mechanical breakaway devices such as frangible connections, or by incorporating bolts that shear upon impact. The unmodified weak post, by its inherent cross-sectional properties and material properties, readily yields or is deflected in a collision. It is preferred that the weak posts 22 be formed of metal rather than of wood. An unmodified “weak” support post is a support post that readily yields or is deflected in a collision. Further, an unmodified weak support post is one that will meet “preferred” occupant impact velocity and occupant ridedown acceleration limits, as recommended in NCHRP Report 350 or its successor, when impacted in a direction consistent with the direction it would be impacted in end-on tests of a guardrail terminal by design vehicles recommended in NCHRP Report 350 or its successor, traveling at speeds of approximately 15 mph or greater with the post embedded in soils as recommended in NCHRP Report 350 or its successor. Weak support posts are further characterized by a greater amount of deflection upon impact than strong posts.
In addition, an unmodified weak guardrail post is one that will meet Impact Severity Class A, as specified in CEN prEN 1317-4, Trento, June 1999, or its successor, when impacted in end-on tests of a guardrail terminal by test vehicles specified in CEN prEN 1317-4, Trento, June 1999, or its successor, traveling at speeds or approximately 25 km/h or greater, with the posts embedded in soils as recommended in CEN prEN 1317-4, Trento, June 1999, or its successor.
Examples of commercially available unmodified weak posts are 4″ diameter circular wood posts, 4″×6″ rectangular wood posts and S3×5.7 steel section posts. It is preferred, particularly for application in many non-U.S. countries, that the weak posts comprise either C-120 or S3×5.7 steel section posts since these posts are not made of wood. Presently, it is highly preferred that the weak posts 22 comprise a C-120-type post, which is a standard Spanish support post. A U-shaped post is illustrated in FIGS. 2 , 3 and 4 . It can be seen that the U-shaped post has a U-shaped cross-section. This U-shape has a weak axis 61 running parallel to the cross-member 25 of the post 22 , and a strong axis 63 running parallel to the two legs 23 of the post 22 . The U-shaped post is, therefore, more easily bent around the weak axis 61 than around the strong axis 63 . As a result, the U-shaped post has the advantageous property of yielding more easily in response to an end-on impact than to a lateral impact upon the rail 18 .
FIG. 5 illustrates an embodiment of the invention wherein the rail 18 is being supported by unmodified posts 22 ′ that comprise S 3×5.7 steel section post members. The S 3×5.7 steel section post has an H-shaped cross-section made up of a central web 27 and two end flanges 29 . Two connectors 31 are used to affix the rail 18 and bracket 50 to one of the end flanges 29 . As can be seen, the S 3×5.7 post provides the same sort of weak and strong axes as the C-120 post member, and it will also provide the advantage of more readily yielding in response to an end-on collision than a lateral impact to the rail 18 .
Posts 19 located along the central portion of the guardrail installation may be the same as posts 22 or 22 ′, or they may be different in size, shape or material.
FIGS. 2 and 3 illustrate the details of attachment of the rail 18 to U-shaped post 22 . A U-shaped standoff bracket 50 is disposed between the rail 18 and each post 22 . The U-shaped bracket 50 has a central web 52 and two legs 54 , as FIG. 3 shows. The bracket 50 is located so that the rail 18 is engaged by portions of the web 52 and each leg 54 . A connector 56 , such as a nut-and-bolt assembly, is disposed through the post 22 , bracket 50 and rail 18 to securely affix the rail to the post 22 . The legs 54 of the bracket 50 provide stiffness to the rail 18 and help to distribute the force of a lateral impact upon different areas of the support post 22 . In testing, the presence of the bracket 50 has been shown to reduce the amount of deflection of the rail 18 in response to a lateral impact. Therefore, the brackets 50 compensate somewhat for the weakness of the weak support posts 22 and help ensure that a laterally impacting vehicle will not rupture or penetrate the rail 18 . In a preferred embodiment of the invention, the support posts 22 that are located 3rd, 5th and 7th from each end 14 , 16 of the rail assembly 10 are not affixed to the rail 18 with connectors. This makes it easier for the rail 18 to feed properly into the impact head 30 since the rail is typically spliced together at these posts. An example of a splice in the rail 18 is shown in FIG. 2 where rail members 24 and 26 are joined by connectors 27 .
FIG. 4 depicts the release of the rail 18 from a weak support post 22 during an end-on impact. As shown there, the impact head 30 has received an end-on impact from vehicle 58 that has driven the head 30 down along the rail 18 thereby flattening and displacing the rail 18 to provide flattened portion 44 . In the position shown, the head 30 has traveled downstream past the locations of the two breakaway posts 20 . The feeder chute 38 of the head 30 has contacted the bracket 50 and the connector 56 passing through the bracket 50 that interconnects the rail 18 to the post 22 . The feeder chute 38 has released the connection. Typically, the connection is released as the connector 56 is pulled through the rail 18 . It is noted that the bracket 50 provides a surface upon which the downstream end of the feeder chute 38 is contacted during the downstream movement of the head 30 . The weak support post 22 will later be bent down from the rail 18 by the impact portion 36 and vehicle 58 . The unmodified weak post 22 typically yields by bending proximate the point at which it is buried in the ground. This bending down is very advantageous as it permits support posts to be readily bent down permitting the impacting vehicle 58 to easily traverse the post in the collision.
Referring now to FIG. 6 , a second embodiment of the invention is described. Like components between the two embodiments are numbered alike. Guardrail installation 100 includes a rail-collapsing slotted rail terminal (SRT)-type end treatment 102 at its upstream end 14 . The construction and operation of SRT end treatments is, as noted previously, described in U.S. Pat. Nos. 5,547,309 and 5,407,298. The SRT end treatment 102 features several slotted sections 104 (only one shown) in the rail 18 . The slotted section 102 contains three longitudinal slots 106 that are cut into the rail 18 to weaken its ability to structurally withstand an end-on impact. Slot guards 108 are located at the downstream end of the slots 106 .
The guardrail installation 100 should, in response to a lateral impact upon the rail 18 , react in the same manner as the installation 10 described earlier. The weak posts 22 will yield or be deflected thereby softening the impact for the impacting vehicle. In an end-on impact, the SRT end treatment 102 will result in axial collapse of the rail 18 . The rail 18 will be released from the weak support posts 22 as the connectors 56 are pulled out of the rail 18 .
A principal advantage is that guardrail installations constructed in accordance with the present invention are more forgiving during an impact to the lateral side thereby resulting in less damage to impacting vehicles and their passengers. Strong wooden support posts used in conventional systems do not easily yield in a collision and thus cause significant damage to the impacting vehicle. At the same time, the weak posts 20 used in the invention are capable of arresting an impacting vehicle that would impact the lateral side of the rail 18 . This capability is provided, in part, by the brackets 50 and the anchorage afforded the system by the tension cable assembly 48 . A further considerable advantage provided by the present invention is the savings in cost over installations that utilize more expensive strong wooden posts.
While the invention has been shown or described in only some of its forms, it should be apparent to those skilled in the art that it is not so limited, but is susceptible to other various changes without departing from the scope of the invention.
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Devices and methods for supporting guardrail terminal installations that incorporate safety end treatments such as the GET and the SRT. Preferred embodiments are described wherein guardrail terminal installations are primarily anchored to the ground using weak support posts that are preferably made of metal. The ends of the guardrail installation are secured to the ground using breakaway posts. In operation, the weak posts permit the central portion of the guardrail installation to contain and redirect the vehicle during a lateral collision to the rail member. The anchorage provided by the breakaway end posts helps prevent the guardrail from being excessively displaced, thus preventing the impacting vehicle from breaking through the guardrail. In operation, guardrail terminal assemblies constructed in accordance with the present invention provide an improved support system for the rail member which is more forgiving than conventional strong post anchorages, thereby providing an improvement in safety. At the present time, the invention has particular application in some non-U.S. countries, where it is required or highly preferred that metal support posts be used either completely or primarily within guardrail installations. However, the invention is also applicable to installation within the United States.
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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 the cementing of casing in oil and gas wells by the use of cementing plugs. More specifically, this invention relates to a new and improved plug launching system and surface injection manifold. The cementing plug injection system is designed to selectively release one or more plugs into the well casing ahead of or behind a cement slurry to reduce contamination of the cement. A first cementing plug may optionally be used ahead of an optional chemical spacer fluid, which can further insure a minimum amount of chemical interference with a cement slurry and a minimal amount of contamination. This optional first plug and spacer fluid would then be followed by a second plug which wipes the drilling fluid from the walls of the casing ahead of the cement slurry, which second cementing plug is then followed by a cementing top plug on command. The top plug follows the cement and further prevents contamination or channeling of the cement with the drilling fluid or fluid used to displace the cement.
The new and improved apparatus of the present invention selectively injects at desired intervals at one or more cementing plugs from an assembly which provides a mandrel and may utilize a slip joint which may be suspended inside the casing at any desired location or depth, which mandrel is fitted with one or more cementing plugs which are releasably retained upon the mandrel by shear rings of different capacities, or are held in position above a restriction sleeve. An injection manifold up stream of the mandrel and plug assembly, which can be skid mounted, is provided with an assembly of injection cylinders fitted with spring loaded pistons, which can be loaded or dressed with pick-up balls, which in turn each are held in a loaded position by a second set of air cylinders each fitted with a spring loaded piston, which in the loaded position extends to retain a pick-up ball within the first cylinder set. One ball launcher and pick-up ball is sized and used for each cement plug mounted to the mandrel. Each cement plug is provided with an interior passage, and at or near the lower most end of each cement plug is a landing ring sized for a pick-up ball of a particular diameter. Pick-up balls for the lower cement plugs are slightly smaller in diameter than pick-up balls for upper cement plugs. The plugs are launched by sequentially injecting the pick-up balls, the smaller ones first, into the stream of cement of slurry, or into the drilling fluid stream. The pick-up ball is carried to its landing in a particular cement plug and pressure build up shears a shear ring holding that cement plug to the mandrel combination assembly (or optionally forces one plug past a restriction sleeve), and the cement plug is thereby launched for the purposes as described above. The method and apparatus of the present invention is further provided with both a fail-safe positive mechanical indication for the launching of each pick-up ball, and with a further magnetic pick-up indication of launching for each of the pick-up balls, to provide positive indication when a plug or plugs have been launched. The method and apparatus of the present invention provides a highly adaptable, efficient and inexpensive means of injecting one or more cementing plugs which can be used on any diameter casing, and further can be used for both surface plug launching or subsea plug launching.
The use of cementing plugs in oil and gas well cementing operations has long been known. The prior art operation is best described in U.S. Pat. No. 4,427,065 to James S. Watson. Watson discloses a cylindrical cementing plug container assembly which is loaded with one or more cementing plugs stacked vertically one above the other. This entire cementing plug container housing is mounted above the casing. Each plug is held within its housing by a mechanical cam lock holding/release device. The cam lock release devices are separately remotely actuateable, and when actuated each device will move the plug holder out of the plugs path where upon each plug is pulled/pushed by a combination of fluid flow, vortex action and gravity into the vortex fluid stream where it is caught by the moving fluid and pumped downhole. The cumbersome Watson cementing plug container, which in the usual practice contains two cementing plugs, projects a significant distance above the casing, and thereby necessitates much longer elevator bails than would be required without the cementing plug container assembly. Furthermore, if it is desired to provide more than two cementing plugs, either a separate plug container in a longer length projecting even further above the casing must be fabricated, or some means of connecting a series of the cementing plug containers which utilize twin displacement cementing plugs must be fashioned. If this is not done, Watson provides no significant safety over the earlier method (also described in U.S. Pat. No. 4,427,065) of removing and replacing the dome each time a plug is inserted with the consequent expenditure of time, expense, and creation of hazardous working conditions. In addition, each of the various casing sizes requires a different Watson cementing plug container housing assembly.
The new and improved method and apparatus for injecting displacement cementing plugs disclosed in the present invention remedies all of the short fallings of the prior art devices, and provides method and apparatus for injecting one or more displacement plugs which is readily adaptable to all casing sizes, which can be used either sub-sea or at surface locations, and which provides a simple and efficient skid mounted injection header assembly which provides positive physical evidence directly related to the launching of each displacement plug in the series. Also disclosed in the primary embodiment are a new and improved cement shoe and plug collar which each alone are significant improvements over prior art devices.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention has other objects, features and advantages which will become more clearly apparent in connection with the following detailed description of the preferred embodiments, taken in conjunction with the appended drawings, in which:
FIG. 1 is a cross-section through the surface injection manifold of invention;
FIG. 2 a cross-section through an embodiment of the mandrel mounted displacement plug launching system suspended at or near the surface opening of the casing;
FIG. 3 is cross-section through an alternative embodiment for sub sea launch;
FIG. 4 is a cross-section through a top displacement plug;
FIG. 5 is a cross-section through a bottom displacement plug;
FIG. 6 is a cross-section through a new and improved float collar;
FIG. 7 is a cross-section through a new and improved cementing shoe: and,
FIG. 8 is an elevation/partial cross section of a slip-joint for use in multiple plug applications.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to FIG. 1, and indicated generally by the numeral 1 is a surface injection manifold equipped for launching two pick-up balls 2 and 3. Although the illustrated injection manifold is only equipped for launching two pick-up balls, it should be understood that provision for as many pick-up balls, corresponding to as many displacement plugs as desired, can be provided. The surface injection manifold 1 may be skid mounted on a frame 4 which will be placed on the rig floor (not shown). The inlet end 5 of the injection manifold can be provided with connection means such as the illustrated threaded connection means 6 for connection to a single chicksan (or high pressure hose) to a cement hopper or manifold (not shown). The opposite end 7 or exit will be connected to the inlet 35 of the casing or sub sea launching system by a high pressure hose (not shown).
The pick-up balls 2 and 3 are placed within a bore provided in respective housings 8 and 9, each of which has an opening 10 and 11 respectively from the housing bore into the main interior flow passage 12 of the injection manifold.
Each of the housings 8 and 9 is provided with a piston head 13 positioned within the interior bore of each of the housings 8 and 9. Each piston head is provided with a piston rod 14 which extends from the piston in both directions along and through the housing bore, and which in the illustrated loaded position, extends downward to rest against the upper surface of each of the pick-up balls 2 and 3 and extends upwardly through the center of a coiled actuator spring 15, which in the illustrated loaded position is compressed, and the piston stem 14 further extends upward and projects beyond the upper portion of each of the housings 8 and 9. In general a spring capable of applying 50 psi should be sufficient to launch the pick-up balls, but much higher capabilities are possible. It may also be desirable to provide sealing means around the pistons and to provide hydraulic inlets and connections into the bores of the launch housings 8 and 9 above the piston plunges heads 13 so that the rig pump hydraulics can be applied to force the piston stems 14 down and inject the pick-up balls. Hydraulic pressures of 3000 psi to 5000 psi are thus available for injecting the pick-up balls. Each housing is provided with a threaded cap 16, threadedly attached to threads provided at the exterior of each of the housings 8 and 9. Each threaded cap is provided with a central aperture 17 through which the upwardly projecting portion of the piston stem 14 passes. A threaded stop 18 is attached to the extreme upward end of each the piston stems 14 so that even in the released position with springs 15 fully extended as will be described below, the upper portion of the stem 14 will not pass completely through the caps 16.
Each of the illustrated piston housings 8 and 9 is further provided with a releasable retaining apparatus illustrated generally by the numerals 19 for retaining the two pick-up balls 2 and 3 within their respective piston housings 8 and 9. In the illustrated loaded or dressed position, each retaining apparatus provides an air cylinder housing 20 which is fitted in a similar manner to the cylinder housings 8 and 9 with an interior compression spring 21, which in the loaded or dressed position will be extended. Each retaining apparatus 19 provides a central rod 23 which passes through the cap end of the air cylinder 24, extends through the center of the compression spring 21, further extends through the center of piston plunger heads 22, and then extends through the opposite end of the air cylinders from the cap 24 into the interiors of the cylinders 8 and 9 at a position closely adjacent the apertures 10 and 11 of the respective piston housings 8 and 9 into the interior 12 of the cement injection manifold. In the illustrated position with the compressible springs 21 fully extended as is the case when cylinders 8 and 9 are to be loaded or dressed, the projecting or stop end 25 of the central rods 23 projects through apertures 26 within the housings 8 and 9 in such a manner as to prevent passage of any pick-up ball such as 2 or 3 through apertures 10 or 11 into the main interior passage 12 of the injection manifold 12. Each of the retaining apparatuses 19 is provided with an air inlet means 27 and connection means upon the air inlet means , which provide for introducing air under pressure into the cylinder on the side of the plunger opposite the springs 21, so that as the pressure is increased, the springs 21 will be compressed by the air pressure, which causes the projecting stop ends 25 of the central rods 23 to be withdrawn from the interiors of the housings 8 and 9, and thereby selectively permit the passage of pick-up balls 2 and 3 in desired and timed sequence. The retaining apparatus 19 is further provided at the opposite end of the central rod 23 from the stop end 25 with a cap means 28 to prevent the passage of rod 23 completely through the cap end 24 of the cylinder. In addition, other suitable means such as a threaded means affixed to the housings 20 may be optionally provided to positively lock the central rod 23 in its dressed or loaded position and to mechanically prevent the retraction of the projecting ends 25 until the mechanical lock had been released.
Referring now to FIG. 2, there is illustrated in cross-section a launching system adapted to be suspended near the surface opening of casing to be cemented As was previously mentioned, one of the advantages of the present method and apparatus is that there is no requirement for a housing extending and projecting up above the casing. Another advantage mentioned is that the present method and apparatus can simply and quickly be adapted for use with casing of any size. As illustrated in the cross-section of FIG. 2 the casing 29 projects at least slightly above the surface. A standard casing coupling 30 is affixed to the upper portion of the casing into the casing coupler 30 has fitted a casing adaptor 31, which can be of configured to adapt to any desired size of casing. At the upper portion of the casing adaptor 31 is an inner adaptor ring 32 of standard size which is fitted to the adaptor by an adaptor lock nut 33 which is threadedly attached to the upper portion of the casing adaptor ring and screws down to tighten against the casing adaptor 21, and thereby fixedly mount the inner adaptor ring and casing adaptor into a unit. Also illustrated is a resilient seal, which for example can be an o-ring seal or a poly-pack seal, 34 are thus provided variously about the apparatus which in operation is subjected to fluid pressure, as will be described in more detail below. Further apparatus attached above inner adaptor ring 32 comprises an inlet means 35 which is attached by suitable means to the outlet 7 of the injection manifold of FIG. 1. Above the inlet from the injection manifold there is illustrated a handling sub 36 for pick up and make up of the drill pipe. Immediately below the inlet 35 there is provided a magnetic sensor 37, the purposes of which will be described in more detail below.
The inner adaptor ring 32 comprises an upper cylindrical portion, an intermediate conical portion tapering inwardly, and a lower tubular nose 38 to which is mounted the remaining encasing of the present invention. An interior passage 39 connects the inlet 35, and injection manifold interior 12, and any attached cement manifold (not shown) with the interior of the inner adaptor ring 39. A mandrel adaptor 40 may be threadedly attached to the tubular nose 38 of the inner adaptor. An upper shear ring 41 retains the top plug mandrel 42 of a top plug indicated generally by the numeral 43 in both FIG'S. 2 and 4.
At this point it should be interposed that although the method and apparatus of the present invention can be utilized with conventional cement displacement plugs, the primary embodiment would utilize the new and improved cement displacement plugs described in pending patent application Ser. No. 07/339,483, now abandoned, of which the inventor the present application is a co-inventor. Application Ser. No. 07/339,483, now abandoned, is hereby fully incorporated by reference for all purposes.
Other features of the top plug 43 illustrated in FIG'S. 2 and 4 are as follows, the upper stabilizer and drive plate 44, the upper ball stop 45, and the upper and lower wiper wings 46 and 47 respectively, which are provided in multiples as illustrated and as described in the referenced co-pending application.
Affixed by a lower shear ring 48 to the lower portion of the upper displacement plug 43 is the bottom plug 49, which is illustrated in greater detail in FIG. 5. The lower shear ring 48 is mounted within a shear ring cavity 50 near the upper portion of the bottom plug mandrel 51. FIG. 5. Circulation ports 52 are provided along the sides of the bottom plug mandrel 51, and are sealed at the lower end by rupture disc 53. A lower ball seat 54 is located near the lower end of the bottom plug 49. A centralizer or stabilizer 55 is also provided for the bottom plug, as are multiple sets of upper and lower wiper wings 46 and 47 respectively.
Referring now to FIG. 3, there is illustrated in cross-section, a variant embodiment of the method and apparatus of the present invention configured for a sub sea launch, using a casing hanger 56, which is supporting the casing to be cemented 57 within an outer casing 58, which has already been cemented. A restriction sleeve 59 is provided for landing and locating the interconnected displacement plugs of the present invention. Although a variety of restriction subs or restriction sleeves are suitable, the primary embodiment envisioned for the present method and apparatus is the improved restriction sub described in the co-pending patent application Ser. No. 07/266,266, now U.S. Pat. No. 4,907,649, for the which the present applicant is the sole inventor. Application Ser. No. 07/266,266, now U.S. Pat. No. 4,907,649, is hereby fully incorporated by reference for all purposes.
The connected series of upper 43 and lower 49 restriction plugs, and the mandrel adaptor 40 for the sub sea embodiment of FIG. 3 are identical to the surface embodiment of FIG. 2. An adapting running mandrel 60 connects the apparatus described for the embodiment of FIG. 3 with the running tubing or casing 61 to be utilized for the sub sea launch.
An alternative embodiment will not connect adjacent plugs in a set with lock rings, but will position them within an aligned string upon a slip joint as illustrated in FIG. 8. Only the upper plug mandrel 42 is connected by a shear ring 41, and the lower plug or plugs rest or land in a restriction sleave 85 as illustrated in FIG. 3 and as described in application Ser. No. 07/266,266, now U.S. Pat. No. 4,907,649, hereby fully incorporated by reference.
Referring now to FIG'S. 6 and 7, illustrated in FIG. 6 is a cross section through a new and improved float collar, and in FIG. 7 there is illustrated a new and improved cement casing shoe. Although the previously described apparatus of the present invention can be used with conventional float collars and casing shoes, the anticipated primary embodiment would utilize the illustrated new and improved shoe and float collar. Referring now to FIG. 6, the reference numeral 62 represents an upper casing to which the body 63 of the flow collar is threadedly attached. The upper portion of the body 63 may be cut with threads for attachment to standard casing. The portion of the body 63 which lies below the upper casing 62 is cut with a conical taper narrowing in the downward direction. A resilient seal 64 is positioned as illustrated near the lower of the body 63. A plastic insert 65 is molded or formed to seat into the taper provided within the interior of the body 63. The lower portion of the plastic insert 65 compresses the resilient seal 64 about the circumference within in the lower portion of the body 63. The plastic insert 65 is further retained and seated within the bottom of the taper by the upper casing, which when threaded into the upper portion of the body 63 will abut the top surface 66 of the plastic insert 65. Plastic insert 65 is provided with a cylindrical bore 67 which is provided with resilient seals 72 and 73, which are located above and below apertures 74 into flow areas 75 with the plastic insert 65 and which is closed off and sealed at its lower portion by a retainer plug 68 threadedly inserted into and thereby sealing the bore 67. The threaded retainer plug 68 is itself provided with a cylindrical concavity 70 of smaller diameter than the central cylindrical bore 67 into which is fitted a resilient non-metallic spring 69 atop which is positioned a piston 71. As is illustrated in FIG'S. 6 and 7 in its natural non-compressed state, the non-metallic spring 69 will hold the piston 71 in a position to close off the apertures 74 and flow area 75 and the seals 72 and 73 will prevent any fluid under pressure from entering the flow areas, and thereby passing through the flow area 75 into the lower portion of the flow collar 76.
Referring now to FIG. 7, there is illustrated a new and improved cementing casing shoe, which shows the characteristics, and can be made of components that are interchangeable with those just described for the flow collar. A difference, however, is illustrated in the configuration of the shoe body 77, which is formed at its lower extremity 78 to provide a angled or rounded nose cone appearance. The plastic insert 79 utilized with the cementing casing shoe of FIG. 7 at its lower end 80 is formed to continue the rounded or angled nose cone section of the cementing shoe, and in addition, the flow areas 75 are angled as at 81 to enhance jetting action while circulating in a string of casing, due to a tight hole. The remaining interior components of the cementing shoe comprising the threaded retainer plug 68, the non-metallic spring 69, the piston 71, and seals 72 and 73 are as described the flow collar of FIG. 6, and therefore are illustrated with like referenced numerals.
The float collar is designed to withstand the loading applied while pressure testing the casing string after displacing cement in the casing. It will be fabricated from high tensile plastic, and it is tapered to land out in a tapered housing to improve loading characteristics. The prior art ball check has been replaced with a sliding piston opened by pressure and closed by a rubber spring located below the piston. When pressure is applied the piston moves down below the bypass ports by compressing the resilient rubber string, and allows fluid to bypass the piston. When the pump is stopped, the piston is returned to a closed position by the resilience of the spring, giving a positive closure. The old style ball check system often leaked, due to large particles lodging between the ball and the seat. The float shoe illustrated in FIG. 7 is designed on a similar concept as the float collar with the exception of having bypass ports angling outward at the shoe nose, to enhance jetting action while circulating in a string of casing, due to a tight hold.
DESCRIPTION OF THE OPERATION OF THE PREFERRED EMBODIMENT
The surface injection manifold 1 of FIG. 1 is mounted on a frame 4 and placed on the rig floor (not shown). The inlet end 5 of the manifold is connected to a cement manifold (not shown). The opposite end 7, or exit of the injection manifold 1 will be connected by a high pressure hose (not shown) to the inlet of the casing 35 (FIG. 2), or sub sea launching system. To dress or load the injection manifold, the threaded caps 16 are each removed in turn from the left and right housings 8 and 9 respectively. Pick-up balls 2 and 3 will be placed in the prospective ball housings 8 and 9. The pick up ball utilized with the bottom plug 49 is slightly smaller than the top pick-up plug ball 3 used in the top plug 43. The pick-up balls 2 and 3 rest on top of the projecting or stop end of the central rods 23 of the releasable retaining apparatuses 19, which are held in the projecting position by the springs 21 within each of the air cylinders 20, and which can further be mechanically latched in position by threaded stop means. The top unions or threaded caps 16 are installed and tightened, and the injection manifold 1 is dressed or loaded. The series of upper and lower plugs 43, 49 et. seq. as many as are desired, are installed in the casing, either at the top of the casing as depicted in FIG. 2 by threadedly inserting a casing adaptor 31 into the top of the casing, or into the casing coupling 30, and then next lowering a string of upper and lower displacement plugs 43 and 49, which have been assembled as described in the related patent application Ser. No. 07/339,483, now abandoned. This string of displacement plugs fixed into an in-line unit by plastic shear rings is in turned fixed to a mandrel adaptor 40 by an upper shear ring 41, and the mandrel adaptor is installed onto the inner adaptor ring 32 by means such as a threaded connection. The handling sub 36 is likewise installed at the opposite end of the inner adaptor ring 32, and the assembly of handling sub, inner adaptor, ring mandrel, adaptor and the series of displacement plugs is then lowered into the casing. A lock nut 33 locks the adaptor rigidly into place at the top of the casing adaptor 31. It is apparent that this configuration is adaptable to a wide variety of casing sizes by merely providing casing adapters 31 to fit the different casing sizes.
In operation, to cement a well casing in a well bore, the well will be conditioned by circulating an appropriate fluid down the casing and up through annulus outside the casing, and back up to the surface. The top and bottom plugs which have been located within the casing at the surface as in FIG. 2, or sub sea by resting against a restriction sub as in FIG. 3, are retained in that position during the conditioning step.
The pick-up balls 2 and 3 are launched by applying air from a rigs source to each of the air cylinders 20 through the air inlet means 22 in turn. If a mechanical latching means is provided, that must first be released, and then the application of air pressure to the air inlet means 27 will retract the cylinder piston rods 23 by action of air pressure against the pistons 22, thus causing the spring 21 to compress, and causing the projecting end or stop end 25 of the central rod to be pulled from the interior of housings 8 or 9, depending upon which cylinder 20 has been pressurized. Upon the retraction of the projecting rod end 25 the compression energy stored in the springs 15 are of the upright cylinders 8 and 9 against the pistons 13 will force the rods 14 downward, thereby moving either ball 2 or 3 through apertures 10 or 11, and into the stream or flow area 12 of the manifold, and consequently through the hose down the launching mandrels to come to rest either in seat 54 or 45 as intended. The application of a selected pressure will first shear the lower shearing 48, and thereby allow the lower displacement plug to be forced through the casing. The sequence is repeated by applying air pressure to the second cylinder, causing rod 25 to withdraw, causing rod 14 to force ball 3 into the flow area 12, whereupon it eventually comes to rest in the upper ball seat 45, whereupon an increase in pressure will shear the upper shear ring 41, release the upper displacement plug 43.
A magnetic indicator can be placed in the manifold down stream from the balls to excite a light once the ball is passed the sensor. This magnetic indicator is indicated in FIG. 2 by numeral 37. A small pencil magnetic can be implanted in the balls as indicated by numeral 82 in FIG. 1. This magnetic indicator provides a clear indication that the ball has passed into the throat of the plug mandrels, and is a positive second indication of the proper launching of the pick-up balls in addition to that provided by the physical indication of each piston stem 14 being in the fully extended launch position so that only the cap 18 shows above each cap 16 after launch.
Although the assembly and operation related the improved displacement plugs has been thoroughly described and detailed in the referenced patent application Ser. No. 07/339,483, now abandoned, a procedure will be quickly sketched here as part of the description of the method of use and operation of the present invention.
On the top plug mandrel an upper top ring 83 is installed as in FIG. 4. Next, the first set of upper and lower flex wings 46 and 47 respectively is installed whereupon a second stop ring 83 is installed below the first set of rings. Succeeding sets of flex rings 46 and 43, and succeeding stop rings 83 are installed as desired. The stabilizer 44 is next installed, as is the ball landing ring which is installed through the top of the top plug mandrel until it lands out on a shoulder provided for that purpose on the interior of the top plug mandrel 42.
The bottom plug mandrel assembly is next assembled, by installing an upper stop ring 83 as at FIG. 5, followed by upper and lower flex wings 46 and 47, and further stop rings 83 in series in a similar manner to that for the top plug. The bottom plug stabilizer and internal ball seats are next installed, and a rubber rupture disc is exposed to cover ports of the bottom plug mandrel. Now that the individual top and bottom plugs are dressed, the bottom plug is attached to the top plug by inserting the upper portion of the bottom plug mandrel into the lower portion of the top plug mandrel, whereupon raw plastic is injected into a port into a shearing cavity as illustrated at 50 in FIG. 5, and FIG. 2. The raw plastic is injected and ages with time and temperature to become shear ring 48. In a similar manner the upper portion of the top plug is inserted into the lower portion of the mandrel adaptor 40, and raw plastic is injected into a port to form the upper shear ring 41. The two plugs and adaptor mandrel are now fully dressed, and become a plug set as the raw plastic ages with time and temperature.
In the optional embodiment which utilizes a restriction sleeve 85 as illustrated in FIG. 3, it is not necessary to lock the top and bottom plugs together as the bottom plug lands or rests on the restriction sleeve.
Assuming the tools are to be run conventionally, that is with the casing extending to the surface, the first step is to pick up the handling sub 36 and make that up to the inner adaptor ring 32. The next step is to fit the casing adaptor 31 to the inner adaptor ring 32, and to tighten the adaptor lock nut 33. Following that, the mandrel adaptor is screwed with the plug set to the inner adaptor ring. The plug set assembly is positioned into a casing pump collar, and the casing is made up to the casing collar.
In the optional embodiment, the make up procedure is similar except that the plug set assembly is screwed into a casing pump of an exact length, so that the bottom plug will land out on a restriction sleeve located in the indicator plug. The bottom plug is not attached to the upper plug in this case. This optional embodiment can also use the slip joint of FIG. 8 for applications using more than two displacement plugs.
The surface injection manifold is then placed in position on a rig floor, and the caps on both housings are removed as balls are installed in their respective housing to come to rest against a releasable retaining means connected to the air cylinders. The top caps are both installed, and cement hoses are hooked up, and the system is pressure tested.
For the alternative embodiment utilized in sub sea cementing operations, the installation procedure is slightly varied, and one first picks up the handling sub and installs that with a crossover sub to the drill pipe connection, and then installs that to the stand of drill pipe. The next step is to make up the mandrel adaptor to the sub sea hanger system and stand back in the derrick. Either plug set, the inter-connected set or the set utilizing the restriction sleeve, can be used depending upon whether or not the lower plug is attached to the top plug.
The sub sea and conventional systems are launched in the same manner. The desired amount of casing is run, and the casing elevators are changed out for drill pipe elevators. The sub sea landing string is run and landed out, or the casing pump landing joint with the handling sub is run and landed out. The launching of the balls and picking up the bottom and top plug is achieved as described below:
The surface injection manifold is placed in position on the rig floor. The chicksan is connected from a cement manifold to the injection manifold. A high pressure hose is then attached from the outlet of the injection manifold to the casing handling sub circulating inlet. The system is then pressure tested. The system is circulated with the rig to the desired amount and the bottom plug pick up ball is released by attaching an air line from the rig air supply to the air cylinder of the bottom plug housing. The locking piston retracts allowing the launching piston rod to be forced down by its spring, thus pushing the bottom plug pick-up ball down into the manifold flow line. The fluid then carries the ball through hose past the magnetic sensor and into the lower plug and onto its ball stop. Additional pressure releases the lower plug, either by shearing its shear ring, or forcing it past the restrict sleeve, depending upon which embodiment is being utilized. After cement is mixed, the top plug is picked up in a similar manner by releasing its latching air cylinder, which in turn allows its injection piston rod to force its appropriately sized pick-up ball into the flow stream, past the magnetic sensor, and into the landing seat of the top plug.
The top plug or displacement plug is now displacing cement. When the bottom plug hits the float collar, additional pressure ruptures its rubber rupture disc allowing fluid to pass through the circulating ports within the float collar and the cement shoe, and on through the circulation ports in the shoe. As pressure is applied against the pistons within the float shoe and cement shoe, each piston is forced downward compressing the rubber spring and opening the flow ports, which establishes circulation through the float collar and float shoe.
To check or prevent "U tubing" or back flow of fluid or cement, the pump is stopped and the non-metallic spring forces the piston upward, covering the circulating ports and allowing a trouble free check arrangement, which no foreign manner can block, thereby preventing any leaks. The float collar and float shoe are run in the casing string with the float collar one or two joints above the float shoe.
In summary, the advantages presented by the improved float collar and float shoe arrangement described and disclosed herein are found by eliminating the ball check found in prior art designs, and using the piston arrangement support by the resilient rubber string. The body of the float collar or cement shoe is provided with a taper which mates with a corresponding taper provided on the plastic insert, which in the primary embodiment or injection, are modeled of a high density plastic improving loading characteristics for the float collar and float shoe. An additional feature of the float shoe is that the flow area port outlets are angled, for instance in the primary embodiment at 45° outward to improve jetting action if the casing is washed in for any reason. It is important to note that all internal parts of the float collar and float shoe are fabricated from plastic and rubber, and use no metal to insure the ease of drilling out.
To sum up the advantages of the entire method and apparatus of the present launching and injection system, it should be appreciated that the balls can be launched mechanically, thereby eliminating having to send personnel into the derrick to manually launch. In addition, the launching head is skid mounted with safety pistons to prevent and eliminate premature launching of either ball. The system of the present application can be utilized on any size casing, simply by changing out the adaptor bushing for each casing sizer thread type. The improved system of the present invention is adaptable to any existing sub C system simply by using a cross-over adaptor. The system described herein utilizes both top and bottom flex plugs to give a more positive seal against the wall of the casing, and in optional embodiments can be provided with more than two displacement plugs to run optional chemical spacer fluids if desired. The system of the present invention is installed inside the casing and therefore, requires no additional clearance above the casing for housings or plug installation. The flex plugs the primary embodiment are designed to eliminate wear on all sets of wiper wings simultaneously with only the upper most wing contacting the wall of the casing at any one time. When pressure is applied to the top wing it is forced down forcing the bottom wing out against the wall of the casing. The wiper wings below the top wiper wing are held away from the wall of the casing by applying pressure to the bottom of the wiper wing. For safety reasons, the plug containers of the prior art devices are dangerous and require personnel and a derrick to manually launch the dart in the ball. The plug monitor launching injection head of the present invention can be tested to pressures exceeding the internal yield of any casing string. The flex plug sets, comprising two or more flex plugs which may or not be interlocked by shear rings are fabricated entirely from high tensile plastic, polyurethanes and/or rubber to allow the plugs to be flexible but strong and to allow for the plugs to be easily drilled while drilling out with a rock bit or stratapack bit. The flex plugs utilized with the primarily embodiment of the present invention are so designed to add any amount of wiper wings to a plug set. In deep high angle holes where excessive wear is evident, additional wings sets can be added to accommodate wear. The flex plugs which are interlocked into flex plugs sets utilize plastic sheer rings instead of shear pins for reliability. The alternative embodiment which does not use interlocked sets of plugs utilizes the plastic restriction sleeve which allows the passage of only one flex plug at a time.
While the preferred embodiments of the invention have been described above, will be recognized and understood that various modifications may be made therein and the appended claims are intended to cover all such modifications which may fall with the spirit and scope of the invention.
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A displacement plug injection apparatus and manifold for sequentially injecting cementing plugs into the casing in an oil or gas well to reduce contamination of the interface between the well fluid and the cement, which apparatus includes an injection manifold for injecting pick-up balls into the fluid stream which pass through an inlet port in the casing to selectively pick-up cement displacement plugs in a plug set which are suspended or held in place with in the casing to be cemented. A positive mechanical indication of the injection of each pick-up ball is apparent and in adition a secondary magnetic sensor indicates a passage of a pick-up ball into the throat provided above the set of displacement plugs to indicate the beginning of the launch of each plug in the plug set. Also disclosed is a new and improved check valve apparatus for use in float collars and cementing shoes used in casing cementing operations.
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RELATED APPLICATIONS
[0001] This application is a continuation of U.S. application Ser. No. 14/517,479, filed Oct. 17, 2014, which is a continuation of U.S. application Ser. No. 13/220,260, filed Aug. 29, 2011. The entire content of both prior-filed applications is hereby incorporated by reference.
BACKGROUND
[0002] The invention relates to detection and locating of heavy machine teeth, specifically the use of radio frequency identification (RFID) tags to determine when a metal tooth is no longer on a bucket of a heavy machine.
[0003] Heavy machines (e.g., mining equipment such as draglines and shovels) utilize steel teeth in their bucket designs. The teeth are used for several reasons: They provide a smaller point of surface area when digging into the earth, helping to break up the earth, and requiring less force than the larger surface area of a bucket itself In addition, the teeth provide easily replaceable wear points that save the bucket itself from wearing down. However, as a tooth wears down, there is currently no method to measure wear without physically removing the tooth.
[0004] When the teeth wear down, they typically fall off. The current method of detecting when a tooth falls off is an expensive machine vision system that looks at the bucket and detects when a tooth has gone missing. This system is extremely costly to implement, and only lets the operator know that the tooth has gone missing, not where it is. Once a crew notices a tooth is missing, they haul away an average ten truckloads of material in hopes of locating and separating out the fallen tooth. If they are unable to locate the tooth, the tooth can end up in a crusher. In addition the tooth can become stuck in the crusher and be ejected from the crusher, potentially harming other equipment.
SUMMARY
[0005] In one embodiment, the invention provides a method of monitoring a heavy machine tooth. The method includes coupling an RFID tag to the heavy machine tooth and positioning an RFID reader to read the RFID tag. The RFID reader provides an indication that the heavy machine tooth is separated from the heavy machine.
[0006] In other embodiments, the invention provides a heavy machine tooth monitoring system that includes a heavy machine tooth configured to be mounted on a bucket of a heavy machine, an active RFID tag coupled to the tooth, and an RFID reader configured to read data from the RFID tag.
[0007] In yet another embodiment, the invention provides a method of monitoring a heavy machine tooth. The method includes coupling an RFID tag to the heavy machine tooth, the RFID tag coupled to the heavy machine tooth to move with the heavy machine tooth and positioning an RFID reader to read the RFID tag. The method also includes receiving, by a controller, information from the RFID reader based on the data from the RFID tag, determining, by the controller, when the heavy machine tooth is separated from the heavy machine based on the information from the RFID reader, and determining, by the controller, diagnostic information for the heavy machine tooth based on the information from the RFID reader. In addition, the method includes providing, to a user, the diagnostic information and an indication to a user when the heavy machine tooth is separated from the heavy machine.
[0008] In still a further embodiment, the invention provides a heavy machine tooth monitoring system. The system includes a heavy machine tooth configured to be mounted on a bucket of a heavy machine, an active RFID tag coupled to the heavy machine tooth to move with the tooth, and an RFID reader configured to read data from the RFID tag, The RFID reader is further configured to provide an indication regarding the location of the tooth when the tooth separates from the bucket based on the data read from the RFID tag and provide diagnostic information regarding the heavy machine tooth based on the data read from the RFID tag.
[0009] Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a side view of an exemplary shovel.
[0011] FIGS. 2A and 2B illustrate the operation of an exemplary mining site.
[0012] FIG. 3 is an exploded view of a construction of a bucket tooth incorporating an RFID tag.
[0013] FIG. 4 is another view of the bucket tooth of FIG. 3 .
[0014] FIG. 5 is a cut-away view of the bucket tooth of FIG. 3 .
[0015] FIG. 6 is a plan view of another construction of a bucket tooth incorporating an RFID tag.
[0016] FIG. 7 is a plurality of views of a third construction of a bucket tooth incorporating an RFID tag.
[0017] FIG. 8 is a plan view of a construction of a ceramic plug for inserting an RFID tag into the bucket tooth of FIG. 7 .
[0018] FIG. 9 is a schematic diagram of a wear detection circuit.
DETAILED DESCRIPTION
[0019] Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways.
[0020] Heavy machines are used to move large amounts of earth in industries such as mining and construction. Some heavy machines (e.g., an electric shovel) include buckets for scooping up the earth. The buckets often include a plurality of teeth to help break up the earth, and make it easier to scoop the earth into the bucket.
[0021] FIG. 1 shows an exemplary electric shovel 100 used for surface mining applications. The electric shovel 100 includes a mobile base 105 supported on drive tracks 110 . The mobile base 105 supports a turntable 115 , and a machinery deck 120 . The turntable 115 permits full 360° rotation of the machinery deck 120 relative to the base 105 .
[0022] A boom 125 is pivotally connected at 130 to the machinery deck 120 . The boom 125 is held in an upwardly and outwardly extending relation to the deck by a brace or gantry in the form of tension cables 135 which are anchored to a back stay 140 of a stay structure 145 rigidly mounted on the machinery deck 120 .
[0023] A dipper or bucket 150 includes a plurality of teeth 152 , and is suspended by a flexible hoist rope or cable 155 from a pulley or sheave 160 , the hoist rope is anchored to a winch drum 165 mounted on the machinery deck 120 . As the winch drum rotates, the hoist rope 155 is either paid out or pulled in, lowering or raising the dipper 150 . The boom pulley 160 directs the tension in the hoist rope 155 to pull straight upward on the shovel dipper 150 thereby producing efficient dig force with which to excavate the bank of material. The dipper 150 an arm or handle 170 rigidly attached thereto, with the dipper arm 170 slideably supported in a saddle block 175 , which is pivotally mounted on the boom 125 at 180 . The dipper arm 170 has a rack tooth formation thereon (not shown) which engages a drive pinion or shipper shaft (not shown) mounted in the saddle block 175 . The drive pinion is driven by an electric motor and transmission unit 185 to effect extension or retraction of the dipper arm 170 relative to the saddle block 175 .
[0024] The shovel boom 125 is a major structural component in size, shape, and weight. Its main purpose is to hold the boom pulley 160 in an advantageous position for efficient hoist dipper pull through the bank. Another major purpose of the boom 125 is to mount the shipper shaft at a sufficient height and outward radius from the centerline of rotation of the shovel 100 . The shipper shaft powers the shovel handle to extend and retract the dipper 150 . These two features of an electric shovel digging attachment make the shovel uniquely qualified to reach and dig high bank formations safely away from the shovel. The shovel in this regard is also able to reach a great volume of material in one sitting without propelling closer to the bank.
[0025] The bucket teeth 152 are removably attached to the bucket 150 . This enables broken or worn teeth 152 to be easily replaced. However, this leads to teeth 152 occasionally breaking or falling off of the bucket 150 . In some circumstances, a tooth 152 will break/fall off the bucket 150 and end up in the earth being mined (i.e., in the bucket 150 ). When the earth in the bucket 150 is deposited in a truck, the tooth 152 goes into the truck as well. Often the earth in the truck is taken to a crusher to be crushed. When the truck empties its contents into the crusher, the tooth 152 goes into the crusher as well, potentially damaging the crusher, being expelled from the crusher and damaging other equipment, or being damaged in the crusher.
[0026] FIGS. 2A and 2B represent a typical mining operation. The shovel 100 digs up earth 200 with its bucket 150 , and dumps the earth 200 into a truck 205 . Once the truck 205 is full, the truck 205 takes the earth 200 to another location (e.g., at the mining site or remote from the mining site). In some operations, the truck 205 takes the earth 200 to a crusher 210 . The truck 205 deposits the earth 200 onto a conveyor 215 which feeds the earth 200 into the crusher 210 which crushes the earth 200 into smaller components 220 .
[0027] The invention uses an active RFID tag embedded in or attached to the metal tooth 152 of the heavy machine bucket to enable detection of a tooth 152 missing from the bucket 150 .
[0028] The invention uses an RFID reader 225 located on a structure (e.g., an exit gate) through which the truck 205 passes after being filled. The RFID reader 225 checks if an RFID tag passed near the structure. If an RFID tag is detected, an alarm can be triggered enabling the truck 205 to be searched to determine if the detected RFID tag and corresponding tooth 152 was in the bed of the truck 205 . If a tooth 152 containing an RFID tag had broken/fallen off the bucket 150 and was in the truck 205 , it could be found before leaving the site or being deposited in the crusher 210 . Preferably, the RFID reader 225 is positioned a far enough distance away from the bucket 150 that the reader 225 does not detect RFID tags in the teeth 152 that are still in place on the bucket 150 .
[0029] In addition, an RFID reader 230 can be positioned before the entrance to the crusher 210 to detect the RFID tag on a tooth 152 prior to the tooth 152 entering the crusher 210 (e.g., the reader 230 could be positioned over the conveyor 215 feeding the crusher 210 ). Again, if the reader 230 detects an RFID tag, an alarm is triggered and the conveyor 215 and/or crusher 210 is/are stopped, enabling the tooth 152 to be located prior to entering the crusher 210 .
[0030] An RFID tag in a tooth 152 can include information identifying the tooth 152 . For example, the RFID tag can be written with data such as, but not limited to, a serial number, an origin, a date of manufacture, etc. This stored information can enable a user to quickly determine where the tooth 152 came from promoting faster repair of the bucket 150 or returning of the tooth 152 .
[0031] In some embodiments, an RFID reader 235 is included in the heavy machine 100 itself (see FIG. 1 ). The reader 235 reads all of the RFID tags located on the machine 100 , including the tags on the teeth 152 . A controller or computer receives information from the reader 235 about the tags detected. The controller then provides diagnostic information to a user. This information can include when the tooth 152 was installed, how many hours the tooth 152 has been in operation, etc. In addition, should a tooth 152 break/fall off, the controller alerts the user of this condition enabling the lost tooth 152 to be found quickly and replaced.
[0032] In some embodiments, additional circuitry is included with the RFID tag to determine the amount of wear of a tooth, enabling preventative maintenance to be performed before a tooth fails.
[0033] In some embodiments, the RFID tag 300 is detuned when the tooth 152 is mounted to the bucket 150 . When the tooth 152 breaks/falls off the bucket 150 , the signal strength of the RFID tag 300 increases. The reader 235 detects the increase in signal strength and determines that the tooth 152 has broken/fallen off the bucket 150 .
[0034] FIGS. 3-5 show a view of a heavy machine bucket tooth 152 . The tooth 152 includes an active RFID tag 300 encased in a ceramic enclosure 305 , the ceramic enclosure 305 is then encased in steel 310 . A separate control circuitry can also be included in the ceramic enclosure 305 to activate the RFID tag 300 when the tooth 152 is shipped or installed, saving battery power and extending the life of the RFID tag 300 . The ceramic enclosure 305 with the RFID tag 300 , and any other circuitry, is placed in a mold into which liquid steel is poured to form the tooth 152 . The ceramic enclosure 305 protects the RFID tag 300 from the heat of the liquid steel. The RFID tag 300 is detuned such that the steel of the tooth 152 tunes the RFID tag 300 to the correct frequency, using the tooth 152 as an antenna. In some embodiments, a tuning circuit in the RFID tag 300 tunes the tag 300 once the tag 300 is activated in the tooth 152 .
[0035] FIG. 6 shows another construction of a heavy machine bucket tooth 152 incorporating an RFID tag 300 . The tag 300 is mounted to an end 600 of the tooth 152 . The end 600 is inserted into a mounting bracket 605 and the tooth 152 is secured to the mounting bracket 605 . In this construction, the RFID tag 300 takes advantage of the metal of the tooth 152 and the bracket 605 , using backscattering to increase an intensity of the RFID signal.
[0036] FIG. 7 shows a construction of a heavy machine bucket tooth 152 arranged to receive an RFID tag. The tooth 152 includes a hole 700 drilled into the base of the tooth 152 . A cylindrical RFID tag is inserted into the hole 700 . In some constructions, a ceramic disk is placed over the RFID tag, and the hole 700 is welded shut.
[0037] FIG. 8 shows a construction of a ceramic plug 800 for insertion in the tooth 152 of FIG. 7 . The ceramic plug 800 encapsulates an RFID tag and a tooth wear detection circuit. Four probes 805 , 810 , 815 , 820 extend out of the ceramic plug 800 . When the ceramic plug 800 is inserted into the hole 700 of the tooth 152 , the probes 805 - 820 each contact the tooth 152 and are thereby electrically coupled to the tooth 152 . The wear detection circuit uses the probes 805 , 810 , 815 , 820 to electrically test the tooth 152 and determine the wear of the tooth 152 . The wear detection circuit provides data to the RFID tag 300 regarding the wear of the tooth 152 (e.g., amount of loss, useful life remaining, etc.). The RFID tag 300 then communicates (e.g., via a wired or wireless connection) the wear information to an RFID reader (e.g., in a cab of a shovel, to a portable RFID reader, etc.).
[0038] FIG. 9 shows a wear detection circuit 900 used to determine wear of the tooth 152 . The circuit 900 uses a four-point resistance method to determine wear. A current source 905 produces a current that is applied to two of the probes 805 and 820 . The current flowing through the probes 805 and 820 is detected by a current transducer 910 . A voltage transducer 915 of the circuit 900 detects a voltage across the other two probes 810 and 815 . Using the detected current and voltage, a microcontroller 920 of the circuit 900 determines a resistance of the tooth 152 . The resistance varies based on the material composition of the tooth 152 , the permittivity of the tooth 152 , and the dimensions of the tooth 152 . As the tooth 152 wears, the resistance of the tooth 152 changes. The change in resistance can thus be used to determine the wear and tear on the tooth 152 . In some embodiments, the initial resistance (i.e., when the tooth 152 is new) is recorded in the RFID tag 300 . Also, in some embodiments, other resistance measurements (e.g., the resistance previously determined) are recorded in the RFID tag 300 .
[0039] Various features and advantages of the invention are set forth in the following claims.
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Methods and systems for tracking heavy machine teeth. One system includes a heavy machine tooth configured to be mounted on a bucket of a heavy machine, an active RFID tag coupled to the heavy machine tooth to move with the tooth, and an RFID reader configured to read data from the RFID tag, The RFID reader is further configured to provide an indication regarding the location of the tooth when the tooth separates from the bucket based on the data read from the RFID tag and provide diagnostic information regarding the heavy machine tooth based on the data read from the RFID tag.
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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 wall construction and more particularly to a wall assembly utilizing a double wall construction and associated insulative materials to present a wall assembly highly resistant to air infiltration and thermal flow therethrough.
In conventional wall construction, 2×4 or 2×6 studs are placed on 16 inch centers with the exterior wall sheathing nailed directly to the exterior faces of the studs to present a plurality of side-by-side stud cavities therebetween. Prior to nailing the interior wall board to the interior faces of the studs, insulative material is placed within the stud cavities to resist passage of thermal flow therethrough. The effectiveness of this resistance is conventionally referred to as the "R" value of the insulation.
Insulation in the form of fiberglass batts or a spray applied foam can be inserted between the studs to fill these stud cavities. The foam-type insulation offers a greater R-value per inch of material than that offered by conventional fiberglass batt insulation. Moreover the cured foam hugs the studs to preclude the appearace of cracks or crevices therebetween. The cured-foam may break away from the studs and present undesirable cracks and/or crevices which allow for undesired thermal infiltration therethrough. These cracks/crevices offer a path of lesser resistance to thermal flow between the exterior and interior walls of the wall assembly which degrades the R-value of the overall wall construction. Also, as the interior and exterior walls are nailed directly to the opposed stud faces a path of thermal flow between the interior and exterior walls via the interposed studs is presented. This path offers a lesser resistance to thermal air flow than that offered by the insulated stud cavities.
In response thereto, I have invented a wall construction utilizing the first and second rows of laterally spaced-apart and longitudinally offset studs for supporting a first foam-type and second batt-type insulation materials. The exterior wall sheathing is nailed to the first row of studs with the interior wall nailed to the face of the spatially displaced second row of studs. Subsequent to the affixation of the exterior sheathing to the first row of studs a polyurethane foam is sprayed into the stud cavities formed by the exterior wall sheathing and first row of studs. The foam overlaps the studs to present an uninterrupted sheet of cured form extending among the stud cavities and interposed between the first and second rows of studs so as to isolate the same. Fiberglass batt insulation is then placed between the studs of the second row with a vapor barrier and conventional interior wall sheathing then applied to the faces of the second row of studs.
The use of first and second rows of studs interrupts the extension of the studs between the exterior and interior walls and any accompanying thermal flow therethrough. The continuous, serpentine polyurethane sheet presents an air impervious barrier with the overlapping portions between the stud cavities transversely blocking any thermal flow through cracks or crevices presented upon separation of the cured foam from the studs. Finally the use of the fiberglass batts cost-effectively enhances the R-value of the wall construction. Accordingly, a wall assembly generally impervious to air infiltration and having an R-value approximating 30 is presented.
It is therefore a general object of this invention to provide a wall assembly offering a high degree of resistance to air infiltration and thermal flow therethrough.
Another object of this invention is to provide a wall assembly, as aforesaid, utilizing longitudinally and laterally offset first and second rows of wall-supporting studs for insertion of selected insulating materials therebetween.
A further object of this invention is to provide a wall assembly, as aforesaid, utilizing first and second severally insulated wall sections cooperating to present a jointly insulated wall.
Still another object of this invention is to provide a wall assembly, as aforesaid, utilizing an uninterrupted, spray-applied, insulative foam in one of the wall sections.
Another object of this invention is to provide a wall assembly, as aforesaid, which diminishes the effect of separation of the insulative material from the supporting studs.
A more particular object of this invention is to provide a wall assembly, as aforesaid, which interrupts the thermal flow between the interior and exterior walls via the supporting studs.
Other objects and advantages of this invention will become apparent from the following description taken in connection with the accompanying drawings, wherein is set forth by way of illustration and example, and embodiment of this invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a portion of the wall assembly with portions of the first and second insulating materials, vapor barrier and interior wall broken away to show the cooperation of elements of the wall assembly.
FIG. 2 is a sectional elevation end view of the wall assembly of FIG. 1 extending between the floor and ceiling of a house.
FIG. 3 is a sectional plan view, taken along line 3--3 in FIG. 2, and showing the cooperating elements of the wall assembly.
FIG. 4 is a sectional plan view illustrating a corner construction for intersecting wall assemblies.
FIG. 5 is a sectional plan view illustrating the tie-in of an interior room wall with a wall assembly.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring more particularly to drawings, FIG. 1 illustrates a longitudinal portion of the wall assembly 10. The wall assembly 10 comprises first and second wall sections which respectively include inside and outside rows of studs 12, 14, as best illustrated in FIG. 3, extending between a 2×6 sole plate 16 and 2×6 header plates 18. 2×3 studs 20 of the outside row 14 of studs extend between the outside lateral portions of the sole 16 and header plates 18. Sole plate 16 is nailed atop a horizontal sheet of tongue and groove plywood 54 presenting the sub floor or the room. This sub floor 54 is positioned atop a rim joist 56 which is affixed to a sill plate 58 lying atop the foundation wall 60. Each stud 20 presents narrow nailing faces 22, 24 and web faces 26 and 28 and are spaced-apart on two foot centers along the longitudinal extent of the sole 16 and header 18 plates.
The inside row 12 of studs 30 are 2×4 in dimension and are longitudinally displaced on two foot centers along the length of the sole 16 and header 18 plates. This inside stud row 12 is also laterally displaced from stud row 14 and longitudinally offset (one foot) therefrom. This spatial offset centers the studs 30 between the studs 20 so as to present one foot longitudinal displacements between the outside 20 and inside studs 30. Each stud 30 presents nailing faces 32, 34 and web faces 36 and 38 with nailing face 32 extending into the space spanning adjacent studs 20 of stud row 14.
Affixed to the nailing faces 22 of studs 20 is exterior wall sheathing 42 in the form of sheets of polystyrene bead board, 5/8" thermax board (R-value=5) or the like. In my present embodiment rough sawn siding 43 (3/8") is then applied thereto with the finished exterior siding then placed thereon.
The affixed sheathing 42 forms open stud cavities 50 as vertically defined by the opposed web faces 26, 28 of each pair of adjacent outside studs 20. These cavities 50 are filled with two inches of a sprayed-applied polystyrene foam 61 having an R-value of at least R-13. An example of such an insulation is a polyurethane foam known as RESINATE™ insulation available from the UpJohn Company. The applicator sprays the foam along the opposed web faces 26, 28 of the stud cavity 50 and into the interior of the cavity 50. The sprayed foam rises along the web faces as well as in the stud cavity 50 so as to fill the same.
A sufficient amount of foam is sprayed along the web faces so that upon its normal expansion the foam overlaps the nailing faces 24. This overlap 52 interconnects the cured foam 61 between the adjacent stud cavities 50 which diminishes the effects of any separation of the foam 61 away from the web faces 26, 28 of the studs 20 as a thermal barrier 52 transversing these faces is presented. Accordingly, any lateral air infiltration through gaps arising along the web faces 26, 28 is blocked by this foldover 52. Also as the first row 12 of studs 20 is isolated from the second row 14 of studs 30 no continuous thermal path between the interior and exterior walls via the interposed studs 20, 30 is presented.
Subsequent to spraying, fiberglass batts 60 (R-value=19) are conventionally placed between the opposing faces 36, 38 of the adjacent interior studs 30. It is here noted that such batts 60 being less expensive than the above-described foam 61, are utilized to address the cost of the entire wall assembly 10. A continuous plastic sheet 66 is then applied to the faces 34 of studs 30 so as to present a vapor barrier precluding the passage of damaging moisture therethrough. The paper backing 62 of the batt insulation 60 has been scored 64 to preclude any vapor buildup therebetween. Wall board 70 or the like is then affixed to the nailing face 34 of the studs 30 and conventionally finished to present a second insulated wall section in a side-by-side relationship with the first wall section as above-described.
As shown, it is preferred that the insulation batts 60 of the second wall section contact the polyurethane foam 61 of the first wall section to preclude any gaps therebetween. Also it is preferred that the foam 61 contacts the nailing face 32 of the stud 30 which extends into each cavity 50 so as to preclude any spatial displacement therebetween. Otherwise the temperature differences between the outside and inside walls can promote the appearance of rising hot air and falling cold air in these gaps so as to create convection currents flowing therein. Such air infiltration and/or currents can degrade the overall R-value of the wall assembly 10.
Thus, as best illustrated in FIG. 3, a first wall section including a continuous, serpentine sheet of cured polyurethane foam extending among the stud cavities 50 and between the rows 12, 14 of studs 30, 20 is presented. This first wall section cooperates with the above-described second wall section to present an air impervious wall assembly 10 (R-value=30) which effectively inhibits any air infiltration and cost-effectively resists thermal flow between the interior 70 and exterior sheathings 42, 43.
FIGS. 4 and 5 illustrate the utilization of my wall assembly 10 in corner wall construction (FIG. 4) and interior wall-tie construction (FIG. 5). As illustrated in FIG. 4, the corner studs 20a and 30a are normally butted together to present inside and outside bracing for nailing the sheathing and wall board thereto. The wall-tie construction is illustrated in FIG. 5. An interior 2×6 stud 29 replaces the normal stud 30 and is positioned as shown to allow a 2×4 interior wall stud 31 to be nailed thereto. On the opposed side of the interior stud 30 a 2×3 bracing stud 27 is provided. The foam 61 is then sprayed along the corner bracing (FIG. 4) and wall-tie bracing (FIG. 5) so as to fill the surrounding space as respectively shown in FIGS. 4 and 5. Subsequent to spraying the insulation batts 60 are placed between the adjacent studs in a manner as above described.
It is to be understood that while certain forms of this invention have been illustrated and described, it is not limited thereto, except in so far as such limitations are included in the following claims.
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A wall assembly comprising exterior and interior severally insulated wall sections combined to present a jointly insulated wall. A continuous sheath of cured foam insulates the exterior wall section and isolates the bracing studs therein from those of the interior wall section. The latter section is insulated with conventional fiberglass batts and is laterally adjacent the first wall section resulting in a jointly insulated common wall assembly impervious to air infiltration and highly resistant to thermal flow therethrough.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
FIELD OF THE INVENTION
[0001] The present invention relates to a socket mounted post system. More specifically, the present invention is a crowd control stanchion including a spring mechanism and a miniature socket mounted post that provides for easy installation in a floor with minimal impact to the surface of the floors. The post could alternatively be used in connection with panels, railings, signage, bollards or other types of posts.
BACKGROUND OF THE INVENTION
[0002] A stanchion is a sturdy upright post that provides support for belt, rope, chain or cord that is often used for crowd control or engineering the flow of people. A stanchion system utilizes the upright post which may include a rope support at the top of the post; or, alternatively, it may include a retractable belt. The ropes, chains or retractable belts may be linked together at the stanchions to form a crowd control or crowd flow system. These crowd flow systems are called a queue or a maze. The stanchions are often not intended to be a permanent fixture, so that the post may be expediently implemented or removed, as desired. The stanchion and rope system are typically implemented to form a queue or maze for people to move through.
[0003] Typically, the post of a stanchion is typically mounted on a weighted base. There are several problems with a post that is mounted on a weighted base. First, the base often protrudes into the area of the queue or maze in which people walk—often times causing people to trip on the base. Second, the weighted base is movable. If bumped, the base along with the ropes or belts will move causing the queue to become misaligned. Movement of the post interferes with the movement of traffic through the queue. Third, the base takes up valuable floor space and often interferes with movement of carts or language through the queue. The standard base for a stanchion post has a footprint of almost one square foot which is not desirable in space—constrained areas. When several stanchions are employed, the amount of floor space dedicated to the numerous bases becomes quite significant. Fourth, the base is not aesthetically pleasing and may be considered unacceptable given the aesthetic desire of customers. The design of the weighed bases may not be preferred by the owner of the venue implementing the queue. Fifth, the post, along with the base, may be knocked over because the base is not securely mounted to the floor. Finally, since the base and post are not secured to the floor, the base and post may be picked up by a patron and used as a weapon. This is undesirable in any public forum. A typical prior art weighted base stanchion is shown in FIGS. 1( a ) and 1( b ) .
[0004] Alternatively, the post of the stanchion may be easily removablely mounted into the floor of the facility implementing the queue or maze. The floor mounted posts are commonly implemented in applications where the flow of traffic is steady or constant or where portability of the stanchions becomes impractical. The floor mounted solution is not without its own set of problems. For example, the stanchion posts must be mounted into holes in the floor of the venue which are either pre-formed or drilled into the floor after construction. The floor mounted system is not flexible or moveable. The posts can only be positioned within the pre-formed holes within a venue. Worse, the hole depth must be 6 inches or more in order to accommodate the post; and the diameter of the hole is typically 2 to 3 inches or more. The posts are also easily removable and can be used as a weapon by a customer standing in the queue. Finally, in the floor mounted system, the posts are not flexible. The post does not absorb any impact should a person run into a post, or if a piece of luggage or cart is run into a post. Another problem with the easily removeable stanchion post is that when the post is removed, there is a 3 inch diameter by 6 inch deep hole left in the floor.
[0005] What is desired, therefore, is a post which may be semi-permanently mounted within the floor of a venue without having to install the standard 3 inch by 6 inch hole deep into the floor. There is also a need for a flexible mounting system between the post and the floor which permits the post to absorb impact to the post. It is, thus, desirable to have a semi-permanent post that has minimal impact on the existing flooring of a venue. Providing a post that is easy to install and that has the ability to flex once installed into the floor is highly desirable.
SUMMARY OF THE INVENTION
[0006] Accordingly, one of the objects of the invention is to provide a post that does not have a weighted base which provides a cleaner aesthetic and further provides maximum floor space.
[0007] A further object of the invention is to eliminate a weighted base from the post to prevent luggage from rolling over the base and moving the post from its desired position.
[0008] Another object of the present invention is to provide a semi-permanent securing mechanism to affix the post to the ground which prevents the post from shifting or moving from its desired position in securing the queue or maze and thus causing disorder in the queue lines.
[0009] An alternative embodiment of the present invention is to implement a threaded member in the post such that the threaded member engages with threads with the floor to prevent unwanted removal of the post, yet are easily removable for cleaning, re-routing or other reasons for moving the post.
[0010] An object of the present invention provides for a spring mechanism that is attached to or included as part of the post to permit the post to move from its vertical position when the post is secured to the mount in the floor. The movement may be any amount, but in situations where there may be an abundance of people, the post may move from the vertical position. The flexibility of the spring mechanism absorbs any impact forces impaired upon the post which can cause an anchor or threaded member to fail.
[0011] A further object of the present invention is the use of two interfering tabs which allow for approximately 350 degree adjustment, yet ensure the tension in the spring and securement into the socket to remain intact. This is important for queue posts because the belts must align in some undetermined direction for each layout. The belts may be aligned upon installation of the post, and may be easily rotated to change the configuration of the queue.
[0012] Since there is expected movement in the post from the flex and rotational adjustment the edge of the metal posts can cause damage to floors over time. With the addition of a thick nylon wear disc or other protective cap, the floor is protected and all friction from the movement is removed allowing for a softer and smoother functioning unit.
BRIEF DESCRIPTION OF THE FIGURES
[0013] FIGS. 1( a ) and 1( b ) are perspective views of the prior art stanchions;
[0014] FIG. 2 is a perspective view of the stanchion system of the present invention implemented to form a queue;
[0015] FIG. 3( a ) is a side view of the spring loaded post mounted in the socket in the flooring;
[0016] FIG. 3( b ) is a side view of the spring loaded post mounted in the socket in the floor at a 10° tilt;
[0017] FIG. 4( a ) is a perspective view of the floor socket;
[0018] FIG. 4( b ) is a cross-section of the floor socket;
[0019] FIG. 5 is a perspective view of the spring loaded base assembly of an embodiment of the present invention;
[0020] FIG. 6( a ) is a cross section view of a spring loaded base assembly of an embodiment of the present invention;
[0021] FIG. 6( b ) is a bottom view of a spring loaded base assembly;
[0022] FIG. 7( a ) is a perspective view of an alternative mini socket with a flange and cap; and
[0023] FIG. 7( b ) is a cross-section of an alternative floor socket with a flange and cap having a threaded groove.
DETAILED DESCRIPTION OF THE INVENTION
[0024] FIGS. 1( a ) and 1( b ) depict the prior art stanchion post designs. In FIG. 1( a ) , a prior art stanchion post 10 has a top portion 12 that may include a retractable belt 34 or alternatively a standard velvet rope with hook (not shown) or a sign (not shown). The post 14 is typically of cylindrical shape, but could be any shape. The bottom portion of the post 14 includes an insert portion 50 that is approximately 3 inches in diameter and 6 inches in depth. The insert portion 50 is placed into a hole 60 in the floor 20 that is approximately 3 inches in diameter and 6 inches deep. The removable base requires a workable area of 3 inch diameter by 6 inch deep floor. The large hole poses a problem in airports or other large venues since those venues typically have thin decking that contains reinforcing members, electrical conduit, and plumbing on other items running below the surface of the floor. If the removeably mounted post option is even feasible after initial construction, contractors must carefully x-ray the floor to determine what structural supports or utilities may be located in the floor. Often the posts must be re-adjusted accordingly to the location of the utilities. If the sockets are set in the floor during initial construction, the configuration of the queue must be known at the time of construction. It is very difficult to change the configuration of the queue, once the socket is permanently mounted in the flooring.
[0025] The larger sockets have at least a 3 inch diameter raised flange which is unsightly and becomes a potential tripping hazard. Often times building owners will want the holes for the stanchions to be removed and the floors repaired, thus, adding more cost to the system.
[0026] The prior art stanchion 10 has no method of securing the insert portion 50 of the post 14 to the hole 60 . There is a simple slip-fit of the insert portion 50 into the top 62 of the floor hole 60 . The posts can easily be removed by unauthorized individuals. There have been times where posts have been used as weapons. The prior art systems are more prone to that risk. A cap 64 may be placed in the top 62 of the hole 60 .
[0027] A second prior art embodiment is shown in FIG. 1( b ) . The prior art stanchion 10 is shown with a removable, weighted base 22 that was positioned on the floor 20 . The top 12 of the post 14 may have a retractable belt member 30 that houses a retractable belt 34 . The retractable belt member 30 is typically mounted at the top portion 12 of the stanchion 10 or may be inserted within the top portion 12 of the post 14 . The retractable belt member 30 has a retractable belt 34 which includes a coupling 33 . The retractable belt member 30 also has a receiving coupling 32 that mates with a coupling 33 of the retractable belt 34 . A problem with the prior art stanchion 10 of FIG. 1( b ) is that the weighted base 22 may move on the floor 20 . Additionally, customers may trip on the weighted based 22 of the stanchion 10 .
[0028] FIG. 2 depicts the flexible stanchion 110 of the present invention forming a queue or a maze. The flexible stanchions 110 are mounted in the floor 120 at a predetermined distance from one another. The top 112 of the stanchion includes a retractable belt member 130 . The retractable belt member 130 may have a retractable belt 134 that is 10 feet, 15 feet or 30 feet in length depending on the application. The coupling 32 of the retractable 34 may be coupled to the coupling 32 located on the retractable belt member 130 . The retractable belts 134 are connected in such a fashion to form a queue.
[0029] FIGS. 3( a ) and 3( b ) depict the flexible stanchion 110 of the present invention. The flexible stanchion 110 includes a post 114 with a top portion 112 and bottom portion 116 . On the top portion 112 of the post 114 may include a retractable belt cap 130 . The retractable belt cap 130 includes at least one belt 134 which is used to form a queue line. The belt 134 may be retractable into the belt cap 130 . The belt 130 further has a coupling 133 at one end. The coupling of the belt 133 may be affixed to a receptacle portion 132 (or coupling) of the top portion 130 of a flexible stanchion 110 . The retractable belt cap 130 is sold under the Retracta Belt® trade name. While the preferred embodiment may include a retractable belt, other types of features may be mounted to the post 114 . For example, the post 114 could accommodate a standard velvet rope and classic latch mechanism. The post 114 could also accommodate either sign frame or engraved color sign, alone or in combination with the retractable belt cap 130 . The system of the invention may be used for any post system such as sign posts, TV stands, airports mount TV's to show flight information, railing systems, panel systems, banner systems, any type of barrier. The description in the preferred embodiment focuses on stanchion posts. However, it is important to recognize that, while the detailed description focuses on stanchion posts, the invention may apply to any type of post.
[0030] The lower portion of the post 114 includes a spring assembly 300 and base cap 140 . The spring assembly is described in more detail below with respect to FIGS. 5 and 6 . The base cap 140 can be made of any rigid or semi-rigid material, but preferably is manufactured from a nylon disk. The nylon disk prevents the post from scratching the floor 120 upon installation. The base cap 140 could also include some type of non-scratch surface coating to prevent the disc from marking the floor 120 .
[0031] The flexible stanchion 110 may be mounted in a wide range of floor 120 materials. As shown in FIG. 3( b ) , the flexible stanchion 110 includes a pillar 150 that protrudes from the base cap 140 . The pillar 150 is inserted into a socket 160 installed in the floor 120 . The pillar 150 will be described in more detail later. Referring now to FIG. 3( b ) , the pillar 150 is part of a spring mechanism 300 that permits the post 110 to move a predetermined amount form its vertical position 180 in order to absorb accidental impact caused by pedestrians or luggage. The preferred angular travel 190 of the post 114 from its vertical position is no more than 10 degrees from the vertical position 180 . It must be noted that the degree of travel 170 of the post 114 is not necessarily limited to 10 degrees from the vertical position. The degree of travel could, for example, be up to 90 degrees from the vertical position 180 such that the post 114 is essentially parallel with the floor 120 . The reason it may be advantageous for the post 114 to travel only 10 degrees from is to prevent accidental rebound of the post 114 to the vertical position 180 . The flexibility in the post 114 prevents the accidental fracture of the flexible pillar 150 from spring mechanism of the post 114 .
[0032] The post 114 is typically between 40 inches to 72 inches in height. Because of the height of the post 114 , accidental contact with the flexible stanchion 110 , may cause exceedingly high torsion force to be placed on the pillar 150 . The pillar 150 has a smaller diameter than the post 114 . As such, the torsional force placed upon the pillar 150 can overcome the shear strength of the pillar 150 material causing the pillar 150 to structurally fail. In some instances, any more than 10 degrees of travel may cause the post 114 to snap back to the vertical position 170 and injure a person.
[0033] FIGS. 4( a ) and 4( b ) depict an embodiment of the floor socket 200 of the present invention. In FIG. 4( a ) , the floor socket 200 generally is a cylindrical shaped insert having an outer wall 202 and an inner wall 204 . The floor socket 200 is typically made of a stainless steel but could be made of any suitable material including brass, steel and possibly rubber, PVC or HDPE. The preferred size of the floor socket is ⅞ inch in diameter by 1⅞ inch depth. The outer wall 202 of the floor socket 200 may have a diamond knurl 205 design. Alternatively, the floor socket 200 may have a beveled design in the outer wall 202 . The purpose of having a design in the outer wall 202 of the floor socket 200 is to permit a frictional fit between the socket 200 and the cavity drilled into floor 120 to receive the socket 200 . Alternatively, the diamond kurl 205 and beveled design permit a better bond between the socket 200 and the cavity 170 if an adhesive is used.
[0034] The socket 200 may be up to 4 inches in depth. The benefit of having a socket approximately 2 inches to 4 inches in depth is that there is less chance of contacting decking rebars, electrical supply lines, plumbing or other utilities running below the surface of the floor. The floor socket 200 is typically installed into a preexisting floor 120 . A hole is drilled into the pre-existing floor that is slightly larger size of the floor socket 200 . In an alternative embodiment, the floor socket 200 may be coated with an adhesive and inserted into the hole in the floor such that the top surface of the socket 200 is flush with the surface of the floor 120 . The installation may take as little as 10 minutes per hole, whereas the installation of the standard removable base designs of the prior art would take more than 60 minutes per hole to install. Installation of the socket includes the following steps:
Lay out socket locations, spacing the centerlines at least 6″ less than belt length (ex: 9′6″ or less with 10′ belt); Drill ¾″ hole 170 approximately 2″ deep. A core drill mounted in a stand gives the straightest hole and the cleanest edges for a flush mount socket; Clean out and dry hole 170 ; Inject epoxy into bottom and sides of hole 170 ; Insert socket 200 flush with floor (tap with hammer if required); and Wait for epoxy to cure before installing posts 110 .
Alternatively, socket 200 designs may include:
1) Tapered drive pin which would flare out the bottom of the socket 200 when hammered into a hole in the floor; 2) Threaded screw that drives into a tapered hole, thus spreading the bottom of the socket; and 3) Outside slip collar.
[0044] Often queue layouts may change over time. Additionally, a vendor may prefer to have more than one queue design installed in an existing space. The smaller diameter hole is less intrusive in those scenarios where the queue layouts may change. Even after the installation of the floor socket is complete, it is still easy to modify a layout. The ⅞ inch socket 200 mounts nearly flush to the ground. The socket 200 may include threads 208 to receive either a pillar 150 that has corresponding threads or a socket cap ( FIG. 7( a ) ). The socket 200 does not have to incorporate threads 208 on the interior wall. The floor socket 200 may have a threaded 208 inside wall to receive a thread bolt on the interior wall of the floor socket 200 . The floor socket 200 is unobtrusive and can be left in the ground without further floor repairs. The larger sockets have a 3 inch diameter raised flange which is unsightly and becomes a potential tripping hazard. Often times, building owners will want these to be removed and the floors repaired, adding more cost to the system.
[0045] FIGS. 5 and 6 shows the spring-loaded assembly 300 of the preferred embodiment of invention. The spring-loaded assembly 300 may be positioned within the hollow post 114 of the stanchion 110 described in FIGS. 2 and 3 . Alternatively, it may be attached to the bottom of the post 114 as an attachment to preexisting post. The preferred embodiment of spring-loaded assembly 300 comprises a hex bolt 302 having threads 303 that supports one or more washers 304 . The fully hex bolt 302 has a hexagonal head 301 . The fully hex bolt 302 is preferably a ⅝-11×3½ inch threaded bolt. The spring-loaded assembly 300 may include a hollow tube 306 positioned below the 2 inch steel washers 304 on the threads 303 of the hex bolt 302 , but it is not necessary. The tubing 306 made of polyethylene but could be made out of any suitable material, such as metal, rubber or the like. Situated outside the tubing 306 is a spring 308 . The spring 308 is preferably a compression spring (0.195 wire, 1.5 freeL, 0.945 solid L). The compression may be preloaded 5.5 turns to a set height of 1.0 inches 309 . The compression spring 308 is a helical spring member in the preferred embodiment. While a helical spring is described here, there are other types of springs that may be used with this invention. For example, the spring 308 could alternatively be a tension spring, a leaf spring, or torsional spring that creates a tension on the hex bolt 302 to provide angular movement of the post 314 from the vertical position 180 . The important feature of the spring 308 is that it places sufficient tension on the post to permit the post 314 to move from the vertical position 180 but limits the range of movement of the post 314 . In the current invention, when a force is placed against the post 314 , the hex bolt 302 does not move. Instead, one side of the spring 308 is compressed while the opposing side of the spring 308 is expanded. Thus, the post 314 may move from its vertical position until either the spring 308 reaches the maximum compression force rated for a particular spring 308 , or the washers 304 contact the inside portion of the cup member 310 or the post 314 . In either event, the distance the post may move from its vertical position is limited by the spring assembly 300 .
[0046] There are embodiments of the current invention that do not require a spring 308 . For example, a rubber block may be used in place of a compression spring to add flexibility to the post 114 . Also, a series of belleville washers may be utilized in place of a spring 308 . The spring may be tensioned to constrain movement of the post 114 to no more than 10 degrees from the vertical position 180 . However, the reason for a limitation of movement to no more than 10 degrees from vertical is to prevent accidental snap-back of the post. That is not a requirement of all applications. In fact, in some instances, it may be desirable that the post 114 extend to a substantially parallel position with respect to the floor.
[0047] The preferred method of assembly of the spring loaded assembly 300 comprises the steps of selecting the hex bolt 302 and one or more washers onto the hex bolt 302 . Next, a washer is made of a thermoplastic material, such as delrin, is placed on the hex bolt 302 . A tube 306 surrounded by the helical spring 308 are positioned on the hex bolt 302 . A second thermoplastic washer 390 is placed on the hex bolt 302 as the hex bolt 302 is inserted through a hole 341 in the disc member 340 .
[0048] A nylon lock nut 320 has a pin, tab or set screw 322 . The nylon lock nut 320 is tightened until the spring 308 becomes loaded. In the preferred embodiment, a force is applied to the spring 308 by the nylon lock nut 320 at which time the lock nut 320 is turned 5½ turns. At this point, the disc 340 is installed on the shaft 301 such that approximately two to four inches of the hex bolt 302 extends beyond the disc 340 . The cup member 310 is mounted to the bottom portion of the post 314 . Alternatively, the cup member 310 could be inserted inside a hollow end of the bottom portion 316 of the post 314 and secured to the post 314 . Finally, the cup member 310 could be eliminated completely, and the spring would be affixed to the inside wall of the post 314 .
[0049] The spring-loaded assembly 300 includes a cup member 310 . The cup member 310 is a cylindrical hollow H-cup having a flange 312 including a centered hole 311 to receive the threaded hex bolt 302 . The flange 312 receives at least a portion of the threaded hex bolt 302 , the washers 304 and the compression spring 308 . The flange 312 of the cup member 310 has a hole 314 to receive a space screw 316 . Alternatively, the flange 312 could be fixed directly to the inside wall of the post 314 .
[0050] Positioned below the flange portion 312 of the cup member 310 and adjustably affixed to the hex bolt 302 is a nylon lock nut 320 . The nylon lock nut 320 includes a hole for receiving a space screw 322 with lock washers. The set screw 322 may be tightened to secure the nylon lock nut 320 to the threaded hex bolt 302 . The set screw 322 in the locknut 320 and the set screw 324 in the flange 312 provide for a 350 degree rotation of the post 314 upon installation of the post into the floor 340 . The set screws 322 and 324 are positioned such that the two set screws 322 and 324 interfere with the rotational movement of the post 314 and hex bolt 302 upon installation of the post 314 . As the finger portion 350 is threaded into the threads 208 of the socket 200 , the friction between the threads on the finger portion 350 and the threads 208 of the socket 200 cause the hex bolt 302 to rotate with the set screw 322 until the set screw 322 contacts the second set screw 324 . The contact between the set screws 316 and 322 causes the hex bolt 302 to rotate with the post 314 , such that the finger 350 is threaded into the socket 200 . Once the disc 340 contacts the floor 340 , the post 314 will cease rotation due to contact between the set screws 322 and 324 . Rotation of the post 314 can then be reversed to back out from the pillar socket 200 up to a 350 degree rotation at which point the set screws 322 and 324 again contact each other. The 350 degree of rotation is important because it permits the cap 130 of the post 110 to be aligned with the cap 130 of another post. The coupling 132 of one post 110 may be aligned with coupling 133 and retractable belt 131 of a second post 110 to form a queue as shown in FIG. 2 . While the preferred embodiment uses set screws 324 and 322 ; tab, pins, notches or the like could be used in place of the set screws 322 and 324 .
[0051] There is a base disc 340 that has a hole with threads 341 . The disc 340 is threaded onto the threads 303 of the hex bolt. The base cap 340 serves two purposes: (1) it prevents the cup member 310 and post 314 from scratching the floor 120 and (2) it protects the inner elements of the spring-loaded assembly 300 . There is a portion of the bottom of the threaded hex bolt 302 that extends beyond the disc 340 . The finger 350 may be threaded 330 as shown in FIGS. 5 and 6 . Alternatively, the finger 350 may not have threads. The threaded portion of the finger 350 mate with the threaded inside portion 208 of the socket 200 such that the finger 350 may be securely fastened 350 to the socket 200 by rotating the post 114 such that the bottom disc 341 meets the floor 120 .
[0052] The spring-loaded assembly 300 permits the post 314 to lean approximately 10 from the vertical position 180 . The spring-loaded assembly 300 permits movement of the post 314 in order to absorb impact from contact with the post 314 from carts, or the like, which would impact the force onto the finger 350 engaged with the socket 160 . The post 110 may be positioned on the floor 120 by aligning the pillar 316 with the opening 220 of the socket 200 . The pillar 316 is inserted into the opening 220 of the socket 200 and adjusted to a vertical position 180 . If the pillar 316 is threaded, the pillar 316 is aligned with the threads 208 of the socket 200 . The post 314 is rotated such that the threads of the pillar 316 engage the threads 208 of the socket 200 . The post 314 is rotated until the disc 340 contacts the floor 120 and the post 314 is in a vertical position 180 at 90 degrees in relation to the plane of the floor 120 . The post 314 can be rotated an additional plus or minus 350 degrees from the point the disc 340 contacts the floor 120 to align the belts on the retractable member 130 or to change the queue configuration. To remove the stanchion from the socket 200 , the post 314 is rotated until the threads of the finger 350 are disengaged from the threads of the socket 200 .
[0053] If desired, a cap 490 , may be secured to the socket 400 by engaging the threads 491 of the cap 490 with the threads 408 of the socket 400 as shown in FIGS. 7( a ) and 7( b ) . One benefit of the design of the preferred embodiment is that the cap 490 may be threaded into socket 200 . Other larger sockets just have slip fit caps which can easily be removed with no tools. The preferred embodiment requires a maintenance person to use a key (in our case an Allen key) to lock the cap 490 into place.
[0054] Although the invention has been described with reference to a particular arrangement of parts, features and the like, these are not intended to exhaust all possible arrangements or features, and indeed many other modifications and variations will be ascertainable to those of skill in the art.
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A socket mounted post system including a post with a hollow base portion attached to a spring mechanism. The spring mechanism includes a pillar, the pillar having a finger extending from the hollow base portion. The finger is engageable with a socket that is mountable in a floor. The spring mechanism allows the post to flex angularly relative to a vertical orientation of the post.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Patent Application No. 60/802,171, filed May 22, 2006, the contents of which are hereby incorporated herein by reference in their entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates to building closures, such as doors and windows, in general, and relates to fireproof closures in particular.
[0004] 2. Related Art
[0005] A fireproof door or window is a self-closing barrier designed to prevent the penetration of fire and smoke in through openings in walls for a given period of time. As used herein, the term “fireproof” refers to this ability to prevent the penetration of fire and smoke in through openings in walls for a given period of time, and not to any absolute ability to stop fires from spreading for an extended time.
[0006] There are many types of fireproof doors which are currently available. These doors are entitled to a fireproof rating based on criteria established by various standards setting organizations, such as the Underwriter's Laboratories, Inc. (UL). Typically, the doors must pass a burn test that is applied to one side of a door at a specified high temperature for a certain period of time while keeping heat from the other side of the door. However, in addition to keeping out the heat, in practical applications the doors must also keep smoke from passing through the door opening. As is well known, it is usually smoke inhalation that people die from in fires. Both requirements are difficult to achieve while at the same time retaining the primary function of a door, which is to be operable to permit egress between the spaces the door divides. If the door is too tight against its frame, then it is difficult to operate. If the door is made of a nonflammable material, such as metal or concrete, then it becomes heavy and is usually not conducive to a decorative environment. Thus, as with most doors, there is always a compromise in door thickness, materials and overall weight in order to achieve a certain level of fireproofing (for example, a fire-resistance time, such as 90 minutes).
[0007] Prior art fireproof doors usually include an exterior frame and covering with an internal core. Such doors can use an internal insulation layer consisting of compressed fireproof materials which practically fill out the space within the frame of the door. These known fireproof doors are relatively expensive and can be so heavy in weight that they can be opened and closed only with extreme effort. Another type of door uses an insulation layer made of an elastic, flexible, fireproof textile fabric fixed inside of a metal frame. See for example U.S. Pat. No. 4,270,326, which is incorporated herein by reference in its entirety.
[0008] Some modern fire proof doors use an intumescent material, such as one made from hydrated sodium silicate, which expands with the development of foaming pressure as a reaction to heat. Other intumescent materials include foaming/expanding graphite; and poly-ammonium phosphates. When heated, such as by a fire, a fine-porous, compression-resistant, non-combustible, and heat-sealing foam is formed. This foam fills joints and gaps in the immediate vicinity, and thus prevents the penetration of fire and smoke for a certain period of time. The material can be obtained commercially in sheets, or can be “blown in” as a powder. For example, this material has been used as an edge band in regular doors and French doors, so as to seal the space between a closed door and its frame where there is a fire. Thus, where intumescent strips or sections of the material have been attached onto or inserted into the edges of wooden or steel doors, gateways, and flaps, in the event of a fire, they rapidly expand and reliably seal off joints and gaps in a short time.
[0009] Most fire proof doors are solid, because the prior art teaches that the thicker the door, the greater will be the effectiveness of the door as a fire door, and consequently the greater will be the fire rating. Unfortunately, thicker doors and solid doors are often heavy, and can be expensive. Also, the artistic level of such doors is also quite limited. For example, there is a teaching away from the use of doors that have louvers and other ventilation structures, since ventilation openings are thought to make a door unusable as a fireproof door. Conventional wisdom suggests that a louvered or otherwise ventilated or vent-providing, door cannot function as an effective fire door. There is no known louvered door that can be thought of, much less labeled as, a wooden fireproof louver door. Moreover no louver itself are known to have been fire-rated and installed in a fireproof door.
SUMMARY OF THE INVENTION
[0010] The presently disclosed apparatus, systems, and methods solve the problem of providing a door with both a ventilation function and a fireproof function. The present disclosure teaches a door that can be economically manufactured. Such a door is attractive and readily available for decorative applications, provides the expected air flow during normal times, is rugged and solid, yet is relatively light weight for a fire proof door. The present disclosure, for the first time, teaches a fireproof louvered door.
[0011] The present disclosure teaches a fireproof louver panel that comprises a panel frame and a plurality of longitudinally extending slats attached to the panel frame. One or more of the slats comprises a shell and an intumescent layer that expands under heat to form an airtight seal. In some aspects, the longitudinally extending slats have a thickness, angle, and spacing sufficient to form said airtight seal when subjected to heat. As non-limiting examples, the thickness may be from 0.05 to 0.5 inches, or may be about 0.25 inches, the angle may be from about 30 degrees to 75 degrees, or may be about 60 degrees, and the spacing may be from 0.05 to 0.5 inches, or may be about 0.25 inches.
[0012] In some aspects, the longitudinally extending slats are perpendicular to the plane of the door and have a thickness and spacing sufficient to form an airtight seal when subjected to heat. In some aspects, the shell comprises at least one opening through which the intumescent layer expands under heat. The opening may be shaped to cause the intumescent layer, when under heat, to expand in the plane of the door. In some aspects, the shell breaks open when the intumescent layer expands under heat. In some aspects, the intumescent layer is inside an inner cavity of the shell.
[0013] In some aspects, the shell has an upper layer and a lower layer, and the slat comprises an outer skin which surrounds the upper layer, the lower layer, and the intumescent material. In some aspects, the outer skin comprises a wrapping material structurally configured to open at a chosen location during expansion of the intumescent layer.
[0014] The intumescent material may, as non-limiting examples, be selected from hydrated sodium silicate; foaming graphite; expanding graphite; poly-ammonium phosphates; and combinations thereof.
[0015] In some aspects, the intumescent material forms a non-combustible heat-sealing foam when heated. In some aspects, the slats are jalousie-type slats.
[0016] The present disclosure also teaches a fireproof door having an external frame, an internal core of a fireproof material (among other materials), and a fireproof louver panel. In some aspects, a further intumescent layer is disposed at the outside of the external frame, and the intumescent material and the further intumescent material provide an airtight seal extending beyond the dimensions of the external frame. In some aspects, the door has a window disposed in a window opening, and a fireproof louver panel is disposed in the window opening adjacent the window.
[0017] The present disclosure further teaches a fireproof window having an external frame, a flat translucent internal core of a fireproof material (among other materials), and a fireproof louver panel adjacent a flat side of the flat translucent internal core.
[0018] The present disclosure teaches a method of fireproofing an opening. A movable fireproof closure is affixed in the opening. The closure has a first intumescent layer attached at the exterior of the closure and a panel frame within the closure. The panel frame has attached to it one or more longitudinally extending slats having second intumescent layer. Placement of the first and second intumescent layers is then configured so that the opening is sealed when the first intumescent layer and the second intumescent layer are both subjected to heat.
[0019] The present disclosure also teaches a system for fireproofing an opening in an otherwise fireproofed door. The system has means for supporting longitudinally extending slats in the opening; and means disposed within the slats for expanding under heat to form an airtight seal.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] With reference now to the drawings in which like numbers represent like elements throughout the several views:
[0021] FIG. 1 is a front perspective view of a door having a louver panel in both the upper door portion and the lower door portion;
[0022] FIG. 2 is front elevational view of a louver panel according to the present disclosure;
[0023] FIG. 3 is a schematic side elevational view showing the spacing and details of the louver slats;
[0024] FIG. 4 is an enlarged cross-sectional view of one of the louvers according to the present disclosure;
[0025] FIG. 5 is an enlarged perspective view of two seated louvers; and
[0026] FIG. 6 is an enlarged cross-sectional view of a second aspect of a louver panel in accordance with the present disclosure.
DETAILED DESCRIPTION
[0027] A louvered door 10 according to the present disclosure is depicted in FIG. 1 . Door 10 comprises a frame 12 , a door knob 14 , and upper and lower louver panels 16 and 18 , respectively, in accordance with the present disclosure. It is noted, however, that a louver panel may be placed in only the bottom of the door (as is traditionally done), in the top of the door, in both the bottom and top of the door, or any other region of the door. Door 10 can be made of any contemporary material such as wood, metal, plastic or fiber board. Further, door 10 can be of any style, such as the door depicted in FIG. 1 , or a panel door, or any other kind of door.
[0028] Louver panels 16 and 18 as shown are identical, and thus only panel 16 will be discussed further. As shown in FIG. 2 , panel 16 is comprised of a circumferential frame 20 and a bisecting vertical mid-support member 22 . Frame 20 has an upper and a lower board 24 and 26 , and a left and a right end board 28 and 30 that are rigidly, fixedly attached at their respective ends to the adjacent boards so as to form a unitary, rigid, rectangular, hollow frame. Mid-support member 22 has a number of openings (not shown) which extend completely through it in the longitudinal direction. Through each opening there is a longitudinally extending slat 32 that is embedded at each end thereof in corresponding openings in end boards 28 and 30 . Slats are rigidly fixed in end boards 28 and 30 in a conventional way, such as one or more of an adhesive or a mechanical fastener, such as nails, pins, staples, screws, and dowels. Alternatively, they can just be force-fitted into an appropriately sized opening 34 . Although slats 32 are depicted as being flat, they could also have an inverted “V” shape with equal length arms or different length arms, or be any other slat shape known in the art, so long as room is provided for expansion of the slat in at least one dimension, as will be described below.
[0029] Frame 20 is preferably made out of a good quality hardwood, such as oak, or maple, but it could also be made from High Density Fiberboard (HDF) or Medium Density Fiberboard (MDF) materials and covered with a veneer. In addition, frame 20 could be made of a metal or plastic material. An exemplary dimension of mid-support member 22 is a width of a quarter of an inch (0.25″) and a length that can vary with the design of louver 16 , but in FIG. 2 is 11.5 inches. Exemplary dimensions of top and bottom boards 24 and 26 members are a length of twenty-four inches and a thickness of a quarter of an inch. The width of member 22 and boards 24 , 26 , 28 and 30 are usually the same, varying with the thickness of door 10 , but are usually one inch to two inches. In FIG. 3 , board 30 may, as a non-limiting example, be 1.75 inches wide. Slats 32 are usually set at an angle with the horizontal so that one cannot see through door 10 . In FIG. 3 , this angle is sixty degrees (601) and the spacing or distance along a vertical line, such as line 36 , is 0.5 inches. Another popular angle of slats 32 is forty degrees (401), in which case the vertical spacing along a vertical line would be 0.653 inches. However, they could also be parallel to upper and lower boards 24 and 26 (that is, perpendicular to the plane of the door), as in the case when louver 16 is in a window opening. Slats 32 may be given a length of exactly that of frame 16 if they extend completely through end boards 28 and 30 , or a few sixteenths of an inch less if they do not, or any other necessary length. Slats 32 have an exemplary thickness of a quarter of an inch (0.25″) and a spacing of 0.125 inches, but as explained below, the spacing can vary depending upon the constitution of slat 32 and on any intumescent material therein. For example, in FIG. 3 , slats 32 have a spacing of a quarter of an inch (0.250″). The length of slats 32 in FIG. 3 is 1.75 inches, but that length will vary with the angle and the thickness of frame 20 . As shown in FIG. 4 , each slat 32 comprises a shell 40 and an inner stuffing 42 . Shell 40 completely surrounds stuffing 42 on five sides, but is open on one side. Shell 40 is preferably made of a hardwood, but could be made of a metal material, such as steel, or a plastic material. Such a plastic material, if used in a fire door, must be carefully chosen so as not to melt in a hot fire. This is also true of member 22 and boards 24 , 26 , 28 and 30 . Shell has an exemplary external length of 1.750 inches and an exemplary overall thickness of 0.25 inches. As shown in FIG. 4 , slat 32 has an inner cavity 44 in which stuffing 42 is contained. Inner cavity 44 has an exemplary length of 1.5 inches and thickness of 0.1875 inches. Thus, the thickness of shell 40 along the top thereof (as depicted in FIG. 4 ) is 0.0625 inches.
[0030] Stuffing 42 is preferably made of an appropriate intumescent material. This material expands when heated above a known temperature in one direction if the other directions are confined. A relatively large expansion force and impulse may be provided, depending upon the rate of expansion, which quickly and effectively seals the spaces between (and/or around) the slats. The distance of the expansion depends upon the material and the thickness of the material, as well as the shell material.
[0031] Making reference again to FIG. 2 , when louver panel 16 is subjected to heat, the intumescent material will expand and contact the adjacent slat, thereby forming an airtight seal. The spacing between slats and the type and thickness of the intumescent material are all selected to properly provide this seal. The top slat in panel 16 is sealed with upper board 24 and thus all of the expansions between slats occur in a downward direction. This is merely one example, however, the expansion may occur upwards, or both upwards and downwards, or in any other direction necessary to form a seal.
[0032] FIG. 5 depicts an aspect of an opening 34 in an end board 30 into which one or more louvers 32 may be seated. The end board 30 may be configured to allow the louvers 32 to move at an operator=s request, or when subjected to forces caused by expansion of the intumescent material. The end board 30 may alternatively hold the louvers 32 at a rigid angle, thereby helping direct any expansion of the intumescent material into place for forming a seal. FIG. 6 depicts an alternative aspect of a slat 50 . Slat 50 comprises an outer skin or layer 52 , which may be made of a shrinkwrap or other veneer wrapping material, as is well known in the industry. Inside are upper and lower (as depicted in the figure) layers 54 and 56 , made of HDF, or another structural material such as (as non-limiting examples) wood or MDF. In between layers 54 and 56 is a layer 58 of an intumescent material, such as described above.
[0033] In addition, strips of the intumescent material can be inserted in other parts of the louver door, such as on its edges so as to seal the space between the door and the door frame. Similarly, intumescent material can be used in the frame work. In either case, the material can be attached by conventional methods, such as gluing strips of the material into a solid wooden piece or may be inserted into a veneer and wrapped by HDE or MDE as described above. The presently disclosed louvers may be used in a variety of environments, including (as non-limiting examples) gratings and ventilation ducts; wooden or steel single-leaf or multi-leaf doors, with or without glazing; sliding doors, rolling gates; sound-insulation doors, functioning in the event of a fire at the same time as a fire and smoke doors, for hospitals, schools, hotels, and office buildings; doors with high mechanical stability for industrial construction; enhanced heat-insulating sliding doors for cold-storage rooms; elevator doors; doors on ships; and steel closures for fuel oil or other combustible material storerooms.
[0034] The presently disclosed apparatuses, systems, and methods may be used with many different types of louver door configurations, including (as non-limiting examples): the single flat slat type; the inverted “V” type; and the type that has slats going in one direction on one door side, a central opening, and slats slanting in the other direction on the other door side. The present disclosure may be used with fixed slats or with slats of the adjustable or jalousie type. Portions of the louvers may be made from wood, metal, such as iron, steel, or aluminum, or plastic, such as those to which Ohanesian U.S. Pat. No. 5,778,598, is drawn, for example, which depicts a jalousie shutter door assembly assembled primarily from extruded plastic components.
[0035] The previous description of some aspects is provided to enable any person skilled in the art to make or use the present invention. Various modifications to these aspects will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other aspects without departing from the spirit or scope of the invention. For example, one or more elements can be rearranged and/or combined, or additional elements may be added. Thus, the present invention is not intended to be limited to the aspects shown herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.
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A fireproof louver panel includes a panel frame and a plurality of longitudinally extending slats attached to the panel frame. One or more of the slats has a shell and an intumescent layer that expands under heat to form an airtight seal. A fireproof door or window may include an external frame, an internal core of a fireproof material (among other materials), and one or more such fireproof louver panels. A method of fireproofing an opening includes affixing a movable fireproof closure in the opening, and placement intumescent layers on the closure and on louvers disposed therein so that the opening is sealed when the first intumescent layer and the second intumescent layer are both subjected to heat.
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BACKGROUND OF THE INVENTION
[0001] The present invention relates generally to an adjustable hinge system for use with oversize insulated doors used for commercial walk-in refrigerators and freezers. More specifically, this hinge system is capable of lateral adjustment of the spatial relationship of the door to the frame in order to correct any misalignment of door position in relation to the frame that has occurred through continued opening and closing of the door. Further, any misalignment is corrected by the easy and simple rotation of a cam located within the hinge strap which is accessible from the surface of the hinge so that complete disassembly of the hinge is not required.
[0002] Over the years there have been many attempts at adjusting commercial refrigerator and freezer doors using a variety of mechanisms to accomplish lateral movement for adjustment of the misalignment of the door to the frame. One recent example is U.S. Pat. No. 7,870,642 [Finkelstein, et al.] that describes an anti-sag hinge with a lateral adjustment feature. The anti-sag hinge is divided into two components, a mounting flange attached to the door jamb or frame and a strap assembly mounted to the door and pivotally attached to the mounting flange. The strap assembly has a plurality of slotted or elongated holes for mounting to the door with an adjustment bracket mounted atop the strap with the same number of circular holes generally aligned with the elongated holes of the strap. Extending between the strap and the adjustment bracket are paired flanges connected by a threaded adjustment screw that is capable of inward or outward movement causing relative movement between the strap and the door within the range of the elongated holes. The adjustment bracket remains in fixed position relative to the door with the movement of the door relative to the strap causing a lateral adjustment of the door to the frame or jamb with the turning of the adjustment screw. A similar structure is noted in U.S. Pat. No. 7,584,523 [Finkelstein, et al.] although the focus of this patent is the partial removal of the mounting flange assembly with the removal of the upper barrel portion of the hinge.
[0003] Another earlier method for re-aligning doors to the cabinet frame is described in U.S. Pat. No. 7,055,214 [Finkelstein]. This anti-sag hinge is described as having a mounting flange for attachment to the jamb or frame of a cabinet and a strap assembly for attachment to an associated door. Onto the back side of the strap assembly, between that assembly and the door, is attached an adjustment plate that mates with the underside of the strap assembly by a series of serrated edges arrayed along the opposing surfaces of the strap assembly and the adjustment plate. By loosening the mounting screws and manually relocating the adjustment plate and the underside of the strap assembly from a first mating serration to a second mating serration the door can be laterally adjusted to correct any misalignment from use or wear. As above, a similar apparatus is described in U.S. Pat. No. 6,374,458 [Finkelstein]. In this patent the apparatus is described as having a recess in the underside of the strap assembly to cover and capture the adjustment plate with opposing surfaces having raised surface ridges for locking the strap assembly and the adjustment plate together at predetermined locations. For adjustment, the screws holding the strap assembly and the adjustment plate together are loosened and the two cooperating elements are laterally moved to a different desired position and the screws tightened to re-align the door to the jamb or cabinet frame.
[0004] Another recent commercial walk-in refrigerator/freezer door adjustment apparatus is described in U.S. Patent Application Publication No. US 2006/0032145 A1 [Manders, et al.] In this publication an adjustment screw is accessed from the door edge closest to the hinge and acts against an adjustment plate in the hollow of the door causing the movement of the hinge strap relative to its position against the door to correct misalignment. Another horizontally adjustable hinge is described in U.S. Pat. No. 8,720,008 [Dodge] that provides an adjustment bracket attached to the outer surface of the door which is enveloped in a recess in a strap assembly placed atop the bracket. A slot is machined into the end of the strap assembly closest to the pivot point of the hinge base and an adjustment screw is inserted through the slot such that the head of the screw abuts the outer surface of the strap assembly. The threaded end of the adjustment screw is threadedly coupled to an upstanding flange on the adjustment bracket so that rotational motion of the adjustment screw causes the strap assembly to move relative to the adjustment bracket achieving horizontal adjustment of the door to the frame.
[0005] In the devices discussed above the mechanism for realigning the door has been, for the most part, a threaded screw operating on or through some form of adjustment plate with counterforce against the strap assembly and door. The other devices have been manually relocatable strap assemblies to mate with plates mounted to the doors to achieve repositioning and alignment. These devices are cumbersome to use, may have insufficient force to accomplish the task without external assistance, and may require more than one person to accomplish the re-alignment task.
[0006] There have been other attempts at positioning and realignment of doors using different instrumentalities. At least one earlier device utilized a cam-like apparatus to achieve similar positioning and realignment of doors to associated frames. One such device is described in
[0007] U.S. Pat. No. 2,700,789 [Cornwell] for a hinge system between a standard wooden door and its frame in the door opening. A disk having an elongated slot for mating with an outwardly extending stud from a surface mounted adjustment plate on the door could be manually repositioned over the mounting plate of the hinge to adjust the lateral and vertical position of the door relative to the frame and hinge leaf mounted to the frame. The described apparatus required shimming of the door in order to reposition the elements of the adjustment apparatus properly with a retightening of all elements in the new position before removing the shims. This earlier device was also cumbersome to use and required external elements to properly position the door.
[0008] The present invention eliminates the earlier problems of weight of the door versus size of the adjustment mechanism, or the complexity of manually adjusting the door using shims to achieve the proper realignment before tightening the mounting screws to retain the door in the new position. One should not be persuaded that the shimming of old has been overcome with newer hinge systems as it is still utilized today with some of the hinge systems described above. Counterbalancing a heavy door may be required for realignment if the adjustment mechanism is not of sufficient size to overcome the weight of the door to achieve proper repositioning. The Dodge '008 patent attempted to address this problem by significantly increasing the size of the threaded adjustment screw shaft and thickness of the flange of the adjustment bracket to overcome the significant force of the weight of the door and the gravitational force exerted on the door forcing the door outward and downward away from the hinge base. The Finkelstein '642 patent, with a lighter weight screw and associated threaded flange, did not perform as intended in repeated testing to overcome the significant forces exerted against the adjustment screw and flange with the bending of the flange of the adjustment bracket away from its intended straight-line perpendicularity reducing the effectiveness in the realignment of the heavy door.
[0009] It is, therefore, an object of the present invention to provide an apparatus that overcomes the significant weight forces of the door to achieve realignment of the door with the jamb or cabinet frame. It is another object of the present invention to provide an apparatus that accomplishes the realignment task without significantly altering the mechanical structure of the hinge system or the exterior of the hinge. It is a still further object of the present invention to provide an apparatus that can accomplish the task of repositioning or realigning the door by a single technician.
[0010] It is yet a further object of the invention to provide an apparatus that fits entirely within the unaltered exterior structure of the hinge system and is hidden from view so as to negate any potential for the collection of dirt or other unwanted materials or organisms onto or in the hinge system rendering the hinge system unfit for use in the food storage and service industries. It is also an object of the present invention to provide an apparatus that is simple to use and readily reacts to minimal necessary force from external adjustment.
[0011] Other objects will appear hereinafter.
SUMMARY OF THE INVENTION
[0012] A laterally adjustable hinge system for a walk-in refrigerator or freezer is described comprising a hinge base for mounting to the frame of a door opening and an operationally associated hinge strap extending outward into the door opening and attaching to the door for providing rotational motion of the door about the hinge base. An adjustment bracket for accomplishing lateral displacement of the hinge strap against the door is mounted to the door by a plurality of fasteners and housed within a cooperating recess on the underside of the hinge strap. The adjustment bracket is releasably fastened to the hinge strap by a plurality of fasteners and has a centrally located elongated aperture extending across the bracket for housing an eccentric cam mounted to the shaft of an adjustment bolt extending outward through a cooperating aperture in the hinge strap to expose the adjustment bolt head for manipulation by an adjustment tool. In this fashion the rotational motion of the adjustment bolt head by the adjustment tool causes the cam to move within the elongated aperture about the rotational center of the adjustment bolt causing lateral motion of the hinge strap versus the adjustment bracket for realignment of the door to the frame. The eccentric cam has a flat portion along its perimeter such that when the flat portion comes into abutting contact with a sidewall of the elongated cam aperture this contact indicates that maximum rotation in a clockwise or counterclockwise direction has been accomplished and further indicates that a maximum adjustment point has been reached.
[0013] The laterally adjustable hinge system may be further described such that the releasable fasteners for holding the adjustment bracket to the hinge strap extend through the outer surface of the hinge strap and through a like number of elongated slots in the adjustment bracket mating with a like number of nuts that are held within recesses along the underside of the elongated slots capable of capturing and retaining the nuts, but preventing rotational motion thereof such that loosening and tightening of the fasteners for the hinge strap are independent of the fastening of the adjustment bracket to the door. The adjustment bolt is held in position within the eccentric cam by a C-shaped fastener on the underside of the cam so that rotational motion of the adjustment bolt is directly translated to the cam. The cooperating aperture in the hinge strap has a counterbore for retaining the shaft of the adjustment bolt centered within the aperture to maintain uniform access to the adjustment bolt head for an adjustment tool such that the counterbore acts as a central pivot point for the cam for use in adjusting any misalignment of the door to the frame. The laterally adjustable hinge system is further described as having a cap for overlying and covering the adjustment bolt and cooperating aperture in said hinge strap.
[0014] The laterally adjustable hinge system may be further described for a left-hand oriented hinge system such that the rotational motion of the adjustment bolt in the clockwise direction will cause the adjustment bracket and door to move leftward relative to the hinge strap and the hinge strap rightward versus the position of the adjustment bracket. Likewise, the rotational motion of the adjustment bolt in the counterclockwise direction causes the adjustment bracket and door to move rightward relative to the hinge strap and the hinge strap leftward versus the position of the adjustment bracket. For right-hand oriented hinge system the rotational motion of the adjustment bolt in the clockwise direction will cause the adjustment bracket and door to move rightward relative to the hinge strap and the hinge strap leftward versus the position of the adjustment bracket. Likewise, the rotational motion of the adjustment bolt in the counterclockwise direction causes the adjustment bracket and door to move leftward relative to the hinge strap and the hinge strap rightward versus the position of the adjustment bracket.
[0015] The invention also includes a method for laterally adjusting a hinge system for a walk-in refrigerator or freezer for realignment of the door to the frame. The method includes providing a hinge base for mounting to the frame of a door opening and an operationally associated hinge strap extending outward into the door opening and attaching to the door for providing rotational motion of the door about the hinge base and providing an adjustment bracket for accomplishing lateral displacement of the hinge strap against the door mounted to the door by a plurality of fasteners with the adjustment bracket housed entirely within a cooperating recess on the underside of the hinge strap. The adjustment bracket is releasably fastened to the hinge strap by a plurality of fasteners.
[0016] The method also includes the providing of a centrally located elongated aperture extending across the adjustment bracket for housing an eccentric cam mounted to the shaft of an adjustment bolt extending outward through a cooperating aperture in the hinge strap to expose the adjustment bolt head for manipulation by an adjustment tool. To obtain a realignment of the door and frame, the invention also includes loosening the hinge strap adjustment bracket fasteners and rotating the adjustment bolt by the adjustment tool that will cause the cam to move within the elongated aperture of the adjustment bracket about the rotational center of the adjustment bolt resulting in lateral motion of the hinge strap versus the adjustment bracket to obtain a realigned position of the door to the frame. The method also includes providing a means to prevent excessive rotational movement of the eccentric cam by providing a flat portion along the periphery of the cam indicating a maximum lateral adjustment point has been reached as a flat portion of the cam comes into contact with a sidewall of the elongated aperture. Finally, the method also includes tightening the hinge strap adjustment bracket fasteners to maintain the realigned position of the door to the frame.
[0017] The method for laterally adjusting a hinge system further includes the providing of a cap for overlying and covering said adjustment bolt and cooperating aperture in said hinge strap.
[0018] When the method is used for laterally adjusting a left-hand oriented hinge system, where the rotational motion of the adjustment bolt is in the clockwise direction, the adjustment bracket and door will move leftward in relation to the hinge strap and the hinge strap rightward versus the position of the adjustment bracket. Where the rotational motion of the adjustment bolt is in the counter clockwise direction, the adjustment bracket and door will move rightward in relation to the hinge strap and the hinge strap leftward versus the position of the adjustment bracket. When the method is used for laterally adjusting a right-hand oriented hinge system, where the rotational motion of the adjustment bolt is in the clockwise direction, the adjustment bracket and door will move rightward in relation to the hinge strap and the hinge strap leftward versus the position of the adjustment bracket. Where the rotational motion of the adjustment bolt is in the counterclockwise direction, the adjustment bracket and door will move leftward in relation to the hinge strap and the hinge strap rightward versus the position of the adjustment bracket.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] For the purpose of illustrating the invention, there is shown in the drawings forms which are presently preferred; it being understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown.
[0020] FIG. 1 is an exploded perspective view of a left-hand hinge system having the adjustment for lateral displacement of the present invention.
[0021] FIG. 2 is a plan view of the hinge plate or adjustment bracket of the present invention shown mounted in a left-hand hinge orientation with the cam at a central neutral adjustment position.
[0022] FIG. 3 is a plan view of the adjustment bracket of the present invention with the cam at an adjustment position causing the rightward shifting of the hinge strap in relation to the adjustment bracket.
[0023] FIG. 3A is a plan view of the adjustment bracket of the present invention with the cam at the rightmost adjustment position with the flat of the cam against the sidewall of the cooperating cam pathway indicating such position causing the rightmost shifting of the hinge strap in relation to the adjustment bracket.
[0024] FIG. 4 is a plan view of the adjustment bracket of the present invention with its mounting in a left-hand hinge orientation with the cam at an adjustment position causing the leftward shifting of the hinge strap in relation to the adjustment bracket.
[0025] FIG. 4A is a plan view of the adjustment bracket of the present invention with the cam at the leftmost adjustment position with the flat of the cam against the sidewall of the cooperating cam pathway indicating such position causing the leftmost shifting of the hinge strap in relation to the adjustment bracket.
[0026] FIG. 5 is a plan view of the bottom side of the adjustment bracket of the present invention showing the elongated slots and underside of the cam in a central neutral position.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0027] The following detailed description is of the best presently contemplated mode of carrying out the invention. The description is not intended in a limiting sense, and is made solely for the purpose of illustrating the general principles of the invention. The various features and advantages of the present invention may be more readily understood with reference to the following detailed description taken in conjunction with the accompanying drawings.
[0028] Referring now to the drawings in detail, where like numerals refer to like parts or elements, there is shown in FIG. 1 an exploded view of the laterally adjustable left-hand oriented hinge system 10 of the present invention. Starting at the left, there is a hinge base or mount 12 which is adapted to be securely attached to the frame of a walk-in refrigerator or freezer with three bolts that extend through the countersunk holes 14 in the hinge base and into the frame of the refrigerator or freezer. There is also a hinge blade or strap 16 which is also adapted to be securely attached to the door of a walk-in refrigerator or freezer with three threaded bolts or fasteners 18 that extend through the countersunk holes 20 in the hinge blade or strap 16 and mate with a like number of similarly threaded nuts 22 that are housed in elongated recesses 24 on the underside of an adjustment bracket 30 , the side juxtaposed against the exterior of the door. See, FIG. 5 . The adjustment bracket 30 fits within a recess on the underside of hinge strap 16 such that it is entirely hidden from external view. Adjustment bracket 30 is adapted to be securely attached to the door of a walk-in refrigerator or freezer by a series of threaded bolts or fasteners 32 that extend through a similar number of countersunk holes 34 in the adjustment bracket and into the door fixedly attaching the adjustment bracket 30 with the attached hinge strap 16 to the door. Prior to attaching the adjustment bracket 30 to the door, the nuts 22 are positioned within the elongated slots 24 that are only wide enough to accommodate the width of the nuts 22 . This allows the nuts 22 to be recessed within the adjustment bracket 30 and prevents the nuts 22 from rotational motion when the hinge strap attachment fasteners 18 are being loosened or tightened.
[0029] Referring again to FIG. 1 , the hinge base 12 is rotatably coupled to the hinge strap 16 with a hinge pin 40 . Hinge pin 40 extends through a female cam 42 and a male cam 44 that cooperates with the female cam, and is attached to flange 46 which is a portion of the hinge base 12 and provides support for the hinge blade or strap 16 . The exterior surface of the female cam 42 is six-sided and mates with a like aperture 43 located in the proximal end of the hinge strap 16 preventing any rotational motion of the female cam 42 within the hinge strap 16 . The hexagonal shapes of the cam 42 and aperture 43 may also be four-sided, eight-sided, or any parallel-sided geometric figure retaining a significant surface at each angular junction to prevent rotation of the cam 42 within the aperture 43 . A spring (not shown) acting in compression may be positioned within the female cam 42 to cause a downward force against the male cam 44 which action will urge the hinge blade 16 to swing the door to a closed position relative to the hinge base 12 . A cap 48 is located on the top of the hinge blade 16 and covers the top of the hexagonal aperture 43 housing the female cam 42 and hinge pin 40 .
[0030] The adjustment bracket 30 has a centrally located elongated aperture 36 extending across the short dimension of the bracket 30 for housing and providing a pathway for an eccentric cam 50 that is mounted to the shaft of adjustment bolt 52 . The bolt 52 is held in position by a C-shaped washer or C-clip 54 on the underside of the cam 50 and extends outward from the adjustment bracket 30 a predetermined distance to extend through a cooperating aperture 56 in the hinge strap 16 . The adjustment bolt 52 is housed within the cam 50 by a flattened side of the bolt shaft aligned with a D-shaped hole through the cam 50 , or by cutting a channel in the shaft of the bolt 52 creating a U-shape or keyway that will mate with a like U-shape cut through the cam 50 , both well-known practices in the art, or by any other similar means that enables the exact tracking of rotational motion of the adjustment bolt 52 by the cam 50 . The C-shaped washer or C-clip 54 will not inhibit the rotational motion of the bolt 52 but will retain the adjustment bolt in a full contact position within the eccentric cam 50 . The head of the adjustment bolt 52 may have a head that mates with a flat blade or Phillips screwdriver, a square or hexagonal nut driver, or a recessed hexagonal or other geometric shape for cooperating with an Allen or other geometrically shaped wrench.
[0031] The cooperating aperture 56 in the hinge strap 16 has a lower centering collar or counterbore 57 for retaining the shaft of bolt 52 centered within the aperture 56 to maintain uniform access to the bolt head for an adjustment tool. The centering collar or counterbore 57 also acts as the central pivot point for the cam 50 for use in adjusting any misalignment of the door to the frame. Covering the cooperating aperture 56 in the hinge strap 16 is a removable cover 58 that snaps in place over the adjustment bolt 52 providing a clean look to the external surface of the hinge strap 16 and preventing debris or other materials from entering the aperture 56 that might impair proper operation of the door adjustment cam 50 .
[0032] Referring now to FIGS. 3-5 , the operation of the door adjustment cam 50 and its effect on the realignment of the door can be described as follows. With reference to FIG. 2 , the adjustment bracket 30 is depicted generally in a median or neutral position approximately midway between the maximum left and right deflections. In the position shown, at the bottom of the elongated aperture or cam pathway 36 extending through the adjustment bracket 30 , the cam 50 may be either in a fully downward position, or alternatively in a fully upward position at the top of the cam pathway within the elongated aperture 36 , such that the door is presumed aligned as originally installed. The pivot point, or rotational center point, for the cam 50 is the shaft of the adjustment bolt 52 that, with the adjustment bracket 30 mounted to the door and the hinge strap 16 mounted to the adjustment bracket 30 , provides the pivotal positioning for the cam 50 with the assistance of the centering collar or counterbore 57 of the cooperating aperture 56 in the hinge strap 16 .
[0033] In FIG. 3 the cam 50 is shown partially rotated to the left from the position shown in FIG. 2 . The shaft of the adjustment bolt 52 has acted as the rotational center for the cam 50 causing the hinge strap 16 to move rightward in relation to the adjustment bracket as shown by the rightward displacement of the attachment fasteners 18 that extend between the hinge strap 16 and the adjustment bracket 30 within the elongated slots 24 . If this action is accomplished on the bottom hinge of the two hinges on a left-side hung door, then the door will move inward toward the left side frame, causing the distal bottom edge of the door to move away from the right side of the opening of the frame. If the action is accomplished on the top hinge of the two hinges on a left-side hung door, the top of the door will move inward and upward slightly correcting any rubbing along the bottom of the door frame. FIG. 3A shows the farthest point that the lateral adjustment apparatus can accomplish by placing the flat 51 of the cam 50 against a sidewall of the elongated aperture or cam pathway 36 such that the hinge strap 16 has moved to the farthest right adjustment point. Continuing to rotate the cam 50 beyond the physical indication point of farthest rightward adjustment by the cam flat 51 abutting against the sidewall of the aperture 36 will not continue any further rightward adjustment, but will allow the adjustable hinge 10 to return toward a neutral position.
[0034] In FIG. 4 the cam 50 is shown partially rotated to the right from the position shown in FIG. 2 . The shaft of the adjustment bolt 52 has acted as the rotational center for the cam 50 causing the hinge strap 16 to move leftward in relation to the adjustment bracket as shown by the leftward displacement of the attachment fasteners 18 that extend between the hinge strap 16 and the adjustment bracket 30 within the elongated slots 24 . If this action is accomplished on the bottom hinge of the two hinges on a left-side hung door, then the door will move outward away from the left side frame, lifting the distal bottom edge of the door eliminating a perceived drag of the door against the step of the frame. If the action is accomplished on the top hinge of the two hinges on a left-side hung door, the top of the door will move outward and downward slightly correcting any rubbing along the top of the door frame. FIG. 4A shows the farthest point that the lateral adjustment apparatus can accomplish by placing the flat 51 of the cam 50 against a sidewall of the elongated aperture or cam pathway 36 such that the hinge strap 16 has moved to the farthest left adjustment point. Continuing to rotate the cam 50 beyond the physical indication point of farthest leftward adjustment by the cam flat 51 abutting against the sidewall of the aperture 36 will not continue any further leftward adjustment, but will allow the adjustable hinge 10 to return toward a neutral position.
[0035] In regard to the cam 50 , there are two neutral positions where the cam 50 is positioned at its downward most position or at its uppermost position. These positions are equivalent to the points on a circle at 0° and 180° of a full rotation of the cam 50 . For the left-hand hinge system described, the equivalent position of 270° (as shown in FIG. 3A ) will be the farthest rightward adjustment available for the hinge strap 16 resulting in the repositioning of the door to the frame described above. Concurrently, the position of 90° (as shown in FIG. 4A ) will be the farthest leftward adjustment available for the hinge strap 16 resulting in the repositioning of the door to the frame also described above. These farthest adjustment points are indicated to the person adjusting the hinge/door alignment by the flat 51 of cam 50 fully contacting the sidewall of the aperture or cam pathway 36 . If the cam 50 passes the 90° and 270° positions, once again approaching a neutral position at either 0° or 180°, the extent of the lateral movement of the door relative to the frame lessens as the cam 50 approaches one of its neutral positions. In the case of right-hand oriented hinge systems, the lateral movement of the hinge strap 16 to the adjustment bracket 30 , and the door repositioning relative to the frame, is reversed from the lateral movement and positioning described above.
[0036] In practice, once all of the components are in place and the door is operational, for adjustment of any misalignment of the door, the following steps are to be performed. First, the removable cover 58 is popped out of the aperture 56 exposing the adjustment bolt 52 . Next, the attachment fasteners 18 are loosened permitting a desired opposite direction relational movement between the adjustment bracket 30 and the hinge strap 16 . An adjustment tool is placed over the adjustment bolt 52 and the appropriate clockwise or counterclockwise rotational motion is performed such that the door reacts to the desired rotational movement of the cam 50 . The farthest adjustment point is indicated when the cam flat 51 of the cam 50 comes into contact with the sidewall of cam aperture or pathway 36 such that the force required to move the cam away from the farthest adjustment point is slightly increased and the technician realizes that the maximum adjustment point was reached. Once the repositioning of the door is accomplished and the door is considered to be realigned for ease of motion and door closure, the attachment screws 18 are retightened maintaining the adjustment bracket 30 and hinge strap 16 in the adjusted position and the cover 58 is snapped back into position within the aperture 56 covering the adjustment bolt 52 . All of the foregoing can be accomplished while the door remains in the closed position. The adjustment of the door can also be done without the need for a second technician or the use of shims for maintaining the door in a desired position while the adjustment elements are reconfigured to retain that door in the newly desired position.
[0037] The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof and, accordingly, the described embodiments are to be considered in all respects as being illustrative and not restrictive, with the scope of the invention being indicated by the appended claims, rather than the foregoing detailed description, as indicating the scope of the invention as well as all modifications which may fall within a range of equivalency which are also intended to be embraced therein.
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A laterally adjustable hinge system for use on an insulated door of a commercial refrigerator or freezer including a hinge base and associated position adjustable strap relative to the door. The lateral adjustment is accomplished by rotational movement of an eccentric cam located in an adjustment bracket housed within the hinge strap attached directly to the door. The hinge strap is adjustably attached to the adjustment bracket and capable of lateral relational motion controlled by the position of the cam. Cam rotation is controlled by an adjustment bolt extending outward and through the hinge strap protected by a removable cover with a maximum lateral adjustment indicator in the form of a flat portion on the perimeter of the cam such that contact with the sidewall of the cam aperture by the cam flat indicates maximum lateral adjustment in the desired direction has been reached.
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TECHNICAL FIELD
The present invention relates to a method and apparatus for estimating the physical state of a physical system.
BACKGROUND
In many areas of science and engineering, complex physical problems are solved using mathematical models which are discretized over space. Various methods can be used to convert the continuous mathematical model into a discretized form, the most common being the Finite Difference, Finite Element and Finite Volume methods.
The finite volume method is commonly used in Computational Fluid Dynamics applications, and in related fields such as Oil Reservoir Simulation. This method splits a problem domain into grid blocks (cells) by superimposing a mesh or grid of some type. Fluid conservation equations are then constructed by considering the accumulation of fluids within a cell, and flow across the cell faces to neighboring cells, or to external sinks or sources, such as oil wells. Mass accumulation and flow rates depend on fluid properties such as the pressure, temperature and composition in each grid block and its neighbors. For time varying problems, the model is advanced through time by finding the values of the fluid properties that simultaneously satisfy the conservation equations in every cell for each discrete time-step.
In general these equations are non-linear, and Newton's method (or similar) is used to reduce the problem to the repeated solution of simultaneous linear equations linking all the grid blocks.
Because fluids flow only across the common faces of neighboring cells, and not between distant cells having no common face, the matrix representing the linear equation coefficients is sparse, and has a distinctive structure. For one-dimensional problems, the matrix is tridiagonal. For two- and three-dimensional problems, the matrix has a distinctive nested block tridiagonal structure (see FIGS. 1 and 2 of the accompanying drawings); the ordering of grid blocks that leads to this structure will be discussed further below.
Similar considerations apply to other space discretization methods: the end result is the requirement to solve sparse linear equations, which, with appropriate ordering of nodes, have the distinctive nested block tridiagonal structure described above.
Many common methods for iterative solution of the linear equations depend on the use of a “preconditioner”—a fast procedure for obtaining an approximate solution to the linear equations. The NF (Nested Factorization) algorithm is a preconditioner which, unlike most others, is specifically designed to approximate the nested block tridiagonal matrices which arise from space discretization. In its original form, NF can be applied to topologically rectangular meshes, but not to tetrahedral, and other more general meshes.
One practical application is in the area of oil reservoir simulation. Oil and gas are produced from porous underground rock formations containing both water and hydrocarbons. Fluids, including oil and gas are extracted through wells, and wells are also used to inject fluids, such as water, steam, carbon dioxide or chemicals with a view to improving overall production—for example by pushing oil towards a well, or making sticky oil more mobile.
Engineers use oil reservoir simulators to understand what is happening in the reservoir and to explore alternative strategies for optimizing outcomes. The results of a simulation may determine when and where new wells are drilled, and how they are controlled.
Modeling of a reservoir typically proceeds through two phases—history matching (see FIG. 12 ) and prediction (see FIG. 13 ). In the history matching phase, the past production of a field and its wells is repeatedly modeled with variations to the geological model designed to improve the match between historical fact and simulation. Once an adequate match is obtained, prediction runs can be started. These runs explore the consequences of alternative operating plans, often extending for several decades into the future. After the chosen plan is put into operation, the model will be re-run from time to time to tune the match, and refine the predictions.
The operation of a typical reservoir simulator is summarized in FIG. 14 , and described below:
1. The first step is to read data describing the reservoir model defined by the reservoir engineer. Typically this comprises:—
Geological data from numerous sources, including seismic analysis, rock cores and well log analysis. The rock porosity and directional permeabilities are key variables, and often vary greatly across the reservoir. The location and characteristics of geological faults must also be specified. Details of the computational grid; fine grids give better results, but increase computation time. Fluid properties, such as viscosity, density and phase transition information. Relative permeabilities are used to characterize the mobility of different phases when mixtures are present. Fluid properties also vary spatially. Sufficient information to determine the initial state of the main solution variables; these variables will include pressure, and probably the saturations of oil, water and gas. Other variables may represent the hydrocarbon composition and temperature. There may be from two up to 20 or more independent variables in each grid block. The simulator will model the changes to these variables for every grid block through a series of discrete time-steps. This solution is an n-vector, referred to here as x. n is usually the number of grid blocks multiplied by the number of solution variables per grid block. Additional data specifying detailed control and reporting options.
2. Next the engineer's proposed schedule of operation is read in. This consists principally of the location and characteristics of all production and injection wells, and details of how they will be operated. For example a well may be opened months or years after the start of the simulation, and its production or injection rates determined partly by conditions in the reservoir or constraints of surface facilities. 3. The simulator begins to loop over time steps which will advance the simulation through the schedule of operations. When the end of the schedule is reached, the simulator produces some final summary data and halts. 4. The simulator selects a time-step by which to advance. This may be anything from a few seconds to a year or more, depending on what is required by the schedule, and by numerical considerations. 5. The simulator makes an estimate (dx) of the change in the solution variables between the start and end of the time-step. dx, like x, is an n-vector. 6. The simulator now begins a second loop to solve the non-linear equations which describe mass conservation in each grid block. 7. Calculate the residuals - which reflect the degree to which material is not conserved for each grid block. For a given grid block, the residuals are found by calculating the amount of all fluids in the cell at the beginning and end of the time step. This difference must be made up by flows from neighboring grid blocks and wells. Both quantities (fluid in place and flow in or out) depend on the solution variables (pressure, composition, temperature etc.) for the cell and its neighbors (x and x+dx). 8. If material does not balance, then the residuals are non-zero, and a solution must continue to be sought. 9. If the residuals are sufficiently close to zero, update the solution variables
x=x+dx
and return to step 4
10. If the iteration has not converged, but the maximum permitted number of iterations has been reached, the current iteration is abandoned, and a solution is instead sought to a simpler problem. A shorter time step is selected, and processing returns to step 5. 11. If the non-linear equations have not converged, the simulator assembles a matrix (A) of derivatives using the current best estimate of the solution. Each matrix coefficient represents the rate of variation of a residual (local material balance error) with respect to a solution variable. The resulting matrix equation
A.ddx=r
(where A is an nxn matrix, ddx is an n-vector of changes to the solution variables, and r is an n-vector of residuals) is a linearized version of the non-linear equations. The solution procedure is just an n-dimensional matrix form of Newton's method for finding the zeros of a one-dimensional function.
12. Solve the linear equation formed in step 11. This is often the most time consuming step in the procedure. 13. Update the current estimate of the change to the solution variables during the time step
dx=dx+ddx
and return to step 7
Oil reservoir simulators are extremely demanding applications which constantly push the boundaries of what computers can do. Engineers have always demanded more sophisticated physics (more variables per grid block) and finer meshes (more grid blocks) both of which trends increase computational requirements. In addition, convergence of the linear and non-linear equations to solution is not a forgone conclusion. Many models devised by engineers simply don't work because the simulator cannot find a solution.
The most time consuming part of a simulation is the solution of the linear equations (step 12 above). Direct methods, such as Gaussian elimination, cannot be used because they would require far too much memory, and take far too long. Most simulators now use an iterative method based on GMRES, or a similar Krylov subspace method, with a preconditioner to accelerate convergence. Reference 1 (a list of numbered references is included at the end of the description) contains an excellent summary of these methods. The preconditioner (B) is an approximation to A chosen such that B −1 .x can be calculated quickly for an arbitrary vector x. The choice of preconditioner is critical: with a poor choice, the iteration may be very slow, or may not converge at all. In extreme cases the simulator will fail, even with the best known solution methods.
FIG. 15 shows how a preconditioner fits into the operation of a Krylov subspace iterative solver such as GMRES (in FIG. 15 , forward-references to FIGS. 16 to 18 should not be interpreted as implying that the content of FIGS. 16 to 18 relate generally to the NF method).
1. The first step is to define the ordering of the matrix variables. For some preconditioners, the order is unimportant, but for NF it is critical. This step is discussed in detail below. 2. Next the preconditioner is factored into block upper and lower factors, B=L.U. All the elements of L and U are calculated. In most practical preconditioners, including NF, L and U retain most of the sparsity of A, and most non-zeros are the same as the corresponding terms in A. In contrast, an exact factorization of A would have few non-zeros. Once this is done, the preconditioner can be applied easily to arbitrary vectors during the iteration phase starting at step 4. 3. An initial estimate of the solution (x 0 ) is generated, or supplied by the calling program. Often x 0 is set to 0. The initial residual (r 0 =b−Ax 0 ) is calculated. 4. The iteration counter, m is set to 1. 5. The preconditioner is used to find an approximate solution to the equation A.q m =r m−1
q m =B −1 .r m−1
If B were exactly equal to A, qm would take us to the solution.
6. Use the matrix multiply routine to form the vector z m
z m =A.q m
7. Find the scalar values α 1 . . . α m which minimize the norm of r m where
r
m
=
r
0
+
∑
i
=
1
m
α
i
·
z
i
8. If r m is below the convergence target then exit with the solution
x
m
=
x
0
+
∑
i
=
1
m
α
i
·
q
i
9. If the iteration limit has been reached, then exit reporting that the method has failed
10. Increment the iteration counter, m and return to step 5.
The Nested Factorization (NF) Algorithm is a known pre-conditioning method which may be used to accelerate the convergence of the conjugate gradient, GMRES, OrthoMin and other similar algorithms for iterative solution of large sparse sets of linear equations. The algorithm is described in references (2) to (4), and summarized at http://www.polyhedron.co.uk/nf-Nested Factorization0htm. This original NF algorithm assumes that the matrix is formed by considering connections between neighboring blocks in a simple topologically rectangular grid.
For an n x by n y by n z grid, the banded coefficient matrix A is
A=d+u+l+v+m+w+n
where
d is the diagonal, u and l are the bands immediately above and below the diagonal, which connect adjacent cells within a line v and m are the bands n x elements away from the diagonal, which connect adjacent lines within a plane w and n are the bands n x *n y elements away from the diagonal, which connect adjacent planes
For example, given a 4×4×2 grid ( FIG. 1 ), the matrix has the structure shown in FIG. 2 , based on an ordering of cells as shown in FIG. 1 .
This matrix can be regarded as recursively block tridiagonal. At the outermost level each block element represents a plane, or the coefficients connecting adjacent planes. Within each plane, the blocks represent lines, and coefficients connecting adjacent lines. At the innermost level, there are individual grid blocks and the connections between individual grid blocks within lines.
NF exploits this recursive structure by defining the preconditioner, B, recursively:—
B = (I + n · P −1 ) · (P + w)
(B is block tridiagonal -
block elements are planes)
where
I
is the unit matrix
and
P = (I + m · T −1 ) · (T + v)
(P is block tridiagonal -
block elements are lines)
and
T = d + I + u − approx(ε)
(T is tridiagonal)
and
ε = m · T −1 · v + n · P −1 · w
(the uncorrected error matrix)
approx(ε) is a matrix which is computed to approximate ε. It is usually diagonal, but could be tridiagonal. Common approximations are:—
diag(ε) the diagonal elements of ε rowsum(ε) the diagonal matrix formed by summing the elements of ε in rows colsum(ε) The diagonal matrix formed by summing the elements of ε in columns.
After expansion, the following is obtained:—
B=A+ε−approx(ε)
In summary, B is a partial L.U factorization, but unlike most other similar methods, the factors L and U are block (rather than strictly) lower and upper triangular. For the example 4×4×2 finite difference matrix, (I+n.P −1 ) and (P+w) are 2×2 matrices
I
P a
w
n · P a −1
I
P b
where P a and P b are themselves matrices which connect cells within the 2 planes, and n, w are diagonal matrices containing elements from A. To compute B −1 .x, where x is a vector, first sweep forward through the planes to obtain (I+n.P −1 ) −1 .x, and then back to apply (P+w) −1 . The problem is thus reduced to solving P −1 .x for each plane, and from three dimensions to two.
For a suitable choice of P (P=A−n−w−n.P −1 .w), this factorization of A is exact. However an exact factorization is not practical for large matrices, and instead, each block element of P is approximated in the same way—with an incomplete block L.U factorization.
P a =(I+m.T −1 ).(T+v)
For the example matrix, (I+m.T −1 ) and (T+v) are 4×4 matrices
I
T a
v a
m a T a −1
I
T b
v b
m b T b −1
I
T c
v c
m c T c −1
I
T d
where T a , T b , T c and T d are themselves 4×4 matrices which connect cells within a line, and m, v are diagonal matrices containing elements from A. The evaluation of P a −1 .x proceeds in the same way as that of B −1 .x, and the problem is further reduced from 2 dimensions to 1. The solution of the one-dimensional problems, which are of the form Ta −1 .x (where T a is tridiagonal) is then a simple matter which terminates the recursion. There are three levels of recursion because the computational grid occupies a three-dimensional space.
In fact, the NF preconditioner can be shown to be equivalent to a strictly triangular factorization, but with L and U factors that include a good subset of the fill-in bands produced by a Cholesky factorization. However the computational work and storage required by NF is much less than would be required to calculate the fill-ins. This explains why NF performs better than ILU methods.
The NF algorithm was designed around rectangular grid geometries, and the innermost loops involve the solution of tridiagonal matrices representing lines of grid blocks. In practice, NF has been extended from this simple case in a number of ways, for example:—
Extension to coupled “multi-phase” problems with several independent variables (e.g. pressure, temperature and composition) in each grid block. In this case individual matrix elements are small (e.g. 4×4) dense matrices rather than scalars, but the algorithm is otherwise unchanged. Accommodation of “non-neighbor” connections that can be used to simulate some more complex geometries, such as local grid refinements Accommodation of “nine-point” finite difference terms (non-zero terms connecting diagonally adjacent grid blocks) “Multi-Color” orderings designed to allow efficient execution on parallel computers. Extra levels of recursion to deal with some classes of problem which can be thought of as four or five dimensional (multiple porosity models). Inclusion of higher order error correction terms on the l and u terms in the tridiagonal. Reference 5 describes a method for applying NF to 2D unstructured meshes and 3D prismatic meshes. The method retains the assumption of tridiagonal inner blocks.
In every case, the basic operation in the extended versions of NF remains as the solution of a tridiagonal matrix (or block tridiagonal in the multi-phase case) representing a strictly one-dimensional line of grid blocks. This restriction limits the application of NF in a number of ways:—
There is limited scope for “higher order” versions which produce a more accurate preconditioner at the cost of some additional computation. In contrast, the family of ILU factorizations achieve this by allowing more “fill-in”, so that the factorizations in the series ILU0, ILU1, ILU2 etc. are each more accurate than the one before. “Non-neighbor” connections break the method if they occur between grid-blocks in the same line. For example, in a model representing the surface of a sphere, the natural inner element is a circle rather than a line of blocks. Another example occurs in oil reservoir simulation, where a well passing through several grid blocks may introduce additional connections between non-adjacent cells. NF cannot be used for less regular geometries, for example the tetrahedral or irregular meshes common in CFD and structural analysis.
SUMMARY
According to a first aspect of the present invention there is provided a computer-implemented method of estimating the physical state of a physical system with known physical characteristics and subject to specified boundary conditions, comprising: representing the system as a plurality of nodes arranged in N-dimensional space, where N is an integer greater than 1, each node being associated with a set of physical properties, the physical properties associated with the nodes together forming a vector x when arranged in order, such that the vector x represents the physical state of the system; receiving physical data relating to the boundary conditions and the physical characteristics of the system, and determining from the received data the relations which must be satisfied by the component elements of the vector x, the number of relations being sufficient to determine the value of all elements of x; receiving or determining an initial estimate x 0 of the physical properties which will satisfy the relations; and for each of a plurality of iterations, estimating the change dx in the vector x that results in all of the relations being simultaneously satisfied, and at the end of each iteration updating the current value of x according to x=x+dx; wherein estimating dx comprises: determining an error vector r, each element of r representing the extent to which one of the required relations is not satisfied for the current value of the vector x; determining a matrix A, each element of A representing an estimate of the rate of variation of an element of r with respect to changes to an element of x; and at least approximately solving the matrix equation A.dx=r to obtain dx for each iteration; wherein the method used to solve the matrix equation A.dx=r is iterative, and uses a preconditioning matrix B as an approximation to A; wherein the order of nodes to form the vector x is determined such that the matrix A has a substantially nested block tridiagonal structure, and with at least some inner blocks having non-zero elements which connect an element of r to elements of x from more than three different nodes; and wherein B is a recursively defined incomplete block L.U factorization of A, with the blocking and recursion substantially mirroring the nested block tridiagonal structure of A.
The method may comprise performing an action using the vector x.
The action may comprise outputting the vector x.
The action may comprise operating an apparatus in dependence upon the vector x.
The action may comprise operating the physical system in dependence upon the vector x.
The method may comprise representing the nodes within a structure having a plurality of supercells, the number of supercells being less than the number of nodes, each node being assigned to a supercell according to its physical location or the value of a field variable at the node, or using a heuristic method which depends on the values of matrix coefficients, and further comprising ordering the supercells according to a first scheme, and ordering nodes within each supercell according to a second scheme.
The first scheme may comprise ordering the supercells according to a conventional nested factorization method.
The first scheme may comprise ordering the supercells according to a multi-color ordering designed adapted or arranged to allow efficient execution on parallel processors.
The second scheme may comprise ordering the nodes to reduce bandwidth.
The second scheme may comprise ordering the nodes along each of the N dimensions in turn.
The second scheme may comprise ordering the nodes within each supercell using the Reverse Cuthill-McKee method.
The structure of supercells may effectively be M-dimensional, with M being an integer less than N.
It may be that M=N−1.
Where the N-dimensional space has a dominant direction, the dominant direction may be aligned substantially normal to the M-dimensional structure.
The method may comprise calculating an exact solution for each supercell, and iterating to resolve interactions between supercells.
Each supercell may be assigned an elongate group of nodes, determined geometrically or using a heuristic method which depends on the values of matrix coefficients.
Each elongate group of nodes may be formed substantially along a line. Each of at least some supercells may be arranged to have at least 2 elongate groups of nodes assigned to it, preferably at least 5 elongate groups of nodes, and more preferably at least 10 elongate groups of nodes.
The method used to solve the matrix equation A.dx=r may comprise a preconditioned Krylov subspace based iterative method.
The method used to solve the matrix equation A.dx=r may comprise a preconditioned GMRES method.
The method used to solve the matrix equation A.dx=r may comprise a preconditioned Orthomin method.
The method may comprise representing the nodes within a supergrid structure having a plurality of supercells, the number of supercells being less than the number of nodes, each node being assigned to a supercell according to its physical location or the value of a field variable at the node, or using a heuristic method which depends on the values of matrix coefficients, and the supergrid structure comprising at least one layer of nodes, wherein the preconditioner is defined by the equation B =(I+n.P−1).(P+w), or a mathematical rearrangement thereof, wherein I is the unit matrix, P is a block diagonal matrix containing elements which connect nodes within a supergrid layer, and n and w are respectively lower and upper triangular matrices which connect nodes in different supergrid layers, and wherein individual block elements of P are defined by the equation P=(I+m.T−1).(T+v), or a mathematical rearrangement thereof, wherein I is the unit matrix, T is a block diagonal matrix containing elements which connect nodes within a supercell, and m and v are respectively lower and upper triangular matrices which connect nodes in different supercells within the same supergrid layer, and wherein individual block elements of T: (a) include corresponding elements from the original matrix A, but with the possible addition of corrections which are calculated to make B approximate A as closely as possible; (b) include non-zero elements which connect at least some nodes to three or more neighboring nodes; and (c) are such that matrix equations of the form T.q=r, where q and r are vectors, can be solved directly.
The physical characteristics and initial physical state at an initial time of a dynamically varying system are specified, together with initial boundary conditions at the initial time, and wherein the vector x determined by the method represents the physical state of the system at a discrete time interval dt after the initial time.
The method may comprise using the method to update the vector x in each of a plurality of successive time intervals, with the final physical state determined for each time interval acting as the initial physical state for the next time interval, if any, and with boundary conditions optionally varying over time.
The physical system may comprise a volume containing fluids, such as an oil reservoir, with each node representing a discrete finite volume of the system, and with the discrete finite volumes together representing the entire system.
The physical system may comprise a physical structure, such as a building or a vehicle, with each node corresponding to a boundary point of one or more finite elements of the structure, or an interior point of a finite element of the structure
Each physical property may comprise a measurable characteristic of the system.
The set of physical properties may comprise a measure of at least one of pressure, oil content, water content, gas content, displacement, stress, velocity, and temperature.
The physical characteristics may comprise at least one of physical dimensions, density, viscosity, permeability, porosity, elastic modulus and specific heat, and derivatives of these quantities with respect to physical properties such as pressure and temperature.
The order of nodes to form the vector x may be determined such that the matrix A has a nested block tridiagonal structure except for the presence of at least one extra non-zero element arising from local grid refinement, circular boundary conditions, short circuit links or other extensions to the method, where the number of extra non-zero elements is small relative to the total number of non-zero elements making up the matrix A, preferably less than 5 percent, more preferably less than 3 percent, and more preferably less than 1 percent.
According to a second aspect of the present invention there is provided an apparatus for estimating the physical state of a physical system with known physical characteristics and subject to specified boundary conditions, comprising: means for representing the system as a plurality of nodes arranged in N-dimensional space, where N is an integer greater than 1, each node being associated with a set of physical properties, the physical properties associated with the nodes together forming a vector x when arranged in order, such that the vector x represents the physical state of the system; means for receiving physical data relating to the boundary conditions and the physical characteristics of the system, and determining from the received data the relations which must be satisfied by the component elements of the vector x, the number of relations being sufficient to determine the value of all elements of x; means for receiving or determining an initial estimate x 0 of the physical properties which will satisfy the relations; and means for estimating, for each of a plurality of iterations, the change dx in the vector x that results in all of the relations being simultaneously satisfied, and at the end of each iteration updating the current value of x according to x=x+dx; wherein the means for estimating dx comprises: means for determining an error vector r, each element of r representing the extent to which one of the required relations is not satisfied for the current value of the vector x; means for determining a matrix A, each element of A representing an estimate of the rate of variation of an element of r with respect to changes to an element of x; and means for at least approximately solving the matrix equation A.dx=r to obtain dx for each iteration; wherein the method used to solve the matrix equation A.dx=r is iterative, and uses a preconditioning matrix B as an approximation to A; wherein the order of nodes to form the vector x is determined such that the matrix A has a substantially nested block tridiagonal structure, and with at least some inner blocks having non-zero elements which connect an element of r to elements of x from more than three different nodes; and wherein B is a recursively defined incomplete block L.U factorization of A, with the blocking and recursion substantially mirroring the nested block tridiagonal structure of A.
According to a third aspect of the present invention there is provided a program for controlling an apparatus to perform a method according to the first aspect of the present invention or which, when loaded into an apparatus, causes the apparatus to become apparatus according to the second aspect of the present invention.
The program may be carried on a carrier medium.
The carrier medium may be one of a storage medium and a transmission medium.
According to a fourth aspect of the present invention there is provided a storage medium containing a program according to the third aspect of the present invention.
Regarding the step of receiving or determining an initial estimate x 0 of the physical properties which will satisfy the relations, the final value of x is typically obtained by Newton's method starting from an initial estimate. Typically that estimate is trivial—just zero, or in the time dependent case, “unchanged”.
In the term “variable” physical properties is intended to draw a distinction between state variables such as pressure, displacement and so on which are the output from the procedure, and non-variable physical characteristics, such as porosity or Young's modulus which, together with the boundary conditions, are part of the problem definition.
An embodiment of the present invention has been developed as a revised version of the Nested Factorization (NF) algorithm, and is referred to herein for convenience as “Generalized Nested Factorization” (GNF). GNF relates to a “preconditioner”, an essential component of iterative methods for the solution of large sparse sets of linear equations. GNF and NF are most applicable in problems arising from spatially discretized mathematical models.
The NF algorithm is a preconditioner designed for the nested block tridiagonal matrices which arise when a topologically rectangular mesh is used. GNF extends its applicability to tetrahedral and other non-rectangular meshes, and, even on rectangular grids, provides new ways to solve previously intractable problems.
The NF preconditioner is not widely known, but has been the numerical core of Schlumberger's industry standard ECLIPSE® series of oil reservoir simulators for the past quarter century. The new GNF algorithm has proved to be significantly faster and more robust than the old version when implemented in ECLIPSE®.
NF is very efficient, but is limited to simple topologically rectangular grid structures. On these simple grids, it has repeatedly proved to be superior to the more general ILU factorization methods used elsewhere. When applied to rectangular grids, GNF has two important advantages over NF:
1. It provides a simple method trade the accuracy of the preconditioner for speed of calculation, so that previously intractable problems can be solved. 2. It provides a way to deal with certain non-neighbor connections which limit the applicability of NF 3. It provides great flexibility for ordering equations in a way that reflects the physical characteristics of the system
The GNF algorithm also overcomes the constraints which prevented NF from being used in other applications, such as CFD and structural analysis, which use more complicated computational meshes.
As previously mentioned, reference 5 describes a method for applying NF to 2D unstructured meshes and 3D prismatic meshes. The method is completely different to that proposed in an embodiment of the present invention, because it retains the assumption of tridiagonal inner blocks, which is much less general in its application.
As described with reference to FIG. 15 , for some preconditioners, the order is unimportant, but for NF and GNF it is critical. Also, in most practical preconditioners, including NF and GNF, L and U retain most of the sparsity of A, and most non-zeros are the same as the corresponding terms in A.
It should be noted that FIGS. 12 to 15 are equally applicable to GNF as they are to NF.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a 4×4×2 rectangular grid;
FIG. 2 illustrates a matrix structure for a 4×4×2 rectangular grid;
FIG. 3 illustrates a 4×4×2 rectangular grid with changed grid block ordering;
FIG. 4 illustrates a matrix structure for a 4×4×2 rectangular grid (revised order);
FIGS. 5A and 5C illustrate examples of “brick wall” supergrids;
FIG. 5B illustrates the matrix structure for the FIG. 5A example;
FIG. 6 illustrates a supercell matrix before and after RCM re-ordering;
FIG. 7 illustrates a truncated cone with a tetrahedral mesh (side and top views);
FIG. 8 illustrates a side view showing how it can be split into layers;
FIG. 9 illustrates a top view showing how each layer can be split into “supercells”;
FIG. 10 illustrates an original matrix structure for a truncated cone;
FIG. 11 illustrates a nested block tridiagonal matrix for a truncated cone;
FIG. 12 illustrates a procedure for history matching;
FIG. 13 illustrates a procedure for developing a plan;
FIG. 14 illustrates a procedure for reservoir simulation;
FIG. 15 illustrates a procedure for solving linear equations;
FIG. 16A , 16 B, 16 C and 16 D illustrate procedures for ordering in a 3D problem domain;
FIG. 17 illustrates a procedure for factoring a block matrix (preconditioner);
FIG. 18 illustrates a procedure for solving a block matrix (preconditioner);
FIGS. 19A , 19 B, 19 C and 19 D illustrate a 4×4×2 rectangular grid with two different GNF supergrids, and the corresponding matrix structures; and
FIG. 20 illustrates the supercell concept as applied to the NF ordering of FIG. 1 .
DETAILED DESCRIPTION
In an embodiment of the present invention, referred to herein for convenience as “Generalized Nested Factorization” or GNF, we attempt to address the above-mentioned limitations associated with NF by relaxing the requirement that the inner matrix blocks be strictly tridiagonal. In general we assume instead that there is a central band which contains all the non-zeros, and use appropriate methods for factoring and solving the band matrix. Of course, a tridiagonal is just a special case of the more general band matrix.
To exploit this new freedom, the grid-blocks are ordered differently, so that when we view its sparsity pattern, the coefficient matrix still has a nested tridiagonal structure, but the inner blocks are band matrices rather than tridiagonals. Reordering the equations does not change the solution, but in the case of GNF, it changes the approximate solution produced by the preconditioner.
GNF produces these new orders by superimposing a coarse two-dimensional supergrid over the three-dimensional problem domain (for two-dimensional problems, a one-dimensional supergrid is required). Each of the original cells is assigned to a block in the supergrid (a supercell) based on its physical location, or using a field variable such as potential. Alternatively, heuristic methods can be used to assign nodes to supercells based only on matrix coefficients. The supercells are ordered conventionally, and within each supercell, cells are reordered using the well-known “Reverse Cuthill-McKee” (RCM) method to minimize the bandwidth. The solution procedure provides an exact solution within each supercell, but iteration is required to resolve interactions between the supercells. The solution becomes more exact as the supergrid is made coarser, and in the limiting case, where there is only one supercell, GNF is actually a direct solver.
A very simple example of GNF applied to a rectangular grid can be obtained by modifying the cell numbering of the example in FIGS. 1 and 2 , so that the inner matrix contains two lines instead of one. FIGS. 3 and 4 show the revised numbering and the new matrix structure. In this case the supergrid is 2×2 with each supercell containing two lines from the original grid. The supergrid partitions are illustrated in bold lines in FIG. 3 . To provide a direct comparison with the original NF ordering method, if the supercell concept were applied to the original NF ordering as illustrated in FIG. 1 , each supercell would contain only a single line, as illustrated in FIG. 20 .
The construction of the preconditioning matrix, B is exactly as before, except that T is now a band matrix (pentadiagonal in this case).
B = (I + n″ · P −1 ) · (P + w″)
(B is block tridiagonal -
block elements are planes)
where
I
is the unit matrix
and
P = (I + m″ · T −1 ) · (T + v″)
(P is block tridiagonal -
block elements are lines)
and
T = d + I + u + m′ + v′ + n′ + w′ −
(T is a band matrix)
approx(ε)
and
ε = m″ · T −1 · v″ + n″ · P −1 · w″
(the uncorrected error
matrix)
Here, m′, v′, n′ and w′ represent the parts of m, v n and w that fall within the central band, and m″, v″, n″ and w″ represent the parts that do not.
This procedure requires more computational work than before, but the preconditioning matrix approximates A more accurately, because error terms of the form m′.T −1 .v′ and n′.P −1 .W′ have been eliminated. As a result, the convergence of the iteration will generally be faster.
Ever more accurate approximations can be created by including more lines in the central band. In the simple 4×4×2 block case, the next stage is to include 4 lines—either a whole plane (4×4×1) at a time (see FIGS. 19A and 19B for the GNF ordering and corresponding matrix structure), or in 4×2×2 blocks (see FIGS. 19C and 19D ). In both cases the number of error terms is greatly reduced.
The GNF ordering procedure will now be described, and how it differs from ordering in NF.
FIG. 16A shows the procedure used to create a GNF ordering.
1. The first step is to divide the problem domain into a one-dimensional set of layers. In the original NF algorithm, layers are single planes taken from the rectangular grid, oriented so that the strongest connections fall within the planes. NF cannot handle unstructured grids. GNF can extend this in several different ways:
a. For rectangular grids a simple extension is just to assign two or more adjacent planes to each layer. b. For both rectangular and unstructured grids, the node location can be used to decide on layering. For example, a layer might contain all nodes with an x coordinate in a specified range. c. For both rectangular and unstructured grids, a field variable such as potential can be used to define layers. For example, a layer might contain all nodes with starting potential between specified values. d. For both rectangular and unstructured grids, heuristic methods can be used to construct a pseudo-potential for each node using only the matrix coefficients as input. The pseudo-potential can then be used assign nodes to layers, as described above. (see FIGS. 16B and 16C for an example of a heuristic method for defining layers)
Whichever method is used it is important that layers be oriented so that the largest matrix elements connect nodes within the same layer, and the number and size of matrix elements connecting nodes in different layers is minimized. In some cases, this alignment is easy to achieve; for example in many geological models the vertical direction is dominant, because the formation thickness is much less than its horizontal extent. Other problems may be more or less isotropic, in which case alignment is not critical. The thickness of layers is also an important consideration. Thicker layers will generally produce a more accurate preconditioner, but increase the computer time required to factor and solve the preconditioning matrix. This is because the layer thickness helps determine the bandwidth of supercells (see below). For rectangular grids, the best balance is achieved when layers contain a small number of planes—usually between 2 and 5. For unstructured grids, the layer thickness is more difficult to quantify, but the optimum is similar. In general, the split should be uniform, so that the layers are of roughly equal thickness, but in some cases, it may be desirable to make the layers thicker around computational hot-spots. 2. Next we have to split each layer into a one-dimensional set of supercells which are the basic elements in the solution procedure. The methods used to split a layer into supercells may be geometric or heuristic. A geometric method uses the node location as the basis for assigning it to a supercell. Heuristic methods use only the matrix coefficients to perform the assignment. FIG. 16D shows an example of a heuristic method, which grows supercells by fusing fragments so that the largest matrix elements fall within supercells, but the bandwidth does not exceed specified target values. The heuristic method used to define layers ( FIGS. 16B and 16C ) can also be adapted to this task. For both methods, the supercells should be oriented so that the largest matrix elements connect nodes within the same supercell. The number and size of matrix elements connecting nodes in different supercells should be minimized, most particularly for supercells in different layers. In the original NF algorithm, the basic elements were single lines of grid blocks from a rectangular grid, and “supercells” are a generalization of that idea. In a rectangular grid, a GNF supercell could be a block including several adjacent lines. In an unstructured grid, there may be no lines as such—just groups of grid blocks which combine to form a similar cylindrical shape. In both cases, the cross sectional area of the cylinder, perpendicular to the dominant axis indicates the bandwidth of the matrix. The GNF preconditioner is most accurate when the supercells are large, but this implies a large bandwidth, and that increases the computational work required to factor and solve the preconditioner. A bandwidth of 10 or 20 (equivalent to a block of 10 or 20 adjacent lines of grid blocks in a rectangular grid) generally gives a good balance between accuracy and speed. Higher or lower bandwidths may work well in particular cases. The original NF algorithm gives a bandwidth of 1 (except where there are multiple solution variables in each grid block). There is no requirement that layers be split in the same way as their neighbors. Different splits can results in a “brick wall” supergrid—as shown in FIG. 5A for the 4×4×2 example, FIG. 5B shows the corresponding nested block tridiagonal matrix structure. FIG. 5C shows another arbitrary example. 3. Select the first layer. The first and last layers have only one neighboring layer. Other layers have two. 4. Start the layer block. 5. Select the first supercell in the current layer. The first and last supercells have only one neighboring supercell in the layer. Other supercells have two. 6. Start the supercell block 7. Add all cells in the current supercell. Use the RCM algorithm to optimize the order so that the bandwidth is minimized. 8. End the supercell block 9. If there are more supercells in this layer, select the next and go to step 7. 10. End the layer block 11. If there are more layers, then select the next and go to step 5. 12. Finish
FIGS. 16B and 16C show a heuristic procedure for dividing the problem domain into layers using only the values of matrix elements. No information about node locations or field variables is required. FIG. 16B shows the overall procedure, and FIG. 16C shows a procedure that is invoked at 3 steps in FIG. 16B .
1. Select an arbitrary start node s 1 . If the problem domain has multiple disconnected sections (islands), then s 1 must be on a previously untouched island 2. Use the procedure in FIG. 16C to compute the “pseudo distance”, dist1 of all nodes on the current island from s 1 3. Examine the elements of dist1 to find the node, s 2 which is furthest from s 1 . 4. Use the procedure in FIG. 16C to compute the “pseudo distance”, dist2 of all nodes on the current island from s 2 5. Examine the elements of dist2 to find the node, s 3 which is furthest from s 2 . 6. Use the procedure in FIG. 16C to compute the “pseudo distance”, dist3 of all nodes on the current island from s 3 7. Combine the dist2 and dist3 arrays to form a “pseudo-potential” for every node on the current island. The simplest useful combination is (dist2-dist3). 8. Assign nodes to layers according to the value of the pseudo-potential calculated in step 7. The pseudo-potential is used instead of node position, or other known field variables as a basis for splitting the problem domain into layers. 9. If there are any unprocessed islands, return to step 1.
In FIG. 16C , the steps are:
1. Set the distance for all nodes except the start-node to a very large (effectively infinite) value. For the start-node, set the distance to zero. The distance array is constrained to take non-negative integer values. Set dfront, the distance of the working front from the start-node, to zero. 2. Select the first node (n 1 ) which is at distance dfront from the start-node. On the first iteration, n 1 will be the start node. 3. If n 1 exists, skip to step 6 4. If all nodes have been processed, then exit 5. Increment dfront, and return to step 2. 6. Select the first neighbor (n 2 ) of n 1 . Nodes are neighbors if there is a non-zero matrix element linking them. 7. If n 2 exists skip to step 9 8. Select the next node (n 1 ) which is at distance dfront from the start-node, and return to step 3. 9. Use the value of the matrix elements for nodes n 1 and n 2 to compute d, the “distance” between the nodes. In general d is small if the matrix element linking n 1 and n 2 is large compared to other matrix elements for those nodes. d can take a number of non-negative integer values. Where the nodes are strongly coupled, d should be set to 0. 10. Check whether the distance from the start node to n 2 via n 1 is less than the previous best found (dist(n 1 )+d<dist(n 2 )). If not, skip to step 12. 11. Set dist(n 2 )=dist(n 1 )+d 12. Select the next neighbor (n 2 ) of n 1 and return to step 7.
Once the domain has been split into layers, heuristic methods can also be used to split each layer into an array of supercells. In general, the supercells form a mostly one-dimensional array, so that each supercell has no more than two neighbors within the layer. In addition, the nodes that are most strongly coupled fall within the same supercell, and the bandwidth of the supercell, after application of the RCM (Reversed Cuthill-Mckee) ordering procedure is below a specified limit. FIG. 16D shows a suitable procedure.
1. Initialize the lists of supercells and neighbors within the current layer. Here and elsewhere in this procedure, nodes in other layers are ignored. To start, each node is placed in a separate supercell, and the supercell neighbors are simply the node neighbors. 2. Set nfuse to zero. nfuse is the number of times two supercells have been fused in the current cycle. 3. Select the first supercell, s 1 . 4. Select the strongest link that is not marked as “bad” from s 1 to a neighboring supercell, s 2 . 5. If s 2 does not exist (we have eliminated all neighbors as candidates for fusion with s 1 ), skip to step 11 6. Use the RCM (Reversed Cuthill-Mckee) ordering procedure to compute the bandwidth of the supercell that would be formed by fusing s 1 and s 2 . 7. If the bandwidth is too great, skip to step 10. 8. Fuse s 1 and s 2 , to form an enlarged supercell, s 1 . The original s 2 is deleted. 9. Update the lists of supercells and their neighbors to reflect the fused supercell, and skip to step 11. 10. The bandwidth was too large: mark the link from s 1 to s 2 as “bad”. 11. Select the next supercell, s 1 . 12. If s 1 exists, then return to step 4. 13. No more supercells. We have completed a cycle through all supercells. Were any fused (nfuse>0)? If so, return to step 2. Otherwise, exit the procedure. In the procedures described above, the “Reversed Cuthill-Mckee” (RCM-reference 6) algorithm is used to reorder the supercell equations so that the overall bandwidth is minimized. FIG. 6 shows how RCM brings the outlying coefficients into the central band for an example which includes numerous non-neighbor connections and circular connectivity on one axis. In some simple cases with rectangular grids, RCM is not required because the supercells have a band matrix structure before the application of any re-ordering.
These procedures also assume that the supercells will have a band structure, and that a band solver will be used to solve the supercell equations directly. Band solvers are very efficient if the bandwidth is small (up to about 100). If the bandwidth is larger, it's better to use general purpose direct solvers for the inner block, and in this case GNF becomes a sort of hybrid direct/iterative method.
FIGS. 7 to 11 show the application of the GNF ordering procedure to a more complex space filling mesh, using a tetrahedral grid as an example. FIG. 7 shows side and top views of the object being modeled, complete with the computational mesh. The object might represent a building or a structural component of some sort. FIG. 8 shows how it can be split into layers, and FIG. 9 shows how each layer is split into supercells. In this case the supergrid is a 5×5 rectangular grid, and two of the supercells are empty. GNF solves the equations in each of the 23 remaining supercells directly, using a band solver, and resolves interactions between the supercells using a nested block ILU iteration.
FIG. 10 shows the matrix structure before application of the GNF reordering. The matrix clearly has some structure related to the way the gridding algorithm works, but the nested tridiagonal form required for GNF is not apparent. FIG. 11 shows the matrix after GNF ordering, with boxes added to emphasize the nested tridiagonal structure. The banded matrices for the 23 supercells can be seen on the diagonal (some are very small). The blocks immediately above and below the diagonal represent the links between adjacent supercells in a supergrid layer, and the bigger blocks above and below that represent the links between the 5 layers. The GNF factorization procedure is used to pre-calculate the terms in the block LU factorization of the preconditioning matrix so that it can be applied repeatedly during the iteration. The procedure is recursive. The factorization of the full matrix depends on the existence of a procedure to factorize sub-blocks. A sub-block is a block diagonal element representing all the connections within a single supergrid layer, or, at the deepest level of recursion, all the connections within a single supercell. However the procedure for a sub-block is in fact the same as the procedure to factorize the full matrix. The recursion is terminated when the sub-blocks are small enough to be factorized directly (i.e. the sub-block contains a supercell). FIG. 17 is flow diagram of the procedure.
1. Does this block have sub-blocks? If not skip to step 7. 2. Select the first sub-block 3. Factorize the sub-block (recurse to step 1) 4. If there are no more sub-blocks, then skip to step 8 5. If there are more sub-blocks, then calculate a correction to the next sub-block using the previously factorized sub-blocks. The correction usually takes the form of a diagonal matrix which is added to the diagonal of the next sub-block.
The correction is of the form approx(m.T −1 .v) where m and v are the block lower and upper matrix terms connecting current sub-block to the next. T is the current sub-block—which we have just factorized. In a standard NF version of this procedure, T would be a tridiagonal matrix, but in GNF, it is a banded matrix, or, in fact, any matrix. The approx function is commonly replaced by diag, rowsum or colsum, as defined below
diag(ε) the diagonal elements of ε rowsum(ε) the diagonal matrix formed by summing the elements of ε in rows colsum(ε) the diagonal matrix formed by summing the elements of ε in columns.
6. Select the next sub-block and return to step 3 7. Factorize the block directly. If this were NF rather than GNF, this step would be “Factorize the tridiagonal matrix in the current block directly”. 8. Finish. If we have recursed, then return to the previous recursion level.
The GNF solution procedure computes
q=B −1 .r
where B is the GNF approximation to the coefficient matrix A, and q and r are vectors.
B = (I + n · P −1 ) · (P + w)
(B is block tridiagonal -
block elements are
supergrid layers)
where
I
is the unit matrix
and
P = (I + m · T −1 ) · (T + v)
(P is block tridiagonal -
block elements are
supercells)
and
T = d + I + u − approx(ε)
(T is a band or other matrix)
and
ε = m · T −1 · v + n · P −1 · w
(the uncorrected error matrix)
Here, I and u are now the matrix coefficients connecting cells in the same supercell, m and v connect cells in different supercells, but in the same supergrid layer, and n and w connect cells in different supergrid layers. Many of the terms which would, in the NF preconditioner, have been in the m, v, n and w matrices are now included in l and u. For example, in FIGS. 4 , 5 B, 19 B and 19 D, the terms labelled m′, v′, n′ and w′ would be part of l and u in this revised notation, because they connect cells within the same supercell. As a result, there are many fewer terms in the error matrix, ε, and the GNF preconditioner is more accurate.
The procedure consists of two stages, a forward sweep to calculate
s=(I+m.P −1 ) −1 .r
and a backward sweep to compute
q=(P+w) −1 .s
where s is an intermediate vector. However this procedure, like factorization, is recursive, and smaller sub-block matrices are solved using the same procedure during both the forward and backward sweeps. The recursion terminates when the sub-block matrices are small enough to be solved directly.
FIG. 18 is a flowchart of the procedure for solving a block matrix:
1. Does this block have sub-blocks? If not skip to step 11 2. Select the first sub-block 3. If this is the last sub-block, skip to step 7 4. Solve the sub-block (recurse to step 1) 5. Compute a correction for the solution in the next sub-block. The correction uses the just-solved data from the current sub-block, and is of the form
m.s where m is the lower block matrix connecting the current and next sub-blocks and s is the solution obtained at step 4.
6. Select the next sub-block and return to step 3 7. Solve the sub-block (recurse to step 1) 8. If this is the first sub-block then skip to step 12 9. Compute a correction for the solution in the previous sub-block. The correction uses the just-solved data from the current sub-block, and is of the form
v.q where v is the upper block matrix connecting the current and previous sub-blocks and q is the solution obtained at step 7.
10. Select the previous sub-block and return to step 7 11. Solve the block matrix directly. If this were NF rather than GNF, this step would be “Solve the tridiagonal matrix in the current block directly”. 12. Finish. If we have recursed, then return to the previous recursion level.
It should be noted that many of the extensions to the original NF algorithm are equally applicable to GNF. For example:—
Extension to coupled “multi-phase” problems with several independent variables (e.g. pressure, temperature and composition) in each grid block. In this case individual matrix elements are small (e.g. 4×4) dense matrices rather than scalars, but the algorithm is otherwise unchanged. Accommodation of “non-neighbor” connections that can be used to simulate some more complex geometries, such as local grid refinements Accommodation of “nine-point” finite difference terms (non-zero terms connecting diagonally adjacent grid blocks) “Multi-Color” orderings designed to allow efficient execution on parallel computers. Extra levels of recursion to deal with some classes of problem which can be thought of as 4 or 5 dimensional (multiple porosity models). Inclusion of higher order error correction terms in the band matrix.
The following summaries at least some of the areas in which GNF differs from the prior art:—
The observation that the central blocks (supercells) in Nested Factorization do not have to be tridiagonal (or in the multi-phase case, block tridiagonal)—they can be band matrices, or indeed any other matrices. The observation that it is useful to reorder the grid blocks so that the supercells have increased bandwidth, and represent not just one, but several lines. The observation that a supergrid with a rectangular or “brick-wall” structure can be used to generate suitable orderings for GNF even if the underlying mesh is unstructured. This extension of the method allows a wide variety of more accurate factorizations to be used. It also allows computational effort to be concentrated in areas which are numerically difficult. The extension allows Nested Factorization to be used for general space filling mesh structures, and not just rectangular grids. Previously this was not thought to be practical. Tetrahedral and other mesh grids are commonly used in CFD, structural analysis and other problem domains. The use of RCM to reorder the elements in supercells minimizes the bandwidth, and allows the algorithm to deal with complex geometries.
It should be noted that, in the literature, there are many references to “block methods”, but, as noted in reference 7, that term has a variety of different meanings:—
In some cases, blocking refers to the reordering of computations in a scalar algorithm to make better use of cached data. The revised version is mathematically unchanged, but may execute more quickly on modern computers. Most references to “block methods” in discussion of BLAS, LAPACK and many other publicly accessible libraries are to this type of method. Many algorithms which apply to normal sparse matrices may also be applied where individual elements are not single scalars, but small dense matrices. Such cases may arise when there are several independent variables in each grid block (e.g. pressure, temperature, composition etc.). Both NF and GNF can be used in this way. Both NF and GNF also use blocking on larger scale subsets of the matrix—for example sections representing entire planes in a rectangular grid. In these cases, the block matrices are sparse.
Although an embodiment of the present invention has been described above particularly in relation to oil reservoir simulation, it will be appreciated that the present invention will find practical application in many other related areas, for example including but not restricted to the following:—
Computational Fluid Dynamics (CFD). CFD programs are used for problems involving moving fluids (liquids and gases)—particularly fluids moving around solid objects, such as vehicles, pumps, buildings, chemical apparatus or ventilation systems. The common feature of CFD programs is that they deal with the solution of the Navier-Stokes equations. However they may also deal with other issues. In this sense, a reservoir simulator is just a specialized CFD program: it deals with the Navier Stokes equations, and in addition with multi-phase flow, convection and diffusion, chemical changes, heat transfer, etc. So far as numerical methods go, there is naturally a large overlap between CFD and reservoir simulation. Much of FIG. 14 and all of FIG. 15 could apply to non-oil CFD problems. CFD programs discretize the problem domain—often using the finite element or finite volume method—and this leads to the need to solve large sparse linear equations. CFD programs often use generalized meshes, rather than the rectangular grids common in reservoir simulation, but because the mesh is two or three dimensional, the matrix can be cast in the nested block tridiagonal structure that GNF approximates. Many current CFD programs use Krylov subspace methods similar to those used in reservoir simulators, but NF is not much used outside reservoir simulators, probably because it does not deal with generalized meshes. Ground-water modelling is quite similar to oil reservoir simulation, but involves water rather than hydrocarbons. Salinity and/or chemical impurities may also be variables, and the model may also deal with ground subsidence, land drainage and irrigation. However as with an oil reservoir simulator, the flow domain is discretized using a rectangular or other mesh, which leads to nested block tridiagonal matrices of the type which can be approximated effectively by GNF. Structural Analysis deals with solid artifacts, such as buildings, vehicles and mechanical components, and the usual goal is to assess the ability to withstand loads. The methods used to solve the problem are quite similar to those used in CFD. The structural system being studied is discretized—modeled by a set of finite elements interconnected at points called nodes. Each element has physical properties such as thickness, density, elasticity etc., and may be one, two or three dimensional. Typical 3D elements are tetrahedral or hexahedral, with nodes placed at vertices, and possibly in the element faces. The elements are interconnected only at the exterior nodes, and the program solved for various physical indicators, such as vector displacements at each node. Smaller elements are used to produce a more accurate model around critical parts of the structure, and unstructured meshes are the norm. As before, this leads to a matrix which, with appropriate ordering of the variables, has a nested block tridiagonal structure which is amenable to approximation using GNF. Weather Forecasting and Climate Modeling Programs can, like reservoir simulators, be regarded as specialized CFD applications. Different models use different methods to solve the mathematical equations which model weather and climate dynamics. Some, including many regional models used for detailed short-term forecasts, use a finite difference method to discretize a three dimensional section of the atmosphere. This leads to a matrix which can be cast in the nested block tridiagonal form that GNF approximates. Global models may have circular boundary conditions, which have an impact on matrix structure but with appropriate re-ordering (see RCM below) this is not a problem for GNF.
The reader is referred to the following documents at least some of which are referenced above by number:
(1) Saad, Yousef (2003) Iterative Methods for Sparse Linear Systems, Second Edition, published by SIAM, ISBN 0-89871-534-2 (2) Appleyard J. R., Cheshire I. M., and Pollard R. K. (1981) “Special techniques for fully-implicit simulators.” In Proc. European Symposium on Enhanced Oil Recovery Bournemouth, UK, pages 395-408 (3) Appleyard J. R. and Cheshire I. M. “Nested factorization.” In Seventh SPE Symposium on Reservoir Simulation, pages 315-324, 1983. paper number 12264. (4) Parallel computing—“Using ECLIPSE Parallel”—White Paper (2003) www.sis.slb.com/media/about/whitepaper-parallelcomputing.pdf (5) Kuznetsova, N. N. et al, (2007) “The Family of Nested Factorizations”, Russ J Numer. Anal. Math. Modeling, Vol. 22,. No. 4 pp 393-412 (6) George A. (1971) “Computer Implementation of the Finite Element Method”, Tech Rep STAN-CS-208, Department of Computer Science, Stanford University, Stanford, Calif. (7) Demmel, James W, Higham, Nicholas J and Schreiber, Robert S (1992), “Block LU Factorization” available at ftp.netlib.org/lapack/lawns/lawn40.ps
It will be appreciated that operation of one or more of the above-described components can be controlled by a program operating on a device or apparatus. Such an operating program can be stored on a computer-readable medium, or could, for example, be embodied in a signal such as a downloadable data signal provided from an Internet website. The appended claims are to be interpreted as covering an operating program by itself, or as a record on a carrier, or as a signal, or in any other form.
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A computer-implemented method of estimating the physical state of a fluid reservoir with known physical characteristics and subject to specified boundary conditions is provided. The fluid reservoir is represented as a plurality of nodes arranged in N-dimensional space, where N>1, each node representing a discrete finite volume of the fluid reservoir and being associated with a set of physical properties, the physical properties associated with the nodes together forming a vector x when arranged in order, with the vector x representing the physical state of the fluid reservoir, and where the discrete finite volumes together represent the entire fluid reservoir. The method includes for each of a plurality of iterations, estimating a change dx in the vector x that results in all relations being simultaneously satisfied, and at the end of each iteration updating the current value of x according to x=x+dx.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
This is a continuation application of applications Ser. No. 389,739 filed Aug. 20, 1973 now abandoned.
SUMMARY OF THE INVENTION
This invention relates to prefabricated building sections or room units and to methods for the manufacture of such sections or units.
According to one aspect of the invention, there is provided a method for the manufacture of prefabricated building sections or room units comprising making a panel and subsequently connecting at least one frame beam and/or at least one wall or other partition to that panel, wherein making the panel comprises the steps of forming a frame of beams, arranging a first plate on said frame, arranging a second plate on said frame and providing the panel with at least one tubular service conduit, the completed panel subsequently having the frame beam and/or wall or other partition connected thereto.
For a better understanding of the invention, and to show how the same may be carried into effect, reference will now be made, by way of example, to the accompanying drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a floor panel constructed in accordance with the invention,
FIG. 2 is a sectional view, to an enlarged scale, illustrating the formation of part of the floor panel in a mould,
FIG. 3 is a further sectional view, to the same scale as FIG. 2, showing a subsequent stage in the formation of the floor panel in a jig,
FIG. 4 is a perspective view, to an enlarged scale, showing additional details of the construction of one corner of the floor panel of FIG. 1,
FIG. 5 is a perspective view to the same scale as FIG. 1 showing the floor panel of that Figure provided with walls and frame beams, the latter being in the form of supporting columns,
FIG. 6 is a perspective view, partly in section and to the same scale as FIG. 4, showing the form of cooperation between the panel and the lower end of one of the supporting columns of FIG. 5,
FIG. 7 is a diagrammatic elevation, to a reduced scale, illustrating a block of apartments or other dwellings formed from building sections or room units of the general kind illustrated in FIG. 5, and
FIG. 8 is a horizontal section through part of one story of the building shown diagrammatically in FIG. 7.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIGS. 1 to 3 of the drawings, the floor panel that is illustrated has a frame which is generally indicated by the reference 1 and which is formed from a plurality of metal beams. Two plates 2 and 3 are arranged inside the frame 1 in parallel but spaced apart relationship, said plates 2 and 3 preferably being made from concrete which is cast in the frame 1. The frame 1 which is illustrated is of oblong configuration having two longer side beams 4 and 5 that are parallel to one another and two shorter end beams 6 which are also parallel to one another and perpendicular to the beams 4 and 5. The beams 4, 5 and 6 are all of channel-shaped cross-section and their ends are welded to each other at the four corners of the frame 1. The frame 1 that is illustrated has a length 7 of substantially 12 meters and a width 8 of substantially 3 meters, the length 7 of the frame thus being substantially four times the width 8 thereof.
In order to cast the concrete plates 2 and 3 inside the frame 1 and to obtain a satisfactory bond between the metal beams and the concrete of said plates, the longer beams 4 and 5 are perpendicularly interconnected by a large number of ribs 9 that are of approximately Z-shaped cross-section. The cross-section is, in fact, such that each rib 9 has upper and lower horizontal limbs 11 that are perpendicularly interconnected by a vertical limb in such a way that the upper and lower horizontal limbs are substantially out of vertical alignment with one another. The arrangement of the ribs 9 is also such that, as seen in FIG. 1 of the drawings, a substantially horizontal plane containing the upper limbs 11 thereof is located at a level beneath that of a substantially horizontal plane containing the upper limbs 10 of the channel-shaped (in cross-section) frame beams 4 and 5. Metallic mesh 12 which serves as a reinforcement is arranged above the upper limbs 11 of the ribs 9 (see FIG. 3 of the drawings) and is welded to the beams of the frame 1 after the construction of that frame. If desired, further reinforcing mesh may be provided in contact with the upper limbs 11 of the ribs 9. After the frame 1 has been assembled and has been provided with the ribs 9 and the metallic mesh 12, the whole assembly is inverted and is placed on a jig table 15 as shown in FIG. 2 of the drawings. Concrete is then poured to form the plate 2 to a vertical thickness 16 which may, for example, have a magnitude of substantially five centimeters. An upright concrete rim 17 that is disposed internally of the frame beams 4, 5 and 6 is poured at the same time as the plate 2.
When the plate 2 and rim 17 have set, the partially completed panel is lifted from the jig table 15, subsequently inverted to bring it to its original disposition and is then lowered onto a jig table 15A as shown in FIG. 3 of the drawings. However, before putting the panel on the jig table 15A, a metallic reinforcing mesh 20 is welded between the lower limbs 19 of the frame beams 4, 5 and 6. When required, as will usually be the case, tubular conduits 21 for electric cables together with junction and connection boxes 22 and 23 are placed in position with the metallic reinforcing mesh 20 and may, if desired, be secured to that mesh. The concrete or other castable material of the plate 3 is subsequently poured or otherwise introduced onto the jig table 15A around the parts 20 to 23 inclusive as shown in FIG. 3 of the drawings. Holes may be formed through the plate 2 to enable the semi-liquid concrete or other castable material to be brought to the position in which it is to set to form the plate 3. However, as an alternative, the concrete or other castable material that is to form the plate 3 may be arranged on the jig table 15A before the partially completed panel is itself lowered onto that jig table. When this method of formation is employed, it is possible to lower the partially completed panel onto the jig table 15A in such a way that the lower limbs 19 of the beams of its frame 1 penetrate into the waiting semiliquid concrete or other castable material to a sufficient extent to bring those limbs firmly into contact with the upper surface of the jig table 15A. Once the concrete or other castable material of the plate 3 has set or otherwise hardened, the substantially completed frame 1 can be lifted away from the jig table 15A ready for use as part of a prefabricated building that is to be erected or for use as part of a prefabricated building section or room unit that is itself destined for employment as one part of a prefabricated building.
The panel whose construction has been described with particular reference to FIGS. 1 to 3 of the drawings is intended for use as a floor panel but it is emphasized that panels intended for use as walls and other partitions are made in a similar way. In the case of the floor panel whose construction has been described, the plate 2 is intended to serve as an upper load-bearing surface for human beings, furniture and so on whereas the lower plate 3 is intended to serve as a ceiling for the room or other space that may be formed beneath the floor penel in question. If the floor panel should be part of a story located at ground level, then the plate 3 will co-operate with an underlying foundation. FIG. 5 of the drawings illustrates the floor panel that has been described forming the bottom of a prefabricated three-dimensional building section or room unit. This section or unit is assembled by securing a number of frame beams in the form of supporting columns 40, 41, 42, 43, 44 and 45 inclusive to the panel. In the example which is being described, there are six of the columns 40 to 45 but this is not, of course, essential and other numbers of columns may be used where appropriate. Openings 46, 47, 48, 49, 50 and 51 inclusive (FIG. 1) are formed in the floor panel for the reception of the lower ends of the columns 40 to 45 inclusive and these openings are defined partly by the upper plate 2 and partly by the upper limbs 10 of the beams 4, 5 and 6 of the frame 1.
The connection of each supporting column 40 to 45 to the corresponding one of the openings 46 to 51 is similar and, accordingly, it is only necessary to describe the cooperation of the supporting column 45 with the opening 51 in detail. As can be seen in FIG. 6 of the drawings, the column 45 has a metallic core which, in the example that is being described, is in the form of a tube 52 of substantially square cross-section. This cross-sectional configuration is by no means essential and the core of the column 45 may have other cross-sectional shapes such as, for example, a U-shape or a J-shape. The illustrated tube 52 is surrounded by a layer of fire-proof material 53 such as concrete. The lower end of the tube 52 fits in a matchingly shaped portion 54 of the opening 51 which portion 54 is defined between the frame beams 4 and 6 at one corner of the frame 1. The tube 52 is welded to the beams 4 and 6 at the locations of both the upper and the lower limbs of those beams, the plate 3 and the lower limbs of the beams of the frame 1 being formed with similar openings to the openings 46 to 51 inclusive that are located at the top of the floor panel. The upper and lower openings are, of course, in vertical register with one another.
After the tube 52 has been welded to the beams 4 and 6, it is provided with a layer or sheath of the surrounding fire-proof material 53 to match the remainder of the column 45 that projects above the plate 2. In the illustrated embodiment, the material 53 is concrete and this material, or some other castable fire-proof material, can be cast or otherwise formed around the lower end of the tube 52 after that end has been welded to the frame 1. In order to surround the tube 52 with the concrete affording the fire-proof material 53, that concrete must lie between the upper and lower limbs 55 and 56 of the beams 4 and 6 and the sides 57 and 58 of the substantially square cross-section tube 52. Holes 59 through which the semi-liquid concrete or other castable material can be introduced into these regions are accordingly formed in the upper limbs 55 of the beams 4 and 6. The concrete that affords the portion of the layer fire-proof material 53 that surrounds the sides of the tube 52 remote from the two sides 57 and 58 thereof is kept in its appointed position during setting by jig plates 60 and 61 (FIGS. 4 and 6) that extend between the plates 2 and 3 and into the recesses between the limbs 55 and 56 of the beams 4 and 6. These jig plates 60 and 61, which may be integral, may be placed in their appointed positions at any convenient time during the formation of the plates 2 and 3 of the floor panel or even after the tube 52 has been welded to the frame 1 provided that the necessary access apertures are still available. The concrete or other castable material of the layer 53 that is in the region of the jig plates 60 and 61 can also be introduced through the holes 59.
The fire-proof material 53 can be cast easily around that portion of the column 45 that is located above the plate 2 merely by temporarily arranging a removable jig around said tube 52. Layers of fire-proof material can be provided around the cores of the other columns 40 to 44 inclusive in a similar manner. The necessary jigs are removed immediately after the concrete or other castable material has set or otherwise hardened around the cores of the columns. As an alternative, it is possible to provide the tubes 52 or other column cores with the surrounding layers of fire-proof material 53 before the columns are secured to the frame 1. Under these circumstances, the lowermost ends of the tubes affording the cores will normally be left bare and the concrete or other castable material required to form the fire-proof material 53 around the lower ends thereof will be provided after securing the cores to the frame 1. Walls or other partitions can be arranged between the various supporting columns 40 to 45 above the plate 2 of the floor panel in accordance with the particular part of a building that is to be formed by the building section or room unit in question. The required division of the internal space of the building section or room unit by the walls or other partitions can be effected during the prefabrication of the building section or room unit by forming the partitions from vertical beams 70 and 71 (FIG. 5) between which is a wall portion 72 made of a light cast material, such as concrete. Such a partition comprising the beams 70 and 71 and the intervening wall portion 72 can be prefabricated separately and may then be arranged in a simple manner between two of the supporting columns of the building section or room unit. In the case illustrated in FIG. 5 of the drawings, the partition under discussion is arranged between the supporting columns 43 and 44. The lowermost ends of the beams 70 and 71, which will normally be metal beams, can be welded to the upper limb 55 of the frame beam 4 to secure the partition in position.
The building section or room unit that is illustrated in FIG. 5 of the drawings may be employed as part of a prefabricated dwelling. FIG. 7 diagrammatically illustrates a multi-story block of apartments formed principally from such building sections or room units and FIG. 8 of the drawings shows the internal arrangements of some apartments or flats in one story thereof. Each story comprises a plurality of adjoining building sections or room units and includes two such sections or units 81 and 82 that are located alongside one another at one end of the building to constitute an entrance hall or vestibule for the story concerned and a staircase 83 for access to other stories. The section or unit 81 also comprises two adjoining lift or elevator shafts 84 and 85. It will be evident that different apartments may require more or less space and apartments or flats of different sizes may be provided in one story, as shown in FIG. 8 of the drawings, by forming them from different numbers of building sections or room units. Four adjoining building sections or room units 86, 87, 88 and 89 constitute a larger apartment 90 having a width of substantially 12 meters whereas three such sections or units constitute a smaller apartment 91 having a lesser width of substantially 9 meters. It will be evident from FIG. 8 that each building section or room unit is provided with appropriate partitions and, during the prefabrication of the sections or units, all of the required main service and other service conduits are incorporated in the floor panels, walls or other partitions. FIGS. 2 and 3 of the drawings show the provision of the tubular conduit 21 and associated junction and connection boxes 22 and 23 but, of course other conduits, such as gas pipes, water pipes for water supply and heating, conduits for television and radio aerial leads and the like can all be incorporated in a similar manner. Kitchen appliances, sanitary equipment and the like are also preferably built into the sections or units during their prefabrication so that a prefabricated building incorporating such sections or units only needs those sections or units to be placed in their correct positions relative to one another during the erection of the building thus substantially limiting the finishing work to the interconnection of the various supply and waste pipes, service conduits and the services carried by those conduits. It will be noted from FIG. 8 of the drawings that, at the junctions of the apartments 90 and 91 with their neighbors, the longer sides of the sections or units that afford those junctions provide double walls thus greatly increasing the noise insulation and security against the spreading of fires.
FIG. 8 of the drawings indicates by an arrow V the direction in which the building section or room unit 87 of FIG. 8 is seen alone in FIG. 5 of the drawings. The section or unit 87 includes four walls or other partitions 92, 93, 94 and 95 the last of which is afforded by the previously mentioned vertical beams 70 and 71 and the intervening wall partition 72. The prefabrication of the floor panels is facilitated by providing each of them with the spaced apart upper and lower plates 2 and 3 so that both the load-supporting floor of an upper story and the ceiling of an underlying story are furnished by a single unit. It is emphasized that, as previously mentioned, a panel similar to that of the kind that has been described with particular reference to FIGS. 1 to 3 of the drawings may be intended fo use as a vertical or at least upright double-skinned wall or other partition. The plates 2 and 3 may, if desired, be formed from some material other than concrete when use as a wall or other partition is intended. The upper plate 2 of the floor panel shown in FIGS. 1 to 3 of the drawings incorporates three tubular conduits 21 for electric cables although only one of those conduits is actually visible in FIG. 3 of the drawings. It is to be noted that different numbers of conduits may be provided particularly in the cases in which the panels are to form walls or other partitions in which the two plates 2 and 3 are formed from the same material. In such a case, both of the plates 2 and 3 may incorporate tubular conduits that are similar to the illustrated conduit 21 and junction and connection boxes 22 and 23 will then be provided in both the plates 2 and 3 so that electricity and other services may be available at both sides of the panel concerned. The conduits 21 that have been mentioned, and further conduits, may be arranged in the space between the two plates 2 and 3. When the described panel is to serve as a floor panel, it is advantageous to form the upper plate 2 from heavy or coarse concrete and the lower plate 3 from light or fine concrete. When the panels are to form vertical or at least upright walls or other partitions in generally box-shaped building sections or room units, some of the beams 4,5 and 6 will be vertically and some horizontally disposed and may be connected to horizontal beams of the skeleton of the section or unit concerned to facilitate the panels being retained in their appointed vertical positions and to facilitate further panels being retained in appointed horizontal positions as floors or ceilings or both.
Although various features of the methods of manufacturing building sections or room units have been described and illustrated in the accompanying drawings, and various features of the sections or units themselves, will be set forth in the following claims as inventive features, it is emphasized that the invention is not necessarily limited to those features and includes within its scope each of the constructional steps described illustrated and each part described or illustrated both individually and in various combinations.
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A rectangular panel manufactured for inclusion in prefabricated building sections having a steel frame of beams in with top and bottom horizontal flanges extending inwardly and flush of the top with a concrete floor slab and on the bottom with a ceiling member, the space between same receiving electrical conduits and the like mounted on the floor slap or ceiling member or both. The longer beams are connected by ribs having approximately a Z-shaped cross-section. At each corner of the panel an opening is provided for a vertical steel tube, each opening being defined in part by recesses in the adjacent flanges to which the tube is welded. A jig plate is provided within the panel to surround the tube together with the corner structure and a castable fireproof material is introduced between the tube and jig plate on the outer sides and between the tube and the beams proximate the corner, apertures being provided in the flanges for this purpose if necessary.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims benefit of U.S. Provisional Patent Application Ser. No. 60/592,708, filed on Jul. 30, 2004, which application is herein incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to methods and apparatus for drilling with top drive systems. Particularly, the invention relates to methods and apparatus for retrieving a downhole tool through a top drive system. More particularly still, the invention relates to running a wireline through the top drive system to retrieve the downhole tool and running a wireline access below the top drive system. The invention also relates to performing a cementing operation with the top drive system.
2. Description of the Related Art
One conventional method to complete a well includes drilling to a first designated depth with a drill bit on a drill string. Then, the drill string is removed, and a first string of casing is run into the wellbore and set in the drilled out portion of the wellbore. Cement is circulated into the annulus behind the casing string and allowed to cure. Next, the well is drilled to a second designated depth, and a second string of casing, or liner, is run into the drilled out portion of the wellbore. The second string is set at a depth such that the upper portion of the second string of casing overlaps the lower portion of the first string of casing. The second string is then fixed, or “hung” off of the existing casing by the use of slips which utilize slip members and cones to wedgingly fix the second string of casing in the wellbore. The second casing string is then cemented. This process is typically repeated with additional casing strings until the well has been drilled to a desired depth. Therefore, two run-ins into the wellbore are required per casing string to set the casing into the wellbore.
As more casing strings are set in the wellbore, the casing strings become progressively smaller in diameter in order to fit within the previous casing string. In a drilling operation, the drill bit for drilling to the next predetermined depth must thus become progressively smaller as the diameter of each casing string decreases in order to fit within the previous casing string. Therefore, multiple drill bits of different sizes are ordinarily necessary for drilling in well completion operations.
Another method of performing well completion operations involves drilling with casing, as opposed to the first method of drilling and then setting the casing. In this method, the casing string is run into the wellbore along with a drill bit for drilling the subsequent, smaller diameter hole located in the interior of the existing casing string. The drill bit is operated by rotation of the drill string from the surface of the wellbore, and/or rotation of a downhole motor. Once the borehole is formed, the attached casing string may be cemented in the borehole. The drill bit is either removed or destroyed by the drilling of a subsequent borehole. The subsequent borehole may be drilled by a second working string comprising a second drill bit disposed at the end of a second casing that is of sufficient size to line the wall of the borehole formed. The second drill bit should be smaller than the first drill bit so that it fits within the existing casing string. In this respect, this method typically requires only one run into the wellbore per casing string that is set into the wellbore.
In some operations, the drill shoe disposed at the lower end of the casing is designed to be drilled through by the subsequent casing string. However, retrievable drill bits and drilling assemblies have been developed to reduce the cost of the drilling operation. These drilling assemblies are equipped with a latch that is operable to selectively attach the drilling assembly to the casing. In this respect, the drilling assembly may be preserved for subsequent drilling operations.
It is known in the industry to use top drive systems to rotate the casing string and the drill shoe to form a borehole. Top drive systems are equipped with a motor to provide torque for rotating the drilling string. Most existing top drives use a threaded crossover adapter to connect to the casing. This is because the quill of the top drive is not sized to connect with the threads of the casing.
More recently, top drive adapters has been developed to facilitate the casing running process. Top drive adapters that grip the external portion of the casing are generally known as torque heads, while adapters that grip the internal portion of the casing are generally known as spears. An exemplary torque head is disclosed in U.S. patent application Ser. No. 10/850,347, entitled Casing Running Head, which application was filed on May 20, 2004 by the same inventor of the present application. An exemplary spear is disclosed in U.S. Patent Application Publication No. 2005/0051343, by Pietras, et al. These applications are assigned to the assignee of the present application and are herein incorporated by reference in their entirety.
One of the challenges of drilling with casing is the retrieval of the drilling assembly. For example, the drilling operation may be temporarily stopped to repair or replace the drilling assembly. In such instances, a wireline may be used to retrieve the latch and the drilling assembly. However, many existing top drives are not equipped with an access for the insertion or removal of the wireline, thereby making the run-in of the wireline more difficult and time consuming. Additionally, during the temporary stoppage to retrieve the drilling assembly, fluid circulation and casing movement is also typically stopped. As a result, the casing in the wellbore may become stuck, thereby hindering the rotation and advancement of the casing upon restart of the drilling operation.
There is a need, therefore, for methods and apparatus for retrieving the drilling assembly during and after drilling operations. There is also a need for apparatus and method for fluid circulation during the drilling assembly retrieval process. There is a further need for apparatus and methods for running a wireline while drilling with casing using a top drive. There is yet a further need for methods and apparatus for accessing the interior of a casing string connected to a top drive.
SUMMARY OF THE INVENTION
In one embodiment, a top drive system for forming a wellbore is provided with an access tool to retrieve a downhole tool. The top drive system for drilling with casing comprises a top drive; a top drive adapter for gripping the casing, the top drive adapter operatively connected to the top drive; and an access tool operatively connected to the top drive and adapted for accessing a fluid passage of the top drive system. In one embodiment, the top drive system is used for drilling with casing operations.
In another embodiment, a method for retrieving a downhole tool through a tubular coupled to a top drive adapter of a top drive system is provided. The method comprises coupling an access tool to the top drive system, the access tool adapted to provide access to a fluid path in the top drive system and inserting a conveying member into the fluid path through the access tool. The method also includes coupling the conveying member to the downhole tool and retrieving the downhole tool. In another embodiment, the method further comprises reciprocating the tubular. In yet another embodiment, the method further comprises circulating fluid to the tubular. Preferably, the tubular comprises a casing.
In another embodiment still, a method for releasing an actuating device during drilling using a top drive system is provided. The method comprises providing the top drive system with a top drive, a top drive adapter, and a launching tool, the launching tool retaining the actuating device, and operatively coupling the top drive, the top drive adapter, and the launching tool. The method also includes gripping a tubular using the top drive adapter and actuating the launching tool to release the actuating device.
In another embodiment still, a method for performing a cementing operation using a top drive system is provided. The method comprises providing the top drive system with a top drive, a top drive adapter, and a cementing tool and operatively coupling the top drive, the top drive adapter, and the cementing tool. The method also comprises gripping the casing using the top drive adapter and supplying a cementing fluid through the cementing tool.
BRIEF DESCRIPTION OF THE DRAWINGS
So that the manner in which the above recited features and other features contemplated and claimed herein are attained and can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to the embodiments thereof which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
FIG. 1 shows an exemplary embodiment of a top drive system having an access tool.
FIG. 2 shows an alternative top drive system having another embodiment of an access tool.
FIG. 3 shows another embodiment of an access tool.
FIG. 4 shows yet another embodiment of an access tool.
FIG. 5 shows an alternative top drive system equipped with yet another embodiment of an access tool.
FIG. 6 shows yet another embodiment of an access tool.
FIG. 6A is a partial cross-sectional view of the access tool of FIG. 6 .
FIG. 7 is a partial cross-sectional view of another embodiment of an access tool.
FIG. 8 shows an embodiment of an access tool having a launching tool.
FIG. 8A is a cross-sectional view of the access tool of FIG. 8 .
FIG. 8B illustrates an embodiment of retaining a plug in a casing string.
FIG. 8C illustrates another embodiment of retaining a plug in a casing string.
FIG. 9 shows an alternative top drive system having a cementing tool.
FIG. 10 is a partial cross-sectional view of the cementing tool of FIG. 9 .
FIG. 10A is another cross-sectional view of the cementing tool of FIG. 9 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In one embodiment, a top drive system for drilling includes a top drive adapter for gripping and rotating the casing and a top drive access tool. The top drive access tool is adapted to allow access into the various components connected to the top drive. The access tool is equipped with a sealing member to prevent leakage and hold pressure during fluid circulation. In another embodiment, the access tool is adapted to allow the top drive to reciprocate the casing during wireline work.
FIG. 1 shows an embodiment of a top drive system 100 fitted with a top drive access tool 110 . As shown, the system 100 includes a spear type top drive adapter 20 and a top drive 10 for energizing the spear 20 . The spear 20 includes radially actuatable gripping members 22 for engaging the inner diameter of the casing. Although a mechanically actuated spear is preferred, spears actuated using hydraulics, pneumatics, or electric are equally suitable. The lower portion of the spear 20 includes a valve 24 for supplying fluid and a seal member 26 to prevent leakage. Fluids such as drilling mud may be introduced into the top drive system 100 through a fluid supply line 5 disposed at an upper portion of the top drive 10 . An elevator 30 is suspended below the top drive 10 by a pair of bails 35 coupled to the top drive 10 . It must be noted that in addition to the spear, other types of top drive adapters such as a torque head are also contemplated.
In one embodiment, the top drive access tool 110 is coupled to the upper portion of the top drive 10 . The access tool 110 is adapted to allow wireline access into the interior of the casing in order to perform wireline operations such as retrieval of the drilling assembly or the latch attached to a drilling assembly. As shown in FIG. 1 , the access tool 110 includes a connection member 112 for connecting to the top drive 10 . The connection member 112 includes a bore to receive the wireline 15 and a pack-off assembly 114 for preventing leakage. The pack-off assembly 114 may comprise an elastomeric seal element and sized to accommodate different wireline sizes. A sheave assembly 116 is connected to the connection member 112 . The sheave assembly 116 facilitates and supports the wireline 15 for entry into the top drive 10 . Preferably, the sheave assembly 116 is arranged such that it does not obstruct the operation of the traveling block, which is typically used to translate the top drive 10 . In one embodiment, the sheave assembly 116 includes two wheels 117 A, 117 B adapted for operation with the top drive 10 . The wheels 117 A, 117 B may include grooves disposed around the circumference of the wheels 117 A, 117 B for receiving the wireline 15 . The wireline 15 may be routed around the wheels 117 A, 117 B of the sheave assembly 116 to avoid the traveling block and directed into the pack-off assembly 114 and the connection member 112 . In another embodiment, the fluid supply line 5 may be connected to the connection member 112 of the access tool 110 . A suitable access tool is disclosed in U.S. Pat. No. 5,735,351 issued to Helms, which patent is herein incorporated by reference in its entirety. During wireline operations, the top drive system 100 provided in FIG. 1 may be operated to reciprocate the casing in the wellbore and circulate fluid through the casing. It is believed that these operations will reduce the likelihood of the casing sticking to the wellbore. In addition to a wireline 15 , the embodiments described herein are equally applicable to a cable or other types of conveying members known to a person of ordinary skill in the art.
FIG. 2 illustrates another embodiment of a top drive system 200 equipped with an access tool 210 . Similar to the embodiment shown in FIG. 1 , the top drive system 200 includes a spear type top drive adapter 20 coupled to the top drive 10 . However, the elevator and the bails have been removed for clarity. In this embodiment, the access tool 210 is disposed between the top drive 10 and the spear 20 . The access tool 210 defines a tubular having a main portion 212 and one or more side portions 214 attached thereto. The upper end of the main portion 212 is connected to the top drive 10 , and the lower end is connected to the spear 20 . Extension subs or tubulars 220 A, 220 B may be used to couple the access tool 210 to the top drive 10 or the spear 20 . A central passage 213 in the main portion 212 is adapted for fluid communication with the top drive 10 and the spear 20 . The side entry portions 214 have side entry passages 215 in fluid communication with the central passage 213 . In the embodiment shown, the access tool 210 includes two side portions 214 . Each side portion 214 may include a pack-off assembly 230 to prevent leakage and hold pressure. In this respect, the pack-off assembly 230 also functions as a blow out preventer. In operation, the wireline 15 accesses the casing through one of the side portions 214 . Additionally, the access tool 210 allows the top drive system 200 to reciprocate the casing and circulate drilling fluid using the spear 20 during wireline operation. Fluid may be supplied to the top drive 10 through the fluid supply line 5 . In another embodiment, the access tool 210 may optionally include a valve 216 to isolate the fluid in the top drive 10 from fluid supplied through one of the side entry passages 215 . Exemplary valves include a ball valve, one-way valves, or any suitable valve known to a person of ordinary skill in the art.
In another embodiment, the top drive system 240 may include a sheave assembly 250 attached to the pack-off assembly 245 , as illustrated in FIG. 3 . The sheave assembly 250 may include a sheave wheel 255 to reduce the friction experienced by the wireline 15 . In yet another embodiment, the top drive system 240 may include two spears 261 , 262 , two torque heads, or combinations thereof to increase the speed of modifying the top drive 10 for wireline operation. As shown, a first spear 261 is connected to the top drive 10 and initially retains a casing string for drilling operations. When wireline operation is desired, the first spear 261 may release the casing and retain an access assembly 270 having an access tool 275 , an extension tubular 277 , and a spear 262 . The spear 262 of the access assembly 270 can now be used to retain the casing string and reciprocate the casing string and/or circulate fluid during the wireline operation. After completion of the wireline operation, the access assembly 270 may be quickly removed by disengagement of the spears 261 , 262 . It should be appreciated the spears may be torque heads or a combination of spears and torque heads.
FIG. 4 is a partial cross-sectional view of another embodiment of the access system 230 . The access system 230 is attached to a spear 20 having gripping members 22 adapted to retain a casing. The access system 230 includes a main portion 231 and a side portion 233 . It can be seen that the side entry passage 234 is in fluid communication with the main passage 232 . The side portion 233 is equipped with a pack-off assembly 235 and a sheave assembly 236 . The sheave assembly 236 includes a sheave wheel 237 supported on a support arm 238 that is attached to the main portion 231 . As shown, a cable 15 has been inserted through the pack-off assembly 235 , the side entry passage 234 , the main passage 232 , and the spear 20 .
In yet another embodiment, a top drive system 280 may include an external gripping top drive adapter 285 for use with the top drive 10 and the access tool 290 , as illustrated in FIG. 5 . An exemplary top drive adapter is disclosed in U.S. patent application Ser. No. 10/850,347, entitled Casing Running Head, filed on May 20, 2004 by Bernd-Georg Pietras. The application is assigned to the same assignee as the present application and is herein incorporated by reference in its entirety. In this embodiment, the top drive adapter 285 , also known as a torque head, may release the casing and retain the access tool 290 . The access tool 290 , as shown, is adapted with one side entry portion 292 having a pack-off assembly 293 and a sheave assembly 294 . A casing collar clamp 295 attached to the access tool 290 is used to retain the casing string 3 . It must be noted that other types of casing retaining devices such as an elevator or a cross-over adapter may be used instead of the casing collar clamp, as is known to a person of ordinary skill in the art.
FIG. 6 illustrates another embodiment of the access system 300 . The access system 300 includes an upper manifold 311 and a lower manifold 312 connected by one or more flow subs 315 . Each manifold 311 , 312 includes a connection sub 313 , 314 for coupling to the top drive 10 or the spear 20 . FIG. 6A is a cross-section view of the access system 300 . Fluid flowing through the upper connection sub 313 is directed toward a manifold chamber 317 in the upper manifold 311 , where it is then separated into the four flow subs 315 . Fluid in the flow subs 315 aggregates in a chamber 318 of the lower manifold 312 and exits through the lower connection sub 314 , which channels the fluid to the spear 20 . Although the embodiment is described with four flow subs, it is contemplated any number of flow subs may be used.
The lower manifold 312 includes an access opening 320 for insertion of the wireline 15 . As shown, the opening 320 is fitted with a pack-off assembly 325 to prevent leakage and hold pressure. Preferably, the opening 320 is in axial alignment with the spear 20 and the casing 3 . In this respect, the wireline 15 is centered over the hoisting load, thereby minimizing wireline wear, as shown in FIG. 6 . The access system 300 may also include a sheave assembly 330 to facilitate the axial alignment of the wireline 15 with the opening 320 . The sheave wheel 331 is positioned with respect to the upper manifold 311 such that the wireline 15 routed therethrough is substantially centered with the opening 320 .
In another embodiment, a swivel may be disposed between the access system 300 and the spear 20 . An exemplary swivel may comprise a bearing system. The addition of the swivel allows the casing string 3 to be rotated while the sheave assembly 330 remains stationary. The casing string 3 may be rotated using a kelly, a rotary table, or any suitable manner known to a person of ordinary skill in the art.
FIG. 7 illustrates another embodiment of an access tool 335 . The access tool 335 includes a housing 337 having an upper connection sub 338 and a lower connection sub 339 . The connection subs 338 , 339 are adapted for fluid communication with a chamber 336 in the housing 337 . The housing 337 includes an access port 340 for receiving the wireline 15 . The access port 340 is equipped with a pack-off assembly 341 to prevent fluid leakage and hold pressure. In one embodiment, a sheave assembly 345 is installed in the chamber 336 to facilitate movement of the wireline 15 . Preferably, the sheave assembly 345 is positioned such that the wireline 15 is aligned with the lower connection sub 339 . In another embodiment, a fluid diverter 342 may be installed at the upper portion of the chamber 336 to divert the fluid entering the chamber 336 from the upper connection sub 338 . The fluid diverter 342 may be adapted to diffuse the fluid flow, redirect the fluid flow, or combinations thereof.
In another embodiment, the top drive system 350 may be equipped with a tool 360 for releasing downhole actuating devices such as a ball or dart. In one embodiment, the launching or releasing tool 360 may be used to selectively actuate or release a plug 371 , 372 during a cementing operation, as shown in FIGS. 8-8A . FIG. 8A is a cross-sectional view of the access tool 350 with the launching tool 360 . The access tool 350 is similar to the access tool 300 of FIG. 6 . As shown, the access tool 350 includes an upper manifold 377 and a lower manifold 376 connected by one or more flow subs 375 . Each manifold 377 , 376 includes a connection sub 373 , 374 for coupling to the top drive 10 or the spear 20 . In FIG. 8A , the launching tool 360 has replaced the packing-off assembly 325 shown in FIG. 6 . The launching tool 360 is adapted to selectively drop the two balls 361 , 362 downhole, thereby causing the release of the two plugs 371 , 372 attached to a lower portion of the spear 20 . The launching tool 360 includes a bore 363 in substantial alignment with the bore of the connection sub 374 . The balls 361 , 362 are separately retained in the bore by a respective releasing pin 367 , 368 . Fluids, such as cement, may be pumped through upper portion 364 of the launching tool 360 and selectively around the balls 361 , 362 . Actuation of the releasing pin 367 , 368 will cause these balls 361 , 362 , aided by the fluid pumped behind, to be launched into the flow stream to release the plugs 371 , 372 . It must be noted that any suitable launching tool known to a person of ordinary skill in the art may also be adapted for use with the access tool. In addition, the components may be arranged in any suitable manner. For example, the launching tool 360 may be disposed between the access tool 350 and the spear 20 . In this respect, fluid exiting the access tool 350 will flow through the launching tool 360 before entering the spear 20 .
In operation, the first release pin 367 is deactivated to allow the first ball 361 to drop into the lower manifold 376 and travel downward to the spear 20 . The first ball 361 is preferably positioned between the drilling fluid and the cement. The first ball 361 will land and seat in the first, or lower, plug 371 and block off fluid flow downhole. Fluid pressure build up will cause the first plug 371 to release downhole. As it travels downward, the first plug 371 functions as a buffer between the drilling fluid, which is ahead of the first plug 371 , and the cement, which is behind the first plug 371 . When sufficient cement has been introduced, the second release pin 368 is deactivated to drop the second ball 362 from the launching tool 360 . The second ball 362 will travel through the bore and land in the second, or upper, plug 372 . Seating of the ball 362 will block off fluid flow and cause an increase in fluid pressure. When a predetermined fluid pressure is reached, the second plug 372 will be released downhole. The second plug 372 will separate the cement, which is in front of the second plug 372 , from the drilling fluid or spacer fluid, which is behind the second plug 372 .
In another embodiment, the plugs may be coupled to the casing string instead of the top drive adapter. As shown in FIG. 8C , a plug 400 is provided with a retaining member 410 for selective attachment to a casing string 3 . Preferably, the retaining member 410 attaches to the casing string 3 at a location where two casing sections 403 , 404 are threadedly connected to a coupling 405 . Particularly, the retaining member 410 includes a key 412 that is disposable between the ends of the two casing sections 403 , 404 . The plug 400 , in turn, is attached to the retaining member 410 using a shearable member 420 . The plug 400 and the retaining member 410 include a bore 422 for fluid flow therethrough. The plug 400 also includes a seat 425 for receiving an actuatable device such as a ball or dart. Preferably, the retaining member 410 and the plug 400 are made of a drillable material, as is known to a person of ordinary skill in the art. It must be noted that although only one plug is shown, more than one plug may be attached to the retaining member for multiple plug releases.
In operation, a ball dropped from the launching tool 360 will travel in the wellbore until it lands in the seat 425 of the plug 400 , thereby closing off fluid flow downhole. Thereafter, increase in pressure behind the ball will cause the shearable member 420 to fail, thereby releasing the plug 400 from the retaining member 410 . In this manner, a plug 400 may be released from various locations in the wellbore.
FIG. 8B shows another embodiment of coupling the plug to the casing string. In this embodiment, the retaining member comprises a packer 440 . The packer 440 may comprise a drillable packer, a retrievable packer, or combinations thereof. The packer 440 includes one or more engagement members 445 for gripping the wall of the casing 3 . An exemplary packer is disclosed in U.S. Pat. No. 5,787,979, which patent is herein incorporated by reference in its entirety. As shown, two plugs 451 , 452 are selectively attached to the packer 440 and are adapted for release by an actuatable device such as a ball. Preferably, the first, or lower, plug 451 has a ball seat 453 that is smaller than the ball seat 454 of the second, or upper, plug 452 . In this respect, a smaller ball launched from the launching tool may bypass the second plug 452 and land in the seat 453 of the first plug 451 , thereby releasing the first plug 451 . Thereafter, the second plug 452 may be released by a larger second ball. In this manner, the plugs 451 , 452 may be selectively released from the packer 440 . After the plugs 451 , 452 have been released, the packer 440 may be retrieved or drilled through.
In another embodiment, the launching tool may be installed on an access tool similar to the one shown in FIG. 3 . For example, the sheave assembly 236 and pack-off 235 may be removed and a launching tool such as a ball launcher with a top entry may be installed on a side portion 233 . In this respect, one or more balls may be launched to release one or more cementing plugs located below the spear or torque head.
In another aspect, the top drive system 500 may include a top drive 510 , a cementing tool 515 , and a top drive adapter, as illustrated in FIG. 9 . As shown, the top drive adapter comprises a spear 520 . The cementing tool 515 is adapted to selectively block off fluid flow from the top drive 510 during cementing operations.
FIG. 10 is a partial cross-sectional view of an embodiment of the cementing tool 515 . The cementing tool 515 includes a central bore 522 for fluid communication with the top drive 510 and the spear 520 . A valve 525 is disposed in an upper portion of the bore 522 to selectively block off fluid communication with the top drive 510 . The valve 525 is actuated between an open position and a close position by operation of a piston 530 . As shown, the piston 530 is biased by a biasing member 532 to maintain the valve 525 in the open position. To close the valve 525 , an actuating fluid is introduced through a fluid port 541 to move the piston 530 toward the valve 525 . In this respect, movement of the piston 530 compresses the biasing member 532 and closes the valve 525 , thereby blocking off fluid communication of the cementing tool 515 and the top drive 510 . Thereafter, cement may be introduced into the bore 522 through the cementing port 545 .
In another aspect, the cementing tool 515 may be adapted to release one or more actuating devices into the wellbore. In the embodiment shown in FIG. 10 , the cementing tool 515 is adapted to selectively launch three balls 561 . It must be noted that the cementing tool 515 may be adapted to launch any suitable number or type of actuating devices. Each ball 561 is retained by a release piston 550 A before being dropped into the wellbore. The piston 550 A is disposed in an axial channel 555 formed adjacent to the bore 522 . In one embodiment, the piston 550 A has a base 551 attached to the body of the cementing tool 515 and a piston head 552 that is extendable or retractable relative to the base 551 . The outer diameter of a portion of the piston head 552 is sized such that an annulus 553 is formed between the piston head 552 and the wall of the axial channel 555 . Seal members or o-rings may be suitably disposed in the base 551 and the piston head 552 to enclose the annulus 553 . The annulus 553 formed is in selective fluid communication with an actuating fluid port 542 A. In this respect, the actuating fluid may be supplied into the annulus 553 to extend the piston head 552 relative to the base 551 , or relieved to retract the piston head 552 . Preferably, the piston head 552 is maintained in the retracted position by a biasing member 557 , as shown FIG. 10 .
The release piston 550 A is provided with an opening 563 to house the ball 561 and a cement bypass 565 . In the retracted position shown, the cement bypass 565 is in fluid communication with a radial fluid channel 570 A connecting the cement port 545 to the bore 522 . In this respect, cementing fluid may be supplied into the bore 522 without causing the ball 561 to release. When the piston head 552 is extended, the opening 563 is, in turn, placed in fluid communication with the radial fluid channel 570 A.
As discussed, the cementing tool 515 may be adapted to release one or more actuating devices. In the cross-sectional view of FIG. 10A , it can be seen that three release pistons 550 A, 550 B, 550 C are circumferentially disposed around the bore 522 . Cementing fluid coming in from either of the cementing ports 545 , 545 A is initially circulated in an annular channel 575 . Three radial fluid channels 570 A, 570 B, 570 C connect the annular channel 575 to the bore 522 of the cementing tool 515 . Each radial fluid channel 570 A, 570 B, 570 C also intersect the cement bypass 565 of a respective release piston 550 A, 550 B, 550 C.
To release the first ball 561 , actuating fluid is introduced through the fluid port 542 A and into the annulus 553 of the first release piston 550 A. In turn, the piston head 552 is extended to place the opening 563 in fluid communication with the radial fluid channel 570 A. Thereafter, cement flowing through the cementing port 545 , the annular channel 575 , and the radial channel 570 A urges to the ball 561 toward the bore 522 , thereby dropping the ball 561 downhole. Because either position of the piston head 552 provides for fluid communication with the cementing port 545 , the piston head 552 may remain in the extended position after the first ball 561 is released.
To release the second ball, actuating fluid is introduced through the second fluid port 542 B and into the annulus 553 of the second release piston 550 B. In turn, the piston head 552 is extended to place the opening 563 in fluid communication with the radial fluid channel 570 B. Thereafter, cement flowing through the radial channel 570 B urges to the ball 561 toward the bore 522 , thereby dropping the ball 561 downhole. The third ball may be released in a similar manner by supplying actuating fluid through the third fluid port 542 C.
In another aspect, the cementing tool 515 may optionally include a swivel mechanism to facilitate the cementing operation. In one embodiment, the fluid ports 541 , 542 A, 542 B, 542 C and the cementing port 545 may be disposed on a sleeve 559 . The sleeve 559 may be coupled to the body of the cementing tool using one or more bearings 558 A, 558 B. As shown in FIG. 10 , two sets of bearings 558 A, 558 B are disposed between the sleeve 559 and the body of the cementing tool 515 . In this respect, the body of the cementing tool 515 may be rotated by the top drive 10 without rotating the ports 541 , 542 A, 542 B, 542 C, 545 and the fluid lines connected thereto. During the cementing operation, the swivel mechanism of the cementing tool 515 allows the top drive 10 to rotate the drill string 3 , thereby providing a more efficient distribution of cementing in the wellbore.
In another embodiment, the cementing tool 515 may include additional fluid ports to introduce fluid into the top drive system. For example, hydraulic fluids may be supplied through the additional fluid ports to operate the spear, torque head, weight/thread compensation sub, or other devices connected to the top drive. Additionally, operating fluids may also be supplied through one of the existing ports 541 , 542 A, 542 B, 542 C, 545 of the cementing tool 515 .
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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In one embodiment, a top drive system for drilling with casing is provided with an access tool to retrieve a downhole tool. The top drive system for drilling with casing comprises a top drive; a top drive adapter for gripping the casing, the top drive adapter operatively coupled to the top drive; and an access tool coupled to the top drive and adapted for accessing a fluid passage of the top drive system. In another embodiment, a method for retrieving a downhole tool through a tubular coupled to a top drive adapter of a top drive system is provided. The method comprises coupling an access tool to the top drive system, the access tool adapted to provide access to a fluid path in the top drive system and inserting a conveying member into the fluid path through the access tool.
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RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application No. 60/458,298, filed Mar. 28, 2003, the entire contents of which are herein incorporated by reference.
FIELD OF THE INVENTION
The present invention relates generally to gable roof designs of residential and commercial construction and, more particularly, to a fascia used to conceal the junction at which two rake boards meet at the peak of a gable roof.
BACKGROUND OF THE INVENTION
One popular style of roof design used both in residential and commercial construction is known as a gable roof. Gable roof designs generally resemble the shape of a triangle. Gable roofs designs can be constructed in a variety of angles or pitches, from shallow pitches to very steep pitches. Homes built with gable style roofs are typically trimmed using what is known in the art as a rake board to cover the intersection between a building's facade and its roof. Rake boards typically follow the pitch of a roof and form a junction when two rake boards meet at the peak of the gable roof.
When thin profile materials such as aluminum sheeting, vinyl or the like are used in the fabrications of rake boards, various means are used to minimize, or eliminate the gap formed at the junction of the rake boards. For example, caulking is commonly used to eliminate gaps. Likewise, a piece of sheet aluminum, vinyl, or the like can be custom fit on site to cover the gap. In any event, no matter which of the above-referenced techniques are used to conceal the gap, at best, they are time consuming and expensive. Additionally, because of the expansion and contraction cycles experienced by many thin profile materials, even if gaps are perfectly closed, they open with the passage of time and render an unattractive appearance. The present invention conceals this gap by use of a universal rake-ridge cap which can accommodate any roof pitch and is easily and quickly fitted in place at the job site by using ordinary tools.
SUMMARY OF THE INVENTION
The present invention provides a solution to a field problem by providing a universal rake-ridge cap for the rake ridge of a gable roof that can be quickly cut to fit any roof pitch. The universal rake-ridge cap may consist of any number of stepped arcuate surfaces. The universal rake-ridge cap is cut to so that the stepped arcuate surfaces tangentially intersect the stepped profiles of both rake boards. Further trimming allows the universal rake-ridge cap to conform to the pitch of any gable roof.
The universal rake-ridge cap provides a time savings to the installer of rake boards. The junction of the rake boards at the peak of a gable roof no longer requires precision fitting to create an aesthetically pleasing joint. A gap can be left at the junction of the rake boards to be covered by the universal rake-ridge cap that can be quickly cut to blend the stepped contours of the rake boards with the stepped arcuate surfaces of the universal rake-ridge cap.
The universal rake-ridge cap is also aesthetically pleasing because the stepped arcuate surfaces of the universal cap provide a single sightline at the peak of a gable roof. When the universal rake-ridge cap is cut and installed so that the stepped arcuate surfaces tangentially intersect the stepped contours of the rake boards, a smooth transition is created from rake board to universal cap to rake board.
BRIEF DESCRIPTION OF THE DRAWINGS
The features and inventive aspects of the present invention will become more apparent upon reading the following detailed description, claims, and drawings, of which the following is a brief description:
FIG. 1 is a perspective view of the universal rake-ridge cap shown installed on a gable roof design.
FIGS. 2A and 2B are perspective views of two embodiments of the universal rake-ridge cap.
FIGS. 3A and 3B are perspective views showing a roof gable before and after installation of the universal rake-ridge cap.
FIG. 3C is a plan view of the universal rake-ridge cap showing how the right side portion and left side portion of the universal rake-ridge cap are cut so that it can be fitted onto a gable roof.
FIG. 3D is a rear view of the universal rake-ridge cap of FIG. 3A-3C prior to trimming various portions.
FIG. 3E is a depiction of the universal rake-ridge cap of FIG. 3D wherein various portions are trimmed therefrom to make the universal rake-ridge cap properly fit to match a particular roof slope.
FIGS. 4A and 4B are perspective views showing how that universal rake-ridge cap can accommodate different gable roof pitches.
FIG. 4C is an elevational view showing how the universal rake-ridge cap accommodates different gable roof pitches.
FIG. 5 is an elevational view of the universal rake-ridge cap positioned in place with two rake members.
FIG. 6A is a cross sectional view taken through lines 6 A- 6 A of FIG. 3B displaying a stepped arcuate surface.
FIGS. 6B through 6H are cross sections of the universal rake-ridge cap displaying other contemplated stepped arcuate surface designs.
FIG. 7 is an elevational view of the universal rake-ridge cap showing multiple stepped arcuate surfaces tangentially intersecting with multiple stepped surfaces of the two rake members.
FIGS. 8A and 8B are elevational views of the universal rake-ridge cap showing how the universal rake-ridge cap accommodates different gap widths at the junction of two rake members at the peak of a gable roof.
FIG. 9 is a perspective view of multiple universal rake-ridge caps and their use with a gable roof design that includes a soffit.
DETAILED DESCRIPTION
Referring now to the drawings, the several embodiments of the present invention are shown in detail. Although the drawings represent some embodiments of the present invention, the drawings are not necessarily to scale and certain features may be exaggerated to better illustrate and explain the present invention. Further, the embodiments set forth herein are not intended to be exhaustive or otherwise limit or restrict the invention to the precise forms and configurations shown in the drawings and disclosed in the following detailed description.
The present invention is directed to an innovative universal rake-ridge cap 20 shown in FIG. 1 as part of a structure's trim package including a facade 22 , rake members 24 ′, 24 ″. For clarity, final roof sheating and roofing materials have been omitted from FIG. 1 . FIG. 2A illustrates universal rake-ridge cap 20 according to an embodiment of the invention. In the illustrated embodiment, universal rake-ridge cap 20 includes a first surface 28 , a second surface 30 , and at least one stepped arcuate surface 32 that intersects first surface 28 and second surface 30 . Universal rake-ridge cap 20 further includes a first edge 34 , a second edge 36 , an arcuate surface 38 that intersects vertically with a third edge 40 on first surface 28 , a fourth edge 42 , and a fifth edge 44 . FIG. 2B illustrates universal rake-ridge cap 20 according to a second embodiment of the invention. Universal rake-ridge cap 20 shown in FIG. 2B includes multiple stepped arcuate surfaces 32 .
Universal rake-ridge cap 20 can be manufactured from any number of common construction materials. In a preferred embodiment, it is contemplated that aluminum, vinyl, fiberglass, resin, or the like would be the preferred fabrication materials for universal rake-ridge cap 20 .
Now referring to FIGS. 3A , 3 B, and 3 C, once rake members 24 ′, 24 ″ are installed as shown over a structure's facade 22 , universal rake-ridge cap 20 is placed over gap 46 and a right side portion 20 ′ is cut from universal rake-ridge cap 20 to reveal first edge 34 of universal rake-ridge cap 20 and a left side portion 20 ″ is cut from universal rake-ridge cap 20 to reveal second edge 36 of universal rake-ridge cap 20 . Universal rake-ridge cap 20 is cut such that stepped surfaces 48 ′, 48 ″ of rake members 24 ′, 24 ″ tangentially intersect stepped arcuate surface 32 of universal rake-ridge cap 20 . When right side portion 20 ′ and left side portion 20 ″ are cut, a further arcuate surface 36 , which intersects vertically with third edge 38 , is formed to tangentially intersect the undersides of rake members 24 ′, 24 ″.
Fourth edge 42 and fifth edge 44 of universal rake-ridge cap 20 are cut so that fourth edge 42 and fifth edge 44 are parallel to the top of rake members 24 ′, 24 ″. Fourth edge 42 and fifth edge 44 are cut to generally abut the adjacent extending edge 26 of rake members 24 ′, 24 ″. Fourth edge 42 and fifth edge 44 of universal rake-ridge cap 20 can be cut in a manner that will accommodate a wide variance of gable roof pitches.
Now referring to FIGS. 3D and 3E , the back side of universal rake-ridge cap 20 is demarked by a series of radially extending lines 21 and a series of tangentially extending lines 23 . These lines of demarcation are numbered so that an installer can easily and quickly trim the universal rake-ridge cap 20 to fit the roof pitch under consideration. For example, if radial line “ 9 ” (radial line 9 referenced as 27 ′, 27 ″) corresponds to the correct roof pitch under consideration, the installer simply cuts universal rake-ridge cap 20 along the right 27 ″ and left 27 ′ radial line-marks indicated by “ 9 ”. This assures that when the corresponding rake members 24 ′, 22 ′ are overlayed by universal rake-ridge cap 20 , the step surfaces 48 ′, 48 ″ of rake members 24 ′, 24 ″ will tangentially intersect the stepped arcuate surfaces 32 of universal rake-ridge cap 20 . Likewise, the installer will locate the appropriate upper, tangential guidelines 23 ′, 23 ″ and trims along the appropriately numbered lines 29 ′, 29 ″ to fit the top portion of universal rake-ridge cap 20 . This trimming operation is shown in an exploded view in FIG. 3E wherein the remaining core 20 ′ is the portion of universal rake-ridge cap 20 that is installed on the home. The remaining portions that are trimmed therefrom are discarded.
FIGS. 4A and 4B illustrate two different pitches of gable roof as shown by angle βand angle Θ. FIG. 4B illustrates a steeper gable roof design than the gable roof design of FIG. 4A . FIG. 4C illustrates the two gable roof pitches superimposed on top of one another. The solid lines of rake members 24 ′, 24 ″ illustrate the shallow roof pitch of FIG. 4A . The ghost lines of rake members 240 ′, 240 ″ illustrate the steeper roof pitch of FIG. 4B . Although different gable roof pitches are illustrated, the same universal rake-ridge cap 20 can be trimmed to fit both gable roof designs by adjusting the amount of material removed from fourth edge 42 and fifth edge 44 of universal rake-ridge cap 20 (as illustrated in FIGS. 3D and 3E ).
When universal rake ridge cap 20 is fitted in this manner, stepped arcuate surface 32 of universal rake-ridge cap 20 cooperatively blend with stepped surfaces 48 ′, 48 ″ of rake members 24 ′, 24 ″ thereby forming an attractive finish joint as shown in FIGS. 1 and 5 .
FIG. 6A illustrates a cross section of universal rake-ridge cap 20 taken through lines 6 A- 6 A of FIG. 3B in FIGS. 6B , 6 C, 6 D illustrate other contemplated cross sections of stepped arcuate surface 32 of universal rake-ridge cap 20 that may be in the shape of a “U”, “V”, or “W” or variations thereof. It is important to note that the process set forth above for installing universal rake-ridge caps is quick, requires no special tools, and does not required a skilled craftsman. Yet, the finished look is professional and aesthetically pleasing.
FIG. 7 illustrates universal rake-ridge cap 20 with a plurality of stepped arcuate surfaces 32 a , 32 b , and 32 c that correspond with an equal number of stepped surfaces 48 a ′, 48 a ″, 48 b ′, 48 b ″, and 48 c ′, 48 c ″ of rake members 24 ′, 24 ″. Further, stepped arcuate surfaces 32 a , 32 b , and 32 c and stepped surfaces 48 a ′, 48 a ″, 48 b ′, 48 b ″, and 48 c ′, 48 c ″ increase the detail of universal rake-ridge cap 20 and rake members 24 ′, 24 ″ thereby increasing the aesthetically pleasing look of a gable roof peak. Universal rake-ridge cap 20 may contain any number of stepped arcuate surfaces and rake members 24 ′, 24 ″ may contain any number of stepped surfaces to satisfy the aesthetic requirements of the structure. FIG. 7 illustrates an embodiment of the invention with three stepped arcuate surfaces.
Now referring to FIGS. 8A and 8B , one of the advantages of universal rake-ridge cap 20 of the present invention is how it renders uncritical the fitting of rake members 20 ′, 20 ″ at the junction of the peak of the gable roof. For example, when FIG. 8A is compared to FIG. 8B , FIG. 8A shows rake members 24 ′, 24 ″ being trimmed such that gap 46 is relatively small. In contrast, FIG. 8B shows rake members 24 ′, 24 ″ being trimmed such that gap 46 is relatively large. However, in either application, universal rake-ridge cap 20 is perfectly suited for concealing gap 46 . In both instances a high quality final trim product results regardless of the size of gap 46 .
Now referring to FIG. 9 , not only is universal rake-ridge cap 20 applicable for gabled roof designs having no soffit (such as has been shown in FIGS. 3A , 3 B, 4 A, and 4 B), it is also equally applicable in gabled roof designs that have a soffit 50 . In roof designs such as shown in FIG. 9 , two universal rake-ridge caps 20 a , 20 b would be required. Universal rake-ridge cap 20 a would be used in a manner that has already been described whereas universal rake-ridge cap 20 b would be used on the outermost portion of soffit 50 as shown in FIG. 9 . Universal rake-ridge cap 20 a as it has herein been described is perfectly capable of functioning in the position shown as 20 b (the outermost portion of soffit 50 ), and accordingly no further description is needed in association with universal rake-ridge cap 20 b.
The present invention has been particularly shown and described with reference to the foregoing embodiments, which are merely illustrative of the best modes for carrying out the invention. It should be understood by those skilled in the art that various alternatives to the embodiments of the invention described herein may be employed in practicing the invention without departing from the spirit and scope of the invention as defined in the following claims. 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. This description of the invention should be understood to include all novel and non-obvious combinations of elements described herein, and claims may be presented in this or a later application to any novel and non-obvious combination of these elements. Moreover, the foregoing embodiments are illustrative, and no single feature or element is essential to all possible combinations that may be claimed in this or a later application.
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A universal rake-ridge cap for a gable roof design that includes a first surface, a second surface, and at least one stepped arcuate surface intersecting the first surface and the second surface. The universal rake-ridge cap is employed to conceal any gap at the junction of two rake boards in a gable roof design. The universal rake ridge cap can be cut so that the arcuate surface will tangentially intersect the stepped surfaces of rake members to provide an aesthetically pleasing transition from rake board to universal rake-ridge cap to rake board. The universal rake-ridge cap can quickly be fitted to any gable roof pitch simply by culling the universal rake-ridge cap to the angle or pitch required by the gable roof. No special tools are needed and the final result is both aesthetically pleasing as well as a significant time saver.
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BACKGROUND OF THE INVENTION
Arches have been known for centuries to provide a stable means for spanning a space in a manner capable of supporting significant weight. The curved structure defining the arch eliminates, or at least significantly reduces, tensile stresses over a span thereof by substantially resolving the forces into compressive stresses. Generally, an arch structure is made from materials such as masonry, metal and concrete.
SUMMARY OF THE INVENTION
The invention concerns an arch structure comprised of adjacent segments that are rotatably attached to each other. In particular, the invention concerns an arch structure comprised of at least two segments in which adjacent segments are linked to each other via hinges or equivalent means to form a continuous bendable chain of attached segments, and adjacent segments rotate relative to each other about an axis. The segments have magnets above the hinge or equivalent means on opposed end faces, positioned to oppose magnets on confronting end faces of adjacent arch segments, with like poles facing one another, thereby creating a repulsion force. The repulsion force inhibits the arch segments from being brought together. Due to this effect, the aggregate of the arch segments define an arcuate path (convex upward), maintained by the repulsion forces of the magnets.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of a first exemplary embodiment of an arch structure according to the present invention;
FIG. 1 a is a side view of an alternative exemplary embodiment wherein end segments are immovably attached to horizontal abutments;
FIG. 1 b is a side view of an alternative exemplary embodiment wherein end segments are rotatably attached to abutments via hinges or equivalent means and the abutments are rotatably attached to a support surface via hinges or equivalent means (support surface not shown);
FIG. 1 c is a side view of an alternative exemplary embodiment wherein end segments are rotatably attached to horizontal abutments;
FIG. 1 d is a side view of the alternative exemplary embodiment of FIG. 1 b illustrating the rotation of the abutments and the segments due to load forces on the arch structure;
FIG. 1 e is a side view of the alternative exemplary embodiment of FIG. 1 c illustrating the rotation of the abutments and the segments due to load forces on the arch structure;
FIG. 2 is a top view of two segments from the exemplary embodiment shown in FIG. 1 ;
FIG. 2 a is a top view of two segments from the exemplary embodiment shown in FIG. 1 with an alternative magnet arrangement to prevent “over-arching”;
FIG. 3 is a side view of an alternative embodiment of an arch structure according to the present invention wherein each segment is comprised of an upper part and a lower part;
FIG. 4 is a cross-section view of the alternative embodiment of the arch structure of FIG. 3 ;
FIG. 5 is a top view of a portion of two segments from the alternative embodiment of the arch structure of FIG. 3 illustrating the interleaving of segment transition teeth between adjacent segments;
FIGS. 6 a and 6 b are side views of two segments at differing angles from the alternative embodiment of the arch structure of FIG. 3 illustrating how the segment transition teeth between adjacent segments maintain a relatively smooth continuous surface as the angle between segments changes;
FIG. 7 is a side view of another alternative embodiment of an arch structure according to the present invention wherein adjacent segments are connected by a segment support structure;
FIG. 8 is a side view of an end portion of an arch structure according to another alternative exemplary embodiment of the present invention wherein the end segment is connected to a sub-road surface mechanism comprised of a flat bed with wheels and a flat support surface;
FIG. 9 is a top view of a portion of the end segment of FIG. 8 illustrating how the end segment passes through a road;
FIG. 10 is a side view of an end portion of an arch structure according to another alternative exemplary embodiment of the present invention wherein the end segment is connected to a sub-road surface mechanism comprised of a flat bed with wheels and a flat support surface and a transition portion of the road is supported by a rolling support above the end segment;
FIG. 11 is a side view of an end portion of an arch structure according to another alternative exemplary embodiment of the present invention wherein the end segment is connected to a sub-road surface mechanism comprised of a flat bed with wheels and a curved support surface.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a side view of a first exemplary embodiment of the invention. The arch structure 1 , as shown in FIG. 1 , is comprised of several segments 2 , although there may be as few as two segments 2 . The segments 2 have top and bottom surfaces as well as ends, which generally face ends of adjacent segments 2 , and sides. Although the exemplary embodiment shown has segments with flat top and bottom surfaces, it should be understood that these surfaces could be concave, convex, stepped or any other shape. The segments 2 may be made of any material of suitable strength to carry the load that will be placed upon them. For example, the segments 2 may be made of wood, PVC, steel or concrete. Adjacent segments 2 are connected to each other with a hinge 3 that is secured to the bottom surface of the segments 2 by hinge plates 6 that are rotatably attached by a barrel and pin structure 7 . Alternatively, the segments 2 may be connected with ball joints or equivalent structure. The segments 2 may also be connected to each other by their ends or sides by a hinge or equivalent structure.
On the ends of adjacent segments 2 , which face each other, there are magnets 5 with opposing polarities, which force the segments 2 to remain apart. The magnets 5 may be neodymium magnets, which have a strong magnetic field and are comparatively light-weight. The magnets 5 may also be electromagnets, which are provided electric power when one wants the arch structure to maintain an arch shape. Other types of magnets known in the art may be used for the magnets 5 on the segments 2 , and the magnets 5 may be a combination of different types of magnets. The magnets 5 may be mounted to the segments 2 with an intervening low permeability material.
The load the arch structure 1 will be required to support before the segments 2 come into contact with each other will determine the number, strength and shape of magnets used. The force between the magnets 5 on the segments may be calculated using Ampère's law of force or may be empirically determined by measuring the repulsive force between two segments when brought within an operational distance and angle that will be experienced by the segments 2 in the arch structure 1 . It is understood by one in the art that other mechanical repelling means such as springs or a pneumatic or hydraulic system, may be used as an alternative to or in conjunction with the magnets 5 , to provide the repelling force between the segments 2 .
The end segments 2 y and 2 z at the ends of the arch structure 1 are attached to abutments 4 . The abutments 4 may be immovably or rotatably attached by end hinges 32 - 38 to the end segments 2 y and 2 z, as illustrated in FIGS. 1 and 1 b , respectively. Furthermore, the abutments 4 may be stationary, as illustrated in FIG. 1 . Alternatively, the abutments 4 , may be rotatably attached to the ground or other support structure by abutment hinges 40 - 42 , as illustrated in FIG. 1 b and 1 d , in order to accommodate changes in the arch structure 1 length, due to changes in the load on the arch structure 1 . The abutments 4 or the abutment hinges 40 - 42 may be configured as disclosed in Japanese patent JP 2005-188022, which is hereby incorporated by reference. It should be noted, though, that the abutments 4 rotate independently in FIGS. 1 b and 1 d in contrast to the tension legs ( 5 ) in JP 2005-188022, which must rotate in the same direction to the same angle. It should also be noted that the end segments 2 y and 2 z may be rotatably attached to the abutments 4 whether or not the abutments 4 are rotatably attached to the ground. In FIG. 1 b , the abutments 4 are shown with no rotation, and in FIG. 1 d , the abutments 4 are shown rotated in an outward direction and the angles between the segments 2 are reduced.
As shown in FIG. 1 a , the end segments 2 y and 2 z may be immovably attached to horizontal abutments 104 . The horizontal abutments 104 may be a road, path or simply the ground. Preferably the end segments 2 y and 2 z are attached to the horizontal abutments 104 in a manner that provides a relatively smooth and continuous surface between the end segments 2 y and 2 z and the horizontal abutments 104 . Alternatively, as shown in FIGS. 1 c and 1 e the end segments 2 y and 2 z may be rotatably attached to the horizontal abutment 104 attached by end hinges 32 . In this case, the horizontal abutment 104 may be provided with a transitional surface such as a ramp (not shown) to provide a relatively smooth and continuous surface between the end segments 2 y and 2 z and the horizontal abutments 104 .
FIG. 2 is a top view of a portion of the first exemplary embodiment of the arch structure 1 . The ends of the segments 2 above the hinges 3 have teeth-like projections 8 extending from each segment 2 such that the teeth-like projections 8 fit together in such a manner as to accommodate the gap between the segments 2 and are shaped in such a manner as to provide a relatively continuous surface as the angle and distance of the gap between the segments 2 vary. On the ends of each projection 8 is a magnet 5 whose polarity is opposite to a parallel magnet 5 on the end of the adjacent segment 2 . In the exemplary embodiment of the invention shown in FIG. 2 , a first set of magnets 5 a, 5 b & 5 c on one end of a first segment 2 a are configured with opposite polarities to a second set of magnets 5 d, 5 e & 5 f on one end of a second segment 2 b, although other polarity configurations may be used.
As shown in FIG. 2 a, according to one alternative embodiment of the invention, the magnets 5 located on the projections 8 are configured, sized and shaped so that those located on adjacent segments develop a repelling force between them that resists any force separating the segments 2 from each other. In the exemplary embodiment shown in FIG. 2 a, magnets 5 a and 5 c on segment 2 a develop a repelling force with magnet 5 e on segment 2 b. The repelling force between the magnets 5 on the projections 8 prevents the structure from “over-arching” i.e. prevents the gap between segments 2 from going beyond a certain distance. This may be useful in certain instances such as when a gust of wind applies an upward force on the bottom surface of the segments 5 . It may be understood by one in the art that prevention of “over-arching” may also be accomplished by other structures such as springs or projections from the segments that come into communication with each other when the segments are a predetermined distance apart. These alternative structures may be used alone or in conjunction with the magnets to prevent “over-arching.”
As illustrated in FIGS. 3 and 4 , the segments 2 may be comprised of an upper part 50 and a lower part 52 that are structurally connected at or by their sides. Magnets 5 with opposing polarities are attached to ends of the upper parts 50 of the segments 2 , which face each other. Adjacent segments 2 are connected to each other on the lower parts 52 with the hinge 3 secured to the bottom surface of the segments 2 by hinge plates 6 that are rotatably attached by a barrel and pin structure 7 . Alternatively, the segments 2 may be connected with ball joints or equivalent structure. The segments 2 may also be connected to each other by their ends or sides by a hinge or equivalent structure.
Projecting out from the ends of the segments 2 are several segment transition teeth 62 whose upper surfaces are initially aligned with an upper surface of the lower part 52 and curve in a downward direction. As is illustrated in FIG. 5 , the segment transition teeth 62 of adjacent segments 2 are interleaved. As is illustrated in FIG. 6 a and 6 b, the segment transition teeth 62 are so shaped and configured so as to provide as smooth and continuous a surface as is practicable between the upper surfaces of the lower parts 52 as the segments 2 rotate relative to each other.
In FIG. 7 , another alternative exemplary embodiment of the invention is illustrated. Segment support structures 80 are connected to the bottom or side surfaces of the segments 2 and may only be extant by the sides of the segments 2 or they may span the entire width underneath the segments 2 . Adjacent segment support structures 80 are connected to each other with a barrel and pin structure 7 . On the ends of adjacent segment support structures 80 , which face each other, are the magnets 5 with opposing polarities, which force the segments 2 to remain apart. The magnets 5 may be disposed horizontally underneath the segments 2 in a manner similar to that discussed by previous embodiments of the arch structure. Alternatively, or in addition, the magnets 5 may be disposed vertically along the ends of the segment support structures 80 or magnets 5 may be disposed on the upper part 50 .
As discussed above, the end segments 2 y and 2 z may be attached to the abutments 4 . Alternatively, the end segments 2 y and 2 z may be attached to a sub-road surface mechanism 40 below a road 22 leading on to the arch structure 1 . The sub-road surface mechanism 40 may be any arrangement that provides substantially vertical support for the arch structure 1 and allows for substantially, possibly limited, horizontal movement for the arch structure 1 . As illustrated in FIG. 8 for one end of an exemplary embodiment of the arch structure 1 , the end segment 2 z is attached to the sub-road surface mechanism 40 comprised of a flat bed with wheels 42 and a support surface 44 along which the flat bed 42 may move. The flat bed 42 may be comprised of one or more electric generators with crankshafts that are mechanically connected to the flat bed wheels, for example via a cam shaft, to harness the axial movement of the wheels. Electricity may thereby be generated from the movement of the arch structure 1 .
The portion of the end segment 2 z that intersects with the road 22 may be formed, as illustrated in FIG. 9 , of closely spaced spokes 26 that penetrate corresponding road apertures 24 in the road 22 . Alternatively, as illustrated in FIG. 10 , a transition portion 60 of the road 22 may be supported above the end segment 2 z by a rolling support 64 and connected to the road 22 by a hinge 62 . The rolling support 64 has a suspension system for rolling support wheels 66 to adjust to the changing angles of the end segment 2 z.
The support surface 44 may be flat and horizontal, as illustrated in FIG. 8 . Alternatively, the support surface 44 may be variably angled to provide a resistance force that increases or decreases as an increasing load forces the arch structure 1 to spread. One such alternative support surface 44 is illustrated in FIG. 11 .
The embodiments of the invention described herein are exemplary in nature, and therefore, the spirit and the scope of the invention are by no means restricted to what is described above or intended to represent every possible embodiment of the invention.
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This invention concerns an arch structure. In particular, the invention relates to an arch structure comprised of at least two segments which are rotatably linked to each other via hinges or equivalent means to form a continuous bendable chain of attached segments. The segments have magnets above the rotatable or hinged link on opposed end faces, positioned to oppose magnets on confronting end faces of adjacent arch segments, with like poles facing one another, thereby creating a repulsion force. The repulsion force inhibits the arch segments from being brought together and into contact. Due to this effect, the aggregate of the arch segments define an arcuate path (convex upward), maintained by the repulsion forces of the magnets.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. application Ser. No. 11/305,289 filed Dec. 19, 2005, which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to thin stone or thin brick veneer wall systems and to clips for fastening facing elements thereof.
BACKGROUND OF THE INVENTION
[0003] Masonry veneer walls are typically constructed by laying bricks, blocks or other stone product in courses and mortaring the top of each course as the wall is being built from the bottom up. Conventionally, the lower course of bricks, blocks or other stone product is supported on a foundation (e.g. poured concrete) or an engineered angle iron to carry the mass load. Such construction requires a skilled masonry contractor and is very time consuming. Further, since individual bricks, blocks or other stone products are relatively thick and heavy at full depth, such construction is also expensive and leads to veneer walls of great weight.
[0004] To decrease the weight of the veneer wall, stone-like or brick-like products comprising polymeric materials or polymer/cement composites have been developed. Such materials tend to be lighter in weight but lose aesthetic appeal since they do not look sufficiently like brick or natural stone. In addition, such products are more costly and, in most cases, require a specific contractor to install them.
[0005] So-called thin stone or thin brick products have been developed, which are made by splitting cement blocks and then further dressing the front face if desired. Such products have a more natural stone or brick appearance, however, finding ways to easily, inexpensively and quickly construct veneer walls using such thin stones or thin bricks has been problematic. Typically in the art, thin stone or thin brick veneer walls are constructed by the so-called “lick and stick” method, which involves the use of epoxy adhesive to secure the thin stone or thin brick to plywood or OSB cladding, or which involves the use of metal lath with a scratch coat of Portland mortar. Such an adhered thin stone or thin brick system is inherently less secure since improper application of the adhesive can lead to stones or bricks separating from the wall, which is both a nuisance and a safety problem. Such adhered thin stone or thin brick systems are typically only used in lower floor applications of residential and commercial buildings. Design professionals hesitate to use them on multi-floor buildings. Further, the adhered thin stone or thin brick system has not, in the past, been used in conjunction with other wall elements such as drainage board and weather-resistant wrap, thus thin stone or thin brick products have been preponderantly used in commercial building applications.
[0006] Various bracket or clip systems have been developed to affix veneer panels of various sorts to a structural wall. Although useful in particular cases, such systems lack versatility and simplicity, requiring brackets or clips with complicated structures and/or several separate components. Such brackets or clips are more difficult to secure to structural walls and/or require tedious and time-consuming alignment of panels. There remains a need in the art for a more versatile, secure and mechanically stronger thin stone or thin brick veneer wall system that is easier and faster to install requiring less skilled labor.
SUMMARY OF THE INVENTION
[0007] There is provided a thin stone or thin brick wall system comprising: a plurality of stone or brick facing elements, each facing element having a weight, a thickness, an upper edge and a lower edge, the upper edge, the lower edge or both the upper and lower edges of each facing element having a groove running along the edge at a distance from a rear face of the facing element, the groove having a length, a width and a depth; and, a plurality of clips for linking the facing elements, the plurality of clips comprising one or more first clips for linking upper facing elements to lower facing elements, each of the first clips having one or more connecting flanges housed within the groove in the lower edge of one of the upper facing elements and within the groove in the upper edge of one of the lower facing elements, the one or more connecting flanges of the first clip depending from one or more base flanges of the first clip, the one or more base flanges of the first clip depending from a support flange of the first clip, the support flange having one or more apertures for accepting fastening means for fastening the first clip to a structural wall, and the one or more base flanges having a width just equal to the distance from the rear face to the groove of the upper and lower facing elements.
[0008] There is further provided a clip for linking first and second stone or brick facing elements in a thin stone or thin brick wall system, each facing element having a weight, a thickness, an upper edge and a lower edge, the first facing element having a groove in the lower edge thereof, the second facing element having a groove in the upper edge thereof, each groove running along its respective edge at a distance from a rear face of its respective facing element, each groove having a length, a width and a depth, the clip comprising: one or more connecting flanges housable within the groove in the lower edge of the first facing element and within the groove in the upper edge of one of the second facing elements; the one or more connecting flanges depending at right angles from one or more base flanges; the one or more base flanges depending at right angles from a support flange, the support flange having one or more apertures for accepting fastening means for fastening the clip to a structural wall; and, the one or more base flanges having a width just equal to the distance from the rear face to the groove of each facing element.
[0009] There is yet further provided a sill clip for retaining detail pieces of a thin stone or thin brick wall system, each detail piece being a thin stone or thin brick facing element, the facing element having a thickness and an edge, the edge having a groove therein running along the edge at a distance from a rear face of the facing element, the groove having a length, a width and a depth, the sill clip comprising: a connecting flange that is housable within the groove in the edge of the facing elements; the connecting flange depending at a right angle from a first base flange; the first base flange depending at a right angle from a support flange, the support flange oriented upwardly; the support flange having one or more apertures for accepting fastening means for fastening the sill clip to a structural wall; and, the first base flange having a width just equal to the distance from the rear face to the groove of the facing element.
[0010] There is still yet further provided a starter strip for supporting stone or brick facing elements in a thin stone or thin brick wall system, each facing element having a weight, a thickness and an edge, the edge having a groove therein running along the edge at a distance from a rear face of the facing elements, the groove having a length, a width and a depth, the starter strip comprising: a linking flange that is housed within the groove in the edge of one or more of the facing elements; the linking flange depending from a base flange; the base flange depending from a support flange; the support flange having one or more apertures for accepting fastening means for fastening the starter strip to a structural wall; the base flange having a width greater than the distance from the rear faces to the grooves of the facing elements; and, the starter strip having a length long enough to span two or more adjacent facing elements.
[0011] The wall system of the present invention, including the clips therefor, is useful in constructing so-called “thin stone” or “thin brick” veneer walls. Thin brick and thin stone differs from regular brick or stone cladding by virtue of the way in which the facing element is manufactured and by virtue of the size and weight of the facing element. Thin stone or thin brick may be manufactured by splitting concrete blocks and, if desired, further dressing the outer face of the stone. Thin brick may also be manufactured by molding clay into brick-shaped objects and firing the clay for hardness. Thin stone or thin brick is about 1.25 inches thick and building codes require thin stone or thin brick to be not heavier than 15 pounds per square foot, as opposed to regular stone which is typically 3.5 inches thick and may be heavier than 15 pounds per square foot. The code for thin stone arises primarily from prior art adhered thin stone cladding systems in which the stone is affixed to a building by an epoxy adhesive or with metal lath and a scratch coat of mortar (the so-called “lick & stick” method).
[0012] The wall system of the present invention advantageously provides a more versatile, secure and mechanically stronger veneer wall than has been previously realized in the art for thin stone or thin brick. Facing elements are easier and faster to install than in previous systems, and require less skilled labor thereby permitting general tradesman and even the average building owner to erect a thin stone or thin brick veneer wall.
[0013] Further, the present wall system advantageously permits mounting of facing elements on any variety of structural walls (e.g. wood studs, steel studs and concrete), and may actually increase the strength of a stud wall, rather than decrease it as is the case with prior art systems. Additionally, the present system permits excellent water management and ventilation between the veneer and the structural wall.
[0014] Yet further, the present wall system advantageously permits construction of thin stone or thin brick veneer walls having virtually any kind of appearance. For example, construction of random bond veneer walls having random size coursing by mixing different heights and lengths of stone or brick, or single size coursing with stones or bricks of the same height and length are both possible using the same wall system. It is also possible to do big dimensional stone units without sacrificing strength or appearance. Either a mortar joint wall or a mortarless wall, or even a mixture of both, may constructed using the present wall system. Pre-prepared corner facing elements are easily incorporated into the present wall system and may be used to provide a full Bed-Depth stone appearance at the corners.
[0015] In a wall system of the present invention, facing elements preferably have grooves formed and/or cut into both the upper and lower edges. The grooves preferably run along the edges at a fixed distance from the rear face of the facing element. Preferably, the grooves run along the entire length of the upper and lower edges. The facing elements may also have grooves formed and/or cut into one or both, preferably both, side edges. The grooves in the side edges preferably have the same depth and width as those in the upper and lower edges, and are preferably the same distance from the rear face. In a particularly preferred embodiment, there is one continuous groove running along the edges around the perimeter of the facing element.
[0016] Two types of facing elements may be defined depending on their location in the wall. A first type is used in the middle of the wall and the second type is a corner element. The first type of facing element is generally of a panel type construction having a rear face, a front (outer) face, upper and lower edges and side edges. The front face is a surface that presents in one direction only.
[0017] Corner elements (the second type of facing element) have a rear face, a front (outer) face, upper and lower edges and side edges as well, but they generally have complicated profiles so that the front face presents in two or more directions. Corner elements are preferably one-piece constructions having parts held together by connecting pins, the pins preferably set in an adhesive, e.g. an epoxy adhesive. The pins are preferably steel pins, more preferably stainless steel or galvanized steel, even more preferably stainless steel. Such corner elements permit the use of standard sized stones or bricks while maintaining a clean appearance at corners. In one example, the corner element is generally L-shaped comprising a first part attached to a second part. The outer face of the first part is longer than and at a right angle to the outer face of the second part. A plurality of such corner elements may be vertically overlapped alternating the directions of the first and second parts to provide a veneer wall with a clean looking corner having a full Bed-Depth appearance.
[0018] In forming a veneer wall, a plurality of facing elements are mounted on a structural wall and arranged next to each other in a desired pattern. In order to mount the facing elements on the structural wall and to link the facing elements to each other, a plurality of specially designed clips are used. Each clip comprises a support flange, one or more base flanges, and one or more connecting flanges for insertion into the grooves in the facing elements. Each clip is fastened individually to the structural wall, therefore each facing element is individually secured to the structural wall leading to improved mechanical strength for the veneer wall. The profile of each clip depends on its particular function in the wall system. Three types of clips may be defined depending on where they are used in the wall system.
[0019] A first type of clip is used between upper and lower facing elements to link the upper and lower stone facing elements and to mount the stone facing elements to the structural wall. The first type of clip has a support flange, one or more base flanges depending from the support flange, preferably at a right angle, and one or more connecting flanges depending from the one or more base flanges, preferably at right angles. Preferably, the support flange has one or more apertures, preferably one aperture, for accepting fastening means for fastening the clip to the structural wall. The one or more connecting flanges are housed within the groove on the lower edge of the upper facing element and within the groove on the upper edge of the lower facing element. The one or more connecting flanges preferably do not bottom-out in the grooves so that the weight of the facing elements is borne by the base flange.
[0020] The one or more base flanges of the first type of clip have a width just equal to the distance from the groove to the rear face of the facing elements. The length of the first clip is preferably much less than the length of the groove so that the clip may be positioned at any one of a plurality of positions along the groove. This provides great versatility in respect of where the clip will be fastened to the structural wall and the size of the facing element being used. This versatility leads to the ability to create virtually any pattern of stone or brick on the veneer wall while having each stone or brick mounted individually to the structural wall. This versatility also facilitates retrofitting of old buildings or sections of old buildings.
[0021] Facing elements for veneer walls may be of any convenient length and height. For example, some standard heights for stone include 3.5, 5.5 and 7.5 inches, while some standard lengths include 5.0, 10.5 and 15.5 inches. For bricks, standard width×height×length in inches are, respectively, for modular size 3.625×2.5×7.625, for utility size 3.625×3.625×11.625, and for premier size 3.5×3×9.75. The lengths and heights of facing elements can be customized for any particular application. Dimensions of facing elements are preferably set to allow the system to course out in an architectural grid. Architectural grids are preferably 4″×4″ or 100 mm×100 mm depending on location to allow for windows, openings, corners and overall placement of walls. When using facing elements of various heights in a single veneer wall, it is preferable that the height of one bigger facing element is equal to the height of two smaller facing elements plus the height of the clip, so that level joint lines can be maintained across the span of the veneer wall.
[0022] Preferably, the first clip has a length less than half the length of the groove. However, it is possible to utilize first clips having lengths of 4-foot or 8-foot, for example, and having drainage holes in the base flange or flanges for single height coursing.
[0023] The first clip may be utilized in a similar manner to link facing elements in a side-by-side arrangement. Instead of orienting the one or more connecting flanges linking vertically arranged facing elements, the clip can be positioned to orient the connecting flanges horizontally. The flanges are then housed within the grooves on the side edges of adjacent facing elements.
[0024] A first embodiment of the first clip may be utilized in constructing a veneer wall having mortar joints. The first clip in the first embodiment has two base flanges in spaced-apart relation depending from the support flange. An upwardly depending flange depends from a first base flange and a downwardly depending flange depends from a second base flange. Therefore, when the upper and lower stone facing elements are linked by the clip, the spaced-apart base flanges provide space for a mortar joint between the upper and lower facing elements. In a similar way, mortar joints can be formed between horizontally adjacent facing elements. Preferably, the spaced-apart base flanges are about 10 mm apart, which automatically provides 10 mm mortar joints over the entire veneer wall, which is standard in the stone facing industry. Once the veneer wall has been constructed, the mortar joints may be filled with mortar by any suitable means, for example, mortar guns, grout pumps, trowels, etc. Mortar filling the mortar joint helps prevent the clip from deflecting or collapsing since the mortar fills the space between the base flanges thereby providing support for the base flanges. Mortar may also enter the grooves thereby helping key the upwardly and downwardly depending flanges into the grooves. This helps strengthen the clip and adds to overall strength of the wall system.
[0025] A second embodiment of the first clip may be utilized in constructing a veneer wall having mortar joints. The first clip in the second embodiment has a cylindrical base flange. Depending outwardly at a right angle from one end of the cylindrical base flange is a circular connecting flange. Depending inwardly at a right angle from the other end of the cylindrical base flange is a circular support flange. The diameter of the cylindrical base flange provides spacing for the mortar joint and is preferably about 10 mm. Since the connecting flange is circular, the orientation of the clip when fastened to the wall is not important as the connecting flange will be housed in the grooves of the facing elements on any side of the clip. Fastening the clip to the structural wall may be accomplished by inserting the fastening means (e.g. a screw) through the central bore of the cylindrical base flange and through an aperture in the support flange. Since the base flange is cylindrical, both the length and the height of the clip are equal to the diameter of the base flange. The width of the clip corresponds to the cylindrical height. Once the veneer wall has been constructed, the mortar joints may be filled with mortar by any suitable means, for example, mortar guns, grout pumps, trowels, etc. Mortar filling the mortar joint helps prevent the clip from deflecting or collapsing since the mortar fills the cylindrical bore of the base flange thereby providing support for the base flanges. Mortar may also enter the grooves thereby helping key the connecting flange into the grooves. This helps strengthen the clip and adds to overall strength of the wall system.
[0026] A third embodiment of the first clip may be utilized in constructing a mortarless veneer curtain wall. The first clip in the third embodiment has one base flange with upwardly and downwardly depending flanges depending from one end of the base flange. Therefore, when the upper and lower facing elements are linked by the clip there is virtually no space at the joint between the facing elements. To accommodate the thickness of the base flange, a thin portion of the edges at the rear face of the facing elements may be ground to form a seat. The third embodiment of the first clip can provide consistent horizontal leveling with a standard spacing (e.g. 0.03125 inches). Stacking facing elements in such a mortarless veneer curtain wall can give a stacked-stone appearance. The edges at the front face of the facing elements may be beveled to make the joint look like a mortar joint. Similarly, mortarless joints can be formed between horizontally adjacent facing elements.
[0027] A second type of clip is a sill clip useful for detail pieces such as window/door surrounds, candles, headers, keystones and stencil stones. Sills clips are similar to the first embodiment of the first clip except that they do not have either the upwardly or downwardly depending flange since there is no facing elements on one side of the sill clip.
[0028] A third type of clip is a starter strip. Starter strips are utilized to support facing elements of the veneer wall from below, from above or from one side, but not from any combination thereof simultaneously. Starter strips are particularly useful at the very bottom of the wall, the very top of the wall, the extreme sides of the wall, or over window or door openings. Starter strips are useful wherever there is a significant boundary at an edge of the veneer wall. Starter strips may be straight or curved. Curved starter strips are particularly useful to span archways and the like.
[0029] The starter strip has a support flange, a base flange depending from the support flange, preferably at a right angle, and a linking flange depending from the base flange, preferably at a right angle and preferably depending in the same direction as the support flange. Preferably, the support flange of the starter strip has one or more apertures, preferably two or more apertures, for accepting fastening means for fastening the starter strip to the structural wall. The linking flange is housed within the groove on the edge of the facing element. The linking flange preferably does not bottom-out in the groove. Preferably the base flange of the starter strip has one or more drainage holes for permitting moisture to escape from the behind the veneer wall.
[0030] The starter strip has a length long enough to span two or more adjacent facing elements. The starter strip has a length preferably from about 3 to 12 feet, more preferably about 4 or about 8 feet. The base flange preferably has a width greater than the distance from the groove to the rear face of the facing element. The greater width accommodates other wall elements behind the facing elements.
[0031] Clips are fastened to the structural wall by fastening means, for example screws and nails, preferably screws. All clips and fastening means preferably comprise strong, durable material, for example plastic and/or steel, in particular galvanized steel or stainless steel. Stainless steel is preferred.
[0032] Typical wall construction, residential or commercial, comprises a structural wall clad with a veneer wall. The structural wall may be wood frame construction (e.g. 2×4 or 2×6 wood studs), steel frame construction, or poured concrete block construction. The structural wall preferably includes sheet material, for example wood-based sheet material (e.g. plywood, OSB), non-combustible sheet material or combinations thereof, mounted on the frame. In constructing a thin stone or thin brick veneer wall with the system of the present invention, clips are secured to the structural wall, particularly to the sheet material, and the facing elements set on the clips. The veneer wall is generally built from the bottom up in courses, and, if desired, each course is leveled to ensure a consistent appearance over the entire veneer wall. If mortar joints are used, the mortar joints are then filled with mortar, for example Type N Mortar, which is particularly recommended for thin stone applications. Type N Mortar is 1 part Type N Portland Lime cement mixed with 3 parts masonry sand. Type N Portland Lime cement is a mixture of 1 part Portland cement with 1 part hydrated lime. Type N-High Bond mortar (e.g. Quikrete™) is also particularly useful since it is available in pre-blended bags, and all one must do is add water.
[0033] Although the wall system of the present invention can be mounted on a structural wall without any other wall elements, it is preferable, and often required by building codes, to use other wall elements, in particular to protect the structural wall from the effects of moisture. Other wall elements include, for example, weather-resisting wall wrap (e.g. Tyvek™, Typar™, etc.), rubber membranes, vertical drainage board (e.g. J-DRain™), drain fabric (e.g. felt paper), etc.
[0034] Further features of the invention will be described or will become apparent in the course of the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0035] In order that the invention may be more clearly understood, embodiments thereof will now be described in detail by way of example, with reference to the accompanying drawings, in which:
[0036] FIG. 1A is perspective view of a thin stone facing element useful in a wall system of the present invention;
[0037] FIG. 1B is a top view of the stone facing element of FIG. 1A ;
[0038] FIG. 1C is a side view of the stone facing element of FIG. 1A ;
[0039] FIG. 1D is a perspective view of a thin stone facing element having a shorter length than the stone facing element of FIG. 1A ;
[0040] FIG. 1E is an enlarged view of a portion of the side view of FIG. 1C ;
[0041] FIG. 2A is a perspective view of a corner stone facing element useful in a wall system of the present invention;
[0042] FIG. 2B is a top view of the corner stone facing element of FIG. 2A ;
[0043] FIG. 2C is a right side view of the corner stone facing element of FIG. 2A ;
[0044] FIG. 2D is a left side view of the corner stone facing element of FIG. 2A ;
[0045] FIG. 3A is a perspective view of a starter strip of the present invention;
[0046] FIG. 3B is a side view of the starter strip of FIG. 3A ;
[0047] FIG. 3C is a front view of the starter strip of FIG. 3A ;
[0048] FIG. 3D is a top view of the starter strip of FIG. 3A ;
[0049] FIG. 4A is a perspective view of a first embodiment of a first clip of the present invention;
[0050] FIG. 4B is a side view of the clip of FIG. 4A ;
[0051] FIG. 4C is a front view of the clip of FIG. 4A ;
[0052] FIG. 5A is a perspective view of a second embodiment of a first clip of the present invention;
[0053] FIG. 5B is a side view of the clip of FIG. 5A ;
[0054] FIG. 5C is a front view of the clip of FIG. 5A ;
[0055] FIG. 6A is a perspective view of a third embodiment of a first clip of the present invention;
[0056] FIG. 6B is a side view of the clip of FIG. 6A ;
[0057] FIG. 6C is a front view of the clip of FIG. 6A ;
[0058] FIG. 7A is a perspective view of a sill clip of the present invention;
[0059] FIG. 7B is a side view of the sill clip of FIG. 7A ;
[0060] FIG. 7C is a front view of the sill clip of FIG. 7A ;
[0061] FIG. 8A is a side cross-sectional view of a section of a wall system of the present invention having mortar joints between stones; and,
[0062] FIG. 8B is a side cross-sectional view of a section of a mortarless wall system of the present invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0063] Referring to FIGS. 1A-1D , thin stone facing element 1 comprises front face 2 , rear face 3 , upper edge 4 , lower edge 5 and two side edges 6 . Groove 7 in the upper edge runs the entire length of the stone facing element from one side to the other side. Groove 8 in the lower edge runs the entire length of the stone facing element from one side to the other side. The front face of the stone facing element is dressed for aesthetic appeal since the front face presents outwardly when mounted in a veneer wall. Stone facing element 1 is 15.5 inches long by 7.5 inches in height. Stone facing element 9 depicted in FIG. 1D is the same as stone facing element 1 except that stone facing element 9 is only 5.0 inches long. Stone facing elements 1 and 9 may be used together in a thin stone veneer wall, and together with other sized stone facing elements if desired, to provide a more random appearance to the veneer wall.
[0064] Referring specifically to FIG. 1E , an enlarged portion of the side view depicted in FIG. 1C shows upper edge 4 , groove 7 in the upper edge, a portion of front face 2 and a portion of rear face 3 . Distance A is the thickness of stone facing element 1 and is 1.25 inches. Distance B is the distance from the groove to the rear face and is 0.625±0.0625 inches. Distance C is the depth of groove 7 and is 0.25−0/+0.125 inches. Distance D is the width of groove 7 and is 0.086 inches. Referring to FIGS. 1A-1C , groove 8 in lower edge 5 has similar dimensions and location as groove 7 in the upper edge 4 . Groove size and location is similar in stone facing element 9 of FIG. 1D .
[0065] Referring to FIGS. 2A-2D , one-piece corner stone facing element 10 comprises short part 19 a and long part 19 b having front faces 12 a , 12 b respectively, forming a right angle. Upper edge 14 has groove 17 running the entire length of both the short part and the long part. Where the short part meets the long part, groove 17 undergoes a change in direction of 90-degrees. Groove 18 in lower edge 15 is similar to groove 17 in upper edge 14 . Left side edge 16 a is the side edge of short part 19 a and right side edge 16 b is the side edge of long part 19 b . The short and long parts have rear faces 13 a , 13 b respectively. Front faces 12 a , 12 b form the front (outer) face of the corner stone facing element and rear faces 13 a , 13 b form the rear (inner) face of the corner stone facing element. In building a corner of a veneer wall, corner stone facing elements may by stacked with the short and long parts in alternating directions in order to give a full Bed-Depth appearance to the corner.
[0066] Referring to FIGS. 3A-3D , stainless steel starter strip 20 is 4 feet long and comprises support flange 21 depending upwardly at a right angle from one edge of base flange 22 . Depending upwardly at a right angle from the other edge of base flange 22 is linking flange 23 . Seven apertures 24 (only one labeled) in support flange 21 are 0.177 inches in diameter, which is sized to accept #8 stainless steel screws for fastening the starter strip to OSB, plywood and/or non-combustible sheets of a structural wall. Twelve drainage holes 25 (only one labeled) in base flange 22 permit drainage of moisture out the bottom of the starter strip. The first and last apertures of the seven apertures 24 are each 1.5 inches from their respective ends of the support flange and apertures 24 are 7.5 inches apart, measured from the centers of the apertures. The first and last drainage holes of the twelve drainage holes 25 are each 2 inches from their respective ends of the base flange and drainage holes 25 are 4 inches apart, measured from the centers of the drainage holes. The drainage holes are 0.25 inches in diameter.
[0067] Referring specifically to FIG. 3B , a side (end) view of the starter strip is shown, but not to the same scale as FIGS. 3A , 3 C and 3 D. Distance E is the height of the support flange, which is 1±0.125 inches. Distance F is the width of the base flange, which is 1−0/+0.0625 inches. Distance G is the height of the linking flange, which is 0.1875+0/−0.03125 inches.
[0068] The starter strip is made by stamping out the desired apertures and drainage holes in a single flat strip of #24 AWG stainless steel (0.027 inches thick), and then bending the strip appropriately to form the starter strip.
[0069] Referring to FIGS. 4A-4C , stainless steel clip 30 is useful for linking upper and lower stone facing elements in a thin stone veneer wall with mortar joints. Upwardly depending flange 33 a depends upwardly at a right angle from one edge of upper base flange 32 a . Downwardly depending flange 33 b depends downwardly at a right angle from one edge of lower base flange 32 b . Upper and lower base flanges 32 a , 32 b respectively, are parallel to and spaced-apart from each other to form a mortar joint. Support flange 31 joins upper and lower base flanges 32 a , 32 b at the ends of the base flanges opposite the ends from which the upwardly and downwardly depending flanges depend. Upper base flange 32 a depends from support flange 31 at a right angle from the upper edge of the support flange. Lower base flange 32 b depends from support flange 31 at a right angle from the lower edge of the support flange. Aperture 34 in support flange 31 is 0.177 inches in diameter, which is sized to accept a #8 stainless steel screw for fastening the clip to OSB, plywood or non-combustible sheet of a structural wall.
[0070] Referring specifically to FIG. 4B , distance H is the height of the support flange, which is 10±0 mm. This provides a mortar joint about 10 mm wide. Distance I is the width of the base flange which is 0.75±0.03125 inches and is about the same as the distance from a groove in a stone facing element to the rear face of the stone facing element. Distance I also provides a mortar joint about 0.75 inches deep. Distance J is the height of the clip, which is 0.78125 inches. Distance K is the height of upwardly depending flange 33 a , which is 0.1875+0/−0.03125 inches. The height of downwardly depending flange 33 b is the same as the upwardly depending flange.
[0071] Referring specifically to FIG. 4C , distance L is the distance from the center of aperture 34 to the edge of the clip, which is 0.5 inches. Distance M is the length of the clip, which is 1 inch.
[0072] Referring to FIGS. 5A-5C , stainless steel clip 90 is useful for linking upper and lower stone facing elements in a thin stone veneer wall with mortar joints. Circular outwardly depending flange 93 depends outwardly at a right angle from one end of cylindrical base flange 92 . Circular outwardly depending flange 93 is upwardly depending at 93 a and downwardly depending at 93 b . Support flange 91 forms a base of cylindrical base flange 92 at the end opposite outwardly depending flange 93 . Support flange 91 depends at a right angle from and inwardly into cylindrical base flange 92 . Aperture 94 in support flange 91 is 0.177 inches in diameter, which is sized to accept a #8 stainless steel screw for fastening the clip to OSB, plywood or non-combustible sheet of a structural wall. The cylindrical shape of base flange 92 and the circular shape of outwardly depending flange 93 provides n-fold symmetry around an axis through the middle of base flange 92 and aperture 94 , which removes the need to specifically orient upwardly and downwardly depending flanges in order to connect upper and lower facing elements in a thin stone or thin brick wall system.
[0073] Referring specifically to FIG. 5B , distance HH is the interior diameter of the cylindrical base flange, which is 10±0 mm. This provides a mortar joint about 10 mm wide. Distance II is the width of the base flange (cylindrical height) which is 0.75±0.03125 inches and is about the same as the distance from a groove in a stone facing element to the rear face of the stone facing element. Distance II also provides a mortar joint about 0.75 inches deep. Distance JJ is the height of the clip (circular diameter of outwardly depending flange 93 ), which is 0.78125 inches. Distance KK is the distance that outwardly depending flange 93 extends beyond base flange 92 , which is 0.1875+0/−0.03125 inches.
[0074] Referring specifically to FIG. 5C , distance LL is the distance from the center of aperture 94 to the edge of the clip, which is 0.390625 inches. Distance MM is the length of the clip (circular diameter of outwardly depending flange 93 ), which is 0.78125 inches. Distances JJ and MM are the same.
[0075] Referring to FIGS. 6A-6C , stainless steel clip 40 is useful for linking upper and lower stone facing elements in a thin stone veneer wall with mortarless joints. Upwardly depending flanges 43 a depend upwardly at a right angle from one edge of base flange 42 . Downwardly depending flange 43 b depends downwardly at a right angle from one edge of base flange 42 . Support flange 41 depends upwardly from base flange 42 at a right angle from the end of the base flange opposite the end from which the upwardly and downwardly depending flanges depend. Aperture 44 in support flange 41 is 0.177 inches in diameter, which is sized to accept a #8 stainless steel screw for fastening the clip to OSB, plywood or non-combustible sheet of a structural wall. Since clip 40 has a single base flange, the upwardly and downwardly depending flanges meet and no mortar joint is formed.
[0076] Referring specifically to FIG. 6B , distance N is the height of the support flange, which is 10 mm. Distance O is the width of the base flange, which is 0.8125 inches, and is about the same as the distance from a groove in a stone facing element to the rear face of the stone facing element. Distance P is the height of upwardly depending flanges 43 a , which is 0.1875+0/−0.03125 inches. The height of downwardly depending flange 43 b is the same as the upwardly depending flanges.
[0077] Referring specifically to FIG. 6C , distance Q is the length of downwardly depending flange 43 b , which is 0.375 inches. Distance R is the length of one of the upwardly depending flanges 43 a , which is 0.3125 inches. Both upwardly depending flanges have the same length. Distance S is the length of the clip, which is 1 inch.
[0078] Referring to FIGS. 7A-7C , stainless steel sill clip 50 is useful for retaining stone facing elements around a window sill in a thin stone veneer wall with mortar joints. Downwardly depending flange 53 depends downwardly at a right angle from one edge of lower base flange 52 b . There is no upwardly depending flange. Upper and lower base flanges 52 a , 52 b respectively, are parallel to and spaced-apart from each other to form a mortar joint. Support flange 51 joins upper and lower base flanges 52 a , 52 b at the ends of the base flanges opposite the end of the lower base flange from which the downwardly depending flange depends. Upper base flange 52 a depends from support flange 51 at a right angle from the upper edge of the support flange. Lower base flange 52 b depends from support flange 51 at a right angle from the lower edge of the support flange. Aperture 54 in support flange 51 is 0.177 inches in diameter, which is sized to accept a #8 stainless steel screw for fastening the clip to OSB, plywood or non-combustible sheet of a structural wall.
[0079] Referring specifically to FIG. 7B , distance T is the height of the support flange, which is 10±0 mm. This provides a mortar joint about 10 mm wide. Distance U is the width of lower base flange 52 b which is 0.75±0.03125 inches and is about the same as the distance from a groove in a stone facing element to the rear face of the stone facing element. Distance U also provides a mortar joint about 0.75 inches deep. Distance V is the height of the clip, which is 0.59375 inches. Distance W is the height of downwardly depending flange 53 , which is 0.1875+0/−0.03125 inches.
[0080] Referring specifically to FIG. 7C , distance X is the distance from the center of aperture 54 to the edge of the sill clip, which is 0.5 inches. Distance Y is the length of the sill clip, which is 1 inch.
[0081] Clips may be made by stamping out appropriately spaced apertures in a single strip of #20 AWG stainless steel (0.0359 inches thick), bending the strip appropriately to form a bent strip of the correct profile, and then cutting individual clips out of the bent strip. Also, sill clips may be conveniently produced in small quantities on a job site by cutting off either the upwardly or downwardly depending flange of clips of FIG. 4 .
[0082] Referring to FIG. 8A , a side cross-sectional view of a section of a thin stone veneer wall system having mortar joints depicts upper and lower stone facing elements 101 , 102 respectively, mounted to a wood stud wall clad with ⅝″ plywood 103 . The upper and lower stone facing elements are linked by stainless steel clip 30 , which is secured to the plywood with #8 stainless steel screw 110 . Clip 30 provides for a 10 mm mortar joint 130 between the upper and lower stone facing elements. Lower stone facing element 102 is retained at its lower edge by starter strip 20 , which is secured to the plywood with #8 stainless steel screw 111 . Upper stone facing element 101 is retained at its upper edge by sill clip 50 , which is secured to the plywood with #8 stainless steel screw 112 . Sill clip 50 provides for a 10 mm mortar joint 150 beneath window sill 104 .
[0083] Between the plywood and the stone facing elements adjacent the plywood is a layer of Tyvek™ wrap 105 . Between the Tyvek™ layer and the stone facing elements is a corrugated vertical drainage panel, J-DRain™ 300, 106, and between the J-DRain™ 300 and the stone facing elements is a layer of felt cloth 107 to prevent mortar from clogging channels in the J-DRain™ 300. Screws 110 , 112 securing clip 30 and sill clip 50 respectively pierce the J-DRain™ 300 layer since the clips are only about as wide as the distance from the groove to the rear face of the stone facing elements. Screw 111 securing starter strip 20 does not pierce the J-DRain™ 300 since the starter strip is wider than the distance from the groove to the rear face of the stone facing element and is wide enough to accommodate the stone facing element and the J-DRain™ 300. Drainage holes in the base flange of the starter strip permit drainage of any moisture caught between the stone facing elements and the plywood.
[0084] Referring to FIG. 8B , a side cross-sectional view of a section of a mortarless thin stone veneer wall system depicts upper and lower stone facing elements 201 , 202 respectively, mounted to a wood stud wall clad with OSB 203 . The upper and lower stone facing elements are linked by stainless steel clip 40 a , which is secured to the OSB with #8 stainless steel screw 210 . Lower stone facing element 202 is retained at its lower edge by starter strip 20 , which is secured to the OSB with #8 stainless steel screw 211 . Upper stone facing element 201 is retained at its upper edge by stainless steel clip 40 b , which is secured to the OSB with #8 stainless steel screw 212 . Clip 40 a provides a standard spacing of 0.0625 inches between upper and lower stone facing elements 201 , 202 . The mortarless thin stone veneer wall continues upwardly from upper stone facing element 201 in a similar fashion.
[0085] Between the OSB and the stone facing elements adjacent the plywood is a layer of Tyvek™ wrap 205 . Between the Tyvek™ layer and the stone facing elements is a corrugated vertical drainage panel, J-DRain™ 300, 206. Screw 210 securing clip 40 pierces the J-DRain™ 300 layer since the clip is only about as wide as the distance from the groove to the rear face of the stone facing elements. Screw 211 securing starter strip 20 does not pierce the J-DRain™ 300 since the starter strip is wider than the distance from the groove to the rear face of the stone facing element and is wide enough to accommodate the stone facing element and the J-DRain™ 300. Drainage holes in the base flange of the starter strip permit drainage of any moisture caught between the stone facing elements and the OSB.
[0086] Other advantages which are inherent to the structure are obvious to one skilled in the art. The embodiments are described herein illustratively and are not meant to limit the scope of the invention as claimed. Variations of the foregoing embodiments will be evident to a person of ordinary skill and are intended by the inventor to be encompassed by the following claims.
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A wall system, particularly for thin stone or thin brick veneer walls, has a plurality of stones or bricks with grooves running along the upper and lower edges and a plurality of clips for linking the stones or bricks. One type of clip having one or more connecting flanges links an upper stone or brick to a lower stone or brick with the one or more connecting flanges housed within the groove in the lower edge of the upper stone or brick and within the groove in the upper edge of the lower stone or brick. The one or more connecting flanges of the clip depend from one or more base flanges of the clip and have a width just equal to the distance from the rear face to the groove of the upper and lower stones or bricks. The one or more base flanges of the clip depend from a support flange of the clip. The support flange has one or more apertures for accepting a screw or nail for fastening the clip to a structural wall.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
FIELD OF THE INVENTION
This invention relates to fluid sampling methods and apparatus for use in a borehole in an earth formation, for obtaining samples of the formation fluids in the earth formation.
BACKGROUND OF THE INVENTION
When a borehole is drilled into an earth formation in search of hydrocarbons, the borehole is typically filled with borehole fluids, primarily the re-circulating drilling fluid, or “drilling mud”, used to lubricate the drill bit and carry away the cuttings. These borehole fluids penetrate into the region of the formation immediately surrounding the borehole, creating an “invaded zone” that may be several tens of centimetres in radial extent.
When it is subsequently desired to obtain a sample of the formation fluids for analysis, a tool incorporating a sampling probe is lowered into the borehole (which is typically still filled with borehole fluids) to the desired depth, the sampling probe is urged against the borehole wall, and a sample of the formation fluids is drawn into the tool. However, since the sample is drawn through the invaded zone, and the tool incorporating the sampling probe is still surrounded by borehole fluids, the sample tends to become contaminated with borehole fluids from the invaded zone, and possibly even from the borehole itself, and is therefore not truly representative of the formation fluids.
One way of addressing this problem is disclosed in International Patent Application No. WO 00/43812, and involves using a sampling probe having an outer zone surrounding an inner zone, fluid being drawn into both zones. The outer zone tends to shield the inner zone from the borehole fluids surrounding the tool embodying the sample probe, and thus makes it possible to obtain a relatively uncontaminated sample of the formation fluids via the inner zone.
However, the time taken to obtain a large enough sample having a given relatively low level of contamination can vary widely in dependence on borehole conditions. It is therefore an object of the present invention in some of its aspects to alleviate this problem.
SUMMARY OF THE INVENTION
According to a first aspect of the present invention, there is provided a method of sampling the formation fluids in an earth formation surrounding a borehole, the region of the formation immediately surrounding the borehole being at least partially invaded by borehole fluids, using a borehole tool which is adapted to be lowered into the borehole and which is provided with a sampling probe device and means for urging the sampling probe device into contact with the borehole wall, the sampling probe device comprising an inner probe and an outer probe surrounding the inner probe for withdrawing respective fluid samples from the formation, wherein the ratio between the respective flow areas of the inner and outer probes is selected so as to tend to reduce the time taken to obtain via the inner probe a sample of the formation fluids having a given level of contamination by borehole fluids.
The selecting step is preferably performed in dependence upon at least one parameter selected from the radial depth of the invaded region of the formation around the borehole, the ratio between the viscosity of the borehole fluids which have invaded the formation and the viscosity of the formation fluids, and the permeability and the anisotropy of the formations.
In one implementation of the first aspect of the invention, the selecting step comprises adapting the tool to receive interchangeable sampling probe devices, and choosing the sampling probe device from among a plurality of sampling probe devices each having a different value of said ratio. In another implementation of the invention, the selecting step comprises adapting the sampling probe device to receive interchangeable inner probes, and choosing the inner probe from among a plurality of inner probes each having a different flow area.
According to a second aspect of the invention, there is provided apparatus for implementing the method of the first aspect of the invention, the apparatus comprising a borehole tool adapted to be lowered into a borehole, the tool being adapted to receive any one of a plurality of interchangeable sampling probe devices and including means for urging a received sampling probe device into contact with the borehole wall, each sampling probe device comprising an inner probe and an outer probe surrounding the inner probe for withdrawing respective fluid samples from the formation, the ratio between the respective flow areas of the inner and outer probes being different for each sampling probe device.
According to a third aspect of the invention, there is provided another apparatus for implementing the method of the first aspect of the invention, the apparatus comprising a borehole tool which is adapted to be lowered into a borehole and which is provided with a sampling probe device and means for urging the sampling probe device into contact with the borehole wall, the sampling probe device comprising an inner probe and an outer probe surrounding the inner probe for withdrawing respective fluid samples from the formation, wherein the sampling probe device is adapted to receive any one of a plurality of inner probes each having a different flow area.
In this third aspect of the invention, said inner and outer probes are advantageously substantially circular in cross-section and substantially coaxial with each other, and each said inner probe may be adapted for screw-threaded engagement with the sampling probe device.
According to a fourth aspect of the invention, there is provided a method of sampling the formation fluids in an earth formation surrounding a borehole, the region of the formation immediately surrounding the borehole being at least partially invaded by borehole fluids, using a borehole tool which is adapted to be lowered into the borehole and which is provided with a sampling probe device and means for urging the sampling probe device into contact with the borehole wall, the sampling probe device comprising an inner probe and an outer probe surrounding the inner probe for withdrawing respective fluid samples from the formation, the method comprising adjusting the ratio between the respective flow areas of the inner and outer probes so as to tend to reduce the time taken to obtain via the inner probe a sample of the formation fluids having a given level of contamination by borehole fluids.
In a preferred implementation of this fourth aspect of the invention, the adjusting step is performed in dependence upon at least one parameter selected from the radial depth of the invaded region of the formation around the borehole, the ratio between the viscosity of the borehole fluids which have invaded the formation and the viscosity of the formation fluids, and the permeability and the anisotropy of the formations, and may comprise changing the area of the end of the inner probe in contact with the wall of the borehole.
The end of the inner probe in contact with the wall of the borehole may be deformable, in which case the changing step may comprise varying the force with which said inner probe is urged into contact with the wall of the borehole. Alternatively, the inner probe may comprises a plurality of closely-fitting, coaxially-internested, relatively slideable cylinders, and the changing step may comprise varying the number of said cylinders in contact with the formation.
According to a fifth aspect of the invention, there is provide apparatus for sampling the formation fluids in an earth formation surrounding a borehole, the region of the formation immediately surrounding the borehole being at least partially invaded by borehole fluids, the apparatus comprising a borehole tool which is adapted to be lowered into the borehole and which is provided with a sampling probe device and means for urging the sampling probe device into contact with the borehole wall, the sampling probe device comprising an inner probe and an outer probe surrounding the inner probe for withdrawing respective fluid samples from the formation, and means for adjusting the ratio between the respective flow areas of the inner and outer probes so as to tend to reduce the time taken to obtain via the inner probe a sample of the formation fluids having a given level of contamination by borehole fluids.
Advantageously, the adjusting means is operated to adjust the ratio between the respective flow areas of the inner and outer probes in dependence upon at least one parameter selected from the radial depth of the invaded region of the formation around the borehole, the ratio between the viscosity of the borehole fluids which have invaded the formation and the viscosity of the formation fluids, and the permeability and the anisotropy of the formations.
Conveniently, the adjusting means comprises means for changing the area of the end of the inner probe in contact with the wall of the borehole. Thus the end of the inner probe in contact with the wall of the borehole may be deformable, and the changing means may comprise means for varying the force with which said inner probe is urged into contact with the wall of the borehole. Alternatively, the inner probe may comprise a plurality of closely-fitting, coaxially-internested, relatively slideable cylinders, and the changing means may comprise means for varying the number of said cylinders in contact with the formation.
In another implementation of the fifth aspect of the invention, the outer probe comprises an inner region, and an outer region surrounding the inner region, for withdrawing respective fluid samples from the formation, the tool further comprising valve means selectively operable to combine the fluid sample withdrawn via said inner region of the outer probe with the fluid sample withdrawn via the inner probe.
According to a sixth aspect of the invention, there is provided apparatus for sampling the formation fluids in an earth formation surrounding a borehole, the region of the formation immediately surrounding the borehole being at least partially invaded by borehole fluids, the apparatus comprising a borehole tool which is adapted to be lowered into the borehole and which is provided with a sampling probe device and means for urging the sampling probe device into contact with the borehole wall, the sampling probe device comprising an inner probe, an intermediate probe surrounding the inner probe, and an outer probe surrounding the intermediate probe, all for withdrawing respective fluid samples from the formation, the tool further comprising valve means selectively operable to combine the fluid sample withdrawn via said intermediate probe with the fluid sample withdrawn via the inner probe.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described, by way of non-limitative example only, with reference to the accompanying drawings, of which:
FIG. 1A is a somewhat schematic representation of apparatus in accordance with the present invention disposed in a borehole penetrating an earth formation, the apparatus comprising a borehole tool incorporating a sampling probe device through which fluid samples are withdrawn from the formation;
FIG. 1B shows a modification of the apparatus of FIG. 1A;
FIG. 2 shows at ( a ) and ( b ) alternative forms of the end of the sampling probe device of FIGS. 1A and 1B which is urged into contact with the formation and through which the samples flow into the borehole tool;
FIG. 3 is a sectional view of a preferred implementation of the sampling probe device of FIG. 2 ( a );
FIGS. 4 and 5 are schematic representations of an alternative implementation of the sampling probe device of FIGS. 1A and 1B;
FIG. 6 shows a preferred implementation of the probe sampling device of FIGS. 4 and 5; and
FIGS. 7 to 13 illustrate different implementations of variable area probes which can be incorporated into the sampling probe device of FIGS. 1 A and 1 B.
DETAILED DESCRIPTION OF THE INVENTION
We have found by a combination of theory and numerical simulations that when using a borehole tool with a sampling probe device having an inner probe and an outer probe surrounding the inner probe to obtain a sample of formation fluid having a given low level of contamination by borehole fluid and filtrate (that is, borehole fluid that has seeped into the so-called invaded zone around the borehole), the time taken to obtain the sample not only varies widely with the viscosity of the filtrate and the radial extent of the invaded zone, but is also significantly affected by the ratio of the flow rate of the fluid flowing into the inner sampling probe to the total flow rate into the outer probe and the inner sampling probe. The present invention is based on the appreciation that varying this ratio in dependence upon such parameters as the relative viscosities of the formation fluid and the filtrate, the radial extent of the invaded zone, and the permeability and the anisotropy of the formation, which are often known in advance, can significantly reduce the time taken to obtain the sample.
With reference now to the drawings, the apparatus shown in FIG. 1 comprises an elongate modular borehole tool 10 suspended on a wireline or slickline 12 in a borehole 14 penetrating an earth formation 16 believed to contain exploitable, ie recoverable, hydrocarbons. Surrounding the borehole 14 , to a radial distance of up to several tens of centimetres, is an invaded zone 18 of the formation 16 into which contaminants, typically filtrate from drilling mud used in the drilling of the borehole, have penetrated from the borehole.
The borehole tool 10 is provided with a sampling probe device 20 which will be described in more detail hereinafter and which projects laterally from the tool. The sampling probe device 20 is urged into firm contact with the wall of the borehole 14 adjacent the formation 16 by an anchoring device 22 , which is mounted on the side of the tool 10 substantially opposite the sampling probe and which presses against the borehole wall. As will become apparent, the sampling probe device 20 includes inner and outer probes 24 , 26 having respective flow areas whose ratio can be varied. The inner probe 24 is selectively connectable via an outlet conduit 28 containing a pair of changeover (or diverter) valves 30 either to a sample chamber 32 or to a dump outlet (not shown), while the outer probe 26 is coupled via an outlet conduit 34 to a dump outlet (not shown). Both of the probes 24 , 26 are arranged to draw fluid samples from the formation 16 , under the control of respective pumps 38 and a control system 40 which controls the valves 30 and the pumps 38 . In the event it is determined that a sample of the formation having an acceptably low level of contamination can be obtained via the inner probe 24 , the control system 40 operates pumps 38 to control the relative flow rates or pressures at the inner and outer probes 24 , 26 , and sets the valves 30 to direct the sample from the inner probe 24 into the sample chamber 32 .
It will be appreciated that in the borehole tool 10 of FIG. 1A, fluid is drawn into the sample chamber 32 without passing through the relevant pump 38 . In the modification of Figure of FIG. 1B, the fluid passes through the relevant pump 38 en route to the sample chamber. Other modifications which can be made include using a single pump in place of the two pumps 38 , and providing the conduit 34 with valves and a sample chamber analogous to the valves 30 and sample chamber 32 , so that the fluid obtained via the outer probe 26 can be selectively retained or dumped, rather than always dumped.
As can be seen in FIG. 2, the inner and outer probes 24 , 26 of the sampling probe device 20 can be either circular and concentric, with the outer probe completely surrounding the inner probe, as shown in FIG. 2 ( a ), or rectangular, again with the outer probe completely surrounding the inner probe, as shown in FIG. 2 ( b ). FIG. 3 shows a preferred implementation of the sampling probe device of FIG. 2 ( a ), in which the inner probe 24 is replaceable by virtue of having a screw-threaded connection 42 with the end of its conduit 28 , so that the aforementioned variable flow area ratio feature can be achieved simply by changing the inner probe 24 for one having a different diameter. It will be appreciated that the outer wall of the outer probe 26 can alternatively or additionally be made replaceable by use of a similar screw-threaded connection with the outer wall of its conduit 34 , thus permitting the range of variation of the flow area ratio to be widened. In another implementation, the whole probe device 20 can be made replaceable, so that the variable flow are feature is achieved by selecting one of several sampling probe devices 20 each having inner and outer probes of different flow area ratio.
The alternative implementation of the sampling probe device 20 shown in FIGS. 4 and 5 comprises inner, intermediate and outer probes 44 , 46 and 48 , which are substantially circular and concentric with each other. The intermediate probe 46 completely surrounds the inner probe 44 , while the outer probe 48 completely surrounds the intermediate probe 46 . All three of the probes 44 , 46 , 48 withdraw fluid samples from the formation 16 under the control of the pump 38 and the control system 40 of FIG. 1, but the outlet conduit 50 of the intermediate probe includes a valve 52 , also controlled by the control system 40 , by which the fluid sample withdrawn via the intermediate probe 46 can be selectively combined either with the sample in the conduit 28 from the inner probe 44 , or with the sample in the conduit 34 from the outer probe 48 . It will be appreciated that these alternatives are equivalent to increasing the flow area of the inner probe 44 by the flow area of the intermediate probe 46 on the one hand, and increasing the flow area of the outer probe 48 by the flow area of the intermediate probe 46 on the other hand, thus achieving the aforementioned variable flow area ratio mentioned earlier.
One way of implementing the valve 52 of the sampling probe device 20 of FIGS. 4 and 5 is shown in FIG. 6 . Thus the conduits 28 , 50 and 34 of the probes 44 , 46 and 48 respectively are coaxially internested, and a shuttle valve member 54 is axially movable in the conduit 50 between a first position, in which it opens a port 56 between the conduit 50 and the conduit 28 while closing a port 58 between the conduit 50 and the conduit 34 , and a second position, in which it closes the port 56 and opens the port 58 .
It will be appreciated that the principles underlying the probe sampling device 20 of FIGS. 4 to 6 , which provides two different flow area ratios, can readily be extended by using more than three concentrically arranged probes communicating with a corresponding number of coaxially internested outlet conduits and having an appropriate number of shuttle or other switchover valves. And although it is convenient for the probes and their outlet conduits to be circular in section, it is not essential: as already described, rectangular sections can also be used.
FIGS. 7 to 13 , each of which is made up of four separate figures referenced ( a ), ( b ), ( c ) and ( d ), show different implementations of variable area probes, each of which can be used as the inner probe 24 of the sampling probe device 20 of FIG. 1 (as shown), and/or as the outer probe 26 .
Thus the probe 24 of FIG. 7 comprises a tube 60 made of a soft deformable compound, and is shown undeformed in FIG. 7 ( a ), with its flow area in its undeformed state shown in FIG. 7 ( b ). Applying an axial force to the tube 60 to press it more firmly against the borehole wall deforms the probe and reduces its flow area as shown in FIGS. 7 ( c ) and 7 ( d ) respectively. The axial force can be applied by any suitable mechanism, eg a mechanical, electromechanical or hydraulic mechanism.
The probe 24 of FIG. 8 comprises a tube 62 made from a semi-stiff deformable material which is thinner than the material of the probe of FIG. 7 . Otherwise, its mode of use is basically similar to that of the FIG. 7 probe, and the views of FIGS. 8 ( a ) to 8 ( d ) correspond to those of FIGS. 7 ( a ) to 7 ( d ).
The probe 24 of FIG. 9 comprises an array of close-fitting coaxially-internested cylinders 64 , which are arranged such that an increasing axial force progressively increases the number of them, from the outer one towards the inner one, in contact with the borehole wall, thus progressively decreasing the flow area of the probe. The maximum flow area state of the probe is shown in FIGS. 9 ( a ) and 9 ( b ), while a reduced flow area state is shown in FIGS. 9 ( c ) and 9 ( d ).
FIG. 10 shows a variation of the FIG. 9 probe, in which the cylinders 64 are coupled together at each of their ends 66 , but which otherwise operates in substantially the same manner.
The probe 24 of FIG. 11 comprises a single spirally-wound cylinder 68 , whose staggered inner turns respond to an axial force in a manner analogous to the interested cylinders of FIGS. 9 and 10. Again, the maximum flow area state of the probe is shown in FIGS. 11 ( a ) and 11 ( b ), while a reduced flow area state is shown in FIGS. 11 ( c ) and 11 ( d ).
FIGS. 12 and 13 show probes 24 both made from a cylindrical tightly coiled spring 70 with a trumpet-shaped end 72 for contacting the borehole wall: in the former, the spring has a flat coil at its borehole contact end, while in the latter, the spring is potted in a suitable elastomer. In both cases, axial force increases the number of coils of the spring in contact with the borehole wall, so decreasing the flow area of the probe.
Several modifications can be made to the described embodiments of the invention.
For example, the inner and outer probes need not be circular or rectangular in section, but can be elliptical, ellipsoidal, polygonal or any other convenient shape, or even different from each other, as long as the outer probe surrounds the inner probe. In practice, the geometry of the probes is typically selected in dependence upon such parameters as the depth of invasion of the filtrate, the ratio between the viscosity of the filtrate and the viscosity of the formation fluids, and the permeability and anisotropy of the formations.
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The invention concerns a method of sampling the formation fluids in an earth formation surrounding a borehole, the region of the formation immediately surrounding the borehole being at least partially invaded by borehole fluids, and an apparatus for carrying out such a method. According to the invention, a borehole tool is adapted to be lowered into the borehole and is provided with a sampling probe device and means for urging the sampling probe device into contact with the borehole wall, the sampling probe device comprising an inner probe and an outer probe surrounding the inner probe for withdrawing respective fluid samples from the formation, wherein the ratio between the respective flow areas of the inner and outer probes is selected so as to tend to reduce the time taken to obtain via the inner probe a sample of the formation fluids having a given level of contamination by borehole fluids.
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BACKGROUND OF THE INVENTION
This invention relates to swinging gates and is more particularly concerned with gates adapted to be disposed across a roadway and which can be opened by pressure applied to either side of the gate, such as by an automobile or other vehicle, and which automatically closes.
In providing gates of the aforementioned type, a commonly encountered problem is that after the gate is opened, the automatic means for closing it goes into operation immediately after the gate is opened or after the pressure used to open it is released. Consequently, the vehicles intending to pass through the opened gate often do not have sufficient time to do so before the gate closes. As a result, the vehicle in passing through the gate is frequently struck by the gate as it is closing, resulting in damage to the vehicle or the gate or both. This problem is more severe in the case of long vehicles or combinations of vehicles such as trucks, tractors an trailers, farming equipment, etc.
It is accordingly an object of the present invention to provide a vehicle-operated automatically closing gate which permits vehicles to pass through without danger of being struck by the gate in closing.
It is another object of the invention to provide a gate of the foregoing object which opens rapidly and is held open for a predetermined period of time.
It is a further object of the present invention to provide a gate of the aforesaid nature which can be opened either automatically by a vehicle or manually by a person on foot.
It is a still another object of this invention to provide a gate of the aforesaid nature of rugged durable design amenable to low cost manufacture.
These objects and other objects and advantages of the invention will be apparent from the following description.
SUMMARY OF THE INVENTION
The above and other beneficial objects and advantages are accomplished in accordance with the present invention by a gate apparatus comprising:
(a) a gate member of horizontally elongated rectangular periphery defined by upper and lower edges and first and second vertically disposed ends, and adapted to swing horizontally between open and closed positions,
(b) a straight axle affixed to said first vertical end in substantially parallel orientation thereto within the general plane of said gate member,
(c) latching means associated with said second vertical edge,
(d) a hinge post adapted to be disposed adjacent and parallel to said first vertical end,
(e) upper fixed bushing means adapted to rotatively engage the upper extremity of said axle at a fixed distance from said hinge post,
(f) lower movable bushing means adapted for rotatively engage said axle adjacent its lower extremity and horizontally movable with respect to said hinge post,
(g) a substantially flat cam horizontally disposed below said lower bushing means having rearward and side edges, and a forward edge comprised of two arcuate lobes symmetrically disposed about a center line running between said forward and rearward edges, said lobes meeting in a cusp disposed upon said center line, paired ramps associated with the rearward edge beginning at sites extending beyond said side edges, having flat bottoms coplanar with the lower face of the cam, and terminating in an angled portion directed toward the upper face of the cam, and a circular aperture centered upon said center line adjacent said rearward edge,
(h) a cam rod attached to said hinge post in a manner to pivot in a vertical plane above said cam, and having attached to its free extremity a downwardly directed roller adapted to rotate in a horizontal plane in engagement with the edges and ramps of said cam, said roller being adapted to rest in said cusp in the closed position of said gate member,
(i) a control rod extending vertically from said lower bushing means and downwardly through the aperture in said cam,
(j) spring means extending between said hinge post and control rod, and adapted to urge said rod toward said hinge post,
(k) motion dampening means extending between said hinge post and control rod, and
(l) paired bump levers rigidly associated with each lobe of said cam and extending from the rearward edge thereof toward the center of each side of said gate member, whereby
(m) pressure against either bump lever causes the cam roller to leave the cusp and travel onto the upper face of the cam, causing the lower extremity of the said axle to move away from the hinge post, which action upwardly tilts the gate member so as to disengage from said latching means and swing horizontally to an open position, said spring and motion dampening means causing controlled reversal of said sequence with resultant closing of the gate member.
BRIEF DESCRIPTION OF THE DRAWING
For a fuller understanding of the nature and objects of the invention, reference should be had to the following detailed description taken in connection with the accompanying drawing forming a part of this specification and in which similar numerals of reference indicate corresponding parts in all the figures of the drawing:
FIG. 1 is a front view of an embodiment of the gate of this invention in its closed position.
FIG. 2 is a front view of the gate of FIG. 1 in a partially opened position.
FIG. 3 is an enlarged fragmentary sectional view taken along the line 3--3 of FIG. 1 and showing the path of the cam roller.
FIG. 4 is a fragmentary top view of the gate of FIG. 1.
FIG. 5 is an enlarged fragmentary sectional view taken along the line 5--5 of FIG. 1.
FIG. 6 is a sectional view taken along the line 6--6 of FIG. 3 and showing several positions of the cam roller.
FIG. 7 is a sectional view taken along the line 7--7 of FIG. 3 and showing several positions of the cam roller.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawing, an apparatus of the present invention is shown comprised of hinge post assembly 10, latch post assembly 11, and intervening gate member 12 of horizontally elongated rectangular periphery defined by upper and lower edges 13 and 14, respectively, and vertically disposed first and second ends 15 and 16, respectively. The gate member is preferably fabricated of interconnected metal tubing.
A straight axle 17 is affixed to said first vertical end in a manner forming therewith a downwardly opening angle A of about 5 degrees within the general plane of the gate member. A flat latch blade 18 is attached by pivot pin 21 to second end 16 and is adapted to pivot in a vertical plane, permitting entrance into groove 19 in holding arm 20 attached to post 50 of latch post assembly 11. It is to be noted that groove 19 is bounded by angled surfaces 23 which facilitate sliding movement of blade 18 into said groove.
Hinge post assembly 10 is comprised of rigid vertical post 24, fixed upper bushing 25 adapted to rotatively hold the upper extremity of axle 17, and movable lower bushing 26 adapted to rotatively engage the lower extremity of said axle. Said lower bushing is supported by upper square rod 27 which telescopically engages upper square tube 51 held by post 24 and is adapted for reciprocating horizontal movement in the direction of said latch post assembly.
A pair of coil tension springs 43 are disposed on either side of post 24, extending from an upper holding bracket 44 attached to said post to an upper holding bar 45 that perpendicularly attaches to the free extremity of square rod 27. The function of the springs is to urge the lower extremity of axle 17 toward post 24.
A pair of hydraulic piston-cylinder assemblies 46 are disposed below said springs in similar manner and are adapted to slow movement of square rod 27 and associated components toward post 24. The closed extremity of each hydraulic cylinder 52 is attached to lower holding bracket 44 attached to post 24. The free extremity of each piston 53 is attached to a lower holding bar 45 perpendicularly affixed to lower square rod 27 which telescopically engages lower square tube 51 held by post 24.
A control rod 39 extends vertically from beneath lower bushing 26. The upper and lower extremities of said control rod are pivotably held by said upper and lower holding bars, respectively.
A substantially flat cam 28 is horizontally disposed below lower bushing 26, said cam having rearward edge 30, side edges 31, and a forward edge comprised of two side-by-side arcuate lobes 29 symmetrically disposed about center line 32 running between said rearward and forward edges. Said lobes meet in a cusp 33 disposed upon said center line. Paired ramps 34 associated with rearward edge 30 are comprised of a flat bottom surface 35 disposed in coplanar relationship with the lower face of the cam, and upwardly directed retaining lip 36. Each ramp begins with a downwardly angled portion 54 extending beyond said edge 31, and terminates in an upwardly angled portion 37. A circular aperture 38 is centered upon line 32 in close adjacency to rearward edge 30. Control rod 39 extends through aperture 38 in welded engagement therewith, and thereby supports cam 28 in a horizontally pivotable manner.
A cam rod 40 is attached to post 24 by pivot pin 41 which permits movement of the rod in a vertical plane above said cam. A roller 42, adapted to rotate in a horizontal plane, is held by the underside of the free extremity of cam rod 40. The design of the cam rod and roller is such as to enable the roller to bear sideways against said lobes and ride upon said ramps, the roller being adapted to rest in cusp 33 when the gate member is in its closed position.
Paired bump plates 47, disposed in vertical planes and positioned substantially 1/4 way of the gate member adjacent its lower extremity, are fixedly attached by way of rigid arms 48 to separate lobes of the cam in symmetrical disposition about center line 32. Paired restoring springs 55 extend between each arm 48 and the gate member. Said springs enable the gate member to move between the two bump plates during operation and return to a centered position when latched.
In operation, pressure applied against either bump plate causes the cam roller to leave its position in the cusp, designated as position A in FIGS. 3, 6 and 7. The roller moves around the cam until it enters ramp 34, designated position B. The roller then enters inclined portion 37, designated position C, and is elevated to position D upon the upper surface of cam 28. Such action causes lower extremity of axle 17 to move away from post 24, thereby tilting the gate member upwardly to cause disengagement from the latch post. These effects, and the momentum imparted by the vehicle cause swinging of the gate member to its open position. The energy stored in the open and upwardly tilted gate member causes reversal of said sequence of events to close the gate. The springs function to return the cam back toward post 24, allowing roller 42 to return to the cusp as the gate moves by force of gravity to its lowest, closed position. The duration of the open state can be controlled by adjustment of the tension of the springs and the effectiveness of the hydraulic cylinders. Such factors control the time duration for the roller to move from position B to position C.
While particular examples of the present invention have been shown and described, it is apparent that changes and modifications may be made therein without departing from the invention in its broadest aspects. The aim of the appended claims, therefore, is to cover all such changes and modifications as fall within the true spirit and scope of the invention.
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A swinging gate apparatus is provided having a gate member which automatically opens by pressure applied to either side by an automobile or other vehicle. In opening, the gate member tilts upwardly so that the force of gravity causes it to close. The rate of opening and closing is controlled by the concertive action of spring means, motion dampening means, and a cam mechanism.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Patent Application Serial No. 60/416,532, filed Oct. 8, 2002.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to hand-operated, pole mounted grasping devices and more particularly to an animal waste scooper for sanitary handling of animal droppings from pet dogs, cats, and the like, of the type commonly referred to as a pooper scooper.
[0004] 2. Description of Related Art
[0005] Devices for picking up animal feces are well known. These devices usually have two opposing jaws, pivotally mounted at the bottom of a pole. The top end of the pole usually has a handle having a lever, trigger, button, or other device for actuating the jaws. With such a device, people may retrieve trash or animal feces from the ground without bending or reaching excessively, and further, may do so without coming into contact with the items to be picked up. However, the practical usefulness and reliability of these devices varies greatly.
[0006] One of the most appealing reasons for using such a grasping device is that the user's hands remain clean when picking up animal waste. However, typically the jaws of the device do not stay clean. The jaws are often unprotected and in direct contact with the waste material. The device will quickly become unwelcome in the user's home, due to the contamination. Thus, the device will be left outdoors and subject to the elements. This rapidly ages the device and leads to early failure or breakage. Alternatively, the user must take the time to clean the device, a chore that typically must be done by hand, preferably using rubber gloves to avoid soiling one's hands.
[0007] A few of the devices available today make use of covers for the grasping jaws, usually with plastic bags. However, there are no bag retention clips on those devices. The bags are loosely wrapped around the jaws with no regard for retention. The devices have no mechanical means for averting the external influences of wind, gravity, etc., in order to remain in place unassisted. In addition, where the device's jaws close automatically, the user must fight the tendency of the jaws to close while simultaneously attempting to place a plastic bag over the jaws.
[0008] A variation on that theme is jaws that are open when the machine is at rest. The jaws close when the device is actuated. Such a device requires the user to keep a tight grasp of the trigger or handle to keep from dropping the jaws' contents.
[0009] Various devices have been proposed for solving these problems.
[0010] U.S. Pat. No. 4,179,145, issued to Joe Shinsako in December 1979, describes a sanitary dog litter bagger that uses bags over a pair of jaws. The bags are not secured to the jaws. Actuation is by rotating the handle, requiring two hands.
[0011] U.S. Pat. No. 5,380,054, issued to Misael Galvis in January 1995, describes a handheld device for picking up objects. The device may be operated with one hand, but is not intended for use with bags.
[0012] U.S. Pat. No. 5,503,442, issued to Ke-Chiang Lee in April 1996, describes a pick-up device for picking up animal feces. The device is intended for use with bags and requires the use of a bag dispenser attached to the device's handle.
[0013] None of the above patents describes a sanitary waste handling device that can be operated with a single hand, uses ordinary plastic shopping bags to line the jaws, locks open so that bags may be affixed more easily, and includes bag clips to hold the bag in place during operation.
[0014] None of the above inventions and patents, taken either singly or in combination, is seen to describe the instant invention as claimed.
SUMMARY OF THE INVENTION
[0015] The animal waste scooper is a pole-mounted device for picking up waste and simultaneously placing the waste into a bag. The scooper includes a control assembly, an extension assembly, a support structure, a linkage assembly, a pair of jaws, and a bag. The control assembly comprises a handle, a trigger and a latch. The extension structure comprises a hollow pole having an upper end and a lower end, the handle being attached to the upper end of the pole. The support structure is an inverted bowl shape, with two extensions providing for linkage attachment, and is attached to the lower end of the pole. The support structure comprises a support bridge, a plurality of guide slots and a plurality of bag clips to secure a bag in place. The linkage assembly includes an actuation rod, a four-bar linkage including a double bell crank, a hinge pin, a pair of guide pins and a linkage shield. Each half of the double bell crank has its corner attached to the hinge pin, which serves as a fulcrum. The actuation rod is routed through the hollow pole and attaches to the trigger at one end and to the four-bar linkage at the other end. The hinge pin pivotally connects the jaws, and is fixed to opposing sides of the support bridge. The guide pins are disposed through the lower arm of each half of the double bell crank and the jaws, and engage the guide slots in the support bridge. A pair of springs is biased between the guide pins adjacent to the guide slots of the support bridge. The linkage shield is suspended from the hinge pin.
[0016] In use, the jaws are opened by pulling up the trigger and are latched by a hook connected between the trigger and a handle. An ordinary plastic shopping bag is opened, inverted, and placed over the jaws, the sides of the bag being retained over the jaws by retainer clips on the sides of the support bridge. The latch is released while holding the trigger to keep the jaws open, the jaws are positioned over the animal waste, and the trigger is released, closing the jaws to enclose the animal waste in the plastic bag.
[0017] Accordingly, it is a principal object of the invention to disclose an animal waste scooper which picks up animal waste and encloses the waste in common plastic shopping bags for disposal.
[0018] It is another object of the invention to provide an animal waste scooper having bag retention clips to securely hold an ordinary plastic shopping bag in place around the jaws of the scooper.
[0019] It is a further object of the invention to provide an animal waste scooper that may be operated with one hand.
[0020] Still another object of the invention is to disclose an animal waste scooper having jaws that may be latched open to simplify the bag-loading process.
[0021] It is an object of the invention to provide improved elements and arrangements thereof in an apparatus for the purposes described which is inexpensive, dependable and fully effective in accomplishing its intended purposes.
[0022] These and other objects of the present invention will become readily apparent upon further review of the following specification and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] [0023]FIG. 1 is a fragmented perspective view of an animal waste scooper according to the present invention.
[0024] [0024]FIG. 2 is a side view of the animal waste scooper with the jaws closed according to the present invention.
[0025] [0025]FIG. 3 is a side view of the animal waste scooper with the jaws open according to the present invention.
[0026] [0026]FIG. 4 is a front view of the animal waste scooper, the opposite side being a mirror image.
[0027] [0027]FIG. 5 is a fragmented side view showing the linkage and jaws of the animal waste scooper.
[0028] [0028]FIG. 6 is a fragmented side view showing the linkage and jaws of the animal waste scooper, with bag attached and shown in phantom.
[0029] Similar reference characters denote corresponding features consistently throughout the attached drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0030] The present invention is an animal waste scooper comprising a control assembly, an extension structure, a support structure, a linkage assembly, a pair of jaws, and a plurality of springs.
[0031] Referring to FIGS. 1 and 2, the present invention is a generally vertically disposed animal waste scooper, designated generally as 8 in the drawings. The device 8 is held and operated with one hand, with the opposed scoop-shaped jaws 10 being placed over the object to be picked up. The scoop-shaped jaws have an upper containment portion and a lower grasping portion with opposing sidewalls. The user squeezes the trigger 18 to operate the linkage assembly 50 and open the jaws 10 against the biasing springs 40 (only one spring 40 is shown in the drawings, the opposite side of the scooper 8 being identical). The jaws 10 are supported by an inverted bowl-shaped support bridge 34 , which in its preferred embodiment are made of a strong, lightweight, corrosion-resistant metallic or nonmetallic material, such as aluminum, vinyl, polycarbonate, fiberglass, or other synthetic polymeric material.
[0032] An ordinary plastic shopping bag is secured around the jaws with the bag clips 42 . The jaws 10 are placed over and around the object on the ground and the trigger 18 is released. The springs 40 bias the jaws 10 to a closed position, capturing the object in the jaws 10 and returning the linkage assembly 50 and trigger 18 to their original positions. The object may be transported to another place, such as a waste receptacle, within the device's jaws 10 . The object is released by removing the bag from the clips 42 and squeezing the trigger 18 to open the jaws 10 . The bag and its contents drop out and away from the jaws 10 . For ease of manufacture, each half of the jaws 10 is identical,
[0033] Referring particularly to FIG. 2, the handle 12 of the scooper 8 comprises a grip portion 14 with a side rail 16 at each end. In the preferred embodiment, the handle 12 and the grip portion 14 are each half-round shape, with the flat side of the handle 12 oriented down and the flat side of the grip portion 14 oriented up, so that when the trigger is squeezed toward the handle 12 the flat sides are together. Each side rail 16 includes a guide rib (not shown). The channels are parallel and face toward each other. The trigger 18 is disposed in a generally D-shaped opening defined by the handle 12 and also has a grip 22 portion and two side rails 20 . The trigger's side rails 20 contain slots to engage the side rails guide ribs. The trigger 18 slides upon the handle's side rail 20 , guided by the engagement of the guide ribs and slots.
[0034] The handle 12 attaches to an upper end of a hollow pole extension structure 24 . In the preferred embodiment, the pole 24 may also be made from a strong, lightweight, corrosion-resistant metallic or nonmetallic material, such as aluminum, vinyl, polycarbonate, fiberglass, or other synthetic, polymeric material. An actuator 26 is attached at one end to the trigger 18 , and is routed through the hollow pole 24 , where the other end of the actuator 26 attaches to a pin of a four-bar linkage mechanism 50 . The actuator 26 may be a cable, a rod, or other elongated material capable of withstanding the tension created by the biasing springs 40 . The linkage mechanism 50 includes a pair of upper links 28 pivotally connected to the actuator at one end, and pivotally attached to a pair of bell cranks 30 at the opposite end. Alternatively, the upper links 28 may be replaced by a single, flexible piece of material, such as a cable or monofilament line joined at its midpoint to the actuator 26 .
[0035] Each bell crank 30 has an upper arm and a lower arm rigidly attached at approximately a 90° angle, defining a corner. Each upper link 28 is pivotally attached to the upper arm of one of the bell cranks 30 , which form the lower links in the four-bar linkage 50 . The corners of each bell crank 30 are pivotally attached to the hinge pin 32 . The lower legs of each bell crank 30 are pivotally attached to guide rods 36 , which are rigidly attached to the opposing jaws 10 . The double bell crank 30 provides the leverage necessary to open the jaws 10 , when the trigger 18 is squeezed.
[0036] When the trigger 18 is pulled upward, one bell crank 30 rotates about the hinge pin 32 in a clockwise direction, while the other bell crank 30 rotates in a counterclockwise direction, thereby opening the jaws 10 . The hinge pin 32 also pivotally connects the jaws 10 and is rigidly positioned and supported by the support bridge 34 . The guide rods 36 are fixed to the jaws 10 , while the ends of the guide rods 36 extend through and slide within the guide slots 38 defined in the support bridge 34 . The ends of guide pins 36 are biased together by a pair of compression springs 40 . In the preferred embodiment, the compression springs 40 are located inside the walls of the support bridge 34 . The support bridge 34 includes a pair of bag clips 42 , one on each outward facing side, for securing ordinary plastic shopping bags. A linkage shield 52 provides a horizontal barrier within the jaws 10 and just below the guide pins 36 . The linkage shield 52 is suspended by a pair of supports attached to the hinge pin 32 . The supports extend between the guide pins 36 , without interfering with the closure of the jaws 10 . The linkage shield 52 prevents fingers and bags from becoming entangled in the linkage mechanism.
[0037] [0037]FIG. 3 is a side view of the animal waste scooper 8 according to the present invention with the jaws 10 open.
[0038] In operation, when the trigger 18 is squeezed toward the handle 12 , the actuator 26 is pulled upward, pulling the pin joining the upper links 28 upward toward the handle 12 . The linkage pulls the upper arms of the bell cranks 30 upward, drawing the upper arms of the double bell crank 30 together. The corners of the bell cranks 30 pivot on the hinge pin 32 , forcing the lower arms of the bell crank 30 apart. The attachment of the lower arms of the double bell crank 30 to the jaws 10 forces the jaws 10 open against the biasing force of the springs 40 attached to the guide rods 36 . A linkage shield 52 is suspended from the hinge pin 32 and between the guide pins 36 to provide a horizontal barrier to protect the linkage assembly.
[0039] When the trigger 18 is adjacent to the handle 12 , the latch 46 may be set, thereby locking the trigger 18 to the handle 12 and locking the jaws 10 open. Latch 46 may be a hook pivotally attached to trigger 18 which engages a pin or eyelet extending from the handle 12 , however any appropriate latch may be used in the present invention. With the jaws 10 locked open, the user may place an ordinary plastic shopping bag around the jaws 10 and secure it to the bag clips 42 without working against the mechanism, simplifying the process.
[0040] [0040]FIG. 4 is a front view of the animal waste scooper 8 , the opposite side being a mirror image. The jaws 10 are skeletonized to reduce weight, presenting an open frame which discourages the use of the device without bags. This keeps the device clean and aids in its longevity. The linkage assembly 50 is located midway between the opposing sides of the support bridge 34 and in line with the longitudinal axis of the hollow pole 24 to enable proper function of the linkage assembly 50 through the actuator 26 . The bags clips 42 are located at the sides of the support bridge 34 .
[0041] [0041]FIG. 5 is a side view showing the linkage assembly 50 and jaws 10 of the animal waste scooper 8 . Here the actuator 26 is in tension, pulling the upper links 28 toward the handle 12 . The upper links 28 pivot about the pin joining the upper links 28 , thus drawing the opposite ends of the upper links 28 together. Alternatively, a one-piece flexible cable (not shown) may be used. As the ends of the upper links are drawn together, the bell cranks 30 are forced to rotate about the stationary hinge pin 32 . The upper arms of the bell cranks 30 are drawn together, and the lower arms of the bell cranks 30 are forced apart due to rotation about the hinge pin 32 . The lower arms of the double bell crank 30 are attached to the jaws 10 via the guide rods 36 . The guide rods 36 engage the guide slots 38 in the support bridge 34 . At their closest points, the guide slots 38 are close enough together to permit the jaws 10 to fully close. At their extreme ends, the guide slots 38 are far enough apart to permit the jaws 10 to accept a plastic bag and to be placed around an object to be picked up.
[0042] [0042]FIG. 6 is a view of the linkage assembly 50 and jaws 10 of the animal waste scooper 8 , with bag 44 (shown in phantom) attached. To secure a bag 44 around the jaws 10 , the user must squeeze the trigger 18 to the handle 12 and operate the latch 46 . This locks the jaws 10 open. With the jaws 10 open, the user places the jaws 10 into an inverted, open, conventional plastic shopping bag 44 , with one of the bag's two loop handles 48 located on each side of the support bridge 34 . Each handle loop 48 is secured into a bag clip 42 on the support bridge 34 , and the remaining portion of the bag 44 is pushed up into the space between the jaws 10 , thus covering the jaws 10 and allowing a space between the jaws 10 large enough to encompass the object desired for retrieval.
[0043] When the object is between the jaws 10 , the latch 46 may be released. The springs 40 act to bias the jaws 10 to the closed position, whereby the object is captured between the jaws 10 and inside the bag 44 . In this manner, the jaws 10 stay clean.
[0044] It is to be understood that the present invention is not limited to the embodiments described above, but encompasses any and all embodiments within the scope of the following claims.
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A hand-operated sanitary grasping device for grasping an object such as animal feces includes a control assembly, and extension structure, a support structure, which includes a pair of bag clips, a linkage assembly, a pair of scooped-shaped opposed jaws, and a pair springs. A plastic bag is placed over the jaws and attached to the bag clips on the support structure. The control assembly operates the jaws via the linkage assembly and has a latch to lock the jaws open before installing the inverted bag. The bag and jaws are placed around the object and the latch opened, allowing the jaws to grasp the object within the bag. The bag is then detached from the clips, allowing the bag to be pulled down over the jaws. The jaws may then be opened for removal of the bagged object.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation-in-part of copending application Ser. No. 10/885,358, filed Jul. 6, 2004.
FIELD OF THE INVENTION
[0002] The present invention generally relates to flagpole winches, cleats and fastening plates, and more particularly to flagpole fastening plate assemblies and flagpole winch or cleat assemblies mounted internally to a flagpole.
BACKGROUND OF THE INVENTION
[0003] It is often desirable to substantially eliminate exposed flag halyards, especially while a flag is flying from a flagpole. There are flagpole assemblies in which the halyard remains substantially concealed from view but allows the flag to be raised and lowered. The flagpole assembly includes a hollow pole mounted at its base to a support. A first end of a halyard is connected to a winch. The winch is typically mounted near the base of the pole. The halyard passes through the hollow pole and out an exit opening at the pole tip.
[0004] Paying out the halyard from the winch causes the flag to lower as the length of the halyard extending from the exit opening in the hollow pole increases. The halyard is retracted by winding the halyard onto the winch. If the halyard has a flag attached to it, the flag is raised by this operation. If not, substantially the entire halyard is housed within the hollow pole or on the halyard winch.
[0005] A primary advantage of this design is that it simplifies raising and lowering of a flag while keeping the halyard substantially concealed. Keeping the halyard substantially concealed reduces deterioration of the halyard by preventing its exposure to the elements. It also eliminates problems caused by tangled halyards and flags.
SUMMARY OF THE INVENTION
[0006] The present invention provides a flagpole assembly including a hollow flagpole body, one or more internal fastening plates, an external fastening plate, and plural fasteners for securing the plates to the flagpole body. The embodiments of the invention may also include halyard handling mechanism disposed in the flagpole body.
[0007] The flagpole body is generally-cylindrical having a first end, a second end, a principal axis, an inner surface, an outer surface and an aperture disposed in the side thereof. The aperture extends from the inner surface to the outer surface along a radial axis substantially orthogonal to the principal axis. At least one internal fastener receiving hole or opening extends from the inner surface to the outer surface.
[0008] One or at least two internal fastening plates may be disposed at least partly within the flagpole body, and include inner surfaces, outer surfaces, an aperture disposed therein, or formed thereby, and threaded fastening holes generally aligned to fastener openings or passages in the flagpole body, respectively. The external fastening plate may be disposed at least partly outside of the flagpole body, and has an inner surface, an outer surface, an aperture disposed therein and external fastener passages generally aligned to corresponding fastener passages in the flagpole body. Threaded fasteners are disposed partly within external fastener passages, partly within internal fastener passages and partly within threaded fastener receiving holes.
[0009] In a second or alternate embodiment, the present invention provides a flagpole assembly including a flagpole body, an internal fastening plate or plates, an external fastening plate, plural threaded fasteners and a halyard engaging cleat or a winch mount. In other respects the embodiment which includes the winch mount is substantially like the embodiment mentioned hereinabove.
[0010] In a third embodiment, the present invention provides a flagpole assembly including a flagpole body, one or more internal fastening plates, an external fastening plate and door assembly and a winch mount. In the third embodiment, the external fastening plate and door assembly is disposed at least partly outside of the flagpole body, and has an inner surface, an outer surface, a door aperture having a door disposed therein and at least four external fastener passages, each external fastener passage being generally aligned to an internal fastener passage in the flagpole body. The winch mount includes an internal fastening plate and a winch secured thereto.
[0011] Those skilled in the art will further appreciate the above-mentioned advantages and features of the invention together with other important aspects thereof upon reading the detailed description which follows in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is an exploded perspective view of a flagpole assembly according to one preferred embodiment of the present invention;
[0013] FIG. 2 is an exploded section view of the flagpole assembly of FIG. 1 taken along line 2 - 2 of FIG. 1 ;
[0014] FIG. 3 is an unexploded section view of the flagpole assembly of FIG. 1 taken along line 2 - 2 ;
[0015] FIG. 4 is an exploded perspective view of a flagpole assembly according to another preferred embodiment of the present invention;
[0016] FIG. 5 is an exploded section view of the flagpole assembly of FIG. 4 taken along line 5 - 5 of FIG. 4 ;
[0017] FIG. 6 is an unexploded section view of the flagpole assembly of FIG. 4 taken along line 5 - 5 ;
[0018] FIG. 7 is a detail section view of the flagpole assembly of FIG. 4 taken along line 7 - 7 of FIG. 4 ;
[0019] FIG. 8 is a front elevation view of an external plate which may be used in the flagpole assembly of FIG. 4 ;
[0020] FIG. 9 is a top plan view of the external plate of FIG. 8 ;
[0021] FIG. 10 is a detail section view of the external plate of FIG. 9 taken along line 10 - 10 of FIGURE 9 ;
[0022] FIG. 11 is a detail section view of the external plate of FIG. 8 taken along line 11 - 11 of FIG. 8 ;
[0023] FIG. 12 is a front elevation view of an internal plate which may be used in the flagpole assembly of FIGS. 1 and 4 ;
[0024] FIG. 13 is a top plan view of the internal plate of FIG. 12 ;
[0025] FIG. 14 is a transverse section view of another embodiment of the flagpole assembly;
[0026] FIG. 15 is a transverse section view of still another embodiment of the flagpole assembly;
[0027] FIG. 16 is a top plan view of another embodiment of plural internal plates which may be used with the flagpole assemblies of the present invention; and
[0028] FIG. 17 is a front elevation of the plural internal plates shown in FIG. 16 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0029] In the description which follows like elements are marked throughout the specification and drawing with the same reference numerals, respectively. The drawings are not necessarily to scale and certain features may be shown in somewhat schematic or generalized form in the interest of clarity and conciseness.
[0030] Flagpole assembly 100 includes a tubular flagpole body 102 having a principal central axis 104 , an inner surface 106 , an outer surface 108 and an aperture 110 disposed in its side along radial axis 112 , which is generally-orthogonal to principal axis 104 . A set of fastener receiving passages 114 , one shown in FIG. 1 , is disposed adjacent to aperture 110 .
[0031] Flagpole assembly 100 also includes an internal fastening plate 116 having an inner surface 118 , an outer surface 120 and an aperture 122 . Plate 116 has a somewhat circular segment shape in cross section as shown in FIGURE 2 . A set of threaded fastener receiving holes 124 is disposed about aperture 122 . Each of the threaded holes 124 is positioned to be aligned with a corresponding internal fastener passage 114 .
[0032] Flagpole assembly 100 also includes an external fastening plate 126 having an inner surface 128 , FIG. 1 , an outer surface 130 , an aperture 132 and a somewhat circular segment shape in cross section, also as shown in FIG. 2 . A set of fastener receiving passages 134 is disposed in the external fastening plate 126 adjacent to the aperture 132 . Each of the external fastener passages 134 is positioned to be aligned with a corresponding internal fastener passage 114 and a threaded fastener receiving passage or hole 124 . A mount 138 , including a halyard cleat 140 , is secured to or formed integral with external fastening plate 126 . In alternate embodiments, a pulley, a winch or other mechanism, not shown, may be supported on mount 138 . A set of threaded fasteners 136 is operable to fasten the components described above of flagpole assembly 100 together.
[0033] Another preferred embodiment of the present invention is shown in FIGS. 4-7 and comprises a flagpole assembly 200 . Flagpole assembly 200 includes a flagpole body 202 having a principal central axis 204 , an inner surface 206 , an outer surface 208 and an aperture 210 disposed in its side along a radial axis 212 , which is generally-orthogonal to principal axis 204 . Fastener receiving passages 214 are disposed adjacent to aperture 210 , as shown and similar to the arrangement for the embodiment of FIGS. 1 through 3 .
[0034] Flagpole assembly 200 also includes a generally rectangular internal fastening plate 216 having an inner surface 218 , an outer surface 220 and an aperture 222 . A set of threaded fastener receiving holes 224 is disposed about aperture 122 . Each of the threaded fastening holes 224 is aligned with a corresponding fastener receiving passage 214 . Flagpole assembly 200 includes an external fastening plate 226 having an inner surface 228 , an outer surface 230 and a door aperture 232 . A set of external fastener receiving passages 234 is disposed in the external fastening plate 226 adjacent to the door aperture 232 . Each of the external fastener passages 234 is aligned to a corresponding fastener receiving passage 214 and a threaded fastener receiving hole 224 . A mount plate or block 238 includes an arcuate surface 239 and a threaded fastener receiving hole 238 a formed therein, FIGS. 5 and 6 . Plate or block 238 is operable for securing a winch 240 , FIG. 6 , to the flagpole body 202 . Plate 238 is adapted to be secured to body surface 206 by a fastener assembly 207 , 209 , FIG. 5 . A set of threaded fasteners 236 fastens the plates 218 and 226 of the flagpole assembly 200 together.
[0035] The internal and external plates used in flagpole assemblies may vary from one application to another. FIGS. 8 through 17 depict variations on the shapes and configurations of the internal and external plates, which may be operable in the flagpole assemblies of the present invention.
[0036] Referring to FIGS. 8 through 11 , external plate 326 has a transverse shape of a segment of a cylinder. External plate 326 has an arcuate external surface 330 , an arcuate internal surface 338 and an aperture 332 disposed in the center thereof. A set of fastener receiving passages or bores 334 is spaced about the aperture 332 in a generally rectangular pattern. In the embodiment shown in FIGS. 8-11 , the fastener receiving bores 334 are preferably countersunk.
[0037] Referring to FIGS. 12 and 13 , internal plate 316 also has the general profile or transverse cross section shape of a segment of a cylinder. Internal plate 316 has an internal surface 318 , an external surface 320 and an aperture 322 disposed in the center thereof. A set of fastener receiving holes 324 is spaced about the aperture 322 in a generally rectangular pattern. In the embodiment shown in FIGS. 8-11 , the fastener or receiving holes 324 are preferably threaded, as shown.
[0038] Alternate flagpole assemblies 400 and 500 are shown as examples of variations on the geometry of flagpole assembly 200 . Flagpole assembly 400 is shown in FIG. 14 and includes a flagpole body 402 having an internal plate 416 and a winch assembly 440 disposed therein, and an external plate 426 disposed on the outside thereof. Internal plate 416 and external plate 426 are fastened to the flagpole body 402 and to one another by fasteners 436 . Flagpole assembly 400 incorporates an operable or removable door or cover 442 covering an aperture 444 to enclose and protect winch assembly 440 or other device from the elements and unwanted tampering. Similarly, flagpole assembly 500 includes a flagpole body 502 having an internal plate 516 and winch assembly 540 disposed therein and an external plate 526 disposed on the outside thereof. Internal plate 516 and external plate 526 are fastened to the flagpole body 502 and to one another by fasteners 536 . Flagpole assembly 500 also incorporates a removable door 542 to enclose and protect the winch assembly from the elements and tampering. It can be seen that flagpole assemblies 400 and 500 employ the same basic layout as flagpole assembly 200 , although the geometry of the components varies between the three, as seen in FIGS. 6 , 14 and 15 .
[0039] Referring now to FIGS. 16 and 17 , the internal plates previously described are single piece structures. However, in certain instances certain dimensions, such as the wall thickness of the flagpole body, may vary whereby the fastener receiving holes in the internal plates will not necessarily be aligned with the fastener receiving holes in the flagpole body or the external plates. Accordingly, the present invention contemplates the provision of separate but substantially identical internal plates designated by the numerals 616 in FIGS. 16 and 17 . The internal plates 616 include arcuate external surfaces 620 and may have a somewhat shallow U-shape with opposed relatively short legs 622 formed thereon, respectively, and interconnected by web portions 623 , respectively. Accordingly, the internal plates 616 have essentially the shape of the internal plates described above, in some respects. Internal plates 616 are also provided with spaced apart threaded fastener receiving holes 624 , as shown, for receiving fasteners, such as the fasteners 136 , 236 , 336 or 436 , not shown in FIGS. 16 and 17 .
[0040] The components of the flagpole assemblies described herein may be fabricated as cast metal, such as aluminum or similar metals or other materials suitable for exposure to the elements and incorporating the strength requirements of such structures.
[0041] Those of skill in the art will appreciate that flagpole assemblies 200 , 300 , 400 , 500 are only exemplary and that other geometries may be employed.
[0042] In general, although preferred embodiments have been described herein, those skilled in the art will appreciate that substitutions and modifications may be made without departing from the scope and spirit of the appended claims.
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A flagpole assembly comprising a flagpole body having an aperture disposed in the side thereof, one or two internal fastening plates, disposed within the flagpole body, an external fastening plate and door assembly and a set of threaded fasteners securing the flagpole assembly together. A cleat or winch mount may be secured to the internal fastening plate, having a winch secured thereto for securement of a flag halyard inside the flagpole body.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND
1. Field of Invention
This invention relates to detachable insulating covers that are particularly suited for use in connection with windows and entrances of residential and commercial dwellings.
2. Prior Art
It is known from prior art that heat transfer through the windows and entrances of residential and commercial dwellings can be greatly reduced through the use of insulating covers.
Prior art has shown application of thin sheets of transparent plastic material and the like affixed to the windows and entrances. This method does offer some thermal insulation properties; however, in older dwellings with inept windows and entrances this method will have very little if any effect. In addition this application has problems with condensation build-up when in use.
Another solution of prior art in U.S. Pat. No. 4,610,292 (1986) suggested the use of insulated window shades and curtains. In this method window shades have a separate or detachable insulating layer behind the cloth fabric of shade or curtain. The insulating layer could be added during winter months and removed during the warmer months. This method did offer a portable way of insulating window areas; however this method did very little for drafty inept window systems for older dwellings. In cold weather months if a furnace is used to heat the dwelling, the produced warm air will rapidly escape through the drafty windows making it uncomfortable and thereby lowering the efficiency of the furnace or requiring a greater increase in fuel consumption to warrant eliminating the problem.
Another solution of prior art in U.S. Pat. No. 4,131,150 (1978) suggested the use of a window enclosure that is permanently mounted inside of window framing. The window enclosure used siding panels to remove or add insulating material. This method required a permanent alternation to the window framing.
These methods listed above are known to suffer from the following disadvantages:
a) poor thermal protections during cold weather months, by permitting warm air to escape between small crevices in inept window systems; (b) neither system is designed to have an insulating layer fit firmly inside the window framing while utilizing surrounding wall element for fastening without altering the window and/or framing itself.
SUMMARY OF THE INVENTION—OBJECTS AND ADVANTAGES
A need for a long period of time has existed for a portable window insulating system that is simple and cost effective to install at first application, which will not alter the current window or entrance framing.
An important object of the present invention is to enable a person to remove the cover from the window framing is a simple manner.
Another important object of this invention is to provide a thermal barrier which seals around the edges of the window framing with an insulating layer and which may be adjusted to overlap around window framing edges onto the adjacent wall area.
During cold weather months the present invention, when installed inside a dwelling, will greatly restrict warm air and radiant heat from escaping between small crevices in inept window systems by fitting firmly into window framing using an insulating material.
This lightweight portable and removable insulating cover is placed over the interior-side generally (or the exterior) of typical commercial and residential building windows and entrances, providing added thermal protection inside of the dwelling, whereby creating a thermal barrier.
The present invention could be modified to have a viewer's opening for viewing out of the window/entrance when cover is installed. The present invention can also be modified to have decorative designs or embroidery on the exterior of device that is attractive and decorative to the eye of the beholder on the interior or exterior of the house.
This insulating cover can also be fabricated as a solid one-piece pre-molded insulating material using various molding/casting manufacturing techniques or using various fibrous felt-type insulating materials.
It is still another object of this invention to provide a complete window assembly that is simple, reusable, easy and economical to maintain.
This invention will be better understood and appreciated from the following detailed description of one embodiment thereof, selected for purposes of illustration and shown in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the portable insulation device of the present invention.
FIG. 2 is a partial elevation view showing the installation of the present invention covering the interior side of a window unit 21 inside a building.
FIG. 2A is a modified version of FIG. 2 showing an option for the present invention wherein a viewer's opening is provided.
FIG. 3 is a cross sectional transverse view of a window unit showing the insulating cover insertion wherein the view is taken along lines 3 — 3 of FIG. 2 .
FIG. 4 is a detailed orthographic view of the portable insulation device illustrated in FIG. 1 .
FIG. 5 is a typical installation and application method for the present invention.
FIG. 6 is a cross-sectional view showing the portable insulation device insertion along lines 6 — 6 of FIG. 2 .
FIG. 6A is an alternative method of installing the present invention by using an extension adapter, whereby permitting the present invention to be installed over irregular, large and over-sized window units.
FIG. 6 b is a perspective view of the extension adapter identified in FIG. 6 A.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows the portable insulation device of the present invention. Shown in this view is an insulating core-element fabricated utilizing two functional sections which are the outer portion attachment pad section 01 and the inner portion insert pad section 02 . Both the outer and inner portions or pads are illustrated here as completely and individually encased in a fabric material 03 . As illustrated, the outer portion attachment pad section 01 is larger than the inner portion insert pad section in at least two dimensions, namely for example in height and width as viewed. Thus the attachment pad section effectively overlaps the insert pad section, and on this overlap segment are shown fasteners as will be further described herebelow. Said inner portion insert pad section is seen to protrude or jut out from the outer portion attachment pad section. All seams, corners, and edges of the fabric material 03 are bound together using heavy-duty nylon threading material 04 . Spaced uniformly along the topside of the inner portion pad 02 are buttons associated with threading holes 05 . Another set buttons associated with threading holes 05 is located on the backside of the outer portion pad 01 , and spaced in a manner in that they are directly aligned with buttons and threading holes 05 of the inner portion pad 02 . The buttons with threading holes 05 on both the outer portion pad 01 and the inner portion Pad 02 are illustrated as laced together by tightly drawn heavy-duty nylon threading material or lacing 04 . The tightly drawn lacing passes through both the outer portion pad 01 and the inner portion pad 02 . Along the perimeter of the outer portion pad 01 where it overlaps the inner portion pad 02 are uniformly spaced Velcro® hook and loop fasteners 06 . Besides hook and loop fasteners, these may also include any other conventional fastening means, for example, snaps or hooks.
FIG. 2 is a partial elevation view showing an inside building wall structure 20 with the portable insulation device installed over a window unit 21 . The inner portion of pad 02 is fitted inside of the window framing area. The Outer portion pad 01 overlaps onto building wall structure 20 along the edges of the window framing.
FIG. 2A is a modified version of FIG. 2 , which is a partial elevation view showing a building wall structure 20 with the portable insulation device installed over a window unit 21 . The inner portion pad 02 is fitted inside of the window framing area. The Outer portion pad 01 overlaps onto the building wall structure along the edges of the window framing.
This drawing also shows a viewer's opening 22 which allows the viewer inside a dwelling to view the environment on the outside of the dwelling when the present invention is installed. The viewer's opening shall be fabricated, for example, by providing an opening completely through the insulating cover then sealing the exposed fiberglass insulation 09 and polyester filler batting 07 by encasing them with fabric material 03 . All seams shall be bound together by using heavy duty nylon threading Material 04 .
FIG. 3 is a cross sectional transverse view of window unit 21 and the portable insulation device taken along 3 — 3 of FIG. 2 . The inner portion pad 02 is fitted inside of the window framing area and is seen as substantially filling said surrounding framing area. The outer portion pad 01 overlaps onto the building wall structure 20 along the edges of the window unit 21 framing. Along the perimeter of the building wall structure 20 encircling the window unit 21 are mounted fasteners 06 . These fasteners 06 are firmly attached using matching spacing to fasteners 06 attached to the topside of the outer portion pad 01 . All
Sides and corners of outer portion pad 01 are checked to make sure that all fasteners 06 are attached to corresponding fasteners mounted to building wall structure 20 encircling the window unit 21 .
FIG. 4 is a detailed orthographic and cross-sectional view of the portable insulation device. The orthographic view shows the relationship and arrangement of an embodiment of the outer portion attachment pad section 01 to the inner portion insert pad section 02 .
Cross-sectional view taken along lines 4 — 4 shows the internal features of an embodiment of the present Invention. The inner portion pad 02 internally may be fabricated mostly of Polyester filler Batting 07 . A sheet of general use grade aluminum foil 08 may be sandwiched between polyester filler batting 07 and fiberglass felt type insulation 09 . In this embodiment, the outer surfaces of both the outer portion pad 01 and inner portion pad 02 are completely encased in a fabric material 03 . Spaced uniformly along the topside of the inner portion pad 02 are buttons with threading holes 05 . A second set of buttons with threading holes 05 is placed on the backside of the outer portion pad 01 , which is spaced in a manner in that they are directly aligned with buttons with threading holes 05 of the inner portion pad 02 . The buttons with threading holes 05 on both the outer portion pad 01 and the inner portion pad 02 are laced together by tightly drawn heavy duty nylon threading material 04 . This sectional view shows the tightly drawn lacing passing through both the outer portion pad 01 and the inner portion pad 02 . Along a substantial portion of the perimeter of outer portion attachment pad section 01 are uniformly spaced fasteners 06 , for example Velcro® hook and loop fasteners.
FIG. 5 shows the portable insulation device typical installation method. The present invention is mounted over the window unit 21 with the inner portion pad 02 fitting inside window unit 21 framing. This embodiment shows an elevation view of Velcro® hook and loop type fasteners 06 installed on the building wall structure 20 which surround the Window Unit 21 .
FIG. 6 is a longitudinal cross-section view of the building wall structure 20 and window unit 21 taken along 6 — 6 of FIG. 2 . This view shows the insertion of the portable insulation device into the framing of window unit 21 . This cross-sectional view also shows the alignment of the fasteners 06 surrounding the window unit 21 framing and fasteners 06 attached to the top-side of outer portion pad 01 .
FIG. 6A is a modified version of the embodiment illustrated in FIG. 6 which is a longitudinal cross-section view of the building wall structure 20 and window unit 21 taken along 6 — 6 of FIG. 2 . This view shows the insertion of the portable insulation device into the framing of window unit 21 . In addition to the features explained in FIG. 6 , this modified version shows the present invention insertion for an over-sized window unit 21 using the extension adapter 10 . This is a bridging device to attach two insulating covers, whereby permitting the present invention to be expandable and extendable for installation over irregular, large or over-sized window unit 21 . The extension adapter 10 is rectangular and elongated in proportion with one elongated side having a fastener 06 attached to its exterior surface. The general length of the extension adapter 10 shall be proportional to the length of the joining inner port on pads 02 of the present invention. The general width of the extension adapter 10 shall be proportional to general distance between the joining inner portion pads 02 of the present invention while the joining outer portion pads 01 of the present invention are directly in contact. The elongated side of extension adapter 10 with the attaching fastener 06 shall be firmly connected to the corresponding fastener 06 attached along the common perimeter on the topside of the joining outer portion pads 01 of the present invention.
FIG. 6B is a perspective view of the extension adapter 10 identified in FIG. 6 A. The extension adapter 10 includes a fiberglass felt type insulation 09 core element which is encased in fabric material 03 . All seams, corners, and edges of the Fabric Material 03 are bound together using Heavy-duty nylon threading material 04 . The extension adapter 10 is rectangular and elongated in proportion with one elongated side having a fastener 06 attached to its outer surface along its length.
Summary, Ramifications, and Scope
As previously mentioned the following reference part numerals have additional advantages in that;
Fabric material 03 may be made of any suitable material such as flame-retardant material, cotton, plastic, polyester, paper with aluminum foil backing, nylon, and the like.
The fiberglass felt-type insulation 09 may be any conventional type of insulation such as fiberglass, fiberglass sheets with aluminum foil or its equivalent, various plastic foams, foam rubber, and any conventional insulation material including flame retardant material, which can control the transfer of heat and prevent the escape of warm air from the interior of the dwelling.
In addition to Velcro® hook and loop fasteners 06 , other fasteners could be used such as snaps, hooks, or any other types of conventional fastening means.
While nylon threading material 04 has been mentioned, it will be obvious that in addition to nylon threading material 04 , snap fasteners, staples, epoxy or other glue-like material or heat seals can be used.
A particular advantage of the present invention lies in the fact that edge portion of the outer pad 01 proficiently seals around the edges of the window unit 21 . This seal greatly restricts the passage of warm air from inside the dwelling and is easily removable. If the fasteners 06 are appropriately spaced along the window unit framing 21 , the insulating section of the present invention will greatly improve the air tightness of the space between the window unit 21 and the insulating cover.
Referring to FIG. 5 fasteners 06 are shown attached to the wall area surrounding window unit 21 . These fasteners could also be mounted directly to the window unit 21 framing. This method could benefit fixed sash commercial window units with metal framing.
The outer portion pad 01 could be constructed omitting the fiberglass insulation 09 shown in FIG. 4 , thus just using a layer of fabric material 03 or vinyl and plastic-like materials. This method would provide a smooth, flush and sleek appearance inside of the dwelling, thus lending itself to various decorative and ornamental designs, patterns, pictures, textures, writings and embroidery.
Also an additional advantage of the present invention lies in the fact that the materials selected to manufacture this device; when used in combination could produce stain resistant, water-resistant and moisture-resistant properties which would improve the effectiveness of the device. This could include the fabric material 03 , fibrous polyester filler batting 07 , and fiberglass insulation 09 .
Also an additional advantage of the present invention lies in the fact that the materials selected to manufacture this device; when used in combination could make the device a bullet-proof or resistant barrier when installed at windows and entrances. This ramification could have great law enforcement and military potential.
Although the description above contains many specifics, these should not construed as limiting the scope of the present invention but as merely providing illustrations of the presently preferred embodiments.
Thus the scope of this invention should be determined by the appended claims and their legal equivalents, rather than by the examples given.
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An inexpensive, lightweight, reusable and detachable or removable insulation device for residential and commercial dwellings and similar heated structures. The device has an inner-portion insulating pad adapted to fit inside of a typical entrance or window unit framing. The device further has an outer-portion insulating pad adapted to overlap the window or entrance framing. The outer-portion insulating pad is provided fasteners so as to be secured to the building wall structure outside of the framing and surrounding the window or entrance framing by. During cold weather months, the present invention will greatly restrict warm air from escaping between small crevices in inept window systems by fitting firmly into window framing using a insulating material, thus creating a thermal barrier and improving the efficiency of the furnace by reducing the demand for electricity or fuel consumption.
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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 priority to U.S. Provisional Patent application Ser. No. 61/791,187 for “Insulated Block Wall System,” filed Mar. 15, 2013, which is incorporated herein by reference.
FIELD OF THE INVENTION
This patent relates to concrete and other masonry blocks, walls and other structures and, more specifically, to such structures that contain insulation and utilize facing materials.
BACKGROUND OF THE INVENTION
Masonry walls and similar structures have been made with a wide variety of construction materials and methods and therefore exhibit a large number of different characteristics. Among such walls, precast concrete block walls are well known. While precast concrete block or CMU (concrete masonry unit) walls are inexpensive and strong, conventional such walls provide relatively little resistance to heat transmission, may drain water poorly and are often unattractive.
SUMMARY
The terms “invention,” “the invention,” “this invention” and “the present invention” used in this patent are intended to refer broadly to all of the subject matter of this patent and the patent claims below. Statements containing these terms should be understood not to limit the subject matter described herein or to limit the meaning or scope of the patent claims below. Embodiments of the invention covered by this patent are defined by the claims below, not this summary. This summary is a high-level overview of various aspects of the invention and introduces some of the concepts that are further described in the Detailed Description section below. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used in isolation to determine the scope of the claimed subject matter. The subject matter should be understood by reference to appropriate portions of the entire specification of this patent, any or all drawings and each claim.
This invention provides complementary components for the construction of clad, faced or other masonry walls and similar structures that are strong, inexpensive, avoid thermal bridges, resist transmission of heat, and are attractive and versatile because an enormous variety of decorative face members may be utilized. Moreover, embodiments of this invention effectively drain water while resisting penetration of the entire structure by water and provide structures that prevent facing materials from falling even if fire destroys insulating foam between the structural block and the facing. They may also present attractive systems in seismic properties and resistance to wind loading.
The wall and other structures components and system of this invention include anchoring components that physically connect face materials to structural materials that are separated from the face materials by heat insulation and, generally, without undesirable thermal bridges. The components and system provide anchors that are coated with or imbedded in thermal insulation materials such as expanded polystyrene foams or a wide variety of other plastic or polymeric materials. Alternatively, the anchors may be fabricated from materials or combinations of materials (including, without limitation, materials coated with a thermal insulating coating) that themselves do not efficiently transmit heat and thereby avoid undesirable thermal bridges. Such materials may include, without limitation, basalt fibers, ceramic fibers, glass fibers or carbon fibers and other compatible and appropriate composite materials.
The anchoring components of this invention may have a wide variety of shapes and structures for anchoring face materials to structural wall or other building materials across or through thermal insulation. Generally such anchors will maintain connections between building structure and face materials even if fire or other destructive seismic and other events damage or destroy insulation between the face materials and building structure so that such destructive events do not cause face materials to detach and fall. Generally such anchors have anchor ends that are captured in or otherwise attached to the face materials and structural materials. Such connections may include bulbous, spread, cap-like, plate-like, bent, threaded or other anchor ends that are captured in slots, grooves, threaded members or the like. Such receiving structures can include T-slots, dovetail slots or other anchor-engaging structures, and such slots or structures can open above and or below the assembled location of the anchor, such as one or two edges of the structural material or face material. “Key-hole” slots are also usable that have an opening large enough for the anchor end to be inserted in a space that communicates with space partially covered by a structure defining a narrower slot through which a smaller portion of the anchor can extend. Anchor-to-facing or anchor-to-structure connections can simply slide together, can have “insert and slide” structure, can have an “engage and turn” structure, and can include threaded components (including, without limitation, threaded male members like screws and bolts and threaded female members like nuts) among other alternatives.
BRIEF DESCRIPTION OF THE DRAWINGS
Illustrative embodiments of the present invention are described in detail below with reference to the following drawing figures:
FIG. 1 is a perspective view of a first exemplary embodiment of assembled structural block, insulation and facing components of the concrete masonry system of this invention.
FIG. 2 is a perspective view of an exemplary stretcher sub-assembly of this invention.
FIG. 3 is a perspective view of an exemplary sash sub-assembly of this invention.
FIG. 4 is a perspective view of an exemplary right half sash sub-assembly of this invention.
FIG. 5 is a perspective view of an exemplary left half sash sub-assembly of this invention.
FIGS. 6 and 7 are perspective views of exemplary left corner sub-assemblies of this invention.
FIGS. 8 and 9 are perspective views of exemplary right corner sub-assemblies of this invention.
FIG. 10 is a perspective view of an exemplary facing sub-assembly of this invention usable for first course and lintel structures.
FIG. 11 is an enlarged perspective view of the exemplary stretcher unit of this invention shown in FIG. 2 .
FIGS. 12 and 13 are top and right end views of the stretcher unit shown in FIG. 11 .
FIG. 14 is an exploded perspective view of the stretcher unit shown in FIG. 11 .
FIG. 15 is a perspective view of the top, left, end and back of the exemplary facing shown in FIG. 14 .
FIG. 16 is a top view of the facing of FIG. 15 .
FIG. 17 is a perspective view of the exemplary insulation insert shown in FIG. 14 .
FIG. 18 is a top view, and FIG. 19 is an end view, of the insulation insert of FIG. 17 .
FIG. 20 is a perspective view of the exemplary anchor shown in FIG. 14 .
FIGS. 21 and 22 are top and side views, respectively, of the exemplary anchor of FIGS. 14 and 20 .
FIG. 23 is a perspective view of the exemplary stretcher unit shown in FIG. 2 with a vertical section exposing one of the anchors.
FIG. 24 is another perspective view of the exemplary stretcher unit shown in FIG. 2 with a horizontal section taken just above the anchors or anchors to show their positions in the assembly.
FIG. 25 is an enlarged fragmentary top view of the relative geometry of an exemplary sliding dovetail joint between the insulation and structural block of this invention.
FIG. 26 is an end perspective view of a first course or bottom row of an exemplary embodiment of a wall of this invention.
FIG. 27 is a side view of the exemplary installation of FIG. 26 .
FIG. 28 is a perspective view of a face block and a modified insulation block used in a first course or lintel installation such as those depicted in FIGS. 26, 27, 29 and 30 .
FIG. 29 is an end view of an exemplary embodiment of a lintel installation of this invention.
FIG. 30 is a perspective view of the exemplary lintel installation of FIG. 29 .
FIG. 31 is an enlarged end view of exemplary gasket material between two insulation blocks of this invention.
FIGS. 32 and 33 are right hand and left hand corner assemblies, respectively, of this invention.
FIG. 34 is plan view of a corner reinforcement structure.
FIG. 35 is a perspective view of an exemplary wall of this invention, the top course of which utilizes full sash blocks to accommodate movement.
FIG. 36 is a view of an exemplary wall like that of FIG. 35 showing a movement joint using sash half blocks.
FIGS. 37 and 38 are end views of like stacked block sub-assemblies of this invention and gasket material with the thickness of grout in FIG. 37 about twice that in FIG. 38 .
DETAILED DESCRIPTION
The subject matter of embodiments of the present invention is described here with specificity to meet statutory requirements, but this description is not necessarily intended to limit the scope of the claims. The claimed subject matter may be embodied in other ways, may include different elements or steps, and may be used in conjunction with other existing or future technologies. This description should not be interpreted as implying any particular order or arrangement among or between various steps or elements except when the order of individual steps or arrangement of elements is explicitly described.
A basic block wall assembly 10 of a first embodiment of the insulated block system of this invention is depicted in FIG. 1 . It includes an insulated stretcher block sub-assembly 12 (also shown in FIG. 2 ), together with other blocks, reinforcement and gasket material further described below.
Each insulated block assembly is assembled from three components, a structural block, a facing block, and insulation block between these. The insulated stretcher block 12 depicted in FIGS. 11, 12 and 13 incorporates an insulation block 18 containing anchors 20 and sandwiched between a structural stretcher block 14 and a facing block or facing 16 .
As will be appreciated by review of the Figures, the exemplary components depicted in the Figures are consistent in size and relative proportions such as height as compared to length and depth. Components of different sizes than those depicted in the Figures and components with different proportions are easily designed and manufactured utilizing the information provided here. For instance, among many other possibilities, a system of this invention may be produced with structural, insulation and facing blocks nominally one-half as tall as the components illustrated in the Figures as compared to length and depth. Numerous other relative proportions are likewise easily utilized.
Details of the structures of the exemplary components of exemplary stretcher block assembly 12 are well depicted in FIGS. 14-22 .
As is particularly well shown in FIGS. 14 and 15 , each of structural stretcher block 14 and face block 16 have a vertical face penetrated by vertical slots or grooves. Block 14 face 22 includes two “dovetail” cross-section, through slots or grooves 26 and three dovetail cross-section stopped slots or grooves 24 .
Face block 16 face 28 includes two dovetail cross section through slots or grooves 30 on face 28 and three dovetail cross-section stopped slots or grooves 32 .
Through slots or grooves 26 on block 14 penetrate both the top 34 and bottom 36 of block 14 . Through slots or grooves 30 on facing 16 penetrate both of the top 38 and bottom 40 of facing block 16 .
Stopped slots or grooves 30 on face blocks 16 open down (penetrating the bottom 40 of facing block 16 ), and stopped slots or grooves 24 on block 14 open up (penetrating the top 34 of block 14 ).
Insulation block 18 may be a single piece of plastic foam or other appropriate material and could also be built up from components among other alternatives. As depicted in the drawings, block 18 is a generally rectangular slab with faces 42 and 44 configured to mate with blocks 14 and 16 . Portions of each block 18 may lap a portion of each block 18 beside which it is positioned end to end in order to limit transmission of heat through the wall front to back or back to front. For instance, among other alternatives such as half-lap joint, a tongue 48 on one end of each block 18 may be received in a groove 46 on the other end. Ridges 54 on the top 50 and bottom 52 compress gaskets 58 to limit heat transmission above and below insulation blocks 18 .
As is apparent in several of the figures, the tongue 48 and groove 46 ends inter-fit to provide continuous insulation horizontally.
Numerous alternative insulation block end structures are possible, including among others, ship-lapping, multiple tongues and grooves, scarfing and butting.
Gasket strips 58 are captured between opposed tops 50 and bottoms 52 of insulation blocks 18 (and, more specifically between ridges 54 on the tops 50 and bottoms 52 of the insulation blocks 18 ), thereby providing continuous insulation vertically in the system 10 . The exemplary insulation blocks 18 shown in the figures have round regions 178 (marked in FIG. 17 ) that result from the injection of foam during production of blocks 18 in one production method. Ridges 54 entirely encircle these regions 178 to insure a good and continuous seal between the top 50 of insulation blocks 18 and overlying gasket 58 . Such round regions are not necessary to the practice of this invention. Gasket 58 is seated between insulation blocks 18 to provide a continuous thermal barrier up and down the wall 10 of this invention. Additionally, it transmits water vertically and helps prevent mortar from blocking the ends of water management grooves 94 in the faces of insulation blocks 18 . Gasket 58 can be made in a number of different configurations and lengths, and usable gasket could be made with differences in each of the structural characteristic depicted in the Figures and described here.
Gasket 58 may be made of any appropriate material. Compliant material that can compress to adjust for differences in the thickness of mortar between blocks, which mortar establishes the spacing between blocks, is desirable so that a good seal will be achieved notwithstanding such variations in mortar thickness and block spacing. FIGS. 37 and 38 depict gasket 58 between upper and lower insulation blocks 18 with different spacing and differing amounts of compression of gasket 58 . Such gasket material may, for instance, accommodate mortar joints including and between approximately ¼ inch and ½ inch in thickness.
Appropriate gasket materials will typically be somewhat flexible, preferably provides good insulation slowing transmission of heat and should be a resilient material that can be somewhat compressed between insulation blocks 18 to provide a seal between such blocks while resisting passage horizontally of air, water or heat. Usable materials may include expanded styrene, polystyrene, polypropylene and other foams, neoprene, natural and synthetic rubbers and other polymer materials and other suitable conventional and newly-developed gasket materials. Adhesive may be pre-applied to one or both of the top and bottom gasket surfaces, and such adhesive may be protected with a release paper or film that is removed before installation.
The faces 42 and 44 of each insulation block 18 are the same but are rotated 180 degrees (or flipped) about a horizontal axis relative to each other. Each face 42 and 44 includes two vertically oriented dovetail “tails” or keys 60 essentially the full height of block 18 and three dovetail tails or keys 62 that are not full height. Keys 62 are topped by a sloping ramp surface 64 that dies into the face 42 or 44 of the block 18 as the case may be, and each of tails or keys 60 terminates in a shorter ramp 66 that does not extend all the way to face 42 or 44 as the case may be. Grooves 24 in block 14 and grooves 32 in face block 16 terminate in sloping regions or ramps 68 in the case of grooves 24 , and ramps 70 in the case of grooves 32 .
As may be appreciated by reference to FIG. 25 , the cross sectional shape of each groove may actually be more complex than the simple “dovetail” shapes used, for instance, in woodworking, where the “dovetail” shape is usually defined by only three planes, two of which are sloping relative to the face of the workpiece and the third of which is parallel to the face of the workpiece. The exemplary cross sectional shape of the slots or grooves of the embodiment of this invention depicted in the drawings may be defined by: (a) parallel entry walls 72 that face each other, (b) inner walls 74 that are likewise parallel and facing each other, (c) sloping walls 76 that join walls 72 and 74 , and a back wall 78 that joins the two inner walls 74 . This structure avoids inclusion of any “inside” or “outside” acute corners (i.e., corners less than 90°), which facilitates manufacture and the avoidance of damage because such acute corners are easily broken (in the case of outside corners) or jammed with debris (in the case of inside corners).
As can also be seen on FIG. 25 , the tail or key 60 is generally defined by parallel neck walls 80 , sloping walls 82 and exterior wall 84 , with the corner 86 formed by walls 82 and 84 rounded over. Significantly, a small vertical raised area or rub rib 88 on each sloping wall 82 provides an easier slip fit (by reducing the total contact area between grooves and tails), with firm sealing contact (between the groove walls 76 and the rub rib 88 ), and accommodates manufacturing mold wear resulting in changes in component dimensions.
As can be appreciated by reference to FIGS. 20-24 , anchors 20 are imbedded in insulation blocks 18 to prevent separation of facing 16 from structural blocks 14 . Such anchors 20 may insure the integrity of the wall in the event of fire, wind loading or earthquakes. As shown in FIGS. 20, 21 and 22 , anchors 20 may be fabricated of sheet metal to provide two dovetail-shaped opposite ends 90 integrally formed with a neck or plate 92 between them.
Anchors 20 are dimensioned so that they can be positioned within insulation block 18 entirely encapsulated by the material of the insulation block 18 , and with the dovetail-shaped ends 90 positioned within opposed grooves 24 and 32 of face block 16 and structural block 14 , respectively, when insulation blocks 18 are assembled with structural blocks 14 and face blocks 16 . If the insulating material of insulation block 18 burns, melts or otherwise loses its integrity, because, for instance, the structure 10 is loaded beyond the ability of insulation blocks 18 to secure face block 16 to stretcher block 14 , anchors 20 will prevent face blocks 16 from falling away from structural blocks 14 because the ends 90 are wider than the mouths of grooves 24 and 32 . As a result, vertical downward movement of face block 16 will drive the end 90 of anchors 20 up against ramp 70 in facing block 16 and down against ramp 68 in block 14 . This will typically prevent the face block 16 from falling off or otherwise away from the structure provided by blocks 14 .
Because anchor 20 is entirely encapsulated by the insulation material of block 18 (absent fire or other degradation of insulation 18 ), anchor 20 does not contact either of block 14 or face block 16 and thus does not provide a thermal bridge between face block 16 and structural block 14 .
As depicted in the Figures illustrating an exemplary system of this invention, anchor 20 may be fabricated of sheet metal of any suitable type, including steel, stainless steel, aluminum and other metals and alloys. Many other materials and cross sectional and longitudinal shapes are possible. For instance, among other possibilities, anchor 20 could be forged, molded or cast of metal or another material (including, without limitation, polymers and polymer composites) with appropriate thermal and structural properties so that the anchor 20 will not melt or burn at the temperatures encountered in structure fires and have sufficient strength and an appropriate shape to keep the face block 16 coupled to the structural blocks 14 in the event of a fire or other circumstance that damages the material of insulation block 18 .
Anchor 20 also may be made of wire, bar or rod bent or otherwise formed into a suitable shape. Selection of material and configuration of anchor 20 will be typically dictated by the size and composition of the other system components and the temperature (in a fire) and other extreme physical conditions it is desired that anchor 20 be able to withstand. For instance, stainless steel anchors 20 may be desirable in particularly corrosive environments.
This masonry system may provide highly effective management of water. As an example, the components depicted in the figures provide drainage of water away from the interior of structural stretcher blocks 14 and, therefore, away from the interior of a building wall or other structure made of the components of this invention.
First, full length grooves 26 in stretcher block 14 and grooves 30 in face blocks 16 permit any water within those grooves to drain down while remaining near the exterior of a structure made from these components. Water that enters grooves 24 in block 14 drains down and then away from the interior of block 14 when it encounters ramps 68 . The vertical spaces between the interlocking components illustrated in FIG. 25 accommodate such vertical drainage.
Second, vertical water management grooves 94 are incorporated in both the front and rear faces 42 and 44 , respectively, of insulation blocks 18 to permit water to flow down either the front or back of blocks 18 .
Third, gasket 58 ( FIGS. 1 and 31 , among others) that is positioned horizontally between insulation blocks 18 is perforated by vertical holes 96 through which water can drain from grooves 94 in an insulation block 18 above the gasket 58 and into grooves 94 in an insulation block below that gasket 58 . Including relatively closely spaced vertical holes 96 in gasket 58 will insure that at least one such vertical hole 96 will be near each vertical groove 94 in insulation 18 .
Fourth (and finally), an appropriate water path may be provided out the front of the wall at a foundation, at a lintel, or at another location where the downward extending wall stops. Such a “bottom row” detail at a floor or foundation is depicted in FIGS. 26 and 27 . A metal, membrane or other flashing 100 is provided so that there is a path to the outside extending from a location above and behind the lowest course of structural blocks down and under the lowest course of insulation blocks 18 and facing blocks 16 . Because this configuration prevents any connection between the lowest (first course) insulation blocks 18 and the structural blocks, common concrete blocks 104 may be used for the first course, and the tails or keys 60 and 62 are removed (for example, by wire cutting) from the rear-facing side 44 of block 18 to result, for example, in a modified insulation block 106 depicted in FIG. 28 . Cotton cords or other appropriate water conduits may be positioned on top of blocks 104 , over the flashing 100 and out to the front of facing 16 .
Insulation block 106 shown in FIG. 28 may be produced by omitting the anchors 20 and cutting off just the tails or keys 60 and 62 in an upper portion of the block, so that water management grooves 94 are intact, ensuring channels for water to travel down between the upper portion 108 of block 106 . If desired, water management grooves 94 may be enlarged. Adhesive may be positioned on the block 106 to bond to the flashing. More of block 106 may be removed in a lower portion 110 of block 106 . This defines a vertical slot or pocket 112 between the lower portion 110 of block 106 and flashing 100 (well depicted in FIG. 27 ). Such a pocket or slot 112 helps to accommodate a lintel angle 114 used at a header location, as depicted in FIGS. 29 and 30 , which show use of such a lintel angle 114 together with rebar 116 and bond beam concrete masonry units 118 . Although not depicted in FIG. 29 to avoid confusion, gasket 58 may be positioned on top of flashing 100 and lintel angle 114 and under the insulation block 106 .
Insulation blocks 18 may be formed of expanded polystyrene or other expanded, foamed, fused, bonded or other polymer materials or a wide variety of other suitable materials providing the structural and thermal blocking properties appropriate for this member and any other desirable properties that may include strength, flame retardation, smoke suppression and water impermeability.
The insulation block 18 may be made of conventional expandable polystyrene foam and of modified polystyrene foam such as BASF Neopor® foams, which are expandable polystyrene foams formulated with graphite in the cell structure, creating a grey-hued material that, according to the manufacturer, provides better thermal performance than traditional expandable polystyrene foam. Other foams and other insulating materials may also be used, such as polyurethane or isoprene foams, among others. The insulation blocks 18 may be formed in suitably shaped molds that may include magnetic or other clips or hold-downs that hold the anchors in place within the mold while the expandable foam is introduced into the mold cavity and the insulation block 18 is formed. Essentially any front to back thickness of insulation block 18 is usable that is thick enough (i.e., on the order of at least about 1″ thick) to form the desired structure and provide heat insulation. Thicknesses between approximately 1″ and approximately 10″ will typically be appropriate, but thinner and thicker insulation blocks 18 are also possible. The thickness of the insulation block 18 can be adjusted to achieve a desired R value for a particular foam material or to match desired dimensions of the structure within which the block system of this invention is to be used.
As is indicated in FIGS. 14, 23 and 24 , anchors 20 are positioned within the mold so that one will be located with one of its ends in each of the opposing stopped keys 62 located near the ends of the insulation block 18 and approximately centered top to bottom within the insulation block 18 . Thus, in the examples depicted in the drawings, two anchors 20 attach each facing block 16 to each structural block 14 , and there is no anchor 20 in the centrally located stopped keys 62 .
Other numbers of grooves and tails or keys in blocks 14 , 16 and 18 may be used than the number depicted in the drawings and described above, and different numbers of anchors 20 can be utilized than the number depicted in the drawings and described above.
Although not depicted in the drawings or described above, a single facing block 16 may overlap and adhere or otherwise attach to a plurality of insulation blocks 18 containing one or more anchors 20 , and a single insulation block 18 containing one or more anchors 20 may overlap and adhere or otherwise attach to a plurality of structural blocks 14 . Thus, a single facing block 16 may overlap with a plurality of structural blocks 14 , and a single insulation block 18 containing one or more anchors 20 may overlap with a plurality of facing blocks 16 , structural blocks 14 , or both.
One of the advantages of the block system of this invention is that there are three mortar locations within the thickness of a wall rather than the two typical in a conventional concrete block wall. Specifically (with reference to FIG. 2 ), there are mortar locations (1) along the front top 120 and adjacent ends of block 14 , (2) along the rear top 122 and adjacent ends of block 14 (as in a typical concrete block wall), and (3) there are also mortar locations along the top, bottom and end of facing block 16 . This additional mortar line between facing blocks 16 provides additional sealing and integrity in the walls and other structures of this system.
FIGS. 32 and 33 depict construction of successive courses of a wall of this invention at a corner, illustrating an approach for achieving a strong, attractive corner incorporating the insulation and other benefits of this disclosure. Numerous other components consistent with this invention may be used in order to form corners. The approach illustrated here is but one example.
In this example, FIG. 32 depicts a standard or stretcher unit 12 incorporating a stretcher block 14 , a facing block 16 and an insulation block 18 together with a “right hand corner” assembly 126 . Similarly, FIG. 33 depicts a second course including a standard or stretcher unit 12 incorporating a stretcher block 14 , a facing block 16 and an insulation block 18 together with a “left hand corner” assembly 128 .
Right hand corner assembly 126 depicted in FIG. 32 may include right L-corner sub-assembly 146 shown in FIG. 8 and a right lapping corner sub-assembly 148 shown in FIG. 9 . Left hand corner assembly 128 depicted in FIG. 33 may include left L-corner sub-assembly 130 shown in FIG. 6 and a left lapping corner sub-assembly 132 shown in FIG. 7 . These assemblies can be used at structure corners and returns. Each sub-assembly in FIGS. 7 and 9 has a structural block, a facing block and an insulating block, as set forth in this table:
TABLE 1
Sub-assembly element
Sub-assembly
Structural block
Facing block
Insulation block
Left L-corner
134
136
138
130
Left lapping corner
140
142
144
132
Right L-corner
150
152
154
146
Right lapping corner
156
158
160
148
As is apparent in the figures, the four sub-assemblies 130 , 132 , 146 and 148 may be made using only two special structural blocks. More specifically, blocks 134 and 156 may be identical, and blocks 140 and 150 may be identical.
Special purpose blocks and sub-assemblies in accordance with this disclosure can incorporate a wide variety of interlocking and anchoring configurations. In the exemplary configurations shown in the figures where blocks 134 and 156 are the same and blocks 132 and 150 are the same and the blocks have a “standard” size cavity 174 and a smaller cavity 176 (marked in FIGS. 6 and 7 ). Additionally, each of the blocks may have a dovetail groove in one end near the standard size cavity 174 and adjacent to one block longer face, together with three such grooves on the adjacent longer face. The other blocks are the mirror image. Among other things, this configuration permits structure corners to be built with corner blocks 134 / 156 and 132 / 150 having vertically aligned standard size cavities in the corner of the structure. Rebar and grout or concrete can be placed in those vertically aligned cavities to strengthen the structure. This configuration also accommodates the insulation block 18 structure depicted in the figures and described above. A full length block 18 with the appropriate two of its dovetail keys removed (making insulation blocks 144 and 160 ) is used with structural blocks 156 and 140 . An L-shaped insulation block 138 or 154 is fabricated by appropriately cutting and joining (with adhesive or other means) mitered portions of insulation blocks 18 . Using the positioning of anchors 20 within insulation block 18 described above and depicted in the figures, one anchor will remain in insulation blocks 144 and 160 , and two anchors will remain in insulation blocks 138 and 154 . Other numbers and configurations of anchors and keys in insulation blocks are possible.
Corner reinforcement tie wire inserts 162 (see FIG. 34 ) may be used as shown in FIG. 33 where additional corner strength is desired. Similarly, mortar or grout can be placed in any or all of the block 14 cavities. The cavities align vertically so that, rebar can be inserted in vertically aligned block 14 cavities together with mortar to provide further strength, particularly, for instance at corners of structures of this invention.
Accommodation for wall movement because of temperature changes or other factors without creation of an air or water-admitting penetration through the entire wall can be accomplished with (full size) sash blocks 164 as depicted in FIG. 35 and with half sash blocks 166 as depicted in FIG. 36 , together with a gasket or barrier 168 having an X-shaped cross-section that is received in opposed grooves 170 in the sash blocks 164 or half sash blocks 166 . Sash blocks 164 and half sash blocks 166 are shown individually in FIGS. 3, 4 and 5 .
The exemplary structural blocks 14 and other structural blocks of this invention may be made using conventional, typically inexpensive, concrete materials or from a variety of other cementitious materials and other compositions providing sufficient strength, density and other qualities appropriate for the particular application. The blocks 14 shown in the drawings have flat top webs. Such blocks can also be produced with webs with V-shaped tops. Such blocks with V-shaped web tops may provide benefits relative to water drainage, aesthetics and other things.
Face blocks 16 and other such blocks can be made of concrete and virtually any other desired material that will provide adequate strength and weather resistance and, importantly, other desired aesthetic qualities. For instance, face blocks may be made of marble or another natural stone, a wide variety of castable or moldable materials, metals (including aluminum), wood and other machinable or formable materials.
Insulation blocks 18 may be married to blocks 14 and 16 using adhesives or other means, and adhesives can act as lubricants to facilitate assembly of the face insulation and structural blocks. Among other alternatives, when adhesive is used, 3M brand Polystyrene Foam 78 Adhesive may be used. Other adhesives may also be used provided that they do not damage the insulation blocks 18 and otherwise provide appropriate application and performance properties.
Insulation blocks 18 are designed to make use of adhesives unnecessary. The blocks of this invention may be joined simply by sliding the tails or keys 60 and 62 of insulation blocks 18 into the grooves or slots 24 and 26 of blocks 14 and the grooves or slots 30 and 32 of face blocks 16 . Sloping ramps 64 and 68 may facilitate introduction of the tails or keys 60 and 62 into the grooves or slots of blocks 14 and 16 . Whether adhesive is used or not, a hydraulic or other press may be used to facilitate this assembly: (a) by pressing the top 50 of insulation block 18 and bottom 36 of block 14 until the tails 60 and 62 are seated in the grooves 24 and 26 of block 14 , and (b) by pressing the top of 38 of facing block 16 and bottom of insulation block 18 until the tails 60 and 62 of block 18 are seated in the grooves 30 and 32 of facing block 16 . This assembly may be done in any desired order of steps, including simultaneously.
The desired relative positions of the blocks will be maintained under normal circumstances as a result of friction between rub ribs 88 (visible in FIG. 25 and that protrude from and extend up and down the sloping walls 82 of the tails or keys) and the sloping walls 76 of the groove or slot in the structural block 14 or face block 16 as the case may be. As noted above, adhesive may be used to facilitate assembly and secure the assembled block components to each other. Other numbers, shapes, sizes, and locations of rub ribs than those depicted in the drawings may be used. For example, rub ribs could comprise one or more bumps protruding anywhere from the tails or keys 60 and 62 .
The use of sloping ramps 70 on face block 16 , sloping ramps 64 on insulation block 18 and sloping ramps 68 on structural block 14 provide the capacity to align insulation block 18 relative to the face block 16 in structural block 14 more accurately than might be the case using other stopping structures. This is because the opposing faces will “lock up” within a small range of relative positions rather than providing a hard stop as might be the case if stop structures square to the block faces were used. These sloping surfaces also provide better encouragement (than would square ledges) for water to drain down within the wall structure.
Different arrangements of the components depicted in the drawings or described above, as well as components and steps not shown or described are possible. Similarly, some features and subcombinations are useful and may be employed without reference to other features and subcombinations. Embodiments of the invention have been described for illustrative and not restrictive purposes, and alternative embodiments will become apparent to readers of this patent. Accordingly, the present invention is not limited to the embodiments described above or depicted in the drawings, and various embodiments and modifications can be made without departing from the scope of the claims below.
For instance, anchors 20 can be configured in numerous other shapes and of different materials, including various different cross sectional sheet metal and wire shapes and sizes. Alternatives to anchors 20 with round end structures having a diameter just less than the width of the tails or keys 62 at the location where the end structures will be imbedded in the tails 62 may be well-suited for their purpose because, among other reasons, they can be rotated along their longitudinal axis during positioning and molding of insulation blocks 18 , making them easy to position and use. Other alternative anchor shapes may also be used, including, for instance, anchors having vertically oriented, plate-shaped square or rectangular ends of appropriate width, which ends may be joined by a sheet or web of metal or another material. Similarly, an anchor may be made of cast metal with a central, rectangular web and flaring, dovetail-shaped ends embedded in the tails or keys 62 similar in shape to the anchors 20 depicted in the drawings. Among other wires usable for anchors are 0.15″ diameter round galvanized steel wire. Various other wire-making materials can also be used, including, for instance, stainless steel in particularly corrosive environments.
As is indicated in FIGS. 14, 23 and 24 , anchors 20 are positioned within the insulation block 18 mold so that one will be located within with one of its ends in each of the opposing the stopped tails or keys 62 near the ends of insulation blocks 18 and centered top to bottom within the insulation block 18 . Thus, in the examples of standard stretcher assemblies 12 depicted in the drawings, two anchors 20 attach each facing block 16 to one structural block 14 .
Other numbers of grooves and tails in blocks 14 , 16 and 18 can be used than the number depicted in the drawings and described above, and different numbers of anchors 20 can be utilized than the number depicted in the drawings and described above.
Appropriate adjustments and configurations may also be desirable in producing the special-purpose sub-assemblies of this invention. For instance, insulation block 172 used with the half-sash units illustrated in FIGS. 4 and 5 may be produced by wire cutting out a central region of the insulation block 18 of appropriate width. The two insulation block ends can then be adhesively bonded together to result in a half-sash insulation block 172 containing the two anchors 20 that were in insulation block 18 and the same length as the half sash structural blocks 166 .
One aspect of this disclosure includes four main components: a facing block, a structural block, anchors that prevent the facing from separating from the structural block and insulation between the facing block and the structural block. Most of the detailed description and figures contemplate structures in which anchors are embedded in the insulation blocks and are normally thermally insulated from the face and structural blocks so that the anchors do not form a thermal bridge. Other alternatives are possible. For instance the anchors may be separate components from the insulation that are assembled on site or are preassembled with one or more of the insulation, facing or structural components before those components or subassemblies of those components are assembled on site. Furthermore, anchors, facing blocks and structural blocks could be preassembled or assembled on site so that there is a cavity between the facing and structural blocks into which insulation can be installed in solid form or inserted as a liquid that may foam, and in any event solidifies, in situ. Such alternative anchors may be mounted in either or both of the facing and structural blocks and engaged with the other of these blocks during assembly of the components. In another alternative, an anchor component may be attached to each of the facing and structural blocks and then coupled during component assembly.
Block assemblies may be manufactured with a structural block with a vertical side penetrated by at least one groove, a facing block with a vertical side penetrated by at least one groove, an insulation block With front and back vertical sides, With the front side comprising at least one upward facing tail or key and the back side comprising at least one downward facing tail or key, by performing the following steps, in no particular order: sliding the structural block and insulation blocks relative to each other so that the downward facing tails or keys are received in the structural block grooves, and sliding the facing block and insulation block relative to each other so that the upward facing tails or keys are received in the facing block grooves. The blocks may be pressed together with a press.
Insulation blocks may be manufactured by:
a. providing a mold containing a cavity in the shape of the desired insulation block, b. providing at least a first anchor, c. positioning the first anchor within the mold at a location corresponding to a desired anchor location in the insulation block, d. charging the mold with insulation-forming material, e. permitting the insulation-forming material to cure, and f. removing the cured insulation block containing the anchor from the mold.
The mold may include at least one magnet or other structure, and may include multiple magnets or other structures, for holding one or more anchors inn position during the manufacturing process.
A structural block for use at an end, corner or the like in a block wall including structural blocks, insulation blocks and face blocks, each of which face blocks has at least one elongated groove, and each of which insulation blocks has at least one elongated tail or key, may comprise: a concrete masonry unit having a front vertical wall, a back vertical wall and two vertical end walls between the front vertical and back vertical walls, the front and one of the end the walls further comprising at least one vertically extending groove adapted to receive the at least one elongated tail or key.
A facing block for use at a corner, end or the like in a block structure comprising structural blocks, insulation blocks and face blocks, each of which structural blocks has at least one elongated groove, and each of which insulation blocks has at least two elongated tails or keys, may comprise:
a. an L-shaped decorative material comprising:
i. a front face, ii. an end face, iii. a back face and iv. an end inside face, and
b. each of the back face and the end inside face further comprising at least one vertically extending groove or slot adapted to receive one of the insulation block tails or keys.
A thermally insulated wall structure may include structure blocks, face blocks, anchors for joining the face blocks to the structure blocks, and insulation for interposition between the structure blocks and the face blocks. The anchors may be configured to avoid providing thermal bridges.
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A insulated masonry wall system having insulation blocks between structural and face blocks to provide structures that are strong, inexpensive, avoid thermal bridges, and resist transmission of heat. The walls are attractive and versatile, and an enormous variety of decorative face members may be utilized. The face blocks are attached to the structural blocks to prevent facing materials from falling even if fire destroys the insulation blocks between the structural blocks and the facing. The system resists water penetration and effectively drains water that does penetrate any portion of the system.
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BACKGROUND AND SUMMARY OF THE INVENTION
This invention relates to a method of attaching roofing material in sheet form to horizontal roof decks (substrates) and vertically extending roof structures or walls (i.e., parapet) requiring less manpower and time-consumption, while achieving the desired result of securely attaching roofing material that is water-tight and wind-resistant.
Known methods of installing roofing material are time-consuming and require the use of two or more installers. In known methods, tabs are attached to the inside surface of the roofing material. Each tab is installed to the roofing material via a fastener, or anchor (e.g., a screw, nail, or any other equivalent fastening means). A fastener is driven through the tab and into the roofing substrate thereby securely attaching the material to the roof. The first fastener is installed on the horizontal roof substrate just before the material makes a right angle turn to climb the parapet. One or more installers are required to hold the roofing material up, or away, from the roof substrate and/or the parapet while another worker is required to pull the tab taut against the roof substrate. In this position, an additional worker can then fasten the tab to the roof substrate. As discussed, this process requires at least two to three workers. Additionally, this method requires a significant amount of time as the process is inherently cumbersome. Accordingly, a new and reliable process of installing roofing material is needed which can be performed by one installer, thereby significantly decreasing the cost and time of installing roofing material.
The method of the present invention for installing roofing material involves the use of a roof membrane which is comprised of a sheet of roofing material which may have tabs affixed to its outer surface. The ends of the roofing material are first fastened to the wall or roof substrate to be covered. The ends of the roofing material are fastened by tabs which are affixed to the underside of the roofing material. The portions of the roofing material between the fastened ends are fastened to the wall or roof substrate by installing fasteners directly through the roofing material into the wall or roof substrate to be covered. Tabs are affixed to the outer surface of the roofing material which can be folded back so that fasteners can be installed directly through the roofing material. Once fastened, the tabs can be folded back into place to cover the fasteners. The tabs may then be welded, or otherwise sealed, shut so that the roofing material is protected from rain, water, and other elements. The present method of installing roofing material saves significant time since the tabs affixed to the outside surface allow the roofing material to be fastened by one worker (there is no need for another worker to lift and hold the roofing material while fastening). Additionally, the roof membrane of the present invention can be pulled taut one sheet at a time, whereas the known methods require each tab to be pulled taut for each intervening tab.
In addition to the features mentioned above, objects and advantages of the present invention will be readily apparent upon a reading of the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
Novel features and advantages of the present invention, in addition to those mentioned above, will become apparent to those skilled in the art from a reading of the following detailed description in conjunction with the accompanying drawings wherein similar reference characters refer to similar parts and in which:
FIG. 1 is a cross-sectional view of a parapet showing the installation of roofing material on a parapet and a portion of the horizontal roof deck substrate using a known method;
FIG. 2 across-sectional view of a parapet showing the installation of roofing material on a parapet and a portion of the horizontal roof deck substrate according to the method of this invention;
FIG. 3 is a cross-sectional view of roof layer showing the installation of roofing material on a horizontal roof deck substrate using a method known in the art;
FIG. 4 is a cross-sectional view of a roof layer showing the installation of roofing material on a horizontal roof deck substrate according to the method of this invention;
FIG. 5 is a cross-sectional view of a plate and fastener in use in fastening the roofing material to the roof substrate; and
FIG. 6 is a cross-sectional view of a fastener in use in fastening the roofing material to a parapet.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The preferred system herein described is not intended to be exhaustive or to limit the invention to the precise forms disclosed. They are chosen and described to explain the principles of the invention, and the application of the method to practical uses, so that others skilled in the art may practice the invention.
FIG. 1 illustrates the installation of roofing material on a wall (or parapet) using a method known in the art whereby the first fastener is installed at 10 and subsequent fasteners are installed in sequence at predetermined intervals 20, 30, 40 and 50. All fasteners are inserted through tabs which are attached to the underside surface of the roofing material closest to the roof or wall being covered. (Reference number 12 refers to a tab on the underside surface of a known roofing material.) These previously known methods of roofing require at least two workers to install the roofing material. For proper installation, since all the tabs of the known roofing materials are located on the underside of the roofing material, at least one worker is needed to pull the roofing material taut against the roof substrate and/or the wall to be covered, while another worker must position himself so as to be able to insert a fastener through the tab and drive the fastener into the roof substrate or wall. (An additional worker is often needed to hold the roofing material up or away from the worker pulling the tab.)
The method of roofing of the present invention may be accomplished with a pre-fabricated sheet of roof membrane 92 of the present invention. A pre-fabricated sheet of roof membrane 92 is comprised of: a sheet of roofing material 62; tabs 74, 76 affixed to the underside surface 78 of the roofing material 62; and tabs 84 affixed to the exterior surface 72 of the roofing material 62, where the tabs 74, 76, 84 are positioned at a predetermined distance in relation to each other. Additionally, as illustrated in FIGS. 2 and 4, the tabs 84 affixed to the exterior surface 72 of the roofing material 62 are placed along a length of the roofing material 62 and between the tabs 74, 76 affixed to the underside surface 78 of the sheet of roofing material 62.
The length and width of the pre-fabricated sheet of roof membrane 92 will vary based on the width or height of the roofing surface. The sheet of roof membrane 92 can also be standardized to a no material waste standard size that a contractor can fit in the center of a roof, while making the appropriate fitting measurements at the perimeters of the roof. This process will standardize the sheets and cut material costs. Various known materials can be used to manufacture the sheet of roof membrane 92 of the present invention.
FIG. 2 illustrates the installation of a roof membrane 92 onto a parapet (or wall 66) using the method of this invention. The first fastener is installed at 60 and the second at 70 using via the tabs 74, 76 attached to the underside of the material 62. A predetermined number of intervening fasteners are installed directly through the roofing material 62 into the wall 66 at 80, 90, 100 and 110. (The number of intervening fasteners required may vary depending on the particular installer, the thickness and length of the roofing material 62, and the type of roofing material 62 and fastener used.) Once the intervening fasteners are driven into the wall 66, tabs 84, or plates, affixed to the exterior surface 72 of the roofing material 62, are folded down on the fasteners. The perimeters of the tabs 84 are then field-welded, or otherwise sealed, closed to prevent moisture from penetrating the hole made by the fastener.
Referring to FIG. 2 in more detail, the roofing method of the present invention is accomplished by: first fastening the roof membrane 92 of the present invention to the top 64 of a wall 66; then fastening the roofing material 62 at a location 68 near the bottom of the wall 66; and then fastening the roofing material 62 to the intervening portion of the wall 66 by fastening means, where the fastening means securing the intervening portion of the roofing material 62 are installed directly through the exterior surface 72 of the roofing material 62 and into the wall 66. The intervening portion of the wall 66 merely refers to the portion of the wall 66 between the top 64 and bottom areas 68 of the wall 66. The location 68 near the bottom of the wall where the roofing material 62 is fastened is preferably a portion of the roof substrate 82 just beyond the point where the wall 66 and the roof substrate 82 meet (e.g., tab 76 in FIG. 2).
The roofing material 62 is fastened to the top 64 of the wall 66 and to a location 68 near the bottom of the wall 66 by installing a fastening means through the tabs 74, 76 affixed to the underside surface 78 of the roofing material 62.
The present method of roofing can be performed by one worker. For example, once the tab 74 is secured at the top 64 of the wall 66, the worker may allow the roofing material 62 to hang down to the bottom of the wall 66. When a screw, or fastener, is installed at the location 68 near the bottom of the wall 66, the roofing material 62 will draw taut. Since the fastening means securing the intervening portion of the roofing material 62 is installed directly through the exterior surface 72 of the roofing material 62, an additional worker is not required to lift and hold, or pull, the roofing material 62 while the fastening means is installed.
As illustrated in FIGS. 2 and 4, the roofing material 62 of the present invention is comprised of tabs affixed to the exterior surface 72 of the roofing material 62. The tabs 84 may be folded back so that a fastener can be installed directly through the roofing material 62. (The arrow 101 in FIG. 2 shows the direction in which the tab 84 at location 100 may be folded back.) The roofing material 62 may be fastened to the intervening portion of the wall 66 by first folding back the tabs 84 before installing the fastening means directly through the exterior 72 surface of the roofing material 62 and into the wall 66. Subsequently, the tabs 84 may be folded back into position to cover the fastening means. The tabs 84 may be welded, or otherwise sealed (e.g. by glue), shut for purposes of waterproofing the roofing material 62.
Once the wall 66 (or parapet) is covered with the roofing material 62, the roof substrate 82 may also be similarly covered. FIG. 3 illustrates the known method of installing roofing material on a horizontal roof substrate. The known roofing method is accomplished by fastening the roofing material at locations 120, 122, 124, 126, 128, and 132 whereby all fasteners are inserted through tabs located on the interior surface of the roofing material. The fasteners are then driven into the roof substrate 82. Again, as discussed above, these known roofing methods require at least two to three workers to complete; one for holding back the roofing material, another for pulling the tab taut, and an additional worker for fastening the roofing material to the substrate.
FIG. 4 illustrates another embodiment of the present invention showing the installation of a roof membrane 92 on a roof substrate 82 according to the method of this invention. Normally, the roof substrate 82 will be in the horizontal plane. If the roof substrate 82 is connected to a wall 66 (or parapet) which has been covered with the roof membrane 92, as discussed above, the fastener at 70 will already have been installed (see FIG. 5). In this instance, the roofing material 62 would then be fastened to the roof substrate 82 at location 134 (or at the far end of the roof substrate 82 in relation to the wall 66). The roofing material 62 would then be fastened to the intervening portion of the roof substrate 82 as will be described below.
The roof substrate 82 can also be covered with a roof membrane 92 by the method of the present invention, independently of the covering of an attached wall 66, if any. The roofing material 62 is first fastened to the roof substrate 82 at one end (either location 70 or 134) of the roofing material 62. The roofing material 62 is then fastened to the roof substrate 82 at the second end (either 70 or 134 whichever has not yet been fastened) of the roofing material 62. Once the ends 70, 134 have been fastened, the roofing material 62 is fastened to the intervening portion of the roof substrate 82 by fastening means installed directly through the roofing material 62 and into the roof substrate 82. (Again, the intervening portion of the roof substrate 82 is merely the portion of the roof substrate 82 between the end locations 70, 134.)
Again, as illustrated in FIGS. 2 and 4, the roof membrane 92 is comprised of roofing material 62 which is further comprised of tabs 84 placed on its exterior surface 72. The tabs 84 may be folded back to expose the exterior surface 72 of the roofing material 62. The roofing material 62 may be fastened to the intervening portion of the roof substrate 82 by first folding back the tabs 84 before installing the fastening means directly through the roofing material 62 and into the roof substrate 82. Subsequently, the tabs 84 can then be folded back into position to cover the fastening means. The tabs 84 may then be field-welded, or otherwise sealed, shut for purposes of waterproofing the roofing material 62. All remaining fasteners at locations 136, 138, and 140 may be installed according to this method. Accordingly, the method of the present invention saves considerable time and money from the known roofing techniques by enabling one worker to pull the roofing material 62 taut one-time per sheet as opposed to one tab at a time.
FIG. 4 illustrates a roof layer, or deck sheet 94 (i.e., a roof substrate 82 which has been covered with a prefabricated sheet of roof membrane 92) of the present invention. The deck sheet 94, is comprised of a roof substrate 82 and a sheet of roof membrane 92 covering the roof substrate 82. The roof substrate 82 may be comprised of a deck layer 96 and an insulation layer 98.
FIGS. 5 and 6 illustrate cross-sectional views of different types of fasteners, in use, that may be used to fasten the roofing material 62 to a roof substrate 82 or wall 66.
Having shown and described a preferred embodiment of the invention, those skilled in the art will realize that many variations and modifications may be made to affect the described invention and still be within the scope of the claimed invention. Thus, many of the elements indicated above may be altered or replaced by different elements which will provide the same result and fall within the spirit of the claimed invention. It is the intention, therefore, to limit the invention only as indicated by the scope of the claims.
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A method and apparatus for the installation of roofing material. The method of installing roofing material of the present invention requires less manpower and consumes less time. Tabs are affixed to the outside of the roofing material which fold back to allow insertion of a fastener. The ends of the roofing material are first fastened to the roof or parapet to be covered. The intervening portion of the roofing material is then fastened. The tabs affixed to the outside of the roofing material cover the fasteners and can be sealed shut to waterproof the roofing material.
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This is a divisional of application Ser. No. 08/547,472, filed Oct. 24, 1995, now U.S. Pat. No. 5,626,442.
BACKGROUND OF THE INVENTION
Underground service pipes such as sewers which make up the utility infrastructure need replacement or rehabilitation as they age. Through normal service the lines, typically made of concrete, deteriorate or break allowing waste to escape. The buried pipes present access problems. Also, it is desirable to maintain sewer service while the replacement or rehabilitation of the sewer line takes place.
Repairing a service line can involve digging up most or all of the line and replacing the pipe. This is costly, labor intensive and disrupts normal service. Alternative methods such as pipe bursting have been developed which includes breaking up the old pipe underground and following the bursting operation with placement of new pipe in the space provided. Another alternative method involved extracting the old pipe at intervals and replacing it with new pipe by forcing the new pipe into the space provided after the extraction process. The old pipe that was extracted needed to be disposed of adding another economic factor to the method. Some of these methods utilized pipe jacking machines with hydraulic rams or mechanical drivers to push the new pipe in place. In some cases the pipe jacking equipment took up space in the excavation next to the pipe to be burst or extracted. The access thorough existing manholes was insufficient to accommodate the pipe jacking equipment.
The renewal or rehabilitation of the service lines without digging up the line was developed by inserting new pipe or slip lining with materials such as plastic pipe liners inside the old pipe. Rehabilitation of old pipe with a new internal slip lining requires cleaning the existing host pipe of debris that has built up with use. Some methods utilize stationary derricks for the cleaning operations with a drag bucket. The derricks need to be reset after each operation. The bucket size may be limited by the height of the derrick used to hoist the bucket to the surface. The pipe liner is pushed into the host pipe. Often the pressure exerted in the pushing operation is not evenly distributed causing damage to the liners.
The host pipe should be tested after the cleaning process to determine if debris has been removed and the pipe liner can fit. The new joints of liner pipe is then placed in the host pipe. The liner generally has a slightly smaller diameter than the inside of the host pipe.
SUMMARY OF THE INVENTION
This invention is a system for rehabilitating pipe such as sewer lines which renews the existing service lines without disrupting the flow through the lines. In this description the pipe may be described as a sewer line that is in need of rehabilitation. The system retains the host pipe and therefore the value of the structure in place while not creating additional waste disposal concerns with the extracted pipe. The system utilizes mobile equipment such as conventional excavators that are fitted with winches on the attachment points for custom tools, the winch manipulates and lifts the buckets for the cleaning operation, and the test mandrel and the pipe liner in the slip lining renewal operation.
The system for cleaning the sewer line is often needed prior to the slip lining process because of the debris built up in the sewer line after years of use or rapid deposition of debris because of adverse environment conditions. The present invention utilizes equipment that can be used for both the cleaning and relining process as well as testing the host pipe prior to relining to confirm that the interior of the host pipe is clear and the liner pipe will be received without damage.
In the rehabilitating system of the invention the length of host pipe is accessed on both ends. Manholes already present can be used as access on at least one end of the host pipe and are generally large enough for one end of the operation. A larger excavation to accept the new pipe liner and a test mandrel is required on the other end of the host pipe from the manhole.
In an embodiment of the system the host pipe is accessed through a shaft that can be an existing manhole. A down hole boom is inserted into the shaft. The down hole boom has a winch mounted and a guide roller mounted thereon. The guide roller is adjustably mounted so that when the down hole boom is placed in the shaft the guide roller is positioned to guide the cable from the winch over the roller into the host pipe. The down hole boom generally extends above the surface of the shaft. The winch is preferably mounted on the part of the boom above the surface. In one embodiment the winch on the down hole boom is also mounted to a mobile vehicle such as an excavator.
A selected length from the access shaft another access area to the host pipe is provided that is large enough to accommodate other equipment necessary for the rehabilitation process such as lengths of the new pipe liner. A host vehicle with a movable boom such as an excavator is positioned at the surface of the second access area. Various embodiments of the system use conventional excavators which are easily transported from site to site. A second winch is mounted on the end of the boom. The boom operator can manipulate the boom and winch so that the winch can be moved from above the surface into the access area and to the mouth of the host pipe. In the preferred embodiment, a housing is mounted to the end of the boom and surrounds the winch. The housing protects the winch, but allows for free movement of the cable spooled on the winch. The winch housing is attached to the boom on the custom attachment points used for other types of tools. The cables from both winches are capable of disengageable attachment to equipment used to rehabilitate the host pipe.
One of the pieces of equipment used to rehabilitate the host pipe which is part of the system is a cleaning bucket. The semicircular cleaning bucket is sized to be received in the host pipe. The cleaning bucket has a leading edge with a flap door that is generally semicircular and hinged to the top of one end of the bucket. The flap door swings to the inside of the bucket from the closed to open position. An open end is opposite to the flap door on the cleaning bucket. The cleaning bucket has points of attachment for to the cables such as yokes.
An additional piece of equipment of the system is a test mandrel used to determine if there are any obstructions in the host pipe prior to lining. The test mandrel is a cylindrical member with beveled edges on both ends. A plurality of internal ribs and internal pulling yokes are disposed inside the cylindrical member.
Another feature of the system is a pulling mandrel designed to distribute the pulling forces in an even manner around the pipe liner while it is pulled by the cable on a winch and pulled inside the host pipe. The mandrel also provides for areas of flow therethrough so the sewer remains in service during the slip lining operation. The pulling mandrel is a circular member with a diameter sized to be received into the host pipe and to contact the circumference of a liner for the host pipe. A plurality of spokes extend from the circular member and converge to the middle of the circular member to a central hub. The hub has an opening of sufficient size to accompany a cable passing therethrough.
The invention also includes methods for using the system in rehabilitating the sewer lines. The cleaning method starts with the selected length of host pipe described above that has at least two access points with one access that can be a manhole. The cleaning bucket described above is attached to a cable. In an embodiment one cable is strung between the two winches with the cleaning bucket attached. In a preferred embodiment of the system the cable from the winch on the down hole boom attached to a yoke on the leading edge of the cleaning bucket and the cable on the movable boom is attached to the open end of the cleaning bucket.
The cleaning bucket is lowered into the access area serviced by the winch on the movable mount. The cleaning bucket is pulled by spooling the winch on the down hole boom through the host pipe with the leading edge first so that the flap door is open. The drag is reversed by spooling the winch on the movable mount so that when the cleaning bucket is pulled in the opposite direction the flap door closes and traps debris. The cleaning bucket with the debris is hoisted to the surface by spooling the winch on the movable mount and raising the mount. The debris is discharged from the bucket. The processes is repeated until the host pipe is cleaned.
Generally the next method used in sewer rehabilitation that utilizes the system is a testing procedure to determine that the pipe liner will fit suitably in the host pipe. This operation involves pulling a test mandrel which is a tubular member with the approximate diameter and length of the pipe liner through the host pipe. In the preferred system, the test mandrel has beveled edges on each end and performs a final sweep of the host pipe loosening and removing any remaining solids or mineral deposition on the inside of the host pipe. Also, the internal ribbing provide weirs for collection of the debris. The method for using the system for testing includes lowering the test mandrel in the access area next to the host pipe. The cables from both winches are attached to the internal yokes inside the test mandrel. The winch on the down hole boom is spooled so that the mandrel travels through the host pipe toward the access shaft. The travel is then reversed by spooling the winch on the movable mount. The ease of travel by the mandrel through the host pipe is indicative of an obstruction or lack thereof.
The host pipe is lined after the cleaning and testing process. However lining might be necessary if there has been some structural damage to the integrity of the sewer pipe and a cleaning process is not necessary. At one access area the excavation is large enough to accommodate a length of pipe liner. The same system is used in the cleaning and testing operation may be used in relining the host pipe. A cable on the winch on the down hole boom is passed through the length of the host pipe. The cable is then passed through a length of pipe liner and the pulling mandrel that is placed adjacent to the pipe liner that has also been lowered into the access area.
The cable is secured to the pulling mandrel so that when the cable on the down hole boom is spooled it pulls the pipe liner into the host pipe. The cable is spooled approximately the length of the pipe liner section. The end of the cable is released from the pulling mandrel. Another section of pipe liner is placed in the access area at trailing end of the first pipe liner section and the pulling mandrel is placed at the end of the second pipe liner section. The cable is spooled and the next section of the pipe liner is pulled into the host pipe. This process is repeated until the host pipe length is lined.
Another method of the invention is a method for rehabilitating a host pipe that is adaptable to smaller pipe and can be performed while the sewer is in service. The alternate method is suitable for remote or difficult to access areas. This alternate method uses basically the same equipment for all the rehabilitation work to clean and line the pipe. The alternate method involves selecting the host pipe and accessing two ends through shafts that can be existing manholes. An excavation intermediate to the two shafts is dug and a portion of the host pipe is removed. Two down hole booms are inserted into the access shafts and extend above the surface. Winches are positioned adjacent to the down hole booms. The cable spooled on the winches are placed over guide rollers on the down hole booms so that the winches can pull the cable down the access shaft into the host pipe to the intermediate access area. The alternative method includes down hole booms and winches that can be skid mounted or mobile mounted.
A hoist device with at least one cable is placed at the surface of the intermediate access area to the host pipe. A cleaning bucket as described above is lowered into the intermediate access area by the hoist and attached to one of the cables associated with the winch and down hole boom. Cables from the winches on the down hole booms are attached to either end of the cleaning bucket. As the cleaning bucket is pulled through the host pipe and reversed the debris is trapped. The cable on the hoist is attached to the cleaning bucket. The cleaning bucket is withdrawn from the intermediate access area and the collected debris is discharged at the surface. With two access shafts to the host pipe, the cleaning bucket can used on both sections of the host pipe extending from the intermediate access area.
The testing method utilizes the same equipment. A test mandrel is lowered into the intermediate access area by the hoist. Cables from the two winches are attached to either end of the test mandrel and it is pulled through the host pipe to determine if any obstruction exists.
The same equipment is used to line the host pipe. The hoist introduces pipe liner into the intermediate excavation area. Both sections of host pipe that extend from the intermediate access area are lined. A cable extended from one of the winches into the intermediate access area is passed through a section of pipe liner and then secured to a pulling mandrel. The cable is spooled approximately the length of the pipe liner. The pulling mandrel is removed and another section of pipe liner is introduced into the intermediate access area by the hoist and aligned to abut with the first section pulled into the host pipe. The cable is released by the winch and pulled through the second section of pipe liner and secured to the pulling mandrel. The winch spools the cable pulling the first and second sections of pipe liner into the host pipe. The process is repeated using both winches until the host pipe extending from the intermediate area is lined.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic depiction of the sewer rehabilitation system during the cleaning process.
FIG. 2 is a schematic depiction of the sewer rehabilitation system during the testing process.
FIG. 3 is a schematic depiction of the sewer rehabilitation system during the host pipe lining process.
FIG. 4 is a schematic depiction of an alternative embodiment of the sewer rehabilitation system showing the cleaning process of the sewer line.
FIG. 5 is a alternative embodiment of a sewer rehabilitation system showing the testing of the sewer line.
FIG. 6 is a schematic depiction of an alternate system showing the host-pipe lining operation.
FIG. 7 is a perspective view of a cleaning bucket.
FIG. 8 is an end view of the cleaning bucket with the flap door closed.
FIG. 9 is a side view of the cleaning bucket showing the swing of the flap door.
FIGS. 10a, 10b and 10c are perspective views of the cleaning bucket and winch during the discharge process.
FIG. 11 is a perspective view of the pulling mandrel.
FIG. 12 is a perspective view of the pulling mandrel and direction of pipe liner.
FIG. 13 is an exploded view of the pulling mandrel with the locking teacup, cable and pipe liner.
FIG. 14 is a side view of the exploded depiction of the locking teacup, pulling mandrel, pipe liner and cable.
FIG. 15 is a partially perspective view of the test mandrel that also shows the internal ribs and yokes by the dotted lines.
FIG. 16 is a cross-section at line 16 of FIG. 15.
FIG. 17 is a perspective view of the winch and housing.
FIG. 18 is a side view of the winch and housing.
FIG. 19 is a down hole boom with two adjustable guide rollers for use in an alternative embodiment of this system.
FIG. 20 is an alternative embodiment of a down hole boom with two adjustable guide rollers for use in an alternative embodiment of this system.
FIG. 21 is a perspective view of a down hole boom and winch associated with a movable mount.
DETAILED DESCRIPTION OF THE INVENTION
A system for rehabilitating sewer lines is shown in FIG. 1 during cleaning of a host pipe. As shown in FIG. 1, the host pipe 10 has been accessed at one end of the selected length for rehabilitation by access shaft 12 which can be an existing manhole or other existing access shaft to the sewer line which is wide enough to accommodate down hole boom 14. Down hole boom 14, as shown in FIG. 1, extends from above the surface of the manhole entrance to the bottom of the manhole and rests on the bottom of the manhole. In the preferred embodiment down hole boom has a guide roller 16 at the end of the down hole boom close to the mouth of the host pipe. The guide roller is adjustable along the length of the boom so that cable 18 from winch 20 can extend into the access shaft along the down hole boom around guide roller 16 and into the host pipe. Depending on the diameter of the host pipe, guide roller 16 can be adjusted on the down hole roller so that the cable 18 extends preferably to the host pipe. Auxiliary guide roller 13 mounted on the down hole boom 14 is also shown. The extension of the down hole boom may be adjusted by attaching different lengths together. A joinder point 15 is shown on the down hole boom 14 where two lengths are fastened together. Winch 20 is mounted on the part of the down hole boom extending above the manhole. However, the winch could be located beneath the surface in the manhole. Winch 20 is also mounted to a host vehicle 22 which in FIG. 1 is shown as a conventional excavator. However, down hole boom 14 and winch 20 may be supported at the surface above access shaft 12 by a stationary support. FIG. 1 illustrates the use of a host vehicle 22 to illustrate the transportability of the system.
The winch 20 spools and pulls cable 18. The winch may be mechanically driven, but in the preferred system the winch mechanism is hydraulically driven and operated. Cable 18, threaded on winch 20, extends the length of down hole boom 14 may be guided on the down hole boom by additional guide rollers, such as auxiliary guide roller 13 then around guide roller 16 at the mouth of host pipe 10 and into the host pipe. In FIG. 1 the cleaning bucket 26 is attached to cable 18 at yoke 28.
A second access area generally indicated by reference numeral 30 is excavated a selected length from access shaft 12. The second access area extends from the ground surface and a portion of host pipe 10 is removed. As shown in FIG. 1 a system of this invention can be used while the sewer is flowing and the host pipe was removed down to the spring line to contain the sewer effluent. Adjacent to the second access area is host vehicle 32 which is equipped with a movable boom mechanism. Host vehicle 32 is a movable mount and can be a conventional excavator. 0n the end of the boom a second winch 36 is attached to point of attachment for a backhoe. The winch 36 is surrounded by housing 38 that allows for free movement of cable 40 into the access area host pipe. In FIG. 1 cable 40 is shown attached to yoke 42 on cleaning bucket 26. Both cables 18 and 40 are used to engage various pieces of equipment during the rehabilitation of the host pipe.
As shown in FIG. 1 the host vehicle 32 stabilizes the boom and the winch 36 so that there is freedom of movement from the mouth of the host pipe to above ground. Boom 34 in association with winch 36 cam introduce and withdraw equipment used in the rehabilitation process in and out of the second access area.
FIG. 1 is a schematic drawing showing the cleaning process. Cleaning bucket 26 is shown in more detail in FIGS. 7, 8 and 9. Referring to FIG. 7 cleaning bucket 26 is generally semi-circular with a diameter size to be received into the host pipe. The cleaning bucket 26 has a leading edge 70 with a flap door 74 hinged to the top end of one end of the bucket on a rotating hinge rod 72 that allows the flap door to swing inside the bucket from a closed to open position. A built up door stop 80 in the form of a semicircular edge extending from leading edge 70 provides a means for closing flap door 74. Any other closure means can be used. The hinge rod 72 is secured in bushings 71 and 73 that allow for swing of the hinge rod. Other retaining means that allow the hinge rod to swing are also suitable. The bucket is open at end 76 opposite to the flap door 74. Yokes 28 and 42 as shown in FIG. 1 are also shown in FIG. 7 as attachment means to engage the cables. Yoke rod 75 across the top of the bucket is provided at open end 76. FIG. 8 is an end view of the cleaning bucket 26 with the flap door 74 in the closed position. In FIG. 8 yoke pins 81 and 82 are shown which are provided on hinge 72 to hold yoke rings 84 and 86 (shown on FIG. 7) in place. Similar yoke rings and pins may be provided on yoke rode 75. Any means for holding yoke rings in place can be utilized. FIG. 9 shows the flap door 74 movement on hinge rod 72.
In FIG. 1 the cleaning bucket is being drug through the host pipe and the yokes 28 and 42 are pulled outwardly from either end of the cleaning bucket. In the cleaning process the cleaning bucket 26 is lowered into the second access area by boom 34 and winch 38. The cable 18 is attached to yoke 28 and cable 40 is attached to yoke 42. Winch 20 spools cable 18. Cleaning bucket 26 travels through the debris in host pipe 10 with the leading edge 70 being dragged first and flap door 74 pivots to the inside of the cleaning bucket. FIG. 9 shows the swing of flap door 74 that occurs during the spooling of cable 18. The drag on the cleaning bucket is reversed by spooling cable 40 on winch 36. Flap door 74 closes as it collects debris and the cleaning bucket is withdrawn to the surface. As the cleaning bucket is drawn to the surface, cable 18 is slackened to allow for withdrawal of the cleaning bucket without need to detach cable 18.
In FIG. 1 there is a schematic depiction of discharging debris the cleaning bucket into collection bin 44 at the surface near the access area. FIGS. 10a, 10b, and 10c are details of the discharge operation of the cleaning bucket. In the current embodiment fixed cable 102 is attached to the winch housing 38. Cable 102 is a fixed chain that is not attached to the winch or any other spooling mechanism. The chain is attached to yoke 28 by personnel on the site. Cable 40 is spooled to hold the cleaning bucket 26 in a relatively horizontal position so that the debris does not spill out the open end. The boom operator positions boom 34 with the winch and the cleaning bucket over collection bin 44 and spools out cable 40 allowing the bucket to tip and discharge the debris as shown in the details of FIGS. 10b and 10c. The fixed cable 102 holds the end of the cleaning bucket with the flap door in a relatively stationary position. When the leading edge 70 of the bucket is reversed for instance when the cleaning operation is in the opposite direction, the fixed chain 102 can be positioned on the other side of the winch housing.
After the discharge from the cleaning bucket it is reintroduced in the access area by boom 34 and into the mouth of the host pipe. The cable 18 is spooled up and the process is repeated until the debris is cleared from the host pipe.
FIG. 17 is a detailed perspective view of the housing 38 surrounding winch 36. The fixed cable 102 used to hold the cleaning bucket during discharge is also shown. Lines 120a and 120b supply hydraulic fluid to the winch are also shown. The winch housing surrounding the cable has an open bottom to allow for free movement of cable 40. In the preferred embodiment the winch housing is built of strong metal such as heavy steel that can bear the weight of an excavator. The bottom of the winch housing is relatively flat. The winch housing is constructed with attachment plates 121 and 123. The attachment plates are provided with attachment points which are shown as attachment pins at reference numerals 122 and 124 for plate 123 to the stick 35 of boom. The winch housing attachment pins are spaced to correspond to custom tool attachments designed for conventional excavators so that in the preferred embodiment the winch can be used on an excavator just as other custom attachments are used. FIG. 18 is a side view of winch housing 38 and the attachment to the stick portion 35 of the boom where the other custom attachments or tools are typically attached.
FIG. 21 is a detail of an embodiment with the down hole boom 14 shown attached to winch housing 21. The winch housing is constructed in the same fashion so that it attaches to end of a boom of an excavator where a bucket or other tool is generally attached. The down hole boom is configured with back to back C shaped beams spaced apart with guide rollers positioned in between the C-beams. FIG. 21 shows a down hole boom with guide roller 16 and auxiliary guide roller 13. Both guide rollers are adjustable by using pins inserted into openings along the down hole boom. In the case of guide roller 16, pin 17 is inserted through openings in C-beams and held in place by a pin retainer such as a clip, bolt and washer or other means known to those in the art. The down hole boom has numerous pins that are positioned in slots along the length of the down hole boom so that the guide rollers can be positioned as needed. As shown in FIG. 21, guide roller 16 has been positioned so that the cable is positioned to be received in the host pipe (not shown). To facilitate smooth driving of the cable additional guide rollers such as auxiliary guide roller 13 can be included along the length of the down hole boom 14. As shown in FIG. 21 the cable can be fed on either side of guide roller 16 depending on which direction cable is driven into the host pipe.
FIG. 2 is a schematic of the system figured for testing the host pipe with test mandrel 46 to determine if there is any additional debris or obstruction in the host pipe prior to lining. The same equipment is used including the down hole boom 14 with associated guide roller 16 and winch 20 which spools out and pulls cable 18. The second host vehicle 32 and associated boom 34 with winch 36 surrounded by housing 38 and cable 40 are used in the testing process. Winch 20 is shown in housing 21 and mounted to the boom of host vehicle 22. The host vehicle has travelled to the other side of the access shaft. The down hole boom 14 is shown braced against the bottom of the host pipe.
Test mandrel 46 is lowered into the access area by the boom on host vehicle 32. The test mandrel is a cylindrical member sized approximately the same diameter as the pipe liner. The test mandrel should be of sufficient length to test joint deflection in the host pipe to avoid damage to the new liner. Cables 40 and 18 are attached to the test mandrel 46 so that upon spooling the appropriate cable the mandrel may travel through the host pipe if it is clean and free of obstruction. As shown in FIG. 2, winch 20 will spool cable 18 so that the test mandrel travels to the end of the host pipe 10 at the shaft or manhole 12. Then winch 36 will spool cable 40 and pull the test mandrel back to the access area. Winch 36 is positioned so that the cable 40 can be driven into the central part of the mouth of the host pipe as shown in FIG. 2.
Detailed drawings of the test mandrel of the system are shown in FIGS. 15 and 16. Test mandrel 46 is a generally cylindrical member and has circular bevelled edges 48 and 50. FIG. 16 is a cross-section of test mandrel 46. FIG. 15 shows the internal component of the test mandrel, including ribs 52a, 52b and 52c. The ribs provide reinforcement for the test mandrel. Also, beveled edges 48 and 50 provide a final sweeping of the cleaned host pipe and assist in loosening residual deposits such as mineral deposits and other deposited debris. The ribs 52a, 52b and 52c act as weirs to collect the residual deposits inside the test mandrel in addition to providing structural support. The test mandrel of this invention also has internal yokes 54a and 54b. Yoke 54a is attached to rib 52a at slots 49 and 51. Yoke 54b is similarly situated on the other end of the test mandrel. The yokes can be made of any type of material and is shown as two cables attached to the rib with a central joinder for the cable attachment, however any other type of yoke attachment to the test mandrel could be used. The test mandrel has lifting means one of which is illustrated in FIGS. 15 and 16 as lift pin 47 which is fixed inside the test mandrel under a slot. The lift pin 47 provides an attachment means for a cable to lift the test mandrel. Other lift pins may be provided as shown in FIG. 15.
FIG. 3 illustrates the lining process using the system of the present invention. The same equipment as shown in FIGS. 1 and 2 is used to place the liner pipe in position, and in addition a pulling mandrel 56 is employed. As shown in FIG. 3, cable 18 is positioned in the central area of host pipe 10 by guide roller 16 is threaded through the host pipe to the second access area. Pipe liner sections 58, 59, 60 and 61 are shown in FIG. 3 during a lining process. The process in initiated by passing cable 18 through a first section of pipe liner (as shown in FIG. 3 pipe liner section 61) and secured to pulling mandrel 56. This process occurs in the excavated access area 30. Winch 20 pulls cable 18 approximately the length of the section of pipe liner so that the pipe liner is drawn into host pipe 10. As shown in FIG. 3 section 61 was the first section of pipe liner drawn into the host pipe. Pulling mandrel 56 is unfastened from the cable and a second section of pipe liner (pipe liner section 60 as shown in FIG. 3) is lowered into the second access area by the boom on host vehicle 32 and winch 36. The second section of pipe liner 60 is abutted to the first section of pipe liner 61 and cable 18 is pulled therethrough and secured to test mandrel 56. Winch 20 spools cable 18 pulling the first and second lengths of pipe liner so that section 60 is pulled into the host pipe and section 61 travels further into the host pipe. The process is repeated until the section of host pipe is lined.
As shown in FIG. 3 the lining process can be carried on simultaneously while another section of liner pipe 58 is positioned into the access area. Also in FIG. 3 the host vehicle 32 is shown with an operator using a remote control to manipulate the winch and boom while the lowering the pipe liner into the access area 30.
The system of this invention uses a pulling mandrel shown in more detail in FIG. 11. The pulling mandrel 56 has a circular member 62 with the flange 65 which is sized to be received in the host pipe and flange 65 contacts the circumference of the pipe liner. A plurality of spokes converge to a central hub 66. The spokes are designated with reference numerals 64a through 64h. Hub 66 has a circular opening which is sized to accompany a cable passing therethrough. The pulling mandrel allows for flow through the spokes. Also, the pulling mandrel distributes the pulling load evenly on the pipe liner. In FIG. 11 a hook 67 is shown which is used for attachment to a cable for lowering the test mandrel into the access areas when necessary. FIG. 12 shows the pulling mandrel 56 contacting a section of pipe liner 63 and illustrates the detail of the cable 61 passing through hub 66. The end of the cable 61 is secured with attachment 68 known as a teacup. Any attachment that securely fastens the cable to the hub of the pulling mandrel may be used. FIGS. 13 and 14 are exploded views showing the teacup 68, pulling mandrel 56 and section of pipe liner 63 and cable 61.
FIG. 4 is an alternative method for slip lining a host pipe that can also be performed while a sewer is in service. The alternate method can be used for remote or difficult to access areas. The alternate method uses some of the same components illustrated in the system previously described. The host pipe 200 to be cleaned is selected and access areas that will be used for the rehabilitation process are also selected. As shown in FIG. 4 two access areas at either end of the host pipe 200 are access shafts 202 and 204 which can be existing manholes. The manholes can be located in confined areas such as residential property. Down hole booms 206 and 208 are positioned vertically in the access shafts 202 and 204 respectively. Each of the down hole booms shown in FIG. 4 has at least one guide roller positioned on the end of the boom that extends above the access shaft. In the preferred embodiment, guide rollers are adjustable along the length of the down hole boom so that guide rollers can be moved on the down hole boom to position a cable in the access shaft and into the host pipe. In FIG. 4 guide rollers 210 and 212 are shown positioned on down hole booms 206 and 208 respectively.
FIG. 4 shows different types of winch placements. In access shaft 202 the winch 214 is mounted on down hole boom 206 and also mounted to a mobile vehicle 216. Cable 218 extends from winch 214 along down hole boom 206 into host pipe 200. Cable 218 passes around guide roller 210 so that it is aligned to enter the host pipe. In FIG. 4 the winch 214 is mounted on the mobile vehicle and winch 214 can serve as a positioning means to guide the cable 218 along the down hole boom 206. Another guide roller 211 which is optional is also shown on down hole boom 206.
Also shown in FIG. 4 is skid mounted winch 220. A platform or skid 222 is set up at the access shaft 204 and the winch is secured and mounted to the platform 222. When using a skid mounted winch it is preferred that the down hole boom have guide roller 224 on down hole boom 208 to guide cable 226 from winch 220 on down hole boom 208. As shown in FIG. 4, cable 226 passes around guide roller 212 to align cable 226 to enter the host pipe 200.
An excavation 228 provides an intermediate access area 228 to the host pipe 200. As shown in FIG. 4, a portion of the host pipe 200 is removed to approximately the spring line 230. Hoist 232, which may be a conventional crane, is positioned adjacent to the intermediate access area 228. The hoist has at least one cable that can be lowered into the access area. In the preferred embodiment the hoist has two cables 234 and 236 that are operated in conjunction with crane 238.
In the cleaning operation shown in FIG. 4, a cleaning bucket 240 is used essentially in the same manner as described and illustrated previously in FIGS. 1, 7, 8, 9, 10a, 10b and 10c. Cables 218 and 230 are attached to yokes 242 and 244. The cables are spooled and released by the respective winches 214 and 220 so that the bucket collects debris from both sections of the pipe extending from the intermediate access area to access shafts 202 and 204. In the alternate method, cleaning bucket 240 with trapped debris is pulled to the intermediate access area 228. Hoist cables 234 and 236 are attached to yokes 242 and 244 on the cleaning bucket. The hoist raises the cleaning bucket withdrawing it from the host pipe to the surface at the intermediate access area and further raises and tips the cleaning bucket by manipulating cables 234 and 236 to discharge the accumulated debris into collection bin 246. It is not necessary to unfasten cables 218 and 226 because the cable winches can be released out to provide enough slack. The cleaning bucket 240 is lowered into the intermediate access area 228 by hoist 232. The cleaning bucket is then drug through the debris filled host pipe in the same manner of operation as previously described to complete the cleaning of one section of the host pipe between the intermediate access area and one of the access shafts. To clean both sections of the pipe extending from the intermediate access area, it is necessary to reverse the leading edge of cleaning bucket 240 to provide for debris entrapment as previously discussed.
FIG. 5 illustrates an alterative method for testing a host pipe. The access area arrangement is similar to that in FIG. 4 which accesses host pipe 200. A skid mounted winch 250 is placed adjacent to access shaft 252 with down hole boom 254. The down hole boom skid mounted winch arrangement is previously discussed in describing FIG. 4. Access shaft 256 is serviced by winch 258 that is mounted on the bed of truck 260. Down hole boom 262 has guide rollers 264 and 266. The cable 268 from winch 258 goes around the top of guide roller 264 which is placed near the top of down hole boom 262. Guide roller 264 serves as a guide for the cable 268 to travel along down hole boom 254 into access shaft 256. Then cable 268 goes around guide roller 266 into host pipe 200. In the preferred method, guide rollers 264 and 266 are adjustably mounted along the length of the down hole boom so that they may be positioned as needed to guide the cable smoothly from the winch and into the host pipe. Similar guide rollers 270 and 272 are shown on the down hole boom associated with the skid mounted winch.
FIG. 5 shows the test mandrel 274 in host pipe 200 during the testing process. The test mandrel 274 is lowered into the intermediate access area 276 by hoist 232. The test mandrel 274 has been described in these discussions of the invention. Cable 278 from the skid mounted winch is attached to test mandrel 274 at the point of attachment on one end of the test mandrel while the test mandrel 274 is in the intermediate access area. Cable 278 is attached to the opposite end of test mandrel 274 while the test mandrel is in the intermediate access area. The test mandrel 274 is sized to fit inside the host pipe and pulled through the host pipe to be tested for obstructions. In addition, the test mandrel used can be described previously in FIGS. 15 and 16 also provides an additional final sweep to collect mineralized deposits or residual debris. The test mandrel 74 is pulled through the test pipe by alternatively spooling the skid mounted winch 250 and the truck mounted winch 258 through the host pipe 200. The test procedure is completed. The test mandrel is removed from host pipe 200 using hoist 232.
FIG. 6 illustrates the slip lining process of the alternative method. In FIG. 6 the host pipe 200 is accessed at intermediate access area 276. The skid mounted winch 250 is placed in the same position as shown in FIG. 5. Down hole boom 254 is placed in access area 252. Skid mounted winch 255 drives cable 278 into the host pipe using down hole boom 254 and guide rollers 270 and 272 assisting in positioning cable 278. In access area 256 the winch mounted on the truck bed has been replaced by a winch 280 mounted to a down hole boom 282 and also mounted to the stick of boom 284 of excavator 286.
As can be seen from FIGS. 4, 5 and 6, the down hole boom mounts into the access shafts can utilize any type of mounting vehicle or skid placement which will secure a down hole boom vertically in an access shaft. Winch 280 serves as a guide for cable 288 along the down hole boom. Although guide roller 290 is shown, it is optional as previously described. Guide roller 292 at the bottom of down hole boom 282 aligns the cable into host pipe 200. As previously discussed, the guide rollers are adjustable to provide proper alignment of the cable down the access shaft and into the host pipe.
FIGS. 19 and 20 are details of the down hole booms used with alternate method and system shown in FIG. 4, 5 and 6. In FIG. 19 down hole boom 350 is shown with hook 352 fixed to top plate 364 with attachment pins 386a, 386b, 386c and 386d. The top plate 364 is attached to corner pieces 383 and 384 through which pins 386a, 386b, 386c and 386d extend to C-beams 388 and 390. The C-beams are positioned facing each other with spacing to accommodate guide rollers in between, as shown in FIG. 19 which is provided for ease in transport and set up. Adjustable guide roller 354 is disposed in between C-beams 388 and 390. At the end of the C-beams is bottom plate as shown on C-beam 388 extending from the corners of the C-beam. Joinder pins 396 and 398 extend through openings in the bottom plate 388 through top plate 390 of C-beam 400 which abuts C-beam 366. C-beam 402 faces C-beam 400. Adjustable guide roller 356 is disposed between C-beams 400 and 402. C-beam 400 has end plate 394 provided for joinder to additional C-beams. C-beam 402 has top plate 392 and a bottom plate (not shown) for joinder to adjacent C-beams as described above. A series of straps 370, 372, 374, 376, 378 and 380 are welded to the outside corners of the C-beams and provide spacing for the C-beams of the guide rollers. The guide rollers are adjustable as previously discussed to align the cable 358 from a mounted winch such as a skid or truck mounted winch the down hole boom into the host pipe (not shown). The guide rollers are adjustable by removing pins 360 and 362 and repositioning the guide rollers with other pins of the down hole boom as discussed above for FIG. 21.
FIG. 20 is the same embodiment as FIG. 19 except cable 358 is placed on guide rollers 354 and 356 to illustrate how the guide rollers can be used to re-orient the direction of the cable if necessary. The cable 358 can be fed to the same or opposite direction from the winch feed depending on the side of guide roller 356 the cable is wrapped.
Hoist 232 is positioned at intermediate access area 276. During the lining process hoist 232 lowers sections of pipe liner into the intermediate access area. Cables 278 and 288 pass through the host pipe to the intermediate access area. The cable is then passed through a section of pipe liner that has been lowered into the intermediate access area and the cable is further threaded through a pulling mandrel and secured. This general process has been described previously for the system of this invention.
FIG. 6 illustrates the simultaneous lining process for the sections of host pipe extending from the intermediate access area 276. If desired the lining operation could be performed on one section of the host extending from the intermediate area to an access shaft and then the other section. In FIG. 6 pipe liner sections 294, 296, 297 and 298 have been inserted into the host pipe 200.
For example, pipe liner 296 was lowered into the access area 276 and placed adjacent to section 294 which had been inserted into host pipe 200. The cable 288 was passed through both pipe liner sections 294 and 296 and secured to pulling mandrel 302. Winch 280 was spooled to pull pipe liners 294 and 296 into host pipe 200. The same operation was performed with pulling mandrel 302 and pipe liner 294.
When each section of pipe liner has been pulled into the host pipe approximately the length of the liner section another section of pipe liner is introduced into access area 272. The pulling mandrel is removed from the cable and the new section of liner pipe is placed into the mouth of the host pipe, the cable is drawn through the additional section of liner pipe and secured to the test mandrel. In the direction of access shaft 252 pulling mandrel 304 secured to cable 278 pulls pipe liner section 298 and 297 into host pipe 200. The operation of the pulling mandrel has been previously discussed and the pulling mandrel is shown in FIGS. 11, 12, 13 and 14.
The description provided herein is not intended to cover all the embodiments and methods of the claimed invention. Other variations will be understandable to those skilled in the art.
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A rehabilitation system has been developed for cleaning, testing and slip lining pipe particularly sewer lines while in service. The system includes the use of equipment adapted for use on mobile vehicles to increase efficiency and mobility of the system. The cleaning system utilizes a specialized cleaning bucket that can be pulled from excavations and existing manholes. The testing and lining systems also utilize specialized test mandrels and pulling mandrels for the pipe liner that can be used with equipment operating, in part, from existing manholes.
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CROSS-REFERENCES TO RELATED APPLICATIONS.
[0001] This application claims the benefit of the following U.S. Provisional Application No. 60/563,232, filed Apr. 19, 2004, No. 60/563,198, filed Apr. 19, 2004, and No. 60/622,060, filed Oct. 26, 2004.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates generally to the monitoring and management of individual petroleum wells, to the management of multiple wells in a petroleum reservoir.
[0004] 2. Description of Related Art
[0005] The oil and gas industry has attempted to achieve the highest value from a reservoir containing oil and gas by extracting as much as possible as quickly as possible from the wells. There have been many improvements over the last several years in extracting data from existing wells, and from seismic activities, in order to increase the percentage of hydrocarbons recovered from any particular reservoir:
1. Sensors are located temporarily or permanently in wells to indicate amounts from each production location and the condition of the reservoir through examination of pressure and temperatures. 2. Seismic data is now taken at frequent time intervals and combined with geologic and geophysical information to predict the flow of hydrocarbons though the reservoir towards the wells. 3. Large scale models have been built to simulate production under different assumptions. 4. Visualization systems have been developed to show operators in a three dimensional manner the interaction of all the information extracted from the sensors and demonstrate how the hydrocarbons are being produced.
[0010] In spite of these improvements, three core problems remain. First, production is managed with episodic interventions in each individual well's activity. Second, the amounts and types of data generated by sensing systems in wells cause a data overload problem for operators. Too much data is produced at rates which are too high for operators to assess and respond to abnormal conditions. The cost of moving this data throughout an organization, and managing its use, is high.
[0011] Third, even if operators were able to manage these large data streams, no methods exist for exploiting information about each individual well's production, so that production from the entire reservoir can be adjusted continuously. Such a method would enable increased production from the reservoir as a whole. This has been a difficult problem, one characterized by large amounts of data that describe complex environmental interactions. In addition, managing multiple wells in a reservoir demands that decisions be made within a timeframe that allows corrective action to be effective for increased hydrocarbon production.
[0012] What is needed is a method of managing multiple wells in a reservoir, including wells that have very little instrumentation (dumb wells); instrumented wells with surface controls (intelligent and smart wells); and reservoirs that are highly instrumented with fiber optic sensors, seismic sensors, flow meters, and other instruments and controls. In addition, such method should reduce the data overload on operators so they can be more efficient when human intervention is necessary, and the method would provide continuous adjustment of well conditions to achieve optimal production at all times.
SUMMARY
[0013] A method of managing multiple wells connected to a reservoir comprises the steps of:
setting production and performance goals for each individual well; monitoring the performance of each individual well; enabling each individual well to assess its own situational state; and enabling socially interactive corrective actions, comprising enabling collaboration and cooperation among the wells, such that the wells share with each other their situational states, goals, and plan data; developing and refining remediation strategies for problems detected within the wells; allowing execution of the remediation strategies either independently, or by operator intervention; applying the remediation strategies to each individual well; revising and resetting the goals, and integrating pattern recognition and machine learning within all preceding steps.
[0018] These elements are re-usable, and enable replication of the method across most of the activities necessary for the production of hydrocarbons such as drilling; completions; logistics; management of economics, production, earth models; transportation, and refining.
[0019] The method of the present invention can be extended to all components in a hydrocarbon gathering system, including pumps, compressors, pipelines, and transactions related to hydrocarbon sales.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 is a reservoir management processing flow diagram, depicting the top-level processing performed for managing multiple wells in a reservoir.
[0021] FIG. 2 is a processing flow diagram for processes performed during the situation
[0022] FIG. 3 is a fundamental control and command loop, depicting the basic control loop required for situation assessment, planning, and acting.
[0023] FIG. 4 is a processing flow diagram for monitoring and managing a single well.
[0024] FIG. 5 is a concept graph providing a more detailed example of hydrate detection.
[0025] FIG. 6 is a plan-goal graph fragment used for managing hydrate conditions.
[0026] FIG. 7 is a processing flow diagram for functions performed to enhance a system's performance via machine learning.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0027] Referring to FIG. 1 , in step 30 an operator establishes reservoir performance goals. Typically the operator is a human, though this function may be performed by a software agent. In step 32 a coordinator agent, a software program operating to assesses the reservoir performance state, determines the extent to which reservoir performance goals are being achieved. The coordinator agent may receive as input from a human or other software operator, the goals for reservoir performance. Based on this assessment of reservoir state, in step 34 the coordinator agent allocates goals to well(s) in the reservoir. Step 34 does not require a strict centralized command and control paradigm. Distributed command and control strategies such as swarm intelligence or auctioning are appropriate.
[0028] The primary consideration for multi-well management is implementation of an appropriate control strategy for wells distributed across a reservoir. This is a function performed at step 34 . The processing steps 36 through 48 represent activities that occur within a single well. Those processing steps 36 through 48 , executing on a single well, are an intelligent agent 50 . An intelligent agent is a software program that is connected by suitable communication links (such as wires or wireless means) to hardware sensors and actuators. An intelligent agent may perform monitoring tasks to determine when normal versus abnormal conditions exist. Intelligent agents may be connected to fiber optic data gathering systems to perform tasks such as assessment of flow characteristics at multiple intervals in a well. Intelligent agents may incorporate models of an environment (e.g., a well or reservoir) by storing values which describe features of the environment. Intelligent agents may learn and adapt their behavior with experience.
[0029] Intelligent agents can perform many of the functions normally performed by operators, including running models or simulations, or determining best courses of actions. Based on their perception of conditions, intelligent agents may either make recommendations to operators to correct problems detected in the situation or, if authorized by an operator, act autonomously to correct problems.
[0030] In addition to being deployed on wells, intelligent agents are also implemented to execute on other components of the gathering and production system. Representative components of the gathering and production system include pipelines, pumps, compressors, and components monitoring nominations and current market prices. Thus, the method of the present invention uses intelligent agents as well agents, riser agents, pipeline gathering system agents, compressor agents, market nomination agents, and pricing/cost agents. Also, all of these intelligent agents execute on multiple wells, and their associated gathering and production systems, concurrently.
[0031] In step 36 the human operator or a software agent determines the well state with respect to the well's performance goals by comparing current sensor readings to the desired conditions, also expressed as sensor values. In step 38 , to facilitate collaborative achievement of reservoir performance goals, the well shares its situation state with peer wells and with the coordinator agent. Connector A represents situation state data flow from the intelligent agent 50 to the operator in step 32 . Connector B represents situation state data flow from the intelligent agent 50 to a peer intelligent agent.
[0032] In step 40 the operator develops a new plan or adapts an existing plan to satisfy the well's goals. Prior art in the domain of decompositional planning, as implemented in the PreAct toolkit, manufactured by Applied Systems Intelligence, Inc., located in Roswell, Ga., provides this capability. This technology involves decomposition of high-level goals into specific plans and strategies for achieving goals. An approach which uses an “and/or” structure known as a plan-goal graph is discussed below.
[0033] Referring to steps 40 - 48 , given variance in well designs, well location, communications infrastructure, and reservoir characteristics, the method of the present invention for managing multiple wells supports both centralized control (one intelligent agent in charge) and distributed control approaches (control shared among multiple intelligent agents).
[0034] Centralized control architectures use a centralized supervisor to coordinate all of the tasking for the other wells. In this architecture, sensor inputs are fed to the coordinator agent and the other wells accept commands for action assignments. Software within this coordinator agent performs the control function and ensures that activities across multiple wells are coordinated. The coordinator's perspective serves as the most logical place to interface with a human operator. As appropriate, in step 46 human operators delegate authority to the coordinator agent to act autonomously on behalf of the human operator. If the operator has authorized the system to act on the operator's behalf, then in step 46 the plan is executed by the system. Otherwise, the intelligent agent 50 recommends the plan to the operator in step 44 . To facilitate collaborative achievement of reservoir performance goals, the intelligent agent 50 shares its plan state with the coordinator agent in step 48 .
[0035] Referring again to steps 40 - 48 , distributed control systems seek to distribute the task allocation across all of the intelligent agents, thus avoiding any centralized point of control. A number of alternative strategies exist for distributed control, including deployment of redundant facilitators and strategies such as swarm behavior. A software technique called auctioning is a preferred approach for establishing distributed control.
[0036] In an auction, particular well agents called auctioneers communicate conditions to be fulfilled, and receive and evaluate bids from other agents called bidders that can fulfill the conditions by performing certain actions. The auctioneer selects a bidder based on a value calculation in which the resources needed by an agent and the value promised by the bidder are compared among bidders. Bidders receive announcements, prepare and transmit bids, and confirm acceptance of awards. Some agents can act as both auctioneers and bidders, even simultaneously, while participating in separate auctions. The price of an action rises as an agent becomes burdened, and the cost falls as the agent frees up resources.
[0037] Referring now to FIG. 2 , in step 51 data are collected by the agent, in step 52 the method of the present invention provides software mechanisms for detecting, combining, organizing, and conditioning data to be readied for an assessment step. In step 53 the method of the present invention provides a software means of assessing and monitoring a situation. In step 54 the method of the present invention performs tasks such as diagnosis, problem solving, and plan generation. In step 55 the method of the present invention provides software mechanisms for invoking procedures relevant to decisions, such as execution of a plan generated by the planning component according to methods explained below. After step 55 , the method continues back to step 51 .
[0038] Now referring to FIG. 3 : Continuous we see that step 57 the situation assessment component in the loop provides mechanisms for detecting, combining, organizing, assessing and monitoring a situation. Step 58 , the planning component in the control loop can perform tasks such as diagnosis, problem solving, and plan generation. Step 59 , the action component provides mechanisms for invoking procedures relevant to decisions, such as execution of a plan generated by the Planning component according to methods explained hereafter.
[0039] Associate systems provide the functionality shown in FIG. 3 . Associate systems are software programs that enable continuous situation assessment and planning. The development toolkit known as PreAct, (previously listed with respect to step 40 in FIG. 1 ) provides a knowledge-based approach for implementation of continuous situation assessment and planning.
[0040] Again referring to FIG. 2 , the method of the present invention uses two core knowledge structures: concept graphs (which are used for situation assessment) and plan-goal graphs (which are used for planning). Referring now to FIG. 4 , in contrast to FIG. 1 , which concerns an entire reservoir with multiple wells, FIG. 4 depicts the steps in managing an individual well or a set of individual wells. In contrast with FIG. 1 ,
The management of multiple wells in a reservoir, as described in FIG. 1 , improves performance of the reservoir itself. The monitoring and management of an individual well or a set of individual wells, as described in FIG. 4 , enables monitoring and performance improvements on individual wells without regard for how these individual improvements impact the reservoir as a whole.
[0043] Therefore, FIG. 4 describes a part of the invention that is a method that is used as an automated surveillance and monitoring system that tracks multiple performance parameters of a single well, and alerts an operator when abnormal behavior patterns are identified. Thus, this part of the method functions to alert operators of anomalous sand production, or the development of hydrates.
[0044] In step 62 the operator establishes well monitoring and performance goals. For example, the operator may specify that a well is to be monitored for flow assurance problems such as hydrate formation.
[0045] In step 64 , the method of the present invention the human operator or an intelligent agent assesses the well situation by comparing current conditions to patterns of normal or abnormal behavior stored in an associative memory. This method of automated surveillance monitoring is superior to methods which rely on setting thresholds, because abnormal conditions of interest are often indicated by the interactions between values in multiple time-series data streams.
[0046] Associative memories are pattern recognition components, and are disclosed in U.S. Pat. Nos. 6,052,679 and 6,581,049, and in U.S. patent application 20030033265, all of which are incorporated herein by this reference. An implementation of associative memories, named SaffronOne version 3.1, is sold by Saffron Technologies, Inc., located in Morrisville, N.C. Saffron's associative memory can process data from both structured sources (e.g., databases, XML data streams) and unstructured sources (e.g., free text). Unstructured data such as well tests, logs, and reports are commonly available in the petroleum industry but this data is not presently used in automated systems to manage production. Associative memories provide a means to remedy this deficiency.
[0047] Based on the assessment performed in step 64 , the method of the present invention then develops a plan or plans in step 66 to satisfy monitoring and performance goals. If the well situation has not appreciably changed, changes to the current monitoring and management plan may be minor. There may also be hysteresis in the reaction to small changes so that the system does not constantly exhibit “seeking” behavior. If in step 68 the method of the present invention is authorized to act on behalf of the user, then in step 72 the method of the present invention executes the plan on the operator's behalf. If not authorized, then in step 70 the method of the present invention recommends the plan to the operator.
[0048] The process described in FIG. 4 provides a means for continuously adapting the operating parameters of each well and groups of wells, instead of relying on periodic optimization. In addition, the process supports the application of individual well management programs for tasks such as gas lift and beam pump control to multiple wells.
[0049] Referring now to FIG. 2 , this flow diagram provides additional detail for step 36 of FIG. 1 . This processing flow applies whether an operator is monitoring wells individually or monitoring multiple wells to improve performance of the reservoir as a whole.
[0050] In step, 51 situation assessment for a well begins with data collection The data are typically values of parameters such as pressure, temperature, flow rates valve positions, and so on. These are time-series data values, meaning that the data are provided periodically to the system.
[0051] In step 52 the method of the present invention conditions the data, generating values of derived attributes which describe the nature of the time-series data provided to the agent. Representative values include noise-filtered baseline values, rates of change, step change indications, spike detections, and so on. Data conditioning includes use of Fourier transforms and other signal processing mathematical means to identify the values of attributes of the data.
[0052] In step 53 the method of the present invention assesses a situation, applying algorithms to combine data from various sources to determine the nature of the situation. One of the assessments in step 53 is determining that a rising value for downhole pressure in conjunction with a falling value for tubing head pressure indicates flow impairment. Data sources include real-time data streams, data bases, models, and other processes. Concept graphs, such as the one shown in FIG. 5 are the preferred method for performing the assess situation step 53 . As data works its way up through the concept graph the state of the well or wells is identified.
[0053] The situation assessment step 53 employs a concept graph integrated with associative memory components trained to perform specific functions such as detection of a downhole pressure that is not correlated with a well choke valve change. Since associative memories can combine data from multiple sources, a single associative memory can do the work of many concept graph nodes, resulting in more efficient processing. The concept graph effectively functions as a framework for organizing multiple associative memories so that their pattern recognition capabilities can be coordinated. In this way the situation assessment step 53 overcomes the problem of data overload by processing raw data to deliver actionable information to a human or automated operator.
[0054] Referring now to FIG. 5 the method of the present invention uses a sand or hydrate concept graph to recognize sand “and/or” hydrate events. Data enters the graph at the bottom (leaf nodes, i.e., bottom nodes of the graph) and propagates upward through the graph. Referring again to FIG. 5 , in this concept graph for hydrate recognition, each node in the graph identifies representative variables (though not all variables) whose values are used or calculated during processing at that particular node. Time-series data from sensor systems (pressure, temperature, etc.) and from data bases are conditioned using a variety of signal processing algorithms to remove noise, detect trends, and so on. This data flows into leaf nodes in the concept graph. Step 73 represents a Saffron memory trained to detect conditions indicative of a hydrate at a particular point in time. Step 73 produces values such as a current Hydrate Detector State and a current Likelihood value.
[0055] In step 74 the method of the present invention integrates results from an external model during assessment. Data such as hydrocarbon composition, pressure, temperature, and water cut are passed to the agent from sensors. The agent then passes the conditioned values to an external hydrate formation model that can determine whether conditions exist that enable hydrate formation. The method of the present invention then uses a variety of models to address flow control, reservoir characteristics, and other common issues. These models can be invoked by the agent, or data from the model can be incorporated directly in the intelligent agents. In step 74 , the method of the present invention produces a value for current Hydrate Prediction. In step 75 the method of the present invention captures data about the void fraction in the hydrocarbon stream.
[0056] In step 76 the method of the present invention combines data from steps 73 , 74 , and 75 . In addition, in step 76 the method takes a time-averaged view of well conditions, thereby providing an additional means for handling noise in the time-series data streams. Step 76 produces a well state value (e.g., nominal, hydrate indications, or hydrate formation in progress) for the variable “current Hydrate Event State.” In step 77 the method receives data from step 76 and fires a software trigger to notify the planning component (i.e.; step 40 of FIG. 1 or step 66 of FIG. 4 ) when a hydrate event occurs.
[0057] Returning to FIG. 2 , in step 54 , the well's state is shared with the coordinator agent and with peer wells. A preferred method of sharing situation state is by selectively passing concept graph node state data to the coordinator agent and peers.
[0058] The method of the present invention performs a test in step 55 to determine if the current situation is consistent with the desired goals. If not, the planning agent (i.e.; step 40 of FIG. 1 or step 66 of FIG. 4 that is the planning component of the well agent) is notified in step 56 so that a plan can be developed or adapted to address the situation. Thus, the processing functions described in FIG. 2 , steps 51 , 52 , 53 , 54 , and 55 are sufficient to enable implementation of methods for automated monitoring and surveillance of sets of individual wells. The method of the present invention includes an automated monitoring and surveillance method, which performs situation assessment of multiple wells, and notifies the operator (human or software agent) when conditions on any individual well deviate from nominal.
[0059] Referring now to FIG. 6 , the method of the present invention uses a plan-goal graph for managing sand and hydrate events. A plan-goal graph is an “and/or” graph which is decomposed (top-to-bottom) during plan development. In FIG. 6 , ovals represent goals and rectangles represent plans. Goals are processing components that establish a desired state and evaluate the extent to which the state has been achieved. Plans are processing components that specify strategies for accomplishing goals. In steps 78 , 79 , and 80 of FIG. 6 high-level plans and goals enable planning for multiple wells concurrently. Step 81 is a goal which is instantiated for each well being monitored. Depending upon the well state identified through situation assessment, either the Maintain Nominal Conditions step 82 or the Treat Abnormal Hydrate Conditions step 83 will be created. If an abnormal condition is being managed, the plan will be decomposed to further detail to ensure that the goals Engineering Contacted in step 84 and Hydrates Controlled in step 85 are satisfied. Steps 86 , 87 , and 88 represent detailed plans. Tasks such as Increase Inhibitor in step 87 are performed by the operator or by the automated method if the operator has authorized the method to act.
[0060] Referring now to FIG. 7 , the present invention includes a machine learning capability. Associative memories provide a mechanism for machine learning. As new patterns of interest become available, they can be stored in the memories, thereby providing a mechanism for machine learning from experience. For one or more nodes in the method's concept graph and one or more nodes in the method's plan-goal graph, associative memories replace the knowledge bases that are conventionally employed at these nodes. During execution, instead of invoking a knowledge base, the method queries the associative memory to generate data required for further processing.
[0061] In step 89 , in conjunction with situation assessment and planning, an associative memory situated within either a concept graph or a plan-goal graph is queried. This query generates results that comprise at least part of the result set which is presented to the user in step 90 . The system observes the users' actions in step 91 with respect to the situation assessment or planning data presented. For example, during monitoring for sand conditions, the system may notify the operator that sand is being produced at a rate that exceeds nominal. The operator may accept this assessment, or may modify the system's assessment. If in step 92 the operator concurs with the system, no learning occurs (step 94 ). Otherwise, the associative memory is updated in step 93 , providing a means for modifying the system's behavior in the future.
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A method of managing multiple wells connected to a reservoir comprises the steps of: setting production and performance goals for each individual well; monitoring the performance of each individual well; enabling each individual well to assess its own situational state; and enabling socially interactive corrective actions, comprising enabling collaboration and cooperation among the wells, such that the wells share with each other their situational states, goals, and plan data; developing and refining remediation strategies for problems detected within the wells; allowing execution of the remediation strategies either independently, or by operator intervention; applying the remediation strategies to each individual well; revising and resetting the goals, and integrating pattern recognition and machine learning within all preceding steps.
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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 Invention
[0002] The present invention relates generally to the field of well bore packing tools (otherwise known as packers), and more specifically to packers deployed using coiled tubing and methods of using same in various oil and gas well operations.
[0003] 2. Related Art
[0004] Packers and plugs are run to hydraulically isolate the sections above and below the packer and to provide a mechanical anchor to prevent the packer from sliding inside the wellbore. In coiled tubing completion applications, the packer also holds the coiled tubing string in place. Packers are set mechanically, hydraulically, or on wireline. The mechanical-set packer is set by applying either tension or compression on the packer. The hydraulic-set packer is activated by hydraulic pressure. A packer forms a seal for purposes of controlling production, injection or treatment. The packer is lowered downhole into the well in an unset state. However, once in the appropriate position downhole, the packer is controlled from the surface of the well to set the packer. As an example, for a mechanically-set packer, a tubular string that extends from the surface to the packer may be moved pursuant to a predefined pattern to set the packer. In its set state, the packer anchors itself to the casing wall of the well and forms a seal in the annular region between the packer and the interior surface of the casing wall. This seal subdivides the annular region to form an upper annular region above the packer that is sealed off from a lower annular region below the packer. The packer typically includes at least one seal assembly to form the annulus seal and at least one set of slips to anchor the packer to the casing string. When run into the well, the seal assembly and the slips are radially retracted to allow passage of the packer through the central passageway of the casing string. After a particular job is complete, the slips and seals are again retracted, allowing the packer to be removed or moved to another location in the well.
[0005] Mechanically-set packers currently in use suffer from certain inadequacies. One problem is the inability, after annular fracturing, to cleanup sand and other debris that fall out directly on top of the packer. Fall out may occur when multiple perforation sets are present above the packer. For example, if the proppant fracture from the current zone were to grow vertically and/or poor quality cement is present behind the casing, the fracture could intersect the perforation sets above the packer seal such that proppant could “dump” back into the wellbore on top of the packer and prevent or obstruct further upward movement of the packer. Also, it could be difficult to execute circulation operations if multiple perforation sets are open above the packer. For example, if the circulation pressures exceed the breakdown pressures associated with the perforations open above the packer, the circulation may not be maintained with circulation fluid unintentionally lost to the formation. This may result in a higher probability of sticking the packer in the well.
[0006] Thus, there is a continuing need for packers and methods that address one or more of the problems that are set forth above.
SUMMARY OF THE INVENTION
[0007] In accordance with the present invention, packers and methods of use are described that reduce or overcome problems in previously known packers and methods.
[0008] A first aspect of the invention are packers useable with a subterranean well, comprising:
(a) a packer body, a slip to engage a casing of the well and a sealing element to seal an annulus of the well; (b) the body comprising a fluid bypass chamber adapted to allow fluid passage through the packer body during run in hole and in release position; and (c) a re-settable mandrel slideably engaged with guide pins attached to the packer body and adapted to selectively open and close the fluid bypass chamber upon non-rotational motion of the packer body.
[0012] Apparatus of the invention include those apparatus that are compression set, and may comprise a straight pull release mechanism, as well as a connector for connecting the packer body to coiled tubing or jointed pipe. The inventive apparatus may employ one or more ported subs to allow equalization between the tubing and annulus during run in hole and release.
[0013] Inventive apparatus may further include those wherein the mandrel is adapted to be free-spinning and auto-indexing between settings, as well as apparatus wherein the mandrel has a ‘J’ profile for setting via coiled tubing or jointed pipe without substantial rotation of the coiled tubing or jointed pipe. Apparatus of the invention may include integral circulation ports in the packer body above the sealing element to enable cleaning or at least disturbance of debris that accumulates above the packer sealing element.
[0014] Another aspect of the invention are methods of using the inventive packer, one method of the invention comprising:
(a) running a packer to depth in a well bore on coiled tubing or jointed pipe; (b) equalizing pressure between an annulus and the coiled tubing or the jointed pipe during running the packer to depth; (c) mechanically setting the packer in the well bore without substantial rotation of the coiled tubing or jointed pipe; and (d) disturbing debris above a packer sealing element by indexing the packer without substantial rotation of the coiled tubing or jointed pipe.
[0019] Methods of the invention include those comprising wherein the mechanically setting and indexing the packer employs a mandrel attached to the packer, wherein the mandrel may be a free-spinning mandrel, and wherein the mandrel may be auto-indexing and have a J profile. Other methods of the invention are those including bypassing fluid through the packer to allow direct fluid passage below a packer primary seal during the running of the packer to depth and in release position, and wherein the disturbing of debris comprises circulating a fluid above the packer sealing element using one or more circulation ports integral with a packer body above the sealing element. Certain embodiments of the methods of using the inventive packer may include cleaning or at least disturbing debris behind the packer using one or more circulation subs integral with a packer body and below the sealing element of the packer.
[0020] Apparatus and methods of the invention will become more apparent upon review of the brief description of the drawings, the detailed description of the invention, and the claims that follow.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] The manner in which the objectives of the invention and other desirable characteristics can be obtained is explained in the following description and attached drawings in which:
[0022] FIGS. 1A and 1B are schematic partial cross-sectional views of a top and a bottom portion, respectively, of a packer in accordance with the invention in run in hole mode;
[0023] FIGS. 2A and 2B are schematic partial cross-sectional views of the packer of FIGS. 1A and 1B in set mode;
[0024] FIGS. 3A and 3B are schematic partial cross-sectional views of the packer of FIGS. 1 a and 1 B in the release mode; and
[0025] FIG. 4 is a schematic view of a J mandrel useful in the invention.
[0026] It is to be noted, however, that the appended drawings are not to scale and illustrate only typical embodiments of this invention, and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
DETAILED DESCRIPTION
[0027] In the following description, numerous details are set forth to provide an understanding of the present invention. However, it will be understood by those skilled in the art that the present invention may be practiced without these details and that numerous variations or modifications from the described embodiments may be possible.
[0028] All phrases, derivations, collocations and multiword expressions used herein, in particular in the claims that follow, are expressly not limited to nouns and verbs. It is apparent that meanings are not just expressed by nouns and verbs or single words. Languages use a variety of ways to express content. The existence of inventive concepts and the ways in which these are expressed varies in language-cultures. For example, many lexicalized compounds in Germanic languages are often expressed as adjective-noun combinations, noun-preposition-noun combinations or derivations in Romanic languages. The possibility to include phrases, derivations and collocations in the claims is essential for high-quality patents, making it possible to reduce expressions to their conceptual content, and all possible conceptual combinations of words that are compatible with such content (either within a language or across languages) are intended to be included in the used phrases.
[0029] The invention describes packers and methods of using same. A “wellbore” may be any type of well, including, but not limited to, a producing well, a non-producing well, an experimental well, and exploratory well, and the like. Wellbores may be vertical, horizontal, some angle between vertical and horizontal, diverted or non-diverted, and combinations thereof, for example a vertical well with a non-vertical component. Mechanically-set packers currently in use suffer from certain inadequacies. One problem is the inability, after annular fracturing, to cleanup sand and other debris that fall out directly on top of the packer. Fall out may occur when multiple perforation sets are present above the packer. For example, if the proppant fracture from the current zone were to grow vertically and/or poor quality cement is present behind the casing, the fracture could intersect the perforation sets above the packer seal such that proppant could “dump” back into the wellbore on top of the packer and prevent or obstruct further upward movement of the packer. Also, it could be difficult to execute circulation operations if multiple perforation sets are open above the packer. For example, if the circulation pressures exceed the breakdown pressures associated with the perforations open above the packer, the circulation may not be maintained with circulation fluid unintentionally lost to the formation. This may result in a higher probability of sticking the packer in the well. Thus, there is a continuing need for packers and methods that address one or more of the problems that are set forth above.
[0030] Given that safety is a primary concern, and that there is considerable investment in existing equipment, it would be an advance in the art if existing packers could be modified and/or improved to increase safety and efficiency during wellbore operations, with minimal interruption of other well operations. This invention offers methods and apparatus for these purposes.
[0031] Referring now to the figures, FIGS. 1A and 1B illustrate schematically, and not to scale, partial cross-sectional views of a top portion and a bottom portion of a packer 10 of the invention. Illustrated in FIG. 1A is a packer body top portion 1 , and in FIG. 1B a packer bottom body portion 3 , joined together by a flexible connector 18 . A seal assembly having three seal elements 12 and one or more slips 14 are shown as well. Seal elements 12 and slips 14 are in pre-set position, i.e., they are not extended out toward the wellbore casing (not shown) as they would be in use to seal an annulus. Packer body portions 1 and 3 define an inner conduit 16 . A circulating sleeve 17 slides over a circulating sub 31 during various stages of operation. A spring 32 keeps the circulating sleeve 17 biased downward during operations. Circulation Sleeve 17 has one or more passages 21 whose use will become apparent. Also illustrated is a circulation port 19 , as well as a pair of slots 20 adapted to allow fluid to enter and exit as required, as further explained herein. Fluid bypass openings 22 allow fluid to travel in the direction of arrows F 1 and F 2 through flow slots 20 , inner conduit 16 , and out through fluid bypass openings 22 during run in hole. FIG. 1B illustrates a pair of secondary circulation openings 24 in an outer mandrel sleeve 25 of lower packer body 3 , and a corresponding secondary circulation port (sometimes referred to herein as a ported sub) 28 in a coupling 23 , allowing fluid to flow as depicted by arrow F 3 during run in hole. FIG. 1B also illustrates a position of a cycle mandrel 30 and guide or setting pin 26 , it being understood that more than one guide pin may be used. Guide pins 26 are attached to cycle mandrel 30 and guide cycle mandrel 30 moving axially (right to left in the figures) through guide slots 27 in cycle mandrel 30 , as is more clearly illustrated in FIGS. 4A and 4B . In the run in hole position shown in FIG. 1A , note that circulation port 19 is closed off by circulating sleeve 17 .
[0032] FIGS. 2A and 2B illustrate schematically the top 1 and bottom 3 portions, respectively, of the packer 10 of FIGS. 1A and 1B , but in set mode. The same numerals are used throughout the drawing figures for the same parts unless otherwise indicated. Packer 10 may be indexed using coiled tubing or jointed pipe connected to packer 10 . Simple lifting and setting back down of packer 10 using top-side equipment (not illustrated) is typically all that is required, unless some cleanout must be performed to loosen debris, as further discussed herein. Importantly, it is not necessary to twist or rotate the coiled tubing or jointed pipe in order to operate, or “index”, packer 10 using cycle mandrel 30 . Illustrated in FIG. 2A are seal elements 12 in expanded mode, pressing against the well casing (not illustrated). Fluid bypass openings 22 are now closed in top portion 1 of packer 10 , as well as secondary circulation ports 28 ( FIG. 2B ) by virtue of ports 28 moving away from secondary circulation openings 24 and outer mandrel 25 moving upward (to the left in FIG. 2B , guided by guide pin 26 ) into a seal bore in the outer mandrel 25 . Seals 29 on both sides of the secondary circulation ports now close off the secondary circulation ports flow paths. Circulation port 19 is now open as it is lined up with passage 21 . In this set position, once the operation is complete, fluid may be directed through coiled tubing or jointed pipe, through circulation port 19 and passage 21 , thereby allowing any debris to be disturbed or removed and decrease the probability of packer 10 becoming stuck in the wellbore.
[0033] There are many varieties of mandrels. Any type of J-slot mandrel may be used and their foreseeable functional equivalents and considered within the invention.
[0034] FIGS. 3A and 3B are similar to FIGS. 1A and 1B but illustrate schematically packer 10 in release position. Note that cycle mandrel 30 is completely protected by outer mandrel 25 in release position. This helps to prevent guides 27 in inner mandrel 30 from becoming clogged with debris or otherwise damaged as the packer is removed from the wellbore, or moved to another position in the same wellbore. Circulation port 19 is no longer aligned with passage 21 , so there is no fluid flow at the top of the packer. However, note that fluid may traverse through packer bottom portion 3 through secondary circulation openings 24 and secondary flow ports 28 as indicated by arrow F 5 . This conveniently allows the operator to disturb debris below sealing elements 12 , if need be, in order to remove packer 10 or re-position it in another part of the wellbore.
[0035] FIGS. 4A and 4B are schematic views of an inner J mandrel useful in the invention, it again being worth stating that other shaped mandrels that will perform the functions discussed herein will suffice equally as well, and are considered within the invention. FIG. 4A illustrates cycle mandrel 30 in side elevation, clearly showing guide slots 27 for guide pins (the guide pins are not shown in this figure). FIG. 4B illustrates how one or more guide pins 26 , attached to an outer mandrel (not shown in this figure) would slide within guide slots 27 upon alternate lifting and re-setting of the packer. Guide pins 26 would be in “Position 1 :RIH”, which means “run in hole”, for the portion of the methods when the packers are run into the wellbore. A second position, indicated as “Position 2 : Pick Up”, indicates where guide pins 26 would move or index to upon pick up (tension) in the coiled tubing or jointed pipe attached to the packer. To set the packer, coiled tubing or jointed pipe is pushed generally downward into the wellbore (compression set), and guide pins 26 are forced up into guide slots 27 . The final position is “Position 4 : Release”, which actually indexes the mandrel back to a position similar to position 2 , pick up. Compression force applied subsequent to position 4 results in guide pins 26 moving back in to position 1 , run in hole.
[0036] In use, for example in annular frac cleanup, packer 10 thus utilizes hold down slips 14 to anchor it against the casing, when a low compressive load is applied to the coiled tubing or jointed pipe string. Once the slips are anchored into the casing, the primary seal elements 12 are compressed and packed off against the casing ID, the ported sub 28 is closed off and the primary circulation ports 19 , above the packer, are opened for annular frac cleanup. Although some rotation is not excluded, only up/down coiled tubing/jointed pipe manipulation should be required to activate the setting mechanism. The inventive packers use a conventional drag block system to provide external component resistance. This resistance allows for relative movement between internal and external components of the packers, thus allowing the tool to index through the setting sequence.
[0037] A representative method of the invention, including a setting sequence (system responses) of the invention, using coiled tubing (CT) and a packer of the invention, may be as follows:
[0038] The packer is run to depth on the CT. The setting cycle mandrel is in the first position at this stage. Fluid bypass feature is open, thus reducing the swabbing tendency of the primary seal. The ported sub is opened below the sealing elements allowing communication between the CT and the annulus, for tubing fill.
[0039] Once on depth, the CT is picked up. This action indexes the cycle mandrel into its second position. Fluid bypass feature is still open. The ported sub is stroked upward, however remains opened.
[0040] The CT is then slacked off and compressive load is applied (due to the weight of CT). This indexes the cycle mandrel into its third position in the setting sequence. The slips and the primary seal elements are set from this position. The bypass seal is closed, thus isolating the flow path below the sealing element. The ported sub below the packer sealing elements is closed, thus isolating the tubing from the lower annulus. The primary circulation ports above the sealing elements are opened, allowing direct communication between the tubing and upper annulus.
[0041] An annular frac job is then performed. Once complete, the excess proppant and any debris present are then circulated out of the annulus through the primary circulation ports, directly above the sealing elements.
[0042] Once clean up of the annulus is achieved, the CT is picked up and the internal components of the packer are stroked into the release position. This indexes the cycle mandrel into the fourth position. The bypass seal is re-opened, allowing flow from above the sealing elements to below. The primary circulation ports, above the packer sealing elements, are again blanked off. The ported sub below the packer sealing elements is again re-opened. It is now possible to circulate down the CT and exit fluid out below the packer's primary seal; this allows the operator the unique ability to “wash” up the backside of the packer's sealing elements. This fluid flow path will aid in “lifting” or re-suspending sand or other debris that has been packed or settled out just above the sealing elements.
[0043] Continued upward movement of the CT will raise the packer up the well bore and into the next zone. Once the packer is in the correct location for the next interval, the CT can be slacked off. The compressive load generated during this slack off will index the cycle mandrel back into the first position or “run in hole” position.) The setting sequence can be repeated from this point forward.
[0044] In summary, the inventive packers have one or more of the following unique, patentable features:
[0045] Integral circulating ports above the sealing element: this circulation feature is strategically placed on the packer to minimize the distance between the circulation (clean up) ports and the primary seal elements. These circulating ports aid in the removal of proppant/debris from the top of the primary seal.
[0046] In the packer's released position, the circulating ports (above) are closed off and an additional circulation sub below the packer is opened. With the lower ports opened, flow can now be established down the ID and allowed to exit below the packer. By exiting fluid below the packer and flowing up the annulus, the fluid flow can be used to remove or re-suspend proppant/debris from the backside of the packer seal elements.
[0047] The cycle mandrel is the internal setting component of the packer. The cycle mandrel uses a free-spinning, auto “J” profile. This component allows the packer to run in hole, set, release, and reset with up/down tubing manipulation only, or with minimal rotation of tubing. As the packer moves through the different positions on the cycle mandrel, the cycle mandrel will free spin relative to the internal and external components. Alternatively, the cycle mandrel also allows for a secondary setting contingency. If for some reason the cycle mandrel becomes bound and cannot spin, then the outer components will still have the ability to rotate relative to the cycle mandrel, thus indexing into the required positions. This may be accomplished when the up/downward movement of the internal string imparts a torsion load between the cycle mandrel, indexing pins, and outer components. This torsion load only has to overcome the static friction resistance of the drag block assembly; once this threshold is achieved the outer components can then rotate relative to the internal string.
[0048] The cycle mandrel also provide the ability of the inventive packers to move down hole once released. Traditional compression set, non-rotational packers do not offer this ability to move down once released. This movement will traditionally try to re-set the tools. If debris above the primary sealing elements limits upward movement in the release position, then downward movement can be applied thus indexing the cycle mandrel back into the run-in-hole position. From this position the inventive packers may be pushed free from the debris barrier.
[0049] Packers of the invention require very low compressive setting load, typical with CT applications. The low setting load creates an initial low-pressure seal against the casing. Once the low-pressure seal is established, the packer then utilizes the available low differential pressure to continue applying pack-off load into the primary sealing elements. As the differential pressure is increased, so does the pack-off load into the primary sealing elements.
[0050] An optional feature of packers of the invention is one or more sensors located at the tool to detect the presence of hydrocarbons (or other chemicals of interest) in the fluid traversing up CT main passage 16 during a CT or jointed tubing operation. The chemical indicator may communicate its signal to the surface over a fiber optic line, wire line, wireless transmission, and the like. When a certain chemical is detected that would present a safety hazard if allowed to reach surface (such as oil or gas), the packer may be indexed to a safe position, long before the chemical creates a problem.
[0051] 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. In the claims, no clauses are intended to be in the means-plus-function format allowed by 35 U.S.C. § 112, paragraph 6 unless “means for” is explicitly recited together with an associated function. “Means for” clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents, but also equivalent structures.
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Packers and methods of using same are described. The packer includes a packer body, a slip to engage a casing of the well and a sealing element to seal an annulus of the well, a fluid bypass chamber adapted to allow fluid passage through the packer body during run in hole and in release position, and a re-settable mandrel slideably engaged with guide pins attached to the packer body and adapted to selectively open and close circulation paths upon actuation. This abstract allows a searcher or other reader to quickly ascertain the subject matter of the disclosure. It will not be used to interpret or limit the scope or meaning of the claims. 37 CFR 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 is in the field of powered screeds used in the process of leveling, smoothing and creating an improved exposed surface on freshly poured concrete, cement, soil and like materials. Although the present invention is utilized in connection with many materials, the embodiment shown and described herein is directed to concrete. The word concrete includes a mixture of cement, sand, aggregate and water combined in a favorable ratio to create a product useful in the construction of floors, roads, driveways, sidewalks and the like. Concrete also embodies a mixture combined and mixed to a proper consistency and in a state of cure prior to set-up or hardening.
In the process of pouring concrete for floors, sidewalks, highways and the like, the exposed surface must be developed to a finished texture as required by the work specifications. This may vary from a rough nonslip surface to a slick polished finish. This is achieved by a process known as screeding. This process brings a tool into contact with the surface of the poured concrete, and by a reciprocating, dragging action causes the aggregate near and at the surface to settle thereby leaving cement and water exposed while, at the same time, leveling and smoothing the exposed surface material.
In one screeding system, common to the industry, an elongated wood beam or screed of sufficient length is manipulated in a side-to-side sawing motion along pairs of supporting rails temporarily set at the desired finished elevation of the surface being poured. This side-to-side motion is combined with pressure against the beam to force travel along the supporting rails. In this system, all power is applied manually by workmen positioned at opposite ends of the beam.
On larger areas, such as highway lanes and large floors, the typical process utilizes a screed provided with means to mechanically power both the sawing motion and travel along the guiding rails with travel being implemented by powered traction wheels.
A third system, in current use in the industry, includes a screed beam, power means to effect side-to-side sawing motion, a guide with a controlling handle and a frame on which all of the elements are mounted. This system commonly utilizes one operator in the fashion of a push-type lawnmower with the operator causing the machine to travel by applying a push or pull force to the machine handle.
BRIEF SUMMARY OF THE INVENTION
By this invention, a powered screed machine is provided which comprises power means fixed to a support frame together with a machine control system. The machine includes a screed weight module disposed parallel to the axis of the screed blade with a travel weight module disposed perpendicular thereto and being generally coaxially disposed with respect to the direction of travel of the machine.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
In the drawings:
FIG. 1 is a side elevational view showing the control elements of the powered screed machine according to this invention;
FIG. 2A is a view similar to FIG. 1 ;
FIG. 2B is an elevational view taken generally from the right side of FIG. 2A ;
FIG. 3 is a graphical representation showing the combination of reciprocatory movement in the direction of travel of the machine in combination with operation of the screed blade;
FIGS. 4A , 4 B and 4 C show top, end and side views of the machine control elements, respectively;
FIG. 4D is a sectional view taken along the line B-B in FIG. 4A ;
FIG. 4E is a sectional view taken along the line A-A in FIG. 4A ;
FIGS. 5A and 5B are similar to FIGS. 2A and 2B , respectively, and show a modification of the invention;
FIG. 6A is a side view of a portion of the machine control mechanism;
FIGS. 6B-6E are sectional views taken along the line Y-Y in FIG. 4E ;
FIGS. 7A-7E are views similar to FIGS. 6A-6E , respectively;
FIG. 8A is an elevational of the machine with a portion thereof broken away;
FIGS. 8B-8F are sectional views taken along the line X-X in FIG. 4D and FIG. 8A ;
FIG. 9A is a schematic top view of the machine;
FIG. 9B is a side view of the machine control elements;
FIG. 9C is a partial sectional view of the machine; and
FIGS. 9D and 9E are sectional views taken along the line Y-Y in FIG. 9C .
DETAILED DESCRIPTION OF THE INVENTION
With particular reference to FIG. 2B , the screed machine according to this invention includes power means 1 , screed-axis weight module 2 , travel-axis weight module 3 , support frame 4 , elongated screed blade 5 and handle frame 6 . The machine control system includes control cable housing 7 , control cable 8 , travel control arm 9 and control lever 10 .
During operation, the machine is held in an upright position by the operator with screed blade 5 disposed essentially normal to the surface being processed. With power means 1 operating, screed blade 5 is driven in a reciprocating left to right motion by means of screed-axis weight module 2 . Also, the machine is caused to reciprocate in a direction perpendicular to the screed reciprocating direction by means of travel-axis weight module 3 . Travel-axis weight module 3 is designed and constructed to selectively generate a force of variable intensity and in a reversible direction with respect to the machine direction of travel. The operator positions control handle 10 to effect travel forward and reverse along the surface being processed.
In FIGS. 5A and 5B , an alternate embodiment of the machine is shown whereby power means 1 is located remotely on handle frame 6 and is supported by power means mount 11 . Power is transmitted to drive shaft 15 through flexible drive linkage 12 .
With reference to FIGS. 8A-8F , screed-axis weight module 2 is provided with screed weight 21 which is driven by shaft 15 in combination with eccentric cam 22 wherein the axis of cam 22 is offset from the axis of shaft 15 . Weight 21 is supported and guided during travel by screed weight housing 23 and weight guide bushings 14 . Shaft 15 is rotated by power means 1 . The elongation of slot 24 perpendicular to the travel direction of weight 21 allows rotation of shaft 15 and eccentric cam 22 to effect movement of weight 21 only in the direction of the screed axis. As weight 21 is driven in a reciprocating motion by eccentric cam 22 , the inertial force produced by the reciprocation of weight 21 is applied through the combination of eccentric cam 22 , shaft 15 , shaft bearing 17 and support frame 4 to screed blade 5 .
Vibratory conveyors which move material in one direction operate on a principle well known in the art. The structural surface of the machine which contours the material being conveyed is moved in both the direction of material flow and in the opposite direction by means of a reciprocating weight connected to the supporting surface. Movement of conveyed material in the desired direction is effected by causing the reciprocating weight to be greater in magnitude in one direction than in the other. This is accomplished by applying a bias force to the weight in the form of a spring. As the weight is moved against the spring, its acceleration is decreased and energy thus expended is transferred to the compressed spring. As the motion reverses, stored energy in the spring is released thereby increasing the acceleration of the weight in the reverse direction. Therefore, during each cycle of reciprocation of the weight, the machine surface moves at a greater rate in one direction than the other, thereby moving the conveyed material in the desired direction.
With reference to FIGS. 9A-9E , travel-axis weight module 3 is provided with travel weight 13 and elongated slot 24 . Eccentric cam 16 is mounted on and fixed to shaft 15 with the shaft being rotatably driven by power means 1 . Springs 18 c and 18 d are attached to spring frame 20 and to weight 13 . Elongation of slot 24 crosswise to the machine travel direction allows the rotation of shaft 15 and eccentric cam 16 to effect movement to weight 13 only along the axis of travel of weight 13 . Weight 13 is supported and guided by weight guide 19 and weight guide bushings 14 . If the combination of forces causes the machine to veer off line, weight 13 can be angled with respect to the direction of machine travel to counteract these forces and maintain the desired direction of travel of the machine.
As shown in FIGS. 6A-6E , travel-axis weight 13 is attached to springs 18 a and 18 b with the opposite ends of the springs attached to spring frame 20 . The motion of travel of weight 13 causes the compression of spring 18 b thereby resulting in storage of energy in spring 18 b . As shaft 15 and eccentric cam 16 continue to rotate energy stored in spring 18 b is released to accelerate weight 13 to the left as it moves toward spring 18 a.
The continued rotation of shaft 15 and eccentric cam 16 causes the same force to be applied to spring 18 a as was applied to spring 18 b during the first 180 degrees of rotation. As shaft 15 and eccentric cam 16 rotate, there is a cyclic storage and release of energy in springs 18 a and 18 b . During rotation of shaft 15 and eccentric cam 16 , spring frame 20 acts to maintain springs 18 a and 18 b in the same relative position from the central axis of the mechanism thereby causing the storage and release of energy to be equal and symmetrical with respect to the central axis.
With reference to FIGS. 7A-7E , travel-axis weight module 3 is provided with spring frame 20 slidably mounted with respect to frame 4 , weight guide 19 and shaft 15 . The sliding motion of spring frame 20 is effected by the leverage force applied to arm 9 by control cable 8 . Arm 9 is pivotably mounted on pin 25 and pin 25 is fixed to frame 4 . Extension and retraction of control cable 8 , acting upon arm 9 , causes spring frame 20 to change its position relative to frame 4 , shaft 15 , eccentric cam 16 , weight 13 and springs 18 c and 18 d . Specifically, spring frame 20 is caused to move closer to spring 18 c by the retraction of control cable 8 acting on arm 9 . The location of spring frame 20 in this position causes spring 18 c to have a shorter compressed length during all phases of the rotation cycle. This location of spring frame 20 also causes spring 18 d to have a longer compressed length during the same phases of rotation cycle. The result of this difference in effective spring lengths is an imbalance of force on weight 13 and the accompanying imbalance of acceleration due to storage and release of spring energy during all phases of the rotation cycle.
During rotation of eccentric cam 16 from the position shown in FIG. 7C to that shown in FIG. 7E , the energy stored in spring 18 c is released and is combined with the force provided by eccentric cam 16 to enhance the acceleration of weight 13 as it moves toward spring 18 d . Since spring 18 d has a longer compressed length, less energy is absorbed from weight 13 during this phase of rotation of cam 16 .
An imbalance of accelerating forces across weight 13 during movement from the position in FIG. 7C to the position in FIG. 7E results in travel-axis weight 13 being driven at a greater velocity during travel from spring 18 c toward spring 18 d than during travel from spring 18 d toward spring 18 c . Hence, weight 13 applies a net force on frame 4 , through springs 18 c and 18 d , spring frame 20 , eccentric cam 16 and shaft 15 that is greater in the direction from side B to side A than from side A to side B. This net force difference causes the machine to travel in a direction from side B toward side A. Reversing the direction of control handle 10 to cause control cable 8 to extend and reverse the position of arm 9 will move spring frame 20 in the opposite direction and thereby reverse the direction of machine travel in proportion to the extent of movement of control handle 10 .
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A powered screed machine comprising means to drive a screed blade and means to power machine travel. The machine includes a pair of elongated modules disposed perpendicular to each other whereby a reciprocating weight within one of the modules causes forward and rearward movement of the machine and a reciprocating weight in the other module causes vibratory movement of the screed blade to groom the surface of freshly poured concrete.
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FIELD OF THE INVENTION
[0001] This invention relates to systems and methods for magnetic ranging between earth boreholes, and for controlled drilling of an earth borehole in a determined spatial relationship with respect to another existing earth borehole.
BACKGROUND OF THE INVENTION
[0002] In the quest for hydrocarbons, the need can arise for drilling of an earth borehole in a determined spatial relationship with respect to another existing borehole. One example is the so-called steam-assisted gravity drainage (“SAGD”) process which is used to enhance production from an existing section of a generally horizontal production wellbore in a reservoir of high viscosity low-mobility crude oil. A second wellbore, to be used for steam injection, is drilled above and in alignment with the production wellbore. The injection of steam in the second wellbore causes heated oil to flow toward the production well, and can greatly increase recovery from the reservoir. However, for the technique to work efficiently, the two boreholes should be in good alignment at a favorable spacing over the length of the production region.
[0003] Referring to FIG. 1 , a pair of SAGD wells 10 and 20 are shown in the process of being constructed. The lower well is drilled first and then completed with a slotted liner in the horizontal section. The lower well 10 is the producer well and is located with respect to the geology of the heavy oil zone. Typically, the producer well is placed near the bottom of the heavy oil zone. The second well 20 is then drilled above the first well, and is used to inject steam into the heavy oil formation. The second, injector well is drilled so as to maintain a constant distance above the producer well throughout the horizontal section. Typically, SAGD wells are drilled in Canada to maintain a vertical distance of 5±1 meters above the horizontal section, and remain within ±1 meters of the vertical plane defined by the axis of the producer well. The length of the horizontal section can typically vary from approximately 500 meters to 1500 meters in length. Maintaining the injector well precisely above the producer well and in the same vertical plane is beyond the capability of conventional MWD direction and inclination measurements.
[0004] Instead, magnetic ranging is typically used to determine the distance between the two wells and their relative position. In U.S. Pat. No. 5,485,089, a magnetic ranging method is described where a solenoid is placed in one well and energized with current to produce a magnetic field. This solenoid (e.g. 12 in FIG. 1 , which also depicts magnetic field B) comprises a long magnetic core wrapped with many turns of wire. The magnetic field from the solenoid has a known strength and produces a known field pattern that can be measured in the other well, for example by a 3-axis magnetometer (represented at 21 in FIG. 1 ) mounted in a measurement while drilling (MWD) tool. The solenoid must remain relatively close to the MWD tool for the magnetic ranging. The solenoid is pushed along the horizontal section of the well using a wireline tractor (e.g. 14 in FIG. 1 ), or coiled tubing, or it can be pumped down inside tubing (not shown).
[0005] In a typical sequence of operations, the bottom hole assembly (BHA) in the second well drills ahead a distance of 10 m to 90 m, corresponding to one to three lengths of drill pipe. The distance between measurements depends on the driller's ability to keep the well straight and on course. The drilling operation must be halted to perform the magnetic ranging operation. U.S. Pat. No. 5,485,089 teaches that first, the 3-axis magnetometers in the MWD tool measure the (50,000 nTesla) Earth's magnetic field with the current in the solenoid off. Then the solenoid is activated with DC current to produce a magnetic field which adds to the Earth's magnetic field. A third measurement is made with the DC current in the solenoid reversed. The multiple measurements are made to subtract the Earth's large magnetic field from the data obtained with the solenoid on.
[0006] The solenoid is then moved to a second position along the completed wellbore by a tractor or by other means. If the first position is slightly in front of the MWD magnetometer (i.e. closer to the toe of the well), then the other position should be somewhat behind the MWD magnetometer (i.e. closer to the heel of the well). The solenoid is again activated with DC current, and the MWD magnetometers make the fourth measurement of the magnetic field with DC current. The DC current in the solenoid is then reversed, and a fifth measurement is made. The five magnetic field measurements are transmitted to the surface where they are processed to determine the position of the MWD tool magnetometers with respect to the position of the solenoid.
[0007] There are drawbacks to this process. First, the solenoid must be physically moved between the two borehole positions, during which time the BHA is not drilling. This movement requires that the tractor be activated and driven along the wellbore, which is time consuming. Second, any errors in measuring the two axial positions of the solenoid, or errors in the distance the solenoid moves, introduce errors in the calculated distance between the two wells. Third, since the solenoid is driven from one position to another, the distance the solenoid travels may vary from one magnetic ranging operation to the next. Since the MWD tool does not know how far the solenoid moved, it cannot compute the distance to the first well. This means that all five magnetic field measurements must be transmitted to the surface via the typically slow MWD telemetry system. Only after the MWD measurements have been decoded at the surface and the appropriate algorithms processed (including knowledge of the two solenoid positions), can the distance between the two wells be determined and drilling resumed. Hence, this magnetic ranging process results in excess rig time and thus increases the cost of drilling the well.
[0008] Reference can also be made to U.S. Pat. Nos. 3,731,752, 4,710,708, 5,923,170 and Re. 36,569, and also to Grills et al, “Magnetic Ranging Technologies for Drilling Steam Assisted Gravity Drainage Wells Pairs and Unique Well Geometries”. SPE 79005, 2002, and to “Kuckes et al., New Electromagnetic Surveying/Ranging Method for Drilling Parallel, Horizontal Twin Wells,” SPE 27466, 1996.
[0009] It is among the objects of the present invention to provide improved magnetic ranging and improved distance and direction determination between wellbores and to improve controlled drilling of an earth borehole in a determined spatial relationship with respect to another existing earth borehole.
SUMMARY OF THE INVENTION
[0010] A form of the invention is directed to a method for determining the distance and/or direction of a second earth borehole with respect to a first earth borehole, including the following steps: providing, in the first borehole, first and second spaced apart magnetic field sources; providing, in the second borehole, a magnetic field sensor subsystem for sensing directional magnetic field components; activating the first and second magnetic field sources, and producing respective first and second outputs of the magnetic field sensor subsystem, the first output being responsive to the magnetic field produced by the first magnetic field source, and the second output being responsive to the magnetic field produced by the second magnetic field source; and determining said distance and/or direction of the second earth borehole with respect to the first earth borehole as a function of said first output and said second output.
[0011] In an embodiment of this form of the invention, the step of providing a magnetic field sensor subsystem comprises providing a subsystem for sensing x, y, and z orthogonal magnetic field components, the first output comprises sensed x, y and z magnetic field components responsive to the magnetic field produced by the first magnetic field source, and the second output comprises sensed x, y and z magnetic field components responsive to the magnetic field produced by the second magnetic field source. Also in this embodiment, the step of activating said first and second magnetic field sources comprises implementing AC energizing of the magnetic field sources. The first and second magnetic field sources can be activated sequentially, or can be activated simultaneously at different phases and/or frequencies. Also in this embodiment, the step of providing first and second spaced apart magnetic field sources comprises providing first and second solenoids on a common axis, and the common axis is substantially parallel to the axis of said first borehole.
[0012] In another embodiment of the described form of the invention, there is further provided, in the first borehole, a third magnetic field source, and the activating step includes activating the third magnetic field source and producing a third output of the magnetic field sensor subsystem, the third output being responsive to the magnetic field produced by the third magnetic field source. In this embodiment, the step of determining said distance and/or direction of the second earth borehole with respect to the first earth borehole comprises determining said distance and/or direction as a function of the first output, the second output, and the third output. Also in this embodiment, the step of providing first, second and third magnetic field sources comprises providing first, second and third solenoids on a common axis. If desired, more than three magnetic field sources can be employed.
[0013] In accordance with another form of the invention, a method is set forth for drilling of a second earth borehole in a determined spatial relationship to a first borehole, including the following steps: (a) providing, in the first borehole, a plurality of spaced apart magnetic field sources; (b) providing, in the second borehole, a directional drilling subsystem and a magnetic field sensor subsystem for sensing directional magnetic components; (c) activating a first and a second of said plurality of magnetic field sources, and producing respective first and second outputs of the magnetic field sensor subsystem, the first output being responsive to the magnetic field produced by the first magnetic field source, and the second output being responsive to the magnetic field produced by the second magnetic field source; (d) determining the distance and direction of the second earth borehole with respect to the first earth borehole as a function of the first output and the second output; (e) producing directional drilling control signals as a function of the determined distance and direction; and (f) applying the directional drilling control signals to the directional drilling system to implement a directional drilling increment of the second borehole. An embodiment of this form the invention further includes: advancing, in the first borehole the plurality of spaced apart magnetic field sources; and repeating said steps (c) through (f) to implement a further directional drilling increment of the second borehole. Also, an embodiment of this form of the invention includes measuring direction, inclination, and gravity tool face of the directional drilling subsystem, the directional drilling control signals also being a function of the measured direction, inclination, and gravity tool face.
[0014] In accordance with a further form of the invention, a system is set forth for monitoring the distance and/or direction of a second earth borehole with respect to a first earth borehole, including: a first subsystem movable through the first borehole, the first subsystem including a plurality of spaced apart magnetic field sources and an energizer module for activating at least a first and second of the magnetic field sources; and a second subsystem movable through the second borehole, and including a magnetic field sensor for sensing directional magnetic field components, the second subsystem being operative to produce a first output responsive to the magnetic field produced by the first magnetic field source and a second output responsive to the magnetic field produced by the second magnetic field source. The distance and/or direction of the second borehole with respect to the first borehole are determinable from the first and second outputs. In an embodiment of this form of the invention, a downhole processor is provided for determining said distance and/or direction as a function of the first and second outputs.
[0015] Among the advantages of the invention are the following: (1) A knowledge of the strength of the magnetic field sources is not required. This is important since the magnetic field sources may be located inside a steel casing which can have a high and variable magnetic permeability, which reduces the strength of the magnetic field outside the casing. Since the relative magnetic permeability of the casing is generally not known, this introduces an unknown variation in the magnetic field strength. However, the technique of the invention is not affected by the casing. (2) It is not necessary to move the downhole tool containing the two magnetic field sources during a measurement sequence. This reduces the amount of rig time required to make a magnetic ranging survey. (3) It is not necessary to actually know or to determine the position of the magnetometers (e.g. an MWD magnetometer device) with respect to the z direction. (4) Since the distance to the first well and the direction to the first well do not depend on the axial position of the magnetic field sources, the calculations can be performed downhole, e.g. in the processor of an MWD tool, and only the results sent to the surface via MWD telemetry. (5) It is not necessary to determine the distance and direction from the MWD magnetometer to either of the magnetic field sources. Rather, the distance and direction from the MWD magnetometer to the first well are obtained. (6) It is not necessary to move the downhole tool to a known z position in order to determine the direction from the magnetometers to the downhole tool. (7) With an AC drive for the magnetic field sources, it is not necessary to measure the magnetic field with positive DC current, and then to re-measure with negative DC current, to cancel Earth's magnetic field. This saves whatever rig time would be necessary for making two separate measurements and transmitting them to the surface.
[0016] Further features and advantages of the invention will become more readily apparent from the following detailed description when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is a diagram illustrating a prior art technique for magnetic ranging.
[0018] FIGS. 2A and 2B , when placed one over another, illustrate equipment which can be used in practicing embodiments of the invention.
[0019] FIGS. 3A and 3B show, respectively, a plan view, partially in block form, and a cross sectional view of equipment that can be used in practicing embodiments of the invention.
[0020] FIG. 4 is a flow diagram showing steps of a method in accordance with an embodiment of the invention.
[0021] FIG. 5 illustrates the geometry for the two magnetic dipoles on a borehole axis.
[0022] FIG. 6 illustrates geometry useful in determining the direction between wells.
[0023] FIG. 7 shows graphs of magnetic field components measured at a magnetometer for an example useful in understanding the invention.
[0024] FIG. 8 shows inverted radial distance between the two wells for an example illustrating operation of the invention.
[0025] FIG. 9 shows inverted vertical distance between the two wells for an example illustrating operation of the invention.
[0026] FIG. 10 shows inverted horizontal offset between the two wells for an example illustrating operation of the invention.
[0027] FIG. 11 shows inverted location of the MWD magnetometer along the direction for an example illustrating operation of the invention.
[0028] FIG. 12 shows graphs of magnetic field components measured at a magnetometer for another example useful in understanding the invention.
[0029] FIG. 13 shows inverted radial distance between the two wells for another example illustrating operation of the invention.
[0030] FIG. 14 shows inverted vertical distance between the two wells for another example illustrating operation of the invention.
[0031] FIG. 15 shows inverted horizontal offset between the two wells for another example illustrating operation of the invention.
[0032] FIG. 16 shows Inverted location of the MWD magnetometer along the z direction for another example illustrating operation of the invention.
[0033] FIG. 17 shows graphs of magnetic field components measured at a magnetometer for a further example useful in understanding the invention.
[0034] FIG. 18 shows inverted radial distance between the two wells for a further example illustrating operation of the invention.
[0035] FIG. 19 shows inverted vertical distance between the two wells for a further example illustrating operation of the invention.
[0036] FIG. 20 shows inverted horizontal offset between the two wells for a further example illustrating operation of the invention.
[0037] FIG. 21 shows a location of the MWD magnetometer along the z direction for a further example illustrating operation of the invention.
[0038] FIG. 22 shows a downhole tool with three solenoids, which can be used in practicing embodiments of the invention.
[0039] FIG. 23 shows operation of two solenoids in parallel or anti-parallel mode, in accordance with an embodiment of the invention.
DETAILED DESCRIPTION
[0040] FIG. 2A illustrates surface equipment of a type that can be used in practicing embodiments of the invention. Wireline equipment 100 operates in conjunction with the existing producer well 10 and drilling equipment 200 operates in conjunction with the well 20 being drilled and which, in this example, can ultimately be used as a steam injector well.
[0041] The wireline equipment includes cable 33 , the length of which substantially determines the relative depth of the downhole equipment. The length of cable 33 is controlled by suitable means at the surface such as a drum and winch mechanism. The depth of the downhole equipment within the well bore can be measured by encoders in an associated sheave wheel, the double-headed arrow 105 representing communication of the depth level information and other signals to and/or from the surface equipment. Surface equipment, represented at 107 , can be of conventional type, and can include a processor subsystem 110 and a recorder, and communicates with the downhole equipment. In the present embodiment, the processor 110 in surface equipment 107 communicates with a processor 248 , which is associated with the drilling equipment. This is represented by double-headed arrow 109 . It will be understood that the processors may comprise a shared processor, or that one or more further processors can be provided and coupled with the described processors.
[0042] The drilling equipment 200 , which includes known measurement while drilling (MWD) capability, includes a platform and derrick 210 which are positioned over the borehole 20 . A drill string 214 is suspended within the borehole and includes a bottom hole assembly which will be described further. The drill string is rotated by a rotating table 218 (energized by means not shown) which engages a Kelly 220 at the upper end of the drill string. The drill string is suspended from a hook 222 attached to a traveling block (not shown). The Kelly is connected to the hook through a rotary swivel 224 which permits rotation of the drill string relative to the hook. Alternatively, the drill string 214 may be rotated from the surface by a “top drive” type of drilling rig.
[0043] Drilling fluid or mud 226 is contained in a mud pit 228 adjacent to the derrick 210 . A pump 230 pumps the drilling fluid into the drill string via a port in the swivel 224 to flow downward (as indicated by the flow arrow 232 ) through the center of drill string 214 . The drilling fluid exits the drill string via ports in the drill bit and then circulates upward in the annulus between the outside of the drill string and the periphery of the borehole, as indicated by the flow arrows 234 . The drilling fluid thereby lubricates the bit and carries formation cuttings to the surface of the earth. At the surface, the drilling fluid is returned to the mud pit 228 for recirculation. In the present embodiment, as will be described, a well known directional drilling assembly, with a steerable motor, is employed.
[0044] As shown in FIG. 2B , which shows downhole portions of wells 10 and 20 , mounted near the drill bit 216 , is a bottom hole assembly 230 , which conventionally includes, inter alia, MWD subsystems, represented generally at 236 , for making measurements, and processing and storing information. One of these subsystems, also includes a telemetry subsystem for data and control communication with the earth's surface. Such apparatus may be of any suitable type, e.g., a mud pulse (pressure or acoustic) telemetry system, wired drill pipe, etc., which receives output signals from the data measuring sensors and transmits encoded signals representative of such outputs to the surface (see FIG. 2A ) where the signals are detected, decoded in a receiver subsystem 246 , and applied to a processor 248 and/or a recorder 250 . The processor 248 , and other processors, may comprise, for example, suitably programmed general or special purpose processors. A surface transmitter subsystem 252 is provided for establishing downward communication with the bottom hole assembly by any known technique, such as mud pulse control (as represented by line 252 A), wired drill pipe, etc.
[0045] The subsystems 236 of the bottom hole assembly also include conventional acquisition and processing electronics (not separately shown) comprising a microprocessor system, with associated memory, clock and timing circuitry. Power for the downhole electronics and motors may be provided by battery and/or, as known in the art, by a downhole turbine generator powered by movement of the drilling fluid. A steerable motor 270 and under control from the surface via the downhole processor, is provided for directional drilling.
[0046] The bottom hole assembly subsystems 236 also include one or more magnetometer arrays 265 which, in the present embodiment, preferably include AC magnetometers, all under control of the downhole processor in the bottom hole assembly, which communicates with the uphole processor(s) via the described telemetry subsystem.
[0047] In accordance with a feature of the invention, and as illustrated in FIG. 2B , a pair of spaced apart magnetic field sources, denoted by magnetic dipole sources M 1 and M 2 , are provided in a tool mounted on a tractor 170 , moveable under control of wireline cable 33 . Coiled tubing or other motive means can alternatively be used. In this embodiment, the magnetic dipole sources are solenoids; that is, coils wound on respective magnetic cores. Energizing and control is provided by downhole electronics, which can include a downhole processor, represented in FIG. 2B by block 180 , which communicates with the uphole electronics and processor via the wireline.
[0048] FIG. 3 shows, in further detail, the solenoid M 1 and M 2 mounted in housing 190 . As seen in FIG. 3B , wire windings 191 are wound on a tubular magnetic core 192 , the central opening being useful for communicating wiring. The power supply, control electronics, and downhole processor, are housed in cartridge 180 .
[0049] The solenoids M 1 and M 2 are aligned with the borehole axis (z-direction) and have a fixed separation d. The solenoids are contained in the non-magnetic housing or non-metallic (e.g. fiberglass) housing 190 . The distance between the two solenoids may be set depending on the desired inter-well spacing. For example, if the inter-well spacing is 5 m, then the solenoids should preferably be spaced in the range of 5 m to 10 m. If the inter-well spacing is greater, then a longer spacing is desirable. The solenoids' spacing can be adjusted by inserting spacers or additional housings between them. The downhole tool of the present embodiment is in the form of a wireline logging tool, and electronic cartridge 180 thereof is provided with a capability of producing low frequency AC currents for the solenoids.
[0050] As above indicated, the MWD tool in well 20 preferably contains at least one 3-axis magnetometer capable of measuring an AC magnetic field, so that the solenoids of the wireline tool can be driven by an AC current, rather than by a DC current. The advantage is that the Earth's DC magnetic field can be entirely suppressed, and this is achieved in the present embodiment by coupling high pass filters with the magnetometer outputs. Since the 50,000 nTesla Earth's magnetic field is no longer present in the data, much weaker magnetic fields can be accurately measured than is possible for DC magnetic fields. This also can reduce the weight and power requirements for the solenoids and can increase the range between wells.
[0051] Preferably, the frequency of the AC current should generally lie in the range of 1 Hz to 20 Hz; a suitable choice being a frequency of approximately 3 Hz. For frequencies much greater than 20 Hz, the magnetic field may be unduly attenuated if the first well has steel casing, or by drill collar material in the MWD tool when the 3-axis magnetometer is located inside the drill collar. The techniques hereof can also be implemented using DC magnetic fields, albeit less conveniently.
[0052] A flow diagram for a sequence of magnetic ranging and drilling is shown in FIG. 4 . As represented by block 405 , while drilling a stand of pipe (e.g. 10 m to 30 m), the downhole tool is moved so that this operation does not consume rig time. The downhole tool is moved to be approximately opposite the MWD tool magnetometers when the current stand of drill pipe has been drilled. However, it is not necessary to exactly position the downhole tool. When the “kelly is down”, drilling stops and the BHA is not rotating (block 410 ), a standard MWD survey is performed (block 420 ) to obtain direction, inclination, and gravity tool face. This data can be transmitted to the surface via MWD telemetry, e.g. by mud pulse or electromagnetic telemetry. Then, the first solenoid in the downhole tool is activated (block 425 ), preferably by an AC current in the range of 1 to 10 Hz. The resulting AC magnetic field is measured by 3-axis MWD magnetometers and stored in downhole memory. Then, as represented by block 430 , the first solenoid is turned off and the second solenoid is activated. Its AC magnetic field is measured by the same 3-axis MWD magnetometers and stored in downhole memory. As described further hereinbelow, the radial distance between the two wells and the direction from one well to the other can be computed downhole (block 440 ) and then transmitted to the surface (block 450 ). The time required to transmit the radial distance and direction is much less than transmitting the raw data to the surface, so that drilling can commence (block 460 ) immediately. The directional drilling is performed in accordance with the received distance and direction information, to maintain the desired alignment and distance of the second well 20 with respect to the first well 10 . The next cycle can then be performed to implement the next drilling increment. It will be understood that simultaneous activation of the magnetic field sources, such as at different phases and/or frequencies, with suitable selective filtering of the magnetometer outputs, can alternatively be utilized.
[0053] Among the objects hereof are to determine the radial distance from the MWD magnetometer in the second well to the borehole axis of the first well and to determine the direction from the MWD magnetometer in the second well to the first well. Referring to FIG. 5 , let {right arrow over (M)} 1 and {right arrow over (M)} 2 be two magnetic dipole sources (in this case, solenoids) that are located along the borehole axis of the first well. {right arrow over (M)} 1 is located at (x 1 ,y 1 ,z 1 )=(0,0,0), and {right arrow over (M)} 2 is located at (x 2 ,y 2 ,z 2 )=(0,0,d), where d is the known separation between the two magnetic dipoles. Consider the point (x 3 ,y 3 ,z 3 ) located a radial distance r=√{square root over (x 3 2 +y 3 2 )} from the {circumflex over (z)}-axis, where {right arrow over (r)}=x 3 {circumflex over (x)}+y 3 ŷ, and where the angle θ between {right arrow over (r)} and {circumflex over (x)} is given by
[0000]
tan
θ
=
y
3
x
3
.
[0000] In general, the best results are obtained when 0≦z 3 ≦d, although this condition is not a necessity.
[0054] For simplicity, the solenoids will be represented mathematically as point magnetic dipoles that are aligned with the borehole direction. That is, {right arrow over (M)} 1 =M 1 {circumflex over (z)} and {right arrow over (M)} 2 =M 2 {circumflex over (z)}, where {circumflex over (z)} is the unit vector pointing along the axis of the first well. The presence of a steel casing or steel liner may perturb the shape of the magnetic field, but this can be taken into account with a slight refinement of the model. The primary effect of the casing is to attenuate the strength of the magnetic field.
[0055] Now, consider the situation where the first magnetic dipole {right arrow over (M)} 1 is activated and the second magnetic dipole is off, i.e. {right arrow over (M)} 2 =0. In general, the magnetic field at (x 3 ,y 3 ,z 3 ) will have field components along the three directions, {circumflex over (x)}, ŷ, and {circumflex over (z)}, such that {right arrow over (B)} 1 (x 3 ,y 3 ,z 3 )=B 1x (x 3 ,y 3 ,z 3 ){circumflex over (x)}+B 1y (x 3 ,y 3 ,z 3 )ŷ+B 1z (x 3 ,y 3 ,z 3 ){circumflex over (z)}. All three magnetic field components are measured by the 3-axis MWD magnetometer. The three magnetometer axes may not coincide with x, y, and z directions, but it is a simple matter to rotate the three magnetometer readings to the x, y, and z directions based on the MWD survey data.
[0056] Referring to FIG. 6 , the magnetic field along the radial {right arrow over (r)} direction is {right arrow over (B)} 1r (x 3 ,y 3 ,z 3 )=B 1r (x 3 ,y 3 ,z 3 ){circumflex over (r)}=B 1x (x 3 ,y 3 ,z 3 ){circumflex over (x)}+B 1y (x 3 ,y 3 ,z 3 )ŷ, and the direction of {right arrow over (B)} 1r (x 3 ,y 3 ,z 3 ) is given by
[0000]
tan
θ
1
B
1
y
B
1
x
.
[0000] Hereafter, (x 3 ,y 3 ,z 3 ) will be suppressed, e.g. B 1y =B 1y (x 3 ,y 3 ,z 3 ). Hence, the ratio of the two measured magnetic field components B 1y and B 1x can be used to determine the direction from the observation point (x 3 ,y 3 ,z 3 ) to a point on the axis of the first well at (0,0,z 3 ). Note that there can be an ambiguity in the arctangent of 180°. In most circumstances, such as SAGD, the general direction to the first well is sufficiently well known (i.e. down in the case of SAGD) so the 180° ambiguity does not enter.
[0057] The magnetic field at the MWD magnetometer with {right arrow over (M)} 1 activated is given by
[0000]
B
1
r
=
μ
0
4
π
3
M
1
(
z
3
r
)
r
-
3
[
1
+
(
z
3
r
)
2
]
-
5
2
and
B
1
z
=
μ
0
4
π
M
1
[
2
(
z
3
r
)
2
-
1
]
r
-
3
[
1
+
(
z
3
r
)
2
]
-
5
2
.
[0000] Note that B 1r →0 as z 3 →0, hence B 1x →0 and B 1y →0. This means that it is difficult to determine the angle
[0000]
θ
1
=
arctan
(
B
1
y
B
1
x
)
[0000] directly across from the first solenoid.
[0058] Define the quantities
[0000]
u
≡
z
3
r
=
z
3
x
3
2
+
y
3
2
and
α
≡
B
1
z
B
1
r
=
2
u
2
-
1
3
u
,
[0000] where α is obtained from the measured magnetic field components. Solving the quadratic equation yields
[0000]
u
=
3
α
±
9
α
2
+
8
4
,
[0000] where the + sign is used if z 3 >0 and the − sign is used if z 3 <0.
[0059] In the next step, {right arrow over (M)} 1 is deactivated, i.e. {right arrow over (M)} 1 =0, and {right arrow over (M)} 2 is activated. The magnetic field at the MWD magnetometer is now {right arrow over (B)} 2 =B 2x {circumflex over (x)}+B 2y ŷ+B 2z {circumflex over (Z)}. The radial magnetic field can be written as {right arrow over (B)} 2r =B 2r {circumflex over (r)}=B 2x {circumflex over (x)}+B 2y ŷ, and the angle θ 2 obtained from
[0000]
tan
θ
2
=
B
2
y
B
2
x
.
[0060] The magnetic field at the MWD magnetometer due to {right arrow over (M)} 2 is
[0000]
B
2
r
=
μ
0
4
π
3
M
2
(
z
3
-
d
r
)
r
-
3
[
1
+
(
z
3
-
d
r
)
2
]
-
5
2
and
B
2
z
=
μ
0
4
π
M
2
[
2
(
z
3
-
d
r
)
2
-
1
]
r
-
3
[
1
+
(
z
3
-
d
r
)
2
]
-
5
2
.
[0000] Define the quantities
[0000]
v
≡
z
3
-
d
r
=
z
3
-
d
x
3
2
+
y
3
2
and
β
≡
B
2
z
B
2
r
=
2
v
2
-
1
3
v
.
[0000] where β is known from the measured magnetic field components. Solving the quadratic equation yields
[0000]
v
=
3
β
±
9
β
2
+
8
4
,
[0000] where the + sign is used if z 3 >d and the − sign is used if z 3 <d.
[0061] The quantities u and v are now known from MWD magnetometer data. From z=r·u=d+r·v, one obtains the desired radial distance from the MWD magnetometer to the axis of first well,
[0000]
r
=
d
u
-
v
.
[0062] Note that it is not necessary to know any of the axial positions (z 1 , z 2 , or z 3 ) to compute the radial distance between the two wells. The only information required is the known spacing between the two solenoids, d=z 2 −z 1 . However, if it is desired, the axial position of the MWD magnetometer can be computed from
[0000]
z
3
=
ud
u
-
v
.
[0063] Then, the direction from the MWD magnetometer to the first well axis is determined by
[0000]
θ
=
tan
-
1
(
y
3
x
3
)
=
1
2
(
θ
1
+
θ
2
)
,
[0000] with the caveat that the angle can be noisy opposite a solenoid. In this case, it is better to use the magnetic fields from the more distant solenoid. For SAGD wells, the vertical distance between the two wells is given by x 3 =r cos θ and the horizontal offset between the two wells is given by y 3 =r sin θ.
[0064] As described in further detail below, a downhole tool can contain three (or more) solenoids spaced along its length. The processing described above could, for example, be performed with pairs of solenoids to determine the radial distance between the two well bores and the direction from one to the other.
[0065] As first described above in conjunction with FIG. 3 , the solenoids can be constructed with a magnetic core (e.g. mu-metal) and multiple turns of wire. Typical dimensions for the core can be an outer diameter of 7 cm, and a core length between 2 m and 4 m. As seen in FIG. 3 , the magnetic core can have a central hole to allow wires to pass though. In an embodiment hereof, several thousand turns of solid magnetic wire (e.g. #28 gauge) are wrapped over the core and the entire assembly is enclosed in a fiberglass housing. If the downhole tool is to be subjected to high pressures, then the inside of the fiberglass housing can be filled with oil to balance external pressures. If the pressures are less than a few thousand psi, then the housing can be permanently filled with epoxy resin. In one embodiment, the outer diameter of the fiberglass housing is approximately 10 cm.
[0066] The magnetic dipole moment is given by M=N I A FF where N is the number of wire turns, I is the current, and A EF is the effective area which includes the amplification provided by the magnetic core. Experiments show that such a solenoid can produce a magnetic moment in air of several thousand amp-meter 2 at modest power levels (tens of watts). However, the magnetic dipole moment can be attenuated by 20 dB or more in a cased well. The amount of attenuation depends on the casing properties and on the frequency. The attenuation increases rapidly above about 20 Hz, so a desirable frequency range is 10 Hz and below. Experiments in casing indicate that an effective magnetic dipole moment on the order of a few hundred amp-meter 2 can be achieved with casing present.
[0067] To calculate the signal-noise ratio for an embodiment hereof, it is assumed that a precision of 0.1 nTesla can be achieved on each magnetometer axis with an AC magnetic field of a few Hertz.
EXAMPLE #1
SAGD Wells at 5 m Separation
[0068] In this example, the two solenoids are separated by a distance d=10 m and each solenoid has a magnetic dipole moment of M=100 amp-meter 2 . A SAGD injector well is to be drilled 5 m above the producer well. It is assumed that the MWD magnetometer is located at (x 3 ,y 3 ,z 3 )=(5 m,1 m,z 3 ), various quantities are plotted as a function of z 3 . The magnetic field components measured at the magnetometer (B 1r , B 1z , B 2r , and B 2z ) are shown in FIG. 7 . Noise with a standard deviation of 0.1 nTesla noise has been added to field components: B 1x , B 1y , B 1z , B 2x , B 2y , and B 2z . Note that the magnetic field is strongest over the range z 3 =−5 m to z 3 =+15 m. In FIGS. 8 to 11 , the axial position of the MWD magnetometer (z 3 ) is incremented in 1 m steps while inverting for r, x 3 , y 3 , and z 3 , respectively. The average results and standard deviations are also tabulated in Table 1 for two ranges: z 3 ε[0.5 m,9.5 m] and z 3 ε[−5.5 m,15.5 m]. The difference between the inverted value for z 3 and the actual value for z 3 is given (Δz 3 ). The results are best when 0≦z 3 ≦d, and still favorable when −5≦z 3 ≦d+5. These results are well within the tolerances needed for drilling a SAGD well.
[0000]
TABLE 1
Inverted parameters for example #1. The average value and the
standard deviation are given for each range of z 3 .
r (m)
x 3 (m)
y 3 (m)
Δz 3 (m)
Actual values
5.10
5.00
1.00
0.00
Inverted
5.13 ± 0.01
5.04 ± 0.01
1.00 ± 0.03
0.00 ± 0.01
values for
z 3 ∈ [0.5 m,
9.5 m]
Inverted
5.30 ± 0.12
5.20 ± 0.14
1.04 ± 0.08
−0.08 ± 0.32
values for
z 3 ∈ [−5.5 m,
15.5 m]
EXAMPLE #2
SAGD Wells at 10 m Separation
[0069] In this example, the two solenoids are again separated by a distance d=10 m and each solenoid has a magnetic dipole moment of M=100 amp-meter 2 . A SAGD injector well is to be drilled 10 m above the producer well. It is assumed that the MWD magnetometer is located at (x 3 ,y 3 ,z 3 )=(10 m,1 m,z 3 ), various quantities are plotted as a function of z 3 . The magnetic field components measured at the magnetometer are shown in FIG. 12 . Noise with a standard deviation of 0.1 nTesla noise has been added to all field components. In FIGS. 13 to 16 , the axial position of the MWD magnetometer (z 3 ) is varied in 1 m steps while inverting for r, x 3 , y 3 , and z 3 , respectively. The average results and standard deviations are also tabulated in Table 2 for two ranges: z 3 ε[0.5 m,9.5 m] and z 3 ε[−5.5 m,15.5 m]. The results are still good for 0≦z 3 ≦d, and still quite useful for −5≦z 3 ≦d+5.
[0000]
TABLE 2
Inverted parameters for example #2. The average value and the
standard deviation are given for each range of z 3
r (m)
x 3 (m)
y 3 (m)
Δz 3 (m)
Actual values
10.05
10.00
1.00
0.00
Inverted
10.23 ± 0.10
10.19 ± 0.08
0.91 ± 0.24
0.01 ± 0.03
values for
z 3 ∈ [0.5 m,
9.5 m]
Inverted
10.31 ± 0.46
10.26 ± 0.47
1.04 ± 0.06
−0.14 ± 0.17
values for
z 3 ∈ [−5.5 m,
15.5 m]
EXAMPLE #3
SAGD Wells at 15 m Separation
[0070] In this case, it is advantageous to separate the two solenoids to d=15 m and to increase the magnetic dipole moment to M=200 amp-meter 2 . It is assumed that the MWD magnetometer is located at (x 3 ,y 3 ,z 3 )=(15 m,1 m,z 3 ), and various quantities are plotted as a function of z 3 . The magnetic field components measured at the magnetometer are shown in FIG. 17 . Noise with a standard deviation of 0.1 nTesla noise has been added to all field components. In FIGS. 18 to 21 , the axial position of the MWD magnetometer (z 3 ) is varied in 1 m steps while inverting for r, x 3 , y 3 , and z 3 , respectively. The average results and standard deviations are also tabulated in Table 3 for two ranges: z 3 ε[0.5 m,14.5 m] and z 3 ε[−5.5 m,20.5 m]. The results provide an accuracy better than 1 m in all conditions, even with a potential uncertainty in z 3 of ±13 m.
[0000] TABLE 3 Inverted parameters for example #3. The average value and the standard deviation are given for each range of z 3 . r (m) x 3 (m) y 3 (m) Δz 3 (m) Actual values 15.03 15.00 1.00 0.00 Inverted 15.11 ± 0.40 14.93 ± 0.20 0.91 ± 0.86 0.04 ± 0.05 values for z 3 ∈ [0.5 m, 14.5 m] Inverted 15.64 ± 0.43 15.62 ± 0.67 0.43 ± 0.45 0.03 ± 0.17 values for z 3 ∈ [−5.5 m, 20.5 m]
If the first well is an open hole and the downhole tool can be safely run into the borehole, then a much greater range between the two wells can be accommodated because much stronger magnetic dipole moments are possible. Alternatively, if the noise in the MWD magnetometers can be reduced below 0.1 nTesla, then a greater range is also possible. This may be accomplished by averaging the signals over a longer time interval.
[0071] As above noted, more than two solenoids can be deployed in the downhole tool. For example, FIG. 22 displays a downhole tool with three solenoids, labeled {right arrow over (M)} 1 , {right arrow over (M)} 2 , and {right arrow over (M)} 3 , where {right arrow over (M)} 1 is located at z=0, {right arrow over (M)} 2 is located at z=d 1 , and {right arrow over (M)} 3 is located at z=d 1 +d 2 . The three solenoids can be activated sequentially in time to produce three corresponding magnetic fields measured at (x 3 ,y 3 ,z 3 ) . The three magnetic field readings are composed of radial and axial components: {right arrow over (B 1 )}=B 1r {circumflex over (r)}+B 1z {circumflex over (z)}, {right arrow over (B 2 )}=B 2r {circumflex over (r)}+B 2z {circumflex over (z)}, and {right arrow over (B 3 )}=B 3r {circumflex over (r)}+B 3z {circumflex over (z)}. Define
[0000]
u
≡
z
3
r
,
α
≡
B
1
z
B
1
r
=
2
u
2
-
1
3
u
,
v
≡
z
3
-
d
1
r
and
β
≡
B
2
z
B
2
r
=
2
v
2
-
1
3
v
[0000] as before. In addition, define
[0000]
w
≡
z
3
-
d
1
-
d
2
r
and
γ
≡
B
3
z
B
3
r
=
2
w
2
-
1
3
w
.
[0000] Since α, β, and γ are measured quantities, the three quadratic equations can be solved yielding
[0000]
u
=
3
α
±
9
α
2
+
8
4
,
v
=
3
β
±
9
β
2
+
8
4
,
and
w
=
3
γ
±
9
γ
2
+
8
4
.
[0000] The radial distance can be computed from any two pairs of observations. If the measurements from solenoids {right arrow over (M)} 1 and {right arrow over (M)} 2 are used, then
[0000]
r
=
d
1
u
-
v
and
z
3
=
ud
1
u
-
v
.
[0000] If the measurements from solenoids {right arrow over (M)} 1 and {right arrow over (M)} 3 are used, then
[0000]
r
=
d
1
+
d
2
u
-
w
and
z
3
=
u
(
d
1
+
d
2
)
u
-
w
.
[0000] Finally, if the measurements from solenoids {right arrow over (M)} 2 and {right arrow over (M)} 3 are used, then
[0000]
r
=
d
2
v
-
w
and
z
3
=
vd
2
v
-
w
+
d
1
.
[0072] The potential advantages of using three solenoids include the following. First, there is a greater axial range over which the inversion is accurate because the array is longer. The radial distance can be estimated from the nearest pair of solenoids (e.g. from the pair {right arrow over (M)} 1 +{right arrow over (M)} 2 or from the pair {right arrow over (M)} 2 +{right arrow over (M)} 3 ). Second, the accuracy also can be improved by averaging the results from different pairs of solenoids (e.g. from the pair {right arrow over (M)} 1 +{right arrow over (M)} 2 and from the pair {right arrow over (M)} 2 +{right arrow over (M)} 3 ). Third, if the radial distance is much greater than d 1 or d 2 , then the most accurate estimate may be given by the pair {right arrow over (M)} 1 +{right arrow over (M)} 3 . Similarly, arrays with more than three solenoids can be deployed.
[0073] Another embodiment of the invention is illustrated in FIG. 23 . The two solenoids {right arrow over (M)} 1 and {right arrow over (M)} 2 can be driven sequentially in time as previously described, or they can be driven simultaneously in parallel mode and simultaneously in anti-parallel mode. A double pole double throw (DPDT) switch 2311 is used in this embodiment to switch between parallel and anti-parallel modes. In parallel mode, the currents in the two solenoids are in phase so that the two magnetic dipole moments are parallel. In parallel mode, the magnetic field measured at (x 3 ,y 3 ,z 3 ) is {right arrow over (B p )}=(B 1r {circumflex over (r)}+B 1z {circumflex over (z)})+(B 2r {circumflex over (r)}+B 2z {circumflex over (z)}). In anti-parallel mode, the magnetic field measured at (x 3 ,y 3 ,z 3 ) is {right arrow over (B A )}=(B 1r {circumflex over (r)}+B 1z {circumflex over (z)})−(B 2r {circumflex over (r)}+B 2z {circumflex over (z)}). Hence, the magnetic fields from the individual solenoids can be obtained from
[0000]
B
1
r
r
^
+
B
1
z
z
^
=
1
2
(
B
p
+
B
A
)
and
B
2
r
r
^
+
B
2
z
z
^
=
1
2
(
B
p
-
B
A
)
.
[0000] Then, the previous analysis can be use to determine the radial distance from the z-axis.
[0074] As previously noted, yet another method for obtaining the magnetic fields from the two solenoids is to drive them at two different frequencies. Let solenoid {right arrow over (M)} 1 be driven by a current at frequency f 1 and let solenoid {right arrow over (M)} 2 driven by a current at frequency f 2 . Both solenoids can then be activated simultaneously. The magnetic field measured by the magnetometer located at (x 3 ,y 3 ,z 3 ) can be decomposed into the two frequencies by Fourier transform or by other well known signal processing methods. In this manner, the magnetic field contributions from the individual solenoids can be separated, and the previously described processing applied to determine the distance and direction to the z-axis.
|
A method for determining the distance and/or direction of a second earth borehole with respect to a first earth borehole, includes the following steps: providing, in the first borehole, first and second spaced apart magnetic field sources; providing, in the second borehole, a magnetic field sensor subsystem for sensing directional magnetic field components; activating the first and second magnetic field sources, and producing respective first and second outputs of the magnetic field sensor subsystem, the first output being responsive to the magnetic field produced by the first magnetic field source, and the second output being responsive to the magnetic field produced by the second magnetic field source; and determining distance and/or direction of the second earth borehole with respect to the first earth borehole as a function of the first output and the second output.
|
You are an expert at summarizing long articles. Proceed to summarize the following text:
FIELD OF THE INVENTION
This invention relates to an in-situ combustion method for recovering hydrocarbons from a subterranean hydrocarbon-bearing reservoir by fracturing the reservoir with a combustible fracturing mixture, burning the mixture and thereafter injecting fluidized carbon that is burned in the fractures with minimum formation of water of combustion thereby stimulating production of the reservoir hydrocarbons.
DESCRIPTION OF THE PRIOR ART
In modern day production of hydrocarbons from subterranean formations it is common practice to apply secondary recovery techniques to recover additional quantities of hydrocarbons. Among the more commonly used secondary recovery methods are thermal recovery methods. These methods include steam injection, hot water injection and in-situ combustion. Using these thermal methods, the in-situ hydrocarbons are heated to a temperature at which their viscosity is sufficiently reduced and their mobility is sufficiently improved so as to enhance their flow through the reservoir matrix toward a production well from which they are produced.
In the method of in-situ combustion, combustion is initiated in the subterranean hydrocarbon-bearing reservoir by one of many accepted means such as the use of a downhole gas-fired heater or a downhole electric heater or chemical means. After the face of the stratum adjacent the injection wellbore has been heated to at least 650°F and successful ignition has occurred, an oxygen-containing gas, such as air, is injected into the wellbore to support the combustion and to establish and move a combustion front through the reservoir towards a production well. As the combustion front moves through the reservoir, hot gases and liquids are displaced in advance of the combustion front, vaporize the more volatile components of the reservoir fluids and displace them ahead of the front. The higher boiling point components of the reservoir hydocarbons remain and serve to provide fuel for continuation of the combustion process.
The volatilized components of the reservoir fluids move substantially in the vapor phase until they reach a zone where the temperature of the reservoir is such that they are either condensed or absorbed in the oil. As the front moves through the reservoir a bank of reservoir hydrocarbons is built up ahead of the front which bank is displaced towards a production well from which the hydrocarbons are produced.
In the conventional in-situ combustion method wherein a portion of the hydrocarbons of the reservoir are burned, one of the products of combustion is water. This water is moved ahead of the front principally in the vapor phase together with those more volatile components of the hydrocarbon and condense in the cooler portions of the reservoir. The presence of the water and its intermovement with the hydrocarbons promote the formation of water-oil emulsions, that can create serious and costly problems. These problems include not only the adverse mobility effects because of the emulsion but also the difficulty of breaking the emulsion produced from the production well.
In many reservoirs, particularly limestone type reservoirs, the permeability of the reservoir is so low that production therefrom can be seriously limited. In order to stimulate production in these tight reservoirs one of the methods employed is that of fracturing the reservoir whereby artificial fractures or cleavage planes are formed extending from the wellbore into the hydrocarbon-bearing reservoir. These cleavage planes increase the permeability and porosity of the reservoir and thus provide flow channels which enhance the production of hydrocarbons therefrom.
The most commonly used procedure to induce fracturing is high pressure hydraulic fracturing. In that process, a fluid is displaced down a wellbore and into contact with the hydrocarbon-bearing reservoir at a rate higher than that at which the fluid can flow into and through the reservoir. On continued injection of the fluid, the pressure within the wellbore increases to a pressure at which the reservoir breaks down to create one or more fractures extending outwardly from the wellbore into the reservoir. Hydraulic fracturing fluids generally consist of aqueous liquids, hydrocarbon oils, or oil-water emulsions, to which solid particulate propping agents, viscosity thickeners, or other additives have been added.
Usually, after the artificial fractures have been created around a wellbore within a hydrocarbon-bearing reservoir, the solid particulate propping agents are caused to flow into the fracture. These agents function to hold the fracture at least partially open after release of the fracturing pressure on the fluid in the wellbore and in the fracture thereby providing a high capacity flow conduit to improve the fluid conductivities of the reservoir. While sand is the usual propping agent used for maintaining passages or channels within the fracture leading to the wellbore, other particulate materials such as metal shot, glass beads, and plastics, which have a high compressive strength, are used also.
The present invention seeks to overcome the problems caused by the formation of water of combustion by employing a "dry" in-situ combustion in which there is a minimum formation of water of combustion. The present invention is also applicable to tight reservoirs, i.e. those having low permeability, by utilizing a fracturing technique together with in-situ combustion as set forth herein.
SUMMARY OF THE INVENTION
This invention relates to a method for producing hydrocarbons utilizing in-situ combustion wherein the formation of water of combustion is minimized, by fracturing a reservoir with a combustible fracturing mixture, burning the mixture in the fractures and thereafter injecting into the formation finely divided or fluidized carbon in an inert gas carrier, together with an oxygen-containing gas so as to burn the carbon in the created fractures and to establish a hot inert gas drive through the reservoir.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In the instant invention a combustible fracturing mixture is employed, of the type described in U.S. Pat. No. 3,638,727 which relates to stimulating production from a subterranean hydrocarbon-bearing reservoir. This mixture comprises a combustible hydrocarbon fluid or petroleum fraction, such as kerosene, finely dispersed carbon or charcoal, and a particulate propping agent such as sand. Following the teachings of U.S. Pat. No. 3,638,727, in the instant invention after the reservoir has been fractured by conventional means, the fracture mixture is ignited by any of the techniques well-known in the art, and burned in the created fractures, thereby utilizing the combustibles of the mixture to create hot fracture zones in the reservoir. Once the combustion has been attained and the fracture zones are at temperatures high enough to sustain an in-situ combustion, a fluidized stream of finely dispersed carbon in an inert gas carrier is injected via a wellbore and into the created fractures. Simultaneously therewith, an oxygen-containing gas, such as air, is also injected to establish a "dry" in-situ combustion of the fluidized carbon in the fractures. The combustion of the fluidized carbon occurs upon its contact with the hot matrix of the reservoir.
Injection of the fluidized carbon stream and the oxygen-containing gas stream is continued until a predetermined amount of heat has been generated in-situ and transmitted to the reservoir. By the method of operation the heat transfer renders the in-place hydrocarbons more mobile because of viscosity reduction at the increased temperature. Alternatively, the injection of the fluidized carbon and the oxygen-containing gas can be continued, or once the desired amount of heat generated has been attained, injection of the two streams can be terminated. Thereafter, only a stream of inert gas is injected so as to provide a hot gas drive, whereby the heated hydrocarbon fluids are displaced through the created fractures towards a production well from which they are produced.
In one embodiment of the invention an injection well, that traverses the subterranean hydrocarbon-bearing reservoir, is completed with two tubing strings thereby providing means for the separate and simultaneous injection of the stream of the fluidized carbon in an inert gas carrier and the stream of the oxygen-containing gas.
In the application of this invention, there is first introduced into the subterranean reservoir, via the injection well, a combustible fracturing mixture comprising a combustible hydrocarbon fluid or petroleum fraction such as kerosene, a particulate propping agent such as sand, and finely dispersed charcoal. After a conventional fracturing operation has been conducted by well-known techniques to the point where fracturing has occurred as indicated, for example, by a pressure decline and the mixture has been displaced into the reservoir, the mixture is ignited within the formation stratum immediately adjacent the wellbore by any techniques known in the art, such as downhole gas heaters, electrical heating devices or chemical methods. Once ignition has been initiated, injection of the oxygen-containing gas such as air is continued to maintain the combustion of the fracturing mixture so as to heat the formation to a temperature required for the subsequent combustion of the carbon to be injected. A mixture containing 50,000 pounds of charcoal and 50,000 pounds of sand admixed with 3,500 barrels of kerosene is used for fracturing. After ignition and injection of the oxygen-containing gas, combustion of the fracturing mixture occurs. For an estimated air requirement of 190 MMCF, approximately 30 to 40 days are required to complete the combustion. During this period approximately 1.9 × 10 10 BTU of heat are generated and a temperature in the reservoir in the range of at least 650°-750°F is attained, which temperature is sufficient to establish the combustion of the fluidized carbon to be subsequently injected.
After combustion of the fracturing mixture has been completed, the injection of the stream of fluidized carbon and an inert gas carrier and the stream of an oxygen-containing gas (i.e., air) is undertaken. The fluidized carbon is forced into the created fractures wherein combustion occurs at the previously created high temperatures in the reservoir. In some instances it may be desirous to continue the simultaneous injection of these streams and produce the reservoir by the "dry" in-situ combustion process as the recovery mechanism. In other instances it may be desirous to terminate the injection of the stream of fluidized carbon in an inert gas carrier once a sufficient amount of heat has been generated in the created fractures. A sufficient amount of heat is that required to bring the reservoir temperature adjacent the fractures to a level such that the reservoir hydrocarbons are sufficiently mobile to be displaced through the reservoir by a subsequent inert gas drive. In some instances, a temperature level of 400°-500°F is sufficient to reduce the viscosity of the hydrocarbons to make them mobile enough for displacement. The following example illustrates the latter case wherein termination of injection after the desired amount of heat has been generated in the created fracture. Utilizing the air injection rate of 6.6 million cubic feet per day, approximately 588 million BTU's per day of heat are generated. For this amount of heat approximately 42,000 lbs. per day of fluidized carbon are used. Once the desired amount of heat has been generated within the reservoir, the injection of the stream of fluidized carbon in an inert gas carrier and the stream of the oxygen-containing gas is terminated. Injection of an inert drive gas is then undertaken whereby the reservoir is produced by hot gas drive.
The inert gas utilized as a carrier for the fluidized carbon and the inert gas that serves as a drive agent may be any inert gas, such as nitrogen, stack gas, flue gas, carbon dioxide and mixtures thereof. In one embodiment of the invention the source of the inert gas may be provided from the gas produced from the production well which is thereafter recycled to the injection well.
By the method of the invention an in-situ combustion is utilized to recover hydrocarbons from a reservoir in which process the formation of water of combustion has been minimized thereby inhibiting emulsion formation of produced hydrocarbons.
The advantages of minimal production of water also make the invention particularly attractive in its application to reservoirs containing water-sensitive clays. In cases of reservoirs containing clays that swell on contact with water conventional thermal techniques are generally precluded. Fresh water condensate hydrates the water-sensitive clays causing them to swell to the extent that the reservoir becomes substantially plugged. The invention also finds application to tight limestone reservoirs that necessitate a fracturing procedure.
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Hydrocarbons are recovered from a subterranean hydrocarbon-bearing reservoir by in-situ combustion with minimum formation of water of combustion by fracturing the reservoir with a combustible fracturing mixture, burning the fracturing mixture, and thereafter injecting fluidized carbon in an inert gas carrier while at the same time injecting an oxygen-containing gas so that the fluidized carbon is burned in the fractures for thermal stimulation of production of hydrocarbons from the reservoir.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
The structure of a digital lock has been repeatedly improved but such a lock can be opened by a thief who can overcome its mechanical characteristics. For example, by means of a difference in precision of lock rings, one can rotate lock rings one by one and find the exact number for opening the lock. Some locks may be opened by holding or rotating the handle and finding the exact position of lock rings through shaking or by finding a defect in their mechanical structure.
From an analysis the inventor has found that an ordinary digital lock has a projection on its locking piece which is vibrated during a small movement.
The inventor, considering such a defect and with careful research, has designed a floating locking piece without projections for making a reliable digital lock.
SUMMARY OF THE INVENTION
Whenever the position of any lock ring is not proper, the lock is in a locking condition and not an opening condition. The locking piece is then pressed. If the handle is pressed (or rotated), the locking piece is being clipped firmly and it can not be raised.
Whenever the position of all lock rings are proper, i.e., all key slots of lock rings are on the locking piece, the locking piece is automatically raised due to the spring. Then, by means of pressing or rotating the handle, the locking piece is pushed and the lock is opened.
In practice, tension of a spring should be enough to float the locking piece. With a key having a radial slot on the lock ring, when pressing of the locking piece by each lock ring is at an improper position, no one will be able to open the lock with his mechanical sense rather than opening it the proper way.
Another characteristic of the invention is the availability of number adjustment. There is a turn section on a specially designed spring coil. Such a turn is called a number adjustor, which sets its relative position with the key slot of the lock ring and changes the numbers accordingly. The method of adjustment is only by picking up the number adjustor and turning it along the slot way.
Another characteristic of the invention is the design of steel balls which make noise. Steel balls are put into conical spaces so that whenever they are pressed, there is a noise which shows the degree of lock ring turning.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view of the lock.
FIG. 2 is a front view of the lock.
FIG. 3 is a section view taken along line E--E of FIG. 2.
FIG. 4 is a front view of the setting lock ring.
FIG. 5 is a sectional view taken along line C--C in FIG. 4.
FIG. 6 is a back view of the setting lock ring.
FIG. 7 is a sectional view taken along line D--D of FIG. 4.
FIG. 8 is an enlarged view of the steel ball in setting the lock ring prior to its being pressed.
FIG. 9 is an enlarged view of steel ball in setting the lock ring which is being pressed.
FIG. 10 is a top plan view of the setting spring.
FIG. 11 is a front view of the setting spring.
FIG. 12 is a sectional view taken along line F--F of FIG. 1.
FIG. 13 is a sectional view taken along line G--G of FIG. 16.
FIG. 14 is a front view of the locking piece.
FIG. 15 is a side view of the locking piece.
FIG. 16 is a section view of the lock in an opened condition.
FIG. 17 is a sectional view of the lock in an locked condition.
FIG. 18 is a sectional view taken along line B--B of FIG. 1.
FIG. 19 is a sectional view taken along H--H of FIG. 17.
FIG. 20 is a sectional view taken along line A--A of FIG. 1.
______________________________________(1) Lock Barrel (31) Sliding Slot(2) Square Head (32) Aux. Vibrating Piece(3) Lock Cylinder (33) C-Type Fastener(4) Nut (34) Slider(5) Handle (35) Short Sliding Way(6) Cutting Slot (36) Line of Centers(7) Locking Piece (37) Lock Ring(8) Plate Spring (38) Setting Lock Ring(9) Pin (39) Ring Slot(10) Tip of Locking Piece (40) Resetting Block(11) Positioning Block (41) Setting Pin(12) Stop Block (42) Flange(13) Arched Edge (43) Hole(14) Brake Box (44) Steel Ball(15) Opening (45) Circular Inner Edge(16) Spring (46) Radial Key Slot(17) Fixing Disc (47) Metal Plate(18) Hole (48) Plastic Body(19) Tenon (49) Counter Sunk Screw(20) Screw (50) Key Slot(21) Tip Cover (51) Spring(22) Fixing Box (52) Conical Space(23) Tail Fin (53) Direction of Pressure(24) Floating Stop (54) Opening(25) Guide Post (55) Slot Way(26) Conical Spring (56) Setting Ring(27) Push Key (57) Hole(28) Main Vibrating Piece (58) Positioning Key(29) Hinge Pin (59) Key Slot(30) Torsional Spring______________________________________
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows a sectional view indicating the lock in which the floating locking piece is above key slots of all lock rings and once the push key is pressed, the lock is in an opened condition.
The lock has a lock barrel (1). At the front of the lock barrel there is a larger square head (2). Such a square head (2) will cause extension and contraction of lock tongue (not indicated) by means of its own rotation. The lock barrel is surrounded by a lock cylinder (3). Its ends are fixed with a nut (4) and a handle (5) respectively. Its central hole provides space for rotation of the lock barrel (1). On the top of lock cylinder (3) there is a cutting slot (6) for placing a floating locking piece (7) (please refer to FIG. 14 for its detailed structure). On its bottom there is a plate spring (8). Its left lateral is an unfixed free lateral and its right lateral is fixed to the locking piece (7) by means of a pin (9) (please refer to FIG. 14). The right front end of the said locking piece (7) has a corner cut so that when all lock rings are in an opening position, locking piece (7) rises up to the key slot (50) (FIG. 20) where all locking rings are matching, front end (10) of locking piece (7) has its top contacted with a positioning block (11). When locking piece (7) is being pressed and moved forward, the said positioning block (11) can contact the front opening of the locking piece (7) and prevent the locking piece (7) from further moving (please refer FIG. 16). And when any of the lock rings is turned, locking piece (7) is being pressed downward and wholly fallen into the cutting slot (6). Then, the front end of the locking piece (7) is stopped by a stop block (12) and its forward movement becomes impossible, so that turning the lock barrel (1) is not possible and such a state is called "the locking condition" (refer to FIG. 17). At such a condition, if one is trying to open an ordinary digital lock without knowing the number, generally, he will push the handle, and then try every lock ring in order to sense a shaking. With the invention herein, since the locking piece has fallen, if the handle is pressed, the locking piece will be clipped by the pressing force and stop block (12). Therefore, even when the right number is turned, the locking piece (7) will not rise and the one who is trying to open the lock will not know that the lock is in an opened condition.
The said locking piece (7) has an arched edge (13) on the right end. Such an edge contacts with opening (15) of brake bos (14) directly. A spring (16) is also used to keep a constant and close contact between the edge (13) and opening (15). An end of the said spring (16) is fixed to hole (18) of fixing disc (17) and the other end is fixed to external of tenon (19) on the locking piece (7).
Said fixing disc (17) is fixed to the right hand extremity of lock cylinder (3). Handle (5) is directly or indirectly fixed to fixing disc (17) and lock cylinder (3) by means of screws (20) (3 screws in the embodiment herein). Handle (5) is covered with a top cover (21) (FIG. 1).
On the right side of said fixing disc (17) there is a fixing box (22). At the right end of said locking piece (7) there is a tail fin (23), the top of which is controlled by the fixing box (22). The floating stop (24) at fixing disc (17), controls the maximum floating of said locking piece (7).
The said tail fin (23) has a small projection at its bottom so that when the locking piece (7) is pressed down, said projection can stop the lock barrel (1) and improve stability of the locking piece (7) while going downward.
On the fixing box (22) there is a brake box (14), which has two guide posts on both sides of the locking piece (7) (refer to FIGS. 12-13). A concial spring (26) is designed between the fixing box (22) and brake box (14) so that when the brake box (14) is being pressed down, it can be as close as possible to the fixing box (22) (refer to FIG. 13). Above the brake box (14) there is a push key (27) which is projected beyond the handle (5). By means of two springs (26) and pressing by hand on (27), brake box (14) moves up and down. In addition, there is a transmission mechanism between lock barrel (1) and brake box (14). This mechanism transfers the up and down linear movement of push key (27) into rotating movement of lock barrel, (1) which will be discussed in detail soon.
Referring to FIG. 1, surrounding the lock cylinder (3) there are four lock rings (37) and two setting lock rings (38). Structure of the lock ring (37) is shown in FIGS. 2-3. In the ring there is a ring slot (39). At a certain place of the ring slot (39) there is a resetting block (40). Said ring slot (39) allows setting pin (41) of the setting lock ring (38) to move therewithin and by the stopping of setting pin (41) with a resetting block, the number can be reset prior to opening of lock.
The said lock ring (37) has a flange (42) which has ten holes (43) of equal distance. Such holes match with steel ball (44) on the setting lock ring (37). When lock ring (37) is turned, the degree of turning can be clearly read.
At the center of lock ring (37) there is a hole (45) for passing through lock cylinder (3) and there is a key slot (46) for passing locking piece (7) (refer to FIG. 18).
FIGS. 4-7 show the detailed structure of the setting lock ring (38). FIG. 5 is a sectional view taken from line C--C of FIG. 4. FIG. 6 is a sectional view taken from line D--D of FIG. 6. FIG. 4 and FIG. 6 are front views of a setting lock ring (38) at two different viewing directions. As shown in FIG. 6, a setting lock ring (38) is composed of two metal plates (47) with a plastic body (48) between them. It is fixed with two counter sunk screws (49) (refer to FIG. 6). Each setting lock ring (38) has a steel ball (44) and the steel ball (44) tends outwardly by means of a spring (51). A space for moving the steel ball (44) is shown in FIGS. 7-8. It is a conical space (52). When a steel ball (44) is subject to pressure in the arrow direction (53), it will fall into the position shown in FIG. 9. When external force disappears, the ball hits wall surface A directly as indicated by FIG. 9 and thus there is a noise which tells degree of the degree of turning of a lock ring (37).
Both flanges of setting lock ring (38) have ten equi-distant openings (54) respectively. An inner ring of said openings is marked with 0, 1, 2, . . . 9 correspondingly. The flange of said setting lock ring (38) has two slot ways (55) for placing of an elastic setting ring (56). The structure of said setting ring (56) is shown in FIG. 10. An end of it is turned toward the axis to form a setting pin (41) which is to be held in between openings (54) and projected outward. In selecting a number, one will only have to place the setting pin (41) in the required opening (54).
At the center of said setting lock ring (38) there is a hole (57) for inserting of the lock cylinder (3). There is also a positioning key (58) and a key slot (59). The positioning key 58 is to slide along key slot (50) of the lock cylinder (3) (as shown in FIG. 20) in order to fix the setting lock ring (38) and prevent it from rotating, while the key slot (59) is for passing and floating of the locking piece (7).
As shown in FIG. 1, the embodiment herein has four lock rings (37) and two setting lock rings (38), wherein a setting lock ring (38) is located between two lock rings (37) and the setting lock ring (38) is contacting booth lock rings (37). Steel ball (44) is fixed at lock ring (37) by means of spring tension (51) at the hole (43). Setting pin (41) on both sides of the setting lock ring (38) projects into the ring slot (39) on the lock ring (37) beside it. Because of the setting lock ring (38), the pin is fixed and not movable. Either at the locking or opening condition, the setting lock ring (38) can rotate freely along lock cylinder (3). Therefore, in the opening process, all lock rings (37) have to be turned till the resetting blocks (40) contact with and project into the ring slots (39). And then, given a predetermined number sequence, rotate each lock ring (37) and therefore the steel balls (44) which are pressed and fall into holes (43). By means of sensing the contacting noise from the steel balls (44) against the wall surface A is conical space (as shown in FIG. 9), one will know when the number desired is attained and the key slot (46) of lock ring (37) is matched with the locking piece (7). The locking piece (7), as shown in FIG. 1, floats above the key slots (46) of all lock rings (37) so that the lock is in an opened condition. The invention can be opened at night time or in a dark place by human sense and the noise of the steel balls (44) without the draw backs of ordinary digital locks which has its members marked on its surfaces and requires light when opening the lock at night or in a dark place.
For locking the lock, as shown in FIG. 17, one will only have to rotate one or more lock rings (37) which causes the locing piece (7) to fall and press into the cutting slot (6) of lock cylinder (3) (refer to FIG. 19). At this moment, since the front terminal of the locking piece is engaged by the stop block (12) it can not move forward further. Since the push key (27) is not able to be pressed downward for turning the lock barrel (1), then the lock tongue will not be moved (not indicated in the drawing) for opening. After locking, locking piece (7) is "floating" due to the uniform tension of spring (8) and so, it will not be opened easily because of the irregular floating due to stop block (12). A sample for this embodiment is available for experimental and trial use. Since the locking piece (7) will fall uniformly, no one can sense contact between the locking piece (7) and the key slot (46) of lock ring (37) and then find the position of key slot (46). Even if there were a possibility of irregular floating of the locking piece 7 (in fact it is not possible) while ring (37) is being turned, the steel balls (44) are being pressed and there is a force applied thereto which force is larger than the floating force of locking piece (7). Furthermore, when the key slot (46) of the lock ring (37) matches with the locking piece (7), at that instant, the steel ball (44) falls into the hole (43), and since the force received by the steel ball (44) is large, the impact is bigger than the impact of locking piece (7) to key slot (46).
The following describes how lock barrel (1) is rotated to a certain degree by means of pressing the push key (27) in an open condition as indicated in FIG. 1 in order to make the lock tongue contract for opening the door.
Referring to FIGS. 1, 12, and 13, there is shown a mechanism consisting of a main vibrating piece (28), which oscillates with hinge pin (29) as a pivot. There is a torsional spring (30) at hing pin (29) so that the main vibrating piece can keep a close contact with brake box (14). Furthermore, the main vibrating piece (28) has an arched sliding slot (31) on it. The sliding slot (31) provides a path for oscillation of the main vibrating piece (28) so that the scope of oscillation is limited to the sliding slot (31). On the lock barrel (1) there is an auxillary vibrating piece (32) which has a terminal fixed to the lock barrel (1) by means of C-type fasterer (33) and the other terminal slides within the short sliding way (35) of the main vibrating piece (28). Please note the difference between FIG. 12 and FIG. 13. FIG. 12 is at normal condition without pressing key (27) down and the FIG. 13 is when key (27) is pressed, i.e., with the key (27) pressed down, lock barrel (1) is turned and the door is opened.
As shown in FIG. 12, the brake box (14) is subject to tension of the spring (26) and is pushed to the highest position algon with the push key (27). At this moment the position of lock barrel (1) is as that of line of centers (36) (FIG. 12). In FIG. 12, when push key (27) is pressed down, the main vibrating piece (28) turns downward. Lock barrel (1) is driven by the auxillary vibrating piece (32) and then the door is opened (please compare the line of centers (36) and change in degree of (36') for details).
As shown in FIG. 16, when the push key (27) is in a pressed condition, the floating locking piece (7), since there is no stop at its front, allows the push key (27) to be pressed down and this is the so called open condition.
As shown in FIG. 1 and FIG. 17, when lock ring (37) is at a proper position, locking piece (7) can be floated above key slot (46) and if the lock ring (37) is not in a proper postion, the locking piece (7) is pressed into the cutting slot (6).
FIG. 20 shows the installation of setting lock ring (38) at lock cylinder (3).
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Disclosed herein is a structure for an adjustable digital lock which is mainly characterized by its floating locking piece which controls rotation of a locking barrel, especially the one which can not be opened whenever the position of any lock ring is not proper or the opening method is not proper or when user can open the lock through listening to sounds; in which the number for such an adjustable digital lock can be easily changed by user.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of my copending application Ser. No. 912,727, filed Aug. 4, 1992, now U.S. Pat. No. 5,283,976, which is a continuation of my application Ser. No. 729,222, filed Jul. 12, 1991, now U.S. Pat. No. 5,131,186, issued on Jul. 21, 1992, which is a continuation-in-part of my copending application Ser. No. 07/372,839, filed on Jun. 29, 1989, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to apparatus for preventing unauthorized entry into buildings via window openings. More particularly, the invention relates to a portable apparatus which may be installed in a window opening to permit air and light to enter a building, while preventing persons from entering the building through the window opening.
2. Discussion of Background Art
It is an unfortunate fact that the crime rate in our country is on the increase. Thus, many individuals who because of their geographic location, away from high crime rate areas, or for other reasons, felt themselves immune from the crime problem, must now confront one manifestation of that problem; namely the ever-increasing rate of business and residential burglaries.
Most rational individuals would not wish the material fruits of their labors to be stolen from them by burglars. More importantly, most people are genuinely concerned that those criminals who would break into their dwelling places or residences to steal their possessions often are the type of individuals who would just as soon kill or injure the owner or his loved ones, should they be present during the course of a burglary.
As a result of their concern for the protection of their property, and the lives of themselves and their loved ones, a substantial percentage of the population have begun to take measures to protect themselves from burglars. For example, many homeowners and business owners have installed more secure door locks, and burglar alarms in their homes and shops. Another form of protection which has found increasing favor are security bar devices which, when installed over window openings or doorways, provide a very effective barrier to unauthorized entry through the protected opening. Such security bar devices generally take the form of a grill comprising a parallel array, or lattice array of heavy metal bars which are spaced closely enough to prevent passage through the array by a person.
Security bar devices of the type described above generally provide an effective means of preventing undesired entry to buildings through the protected areas. However, most such security bar devices suffer from one or more disadvantages which limit their wider usage. For example, many older security bar devices are not equipped with a safety mechanism which permits escape of the building occupants in the case of fire or other accidents within the building, or the entrance of firemen or other emergency personnel. Unfortunately, the absence of such a safety release provision in some security bar devices has resulted in the tragic loss of life.
Although there are now available security bar devices that are provided with safety release mechanisms, these as well as the older type security bar devices have an inherent feature which limits their more widespread usage. Specifically, most available security bar devices are relatively heavy and costly, and are intended for relatively permanent, and correspondingly costly, installation. Accordingly, such security bar devices are generally unsuitable for people who rent or have limited incomes. Some devices have been disclosed which would seem to address the problem of providing a security bar device which might be usable in non-permanent installation applications. Typical of such disclosures are those contained in the following U.S. patents:
Iyersen, U.S. Pat. No. 4,757,465, Mar. 18, 1986, Security Grill Apparatus for Doors and Windows.
Zilkha, U.S. Pat. No. 4,624,072, Nov. 25, 1986, Adjustable Security Window Gates.
Merklingen, et al., U.S. Pat. No. 4,671,012, Jun. 9, 1987, Security Barrier.
Jokel, U.S. Pat. No. 4,680,890, Jul. 21, 1987, Window Intrusion Barrier.
The present invention was conceived of to provide a security grill apparatus which is highly portable and useable in window openings of various dimensions.
OBJECTS OF THE INVENTION
An object of the present invention is to provide a portable security grill apparatus which may be readily installed in a window opening, while providing an effective bar to entrance by individuals through the window opening.
Another object of the invention is to provide a portable security grill apparatus for windows which is readily adjustable to fit within various height spaces between a window sill and the bottom of a raised window.
Another object of the invention is to provide a portable security grill apparatus for windows which may be quickly and securely clamped into a compressively locking contact between parallel structural members, such as the lower surface of a raised window and the upper surface of a window sill.
Another object of the invention is to provide a portable security grill apparatus for windows which may be optionally secured in locking position with a key lock, after being compressively locked into position.
Another object of the invention is to provide a portable security grill apparatus for window openings which may be quickly unlocked and removed from a window opening.
Various other objects and advantages of the present invention, and its most novel features, will become apparent to those skilled in the art by perusing the accompanying specification, drawings and claims.
It is to be understood that although the invention disclosed herein is fully capable of achieving the objects and providing the advantages described, the characteristics of the invention described herein are merely illustrative of the preferred embodiment. Accordingly, I do not intend that the scope of my exclusive rights and privileges in the invention be limited to details of the embodiments described. I do intend that equivalents, adaptations and modifications of the invention, reasonably inferable from the description contained herein be included within the scope of the invention as defined by the appended claims.
SUMMARY OF THE INVENTION
Briefly stated, the present invention comprehends a portable security grill apparatus for removable installation in openings in the walls of structures such as shops, industrial buildings, and dwelling places such as homes and apartments. The apparatus according to the present invention is particularly well adapted to removable installation in window frames with the window slid to an open upper or side position. The apparatus prevents unauthorized entrance through the window opening, while allowing the window to be open for ventilation purposes, and allowing light to enter the room protected.
The portable security grill apparatus according to the present invention includes a grill comprising a plurality of regularly spaced horizontally disposed rigid metal bars, welded to a plurality of vertically disposed, hollow rigid metal bars. The lower ends of the vertical bars are fastened to a horizontally disposed, flat lower beam adapted to seat firmly against the upper surface of a window sill. The upper ends of the hollow vertical bars slidably contain a short bars. Each of the upper ends of the short bars is in turn attached to a horizontally disposed, flat plate adapted to seat firmly against the lower surface of an open window, or window frame. The lower beam and each of the upper plates support resilient pads which have concave depressions to form suction cups which grip the window frame surfaces. Also, window clamps extend coextensively along the outside edge of the lower beam and upper plates and seat over the inside flanges of the window tracks, thereby firmly interlocking the grill apparatus in place.
Toggle clamp mechanisms are connected between each short bar and the hollow bar in which it is positioned. When the toggle clamp mechanism is compressed into its closed position, the short bar is forced upwards with respect to the hollow bar to which it is joined by the toggle clamp mechanism. Thus, closing the toggle clamp forces a short bar to move telescopically upwards, moving its upper plate upwards.
Means are included within the toggle clamp mechanism to adjust the amount of upward travel of the short bar and its upper plate. Also, the toggle clamp mechanism is so constructed as to have a substantial mechanical force advantage. Therefore, a substantial compressive force may be exerted between the upper and lower window frame members when the toggle clamps are closed. That force is sufficiently large to preclude pulling the security bar apparatus from the window frame, without releasing the toggle clamp operating lever, and the resistance of the apparatus to dislodgement is enhanced by the resilient pads and window clamps which are secured to each of the lower beam and upper plates. Since the toggle clamp lever is located inside the structure protected, it is not accessible to an intruder. In the preferred embodiment of the apparatus, a key lock is attached to the toggle clamp, permitting release of the toggle clamp lever only by first inserting a key and turning the key lock to an unlocked position.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an inside elevation view of the security grill apparatus according to the present invention, showing the apparatus installed in a window opening;
FIG. 2 is a fragmentary side elevation view of the apparatus of FIG. 1, on a somewhat enlarged scale, showing the apparatus in a retracted position;
FIG. 3 is a view similar to FIG. 2, but showing the apparatus in an extended position;
FIG. 4 is a fragmentary side elevation view of the apparatus of FIG. 1, showing the toggle clamp mechanism in a closed and locked position;
FIG. 5 is a fragmentary front elevation view of the apparatus of FIG. 4, showing the lever of a toggle clamp forming part of the apparatus pivoted into an upward position;
FIG. 6 is a top view of the window frame clamp pad used with the security grill apparatus of this invention;
FIG. 7 is an elevational view of the window frame clamp pad shown in FIG. 6;
FIG. 8 is an elevational view of the clamp pad engaged against a window frame;
FIG. 9 is a enlarged view of the area within line 9--9' of FIG. 3, showing the window clamp and clamp pad used in the invention; and
FIG. 10 is a perspective view of a window clamp used with the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIGS. 1 through 5, a portable security grill apparatus 10 is shown. As shown in FIG. 1, the apparatus 10 is vertically positioned for installation in a window frame with a horizontally slidable window. However, the apparatus may also be oriented for installation in a window frame having a vertically slidable window.
As shown in FIG. 1, the security grill apparatus includes a grill 11 having a plurality of elongated straight rigid metal bars 12. Bars 12 are arranged in vertically disposed parallel positions, at regular horizontal intervals, and all lie in a common plane.
As may be seen best by referring to FIGS. 1, 2 and 3, at least the upper end of each of the bars 12A contains a hollow coaxial bore 13 extending longitudinally inward some distance from the upper transverse face 14 of the bar 12A. Preferably, bars 12 and 12A are fabricated from square cross-section, hollow steel tubes. When so fabricated, bore 13 has a square cross-sectional shape, and extends through the entire length of a bar 12 or 12A.
The lower transverse ends 15 of bars 12 are welded or otherwise secured to a flat, elongated rectangular base plate 16 made of steel or other rigid material. The lower surface of base plate 16 supports an elongated rectangular pad 17 formed of an elastomer, preferably rubber, which is secured to plate 16 with a plurality of rivets (not shown) at spaced-apart locations. The rivets pull the pad 17 into a plurality of cup depressions (see FIG. 2) in the uncompressed state. The plate 17 also supports an elongated window clamp 22, described in greater detail with reference to FIGS. 2, 3, 9 and 10.
As may be seen best by referring to FIG. 1, grill 11 of security grill apparatus 10 includes a plurality of elongated, straight rigid metal cross bars such as upper bar 18A and lower bar 18B. Cross bars 18A and 18B are arranged in horizontally disposed parallel positions, at regular vertical intervals. The cross bars are welded to the front, or inner surface of vertical bars 12, thus forming therewith a rigid, planar grill structure. Cross bars 18A and 18B may be fabricated from the same type of steel tubing as vertical bars 12, if desired.
As may be seen best by referring to FIG. 1, grill 11 of security bar apparatus 10 includes at least a pair of upper clamps 19 which are spaced apart at locations which are preferably symmetrical across the apparatus 10. Each of the clamps 19 is vertically telescopable with respect to lower section 20 of the grill 11, in a manner which will now be described.
As shown in FIGS. 1, 2 and 3, each clamp 19 includes an upper elongated rectangular flat steel plate 21, which is substantially identical in thickness and width to base plate 16, and can be of a variable length. Each plate 21 supports a clamp pad 25 of the same rubber material as clamp pad 17 and which is secured to plate 21 by spaced-apart rivets, forming cup shaped depressions, as described for pad 17. Each base plate 21 supports a coextensive window clamp 22.
Each clamp 19 includes a straight, relative short metal bar 23, which is fastened to plate 21, and which extends perpendicularly downwards from the plate. The short metal bars 23 have smaller outer cross-sectional dimensions than the corresponding dimensions of the bores 13 in long vertical bars 12A and are telescopingly received therein, to permit the clamps 19 to move up and down vertically with respect to lower section 20 while maintaining the upper plates 21 in parallel alignment with the lower plate 16.
As shown in FIG. 1, a toggle clamp mechanism 24 is operatively interconnected between the upper portion of a hollow vertical tube 12A and a short vertical bar 23 which is telescopically slidably located within the bore 13 of the vertical bar 12A. Preferably, each security bar apparatus 10 includes two such toggle clamp mechanisms 24, spaced at equidistant intervals from the lateral sides of the grill 11.
The structure and operation of toggle clamp mechanism 24 may be best understood by referring to FIGS. 2, 3, 4 and 5. FIG. 2 illustrates the toggle clamp mechanism 24 in an open position, in which the short metal bars 23 are in a downward, retracted relationship relative to the lower vertical bars 12. In this position, the clamp pad 17 rests on the upper surface or sill A of a window frame and the upper clamp pads 25 are positioned below the lower surface C of the window frame.
The window is a conventional horizontal sliding window with an upper track 64 and a lower track 63 with one or two sliding glass panels 44 and 46.
As shown in FIGS. 2, 9 and 10, each of the plates 16 and 21 support coextensive window clamps 22, formed of sheet metal. Each clamp 22 has a flat web that projects to the inside edges of window tracks 64 and 63. The clamp 22 is bent into a channel 37 having a width sufficient to receive the inside flange of each track 64 and 63.
As shown in FIG. 10, the opposite ends of each channel 37 are chamfered, preferably at 45°, to prevent binding of the sliding window panels.
As shown in FIGS. 2, 3, 4 and 5, the toggle clamp mechanism 24 includes a channel frame section 26 which is fastened to an outer vertical surface of a lower rigid vertical bar 12A. The toggle clamp mechanism 24 also includes a multi-component lever mechanism 27 which is vertically slidably attached to the channel frame section 26, and pivotally attached to a short vertically disposed, metal upper bar 23, the latter being vertically slidable within the bore 13 of lower tubular bar 12A.
As shown in FIGS. 2, 3, 4 and 5, the lever mechanism 27 of toggle clamp mechanism 24 includes a base plate 28, an operating arm 39, and an engagement lug 30. The base plate 28 of lever mechanism 27 is vertically slidably supported within channel frame section 26, as will now be described.
Channel frame section 26 has a tubular lower end 31 of relatively short length, the major, upper portion of the channel frame section 26 having the shape of a vertically elongated, open U-shaped channel 32. The opposite upper edges of the side walls of channel 32 flare inwardly to form opposed laterally spaced-apart, longitudinally disposed parallel flanges 33 (see FIG. 5). Base plate 28 has a generally uniform thickness, and has in elevation view the approximate shape of a vertically elongated trapezoid. The inner vertical surface 34 of base plate 28 is flat and adapted to move slidably on the bottom surface 35 of channel 32 of channel frame section 26. Near the bottom end of base plate 28, are rounded bosses 36 (see FIG. 5) which project perpendicularly outward from the front and rear vertical surfaces 37 and 38, respectively, of base plate 28. The lateral distance between the outer surfaces of bosses 36 is greater than the distance between the inner facing wall surfaces of flanges 33 of channel frame section 26. Thus, base plate 28 is vertically slidable within channel 32 in channel frame section 26, but prevented from moving laterally out of the channel by contact of bosses 36 with flanges 33.
As shown in FIGS. 1 through 5, the lever mechanism 27 of toggle clamp mechanism 24 includes an outer lever arm 39. Lever arm 39 is an elongated member having an upper channel-shaped portion 40 having front and rear side walls 41 and 42 (see FIG. 5) formed therein. The lateral spacing between the inner surfaces of front and rear side walls 41 and 42 of upper channel section 40 of lever arm 39 is slightly larger than the thickness of base plate 28 of lever mechanism 27. This difference permits the upper end of base plate 28 to reside pivotally within channel section 40 of lever arm 39. The pivotal joint between base plate 28 and lever arm 39 consists of a pivot pin 43 which extends through registered holes and in the front and rear sidewalls 41 and 42, respectively, of upper channel section 40 of the lever arm. Pivot pin 43 is located about one-fifth of the longitudinal distance between the upper and lower ends of the lever arm 39.
The upper end of lever arm 39 is secured to a generally trapezoidal or triangular shaped lug 47 of generally uniform thickness, pivotally held between the front and rear walls 41 and 42 of the lever arm. The lug can be fixedly secured, by welding, to the short bar 23. The inner, smaller vertex or base of lug 47 is pivotally attached within the upper channel section 40 of lever arm 34 by means of a pivot pin 48 fastened in holes in the front and rear walls, and passing through a clearance hole through the lug.
The lower end of lever arm 39 has a generally flat plate-like handle section 54. Plate-like handle section 54 has a flat outer lateral surface 55. Plate-like handle section has a generally rectangular plan-view shape and is joined near its upper end to the lower ends of front and rear side walls 41 and 42 of upper channel section 40 of the lever arm 39, perpendicular thereto. A generally uniform-thickness locking tab 56 having a generally triangular-shaped plan-view is fastened to the inner wall surface of the lower end of front side wall 41 of upper channel section 40. Locking tab 56 lies in a vertical plane and extends perpendicularly inward from the inner wall surface 57 of plate-like lower handle section 54.
FIG. 3 illustrates the grill 10 in place and compressed within the window. The compression flattens the base clamp pad 17 and its cup-shaped depressions function as suction cups to enhance the resistance of the grill against dislodgement from the window. Similarly, the clamp pads 25 associated with each clamp 19 are flattened and secure against the under surface C of the window frame.
The channels 37 which extend coextensively with plates 16 and 21 are received over the inner flanges of window tracks 64 and 63 to interlock the grill to the window and prevent its dislodgement.
As may be seen best by referring to FIGS. 2 and 3, lever arm 39 may be pivoted in a vertical plane with respect to channel frame section 26 of toggle clamp mechanism 24, about intermediate pivot pin 43. As shown in FIG. 3, downward and inward pivotal motion of lever arm 39 relative to channel frame section 26 and attached lower tubular vertical bar 12 moves lug 47 upwards. This in turn moves upper vertical bar 23, which is engaged by lug 47 which is rigidly secured to the upper vertical bar 23, upwards with respect to the lower tubular 12. Thus, as shown in FIGS. 2 and 3, base plate 16 and roof plate 21 are spread apart vertically, allowing a compressive force to be exerted between window sill A and window top frame C. Owing to the fact that the ratio of the distance between the lower end of handle section 54 and intermediate pivot pin 43 on the one hand, and the distance between the intermediate pin 43 and upper pivot pin 48, on the other, is about 5 to 1, a substantial, locking compressive force may be exerted which requires only a modest closing force on handle section 54. This force can be sufficiently great to render the removal of the security bar apparatus 10 from a window frame a virtual impossibility unless the window and/or frame are destroyed.
As shown in FIGS. 2 through 5, a threaded stud 58 is contained in a threaded bore 59 in lower tubular end 31 of channel frame section 26. Stud 58 is an adjustable support for the lever mechanism, as the upper end 60 (see FIG. 5) of the threaded stud abuts the lower end 61 of base plate 28 of lever mechanism 27, thus permitting the lower limit of motion of the base plate to be adjusted to a desired value. Thus, turning threaded stud 58 permits adjusting the locked and unlocked vertical extension of security bar apparatus 10 to fit various size window openings.
As shown in FIG. 2, the lower end of base plate 28 and locking tab 56 are provided with through holes 62 and 63, respectively. Holes 62 and 63 are equal distances from intermediate pivot pin 43. Thus, with the toggle clamp mechanism 24 in a locked position, as shown in FIG. 3, holes 62 and 63 are in a registered position, permitting a locking member, such as the hasp of a conventional combination or key lock, to be inserted through the holes.
As may be seen best by referring to FIGS. 1 and 4, the upper portion of each toggle clamp mechanism 24 is preferably concealed by means of a U-channel-shaped cover 71 which is fastened to the outer wall of upper channel-shaped portion 40 of lever arm 39 by any convenient means.
Referring now to FIGS. 6 through 8, the construction and functioning of the resilient pads 25 and 17 will be described. As previously mentioned each pad is formed of an elastomer, preferably rubber, and is attached to its supporting plate 16 or 21 with a plurality of spaced-apart rivets 50. The rivets contort the surface of the rubber pads 25 and 17 and form a plurality of concave depressions, similar to suction cups in the uncompressed state, shown in FIGS. 6 and 7. When the pads are compressed, however, they flatten to the shape shown in FIGS. 8 and 9, creating a suction between the rubber pads and the opposing window frame surface. This suction greatly resists lateral displacement of the grill apparatus. Preferably, each concave depression in the pads 17 and 25 is provided with a through aperture 51 which releases the suction when the toggle clamp mechanism is opened, thereby permitting easy removal of the pads from the window surfaces. The apertures are sealed when the pads are flattened and compressed, as the plates 16 and 21 seat against and seal the apertures 51.
Preferably each plate 16 and 21 also is provided with a window track clamp which extends coextensively the length of the plates 16 and 21. As shown in FIG. 9, the window clamp has a flat web 22 that projects towards the window track 64 and has a channel 37 on its outer edge which is received about the inner flange of the track 64 when the grill apparatus is compressed in the window opening.
The invention has been described with reference to the illustrated and presently preferred embodiment. It is not intended that the invention be unduly limited by this disclosure of the preferred embodiment. Instead, it is intended that the invention be defined by the means, and their obvious equivalents, set forth in the following claims.
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A portable security grill apparatus which may be installed in window openings of buildings includes two rectangular grill sections longitudinally telescopically fastened to one another. Opposite longitudinal ends of the two grill sections have beams disposed perpendicularly to the axis of longitudinal telescoping movability of the two grill sections, the beams having flat outer surfaces adapted to abut a window edge at one end of the grill apparatus, and a window frame edge, at the other end of the apparatus. At least one toggle clamp connected between telescopically joined members of the two grill sections is capable of exerting a large outward extension force when in a closed, clamped position, thereby exerting compressive forces on the window and window frame sufficient to prevent the grill apparatus from being removed from the window opening.
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CROSS REFERENCE TO RELATED APPLICATION
This application is a division of copending application Ser. No. 428,882, filed Dec. 27, 1973 now Pat. No. 3,938,199.
BACKGROUND OF THE INVENTION
The present invention relates to swimming pools.
In particular, the present invention relates to components which may be assembled together to form at least that part of a swimming pool which is concerned with the circulation of the water therein.
Thus, at the present time certain inconveniences and problems are encountered with respect to circulation of pool water for filtering purposes. Pool constructions which include a plastic liner sheet and a backing, such as a metal backing, therefor do not lend themselves to use of an overflow gutter. Therefore it is customary with such constructions to provide an opening in the side of the pool for attachment of a skimmer installation through which water can flow out of the pool to be filtered before being returned to the pool. The attachment of such a skimmer installation itself creates problems because of the complexity of such installations and the inconvenience in connection with the attachment thereof to a metal pool wall.
SUMMARY OF THE INVENTION
It is accordingly a primary object of the present invention to provide a swimming pool made up of components which can be assembled to form a pool of practically any desired configuration while at the same time avoiding the drawbacks referred to above.
In particular, it is an object of the present invention to provide a pool construction of the above type which can conveniently be associated with a gutter assembly into which the pool water can overflow so that inconveniences in connection with skimmer installations can be avoided.
It is also an object of the present invention to provide a pool construction which lends itself to use with a concrete deck.
In addition it is an object of the present invention to provide a pool construction where practically all of the components, except for a plastic liner sheet and some anchoring elements, can conveniently and inexpensively be manufactured from plastic extrusions, so that the pool can be assembled of light-weight inexpensive parts.
According to the invention there is used in the swimming pool an elongated plastic extrusion of channel-shaped configuration forming a gutter for receiving liquid which overflows from the pool. This gutter has an outer upper region, and a concrete-retaining means is connected with this outer upper region of the gutter.
BRIEF DESCRIPTION OF DRAWINGS
The invention is illustrated by way of example in the accompanying drawings which form part of this application and in which:
FIG. 1 is a fragmentary perspective illustration of a pool having one of many possible configurations;
FIG. 2 is a fragmentary vertical sectional view taken along line 2--2 of FIG. 1 in the direction of the arrows and showing at a scale which is considerably large as compared to FIG. 1 the manner in which various components of the invention are assembled and supported on the ground as well as connected with a surrounding concrete deck;
FIG. 3 is a fragmentary sectional plan view taken along line 3--3 of FIG. 2 in the direction of the arrows and showing how a pair of successive units of a backing means are joined to each other as well as illustrating in part how bracing and anchoring is achieved;
FIG. 4 is a fragmentary perspective illustration of a cover means for a gutter as well as part of a connecting means for the top of a plastic liner sheet;
FIG. 5 is a fragmentary perspective illustration of an extrusion forming part of a gutter and the remainder of the sheet-connecting means which cooperates with part of the structure of FIG. 4;
FIG. 6 is a fragmentary perspective illustration of a concrete-retaining means capable of being assembled with the upper outer portion of the gutter extrusion of FIG. 5;
FIG. 7 is a fragmentary perspective illustration of one of the extrusions of a unit of a backing means, with part of the next-lower extrusion shown in phantom lines; and
FIG. 8 is a fragmentary top plan view of a corner of a finished pool illustrating a miter connection which may be utilized.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring to FIG. 1, there is illustrated therein one possible example of a finished pool 104 of the invention, this particular pool 104 having a jog 106 providing the pool with an inwardly directed corner 108 in addition to the remaining corners 110.
As is apparent from FIG. 2, the interior of the pool is provided with a plastic liner sheet 22 supported at its outer surface by a backing means 34 made up, as shown in FIG. 7, of a series of extrusion units 36. Each of these units has an inner vertical wall 50, and outer vertical wall 52 and a plurality of horizontally extending walls 54 interconnecting the walls 50 and 52. The uppermost transverse wall 58 is integrally formed with a springy connecting means 60 in the form of springy connecting tongues 68 having at their lower regions inwardly curved portions 64 which define with the wall 58 longitudinally extending horizontal grooves 62 and 66. At the lower end of each unit 35 there are a pair of inwardly directed flanges 56 which are snapped into the grooves 62 and 66 in the manner apparent from FIG. 7 so that in this way each section of the backing means 34 is assembled.
In order to interconnect the several sections of the backing means, a connecting means as shown in FIG. 3 is provided. This connecting means includes a vertically extending plastic wall structure 76 extending rearwardly and outwardly from an elongated vertically extending structure 74 having a central transverse vertical wall 72 and inner and outer walls 70 providing the substantially H-shaped cross section shown in FIG. 3. One of the units 36 is situated on one side of the transverse wall 72 between the inner and outer wall portions 70 and in engagement with the transverse wall 72 of the connecting structure 74 while the next unit is situated at the other side of the wall 72 in the manner shown in FIG. 3. The outwardly extending vertical wall 76 is joined as by fasteners 86 with an anchoring structure 42. The plastic liner sheet 22 engages the backing means 34 as well as the connecting means 74 therebetween in the manner shown in FIG. 2 and described in greater detail below.
Irrespective of the particular configuration of the pool, it will have an upper structure as illustrated in FIG. 2. Referring to FIG. 2 it will be seen that all along the upper periphery of the pool there is a gutter formed by extrusion sections 122 having the illustrated channel-shaped configuration and joined one to the next as by butting against each other. The configuration of these channel-shaped extrusion sections 122 which form the overflow gutter 124 is shown most clearly in FIG. 5. Thus, as may be seen from FIG. 5, the channel-shaped gutter extrusion 122 has a bottom wall 126 and a pair of outwardly and upwardly inclined walls 128 and 130 which extend upwardly and outwardly from the inner and outer edges of the bottom wall 126.
The upper edge of the wall 128 is integrally extruded with an inwardly extending wall portion 132 which in turn is integrally extruded with a sheet-connecting means 134.
The sheet-connecting means 134 includes a vertical wall 136 extending perpendicularly across the wall 132 and extending parallel to an inner vertical wall 138. These walls 136 and 138 terminate at their lower edges in inwardly directed flanges 140 which are snapped onto the springy connecting means 60 of the uppermost extrusion of each unit of the backing means, as shown most clearly in FIG. 2. Thus, the flanges 140 cooperate with the springy connecting means 60.
The upper region of the inner wall 138 of the sheet-connecting means 134 is in the form of an elongated hollow triangular extrusion portion 142 forming an upper wall part 144 and an inclined wall 146 extending between the wall portion 144 and the vertical wall 138. The inner wall 136 of the sheet-connecting means 134 has an inwardly extending upper wall portion 148 which is integral with an inclined wall portion 150 which is parallel to the inclined wall portion 146, these walls 146 and 150 being interconnected by a wall portion 152 which is integral with the wall portions 146 and 150 and which defines therewith a groove extending downwardly from the top wall of the connecting means 134, this top wall being formed by the portions 144 and 148. Thus, the sheet-connecting means 134 is in the form of a one-piece extrusion which is extruded integrally with the channel extrusion 122 which forms the gutter 124, and this connecting means 134 has the groove 154 which is inclined downwardly and inwardly toward the interior of the pool, as is apparent particularly from FIG. 2.
All of the above extrusions which are used to form the various components of the pool can be manufactured from any desired plastic such as polyvinyl chloride. This plastic wall will the most part be rigid in the finished components. However, in accordance with a particular feature of the invention the walls 146 and 150 are extruded in a known way, with the remainder of the extrusion shown in FIG. 5, in such a way that these walls 146 and 150 have extruded therewith longitudinally extending beads 156 which although extruded integrally with the remainder of the extrusion simultaneously therewith are nevertheless of a softer material which remains resilient and yieldable. Such extrusions which have a material which in part is rigid and in part is soft and elastic are known. Thus the extrusion which forms the connecting means 134 and the gutter channel 122 also has the elastic beads 156 as an integral part thereof. Thus a number of these beads will be located at each side of the groove 154.
The overflow gutter 124 is covered by sections of a plastic cover means 158 which also may be extruded. The cover means 158 is shown most clearly in FIG. 4. In this case also the extruded material is cut into suitable lengths which are situated one next to each other over the gutter 122 so as to cover the latter. The extruded material is however punched through with a number of openings 160 so that the overflow water can fall through these openings 160 into the gutter 124 filling the latter as shown in FIG. 2, while at the same time larger articles such as leaves, twigs, and the like, will be prevented by the openings 160 from entering into the gutter 124. This gutter 124 communicates with an unillustrated pipe system through which the water from the gutter is conveyed through a filter before being returned to the pool, a suitable pump being provided for this purpose.
The cover means 158 thus has the top wall portion 162 which is formed with the openings 160. This top wall portion 162 is integrally joined at its outer edge to an inwardly and downwardly inclined wall 164 which has the same inclination as the wall 130 and which rests against the wall 130 as illustrated in FIG. 2.
At its inner edge region the extrusion 158 is formed with a cover portion 166 which covers the upper part of the connecting means 134 and which cooperates therewith to form part of the structure for connecting the upper edge region of the plastic liner sheet 22 to the sheet-connecting means 134. For this purpose the front region 166 is in the form of a downwardly directed channel which is seated on and snugly fits against the upper part of the connecting means 134 which extends above the wall 132. Thus, the portion 166 has inner and outer walls 168 and 170 which form a channel between which the upper end of the connecting means 134 is received. Also, between these walls 168 and 170 the cover means 158 has an integral inwardly and downwardly inclined tongue 172 which extends into the groove 154 in the manner shown most clearly in FIG. 2. Thus, the extrusion 158 will be extruded in one piece so as to have the configuration shown in FIG. 4 and will be cut into suitable lengths which can be placed one next to the other along the periphery of the pool. Of course, where the pool is curved the extrusions 158 will be suitably curved by being placed against suitable forms while they are still of sufficient pliability upon issuing from the extruder.
As is shown most clearly in FIG. 2, the liner sheet 22 has an upper edge region 174 in the form of a bead which is thicker than the remainder of the liner sheet 22. When the components of the pool are assembled, the sheet 22 is placed against the backing means 34, and in a known manner a suitable vacuum pipe can be applied between the sheet 22 and the backing means to extract any residual air which may remain so that the liner sheet will snugly rest against the inner surface of the backing means. The upper thicker edge 174 of the liner sheet 172 is introduced into the groove 154 all around the periphery of the pool, and then the cover means 158 is assembled with the remaining structure as illustrated in FIG. 2. The thickness of the tongue 172 is such that together with the thickness of the edge 174 of the sheet 22, the total thickness of these parts 172 and 174 is greater than the distance between the beads 156 at opposite sides of the groove 154. As a result after the thicker edge 174 of the sheet 22 is placed in the groove 154 and the tongue 172 is then introduced, the edge 174 is pressed against the left beads 156 of FIG. 2, while the tongue 172 is pressed against the right beads 156 of FIG. 2, these beads becoming deformed and compressed so that with this construction a tight connection of the sheets 22 is achieved. The tightness is achieved not only by reason of the fact that the sheet 22 snugly rests against the backing means going around the upper edge of the connecting means 134 and down into the groove 154, with the sheet being held in this manner by the front channel portion 166 of the cover means 158, but in addition an extremely effective tightness is achieved by the compression of the beads 156. As a result with this construction even though the water in the pool continuously overflows into the gutter 124 in the manner described above, it is not possible for any water to gain access to a location situated between the sheet 22 and the backing means 34, so that the possibility of any water becoming situated behind the sheet 22 with all of the problems resulting therefrom is reliably prevented.
It is possible in a very convenient manner to provide the pools of the invention with a concrete deck. Thus, once the structure as described above is assembled the earth which has been removed will be filled in around the structure so that an arrangement as shown in FIG. 2 will be achieved. In fact as the water is introduced and the level thereof rises up in the pool the earth is filled in so as to always be during initial setting up of the pool at least as high as the level of the water in the pool. When the earth has been filled in approximately to the height of the top ends of the flanges 76, the earth-filling or packing operations are terminated and concrete is then poured to achieve a construction as shown in FIG. 2.
For this purpose the extrusion channel 122 which forms the gutter 124 is extruded integrally with an outer horizontally extending flange 176 which in turn is integrally extruded with a downwardly extending outer wall or flange 178 terminating in an inwardly directed lower flange 180, so that in this way the gutter channel 122 will become reliably and solidly embedded in the concrete 182 when the latter solidifies after pouring. The top outer wall 176 of the single extrusion shown in FIG. 5 is integrally extruded with a springy connecting means 186 which may be identical with the springy connecting means 60 described above and shown in FIG. 6. This spring connecting means 186 serves to connect to the outer portion of the gutter channel 122 a concrete retainer extrusion 188 shown most clearly in FIG. 6. The concrete retainer means 188 has an inner wall 190 which has a lower vertical portion and an upper portion which curves inwardly and then outwardly to form the upper horizontal wall portion 192 which terminates in the downwardly and inwardly directed flange 194. As is shown most clearly in FIG. 2, the upper wall portion 192 is inclined downwardly and outwardly away from the pool. This wall 190 is extruded integrally with a rearwardly extending wall portion 196 which in turn is extruded integrally with a downwardly extending wall portion 198. The walls 190 and 198 terminate at their lower edges in a pair of inwardly directed flanges 200 adapted to snap over the springy tongues of the springy connector means 186 in precisely the manner described above in connection with the flanges 56 and the springy connector means 60. In this way the concrete retainer means 188 can be readily assembled with the outer upper portion of the gutter extrusion in the manner shown most clearly in FIG. 2.
With the parts thus assembled and with suitable supports such as blocks or the like situated at given intervals beneath the gutter extrusion 122 so as to temporarily support the latter at the required elevation, the concrete 182 is poured so as to assume the configuration shown in FIG. 2, and the upper surface 200 which forms the concrete deck is inclined downwardly and outwardly to form a continuation of the upper surface of the wall 192 of the concrete retainer means 188. In this way the concrete deck will be pitched properly so as to cause any water or rain which falls on the deck surface 200 to flow outwardly away from the pool. The wall 192 is the region where an individual will stand preparatory to jumping into the pool, for example. Of course any diving board can be mounted adjacent the pool of the deep end thereof.
As may be seen from FIG. 8, when the parts are assembled, the components such as the cover extrusions 158, the concrete retainer extrusions 188, and the gutter extrusions 122 are suitable mitered so as to butt against each other at the corners in the manner illustrated in FIG. 8. Prior to pouring of the concrete suitable tape may be placed across the mitered connections to hold them together in sealed relation while the concrete sets, and thereafter this tape may be removed if desired.
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A swimming pool includes an elongated plastic extrusion of channel-shaped configuration forming a gutter for receiving liquid which overflows from the pool. This gutter has an outer upper region connected with a concrete-retaining structure.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND
Oil field operators drill boreholes into subsurface reservoirs to recover oil and other hydrocarbons. If the reservoir has been partially drained or if the oil is particularly viscous, the oil field operators will often inject water or other fluids into the reservoir via secondary wells to encourage the oil to move to the primary (“production”) wells and thence to the surface.
This flooding process can be tailored with varying fluid mixtures, flow rates/pressures, and injection sites, but may nevertheless be difficult to control due to inhomogeneity in the structure of the subsurface formations. The interface between the reservoir fluid and the injected fluid, often termed the “flood front”, develops protrusions and irregularities that may reach the production well before the bulk of the residual oil has been flushed from the reservoir. This “breakthrough” of the flood fluid is undesirable, as it typically necessitates increased fluid handling due to the injected fluid's dilution of the oil and may further reduce the drive pressure on the oil. Continued operation of the well often becomes commercially infeasible.
BRIEF DESCRIPTION OF THE DRAWINGS
Accordingly, there are disclosed herein various fiberoptic systems and methods for formation monitoring. In the drawings:
FIG. 1 shows an illustrative environment for permanent monitoring.
FIGS. 2A-2E show various illustrative injected-current system configurations.
FIGS. 3A-3E show various illustrative sensing array configurations.
FIG. 4 shows yet another illustrative sensing array configuration.
FIGS. 5A-5B show illustrative combined source-sensor cable configurations.
FIG. 6 is a function block diagram of an illustrative formation monitoring system.
FIGS. 7A-7C show illustrative multiplexing architectures for distributed electromagnetic (“EM”) field sensing.
FIGS. 8A-8C show various illustrative EM field sensor configurations.
FIG. 9 is a signal flow diagram for an illustrative formation monitoring method.
It should be understood, however, that the specific embodiments given in the drawings and detailed description below do not limit the disclosure. On the contrary, they provide the foundation for one of ordinary skill to discern the alternative forms, equivalents, and other modifications that are encompassed in the scope of the appended claims.
DETAILED DESCRIPTION
The following disclosure presents a fiberoptic-based technology suitable for use in permanent downhole monitoring environment to track an approaching fluid front and enable actions to optimize hydrocarbon recovery from a reservoir. One illustrative formation monitoring system has an array of electromagnetic field sensors positioned in an annular space around a well casing, the sensors being coupled to a surface interface via a fiberoptic cable. Each electromagnetic field sensor is a device that produces signals that are a function of external electric or magnetic fields. Illustrative sensors provide signals that are directly or inversely proportional to electric or magnetic field strength, the temporal or spatial derivative of the electric or magnetic fields, or the temporal or spatial integral of the fields. Other illustrative sensors have reception characteristics that measure both electric and magnetic fields. The sensor measurements in response to an injected current or another electromagnetic field source can be used to determine a resistivity distribution around the well, which in turn enables tracking of the flood front. (Although the term “flood front” is generally used herein to refer to the interface between reservoir fluid and injected fluid zones, the teachings of the present disclosure will apply to the interface between any two fluids having different bulk resistivities.)
Turning now to the drawings, FIG. 1 shows an illustrative permanent downhole monitoring environment. A borehole 102 contains a casing string 104 with a fiber optic cable 106 secured to it by bands 108 . Casing 104 is a tubular pipe, usually made of steel, that preserves the integrity of the borehole wall and borehole. Where the cable 106 passes over a casing joint 110 , it may be protected from damage by a cable protector 112 . Electromagnetic (EM) field sensors 114 are integrated into the cable 106 to obtain EM field measurements and communicate those measurements to a surface interface 116 via fiberoptic cable 106 .
The remaining annular space may be filled with cement 118 to secure the casing 104 in place and prevent fluid flows in the annular space. Fluid enters the uncemented portion of the well (or alternatively, fluid may enter through perforated portions of the well casing) and reaches the surface through the interior of the casing. Note that this well configuration is merely illustrative and not limiting on the scope of the disclosure. Many production wells are provided with multiple production zones that can be individually controlled. Similarly, many injection wells are provided with multiple injection zones that can be individually controlled.
Surface interface 116 includes an optical port for coupling the optical fiber(s) in cable 106 to a light source and a detector. The light source transmits pulses of light along the fiber optic cable, including any sensors 114 . The sensors 114 modify the light pulses to provide measurements of field strength, field gradient, or time derivative for electrical fields and/or magnetic fields. The modifications may affect amplitude, phase, or frequency content of the light pulses, enabling the detector to responsively produce an electrical output signal indicative of the sensor measurements. Some systems may employ multiple fibers, in which case an additional light source and detector can be employed for each fiber, or the existing source and detector may be switched periodically between the fibers. Some system embodiments may alternatively employ continuous wave (CW) light rather than light pulses.
FIG. 1 further shows a power source 120 coupled between the casing 104 and a remote earth electrode 122 . Because the casing 104 is an electrically conductive material (e.g., steel), it acts as a source electrode for current flow into the formations surrounding the borehole 102 . The magnitude and distribution of the current flow will vary in accordance with the source voltage and the formation's resistivity profile. The EM field measurements by sensors 114 will thus be representative of the resistivity profile. This resistivity profile in turn is indicative of the fluids in the formation pores, enabling the flood front to be located and tracked over time.
The surface interface 116 may be coupled to a computer that acts as a data acquisition system and possibly as a data processing system that analyzes the measurements to derive subsurface parameters and track the location of a fluid front. In some contemplated system embodiments, the computer may further control production parameters to reduce risk of breakthrough or to otherwise optimize production based on the information derived from the measurements. Production parameters may include the flow rate/pressure permitted from selected production zones, flow rate/pressure in selected injection zones, and the composition of the injection fluid, each of which can be controlled via computer controlled valves and pumps.
Generally, any such computer would be equipped with a user interface that enables a user to interact with the software via input devices such as keyboards, pointer devices, and touchscreens, and via output devices such as printers, monitors, and touchscreens. The software can reside in computer memory and on nontransient information storage media. The computer may be implemented in different forms including, e.g., an embedded computer permanently installed as part of the surface interface 116 , a portable computer that is plugged into the surface interface 116 as desired to collect data, a remote desktop computer coupled to the surface interface 116 via a wireless link and/or a wired computer network, a mobile phone/PDA, or indeed any electronic device having a programmable processor and an interface for I/O.
FIG. 2A is a schematic representation of the system configuration in FIG. 1 . It shows a borehole 102 having a casing 104 and a fiberoptic cable 106 (with an integrated sensor array) in the annular space. An injected current 202 flows along casing 104 and disperses into the surrounding formations as indicated by the arrows. Two formations are shown, labeled with their respective resistivities R1 and R2. The heavier arrows in the lower formation represent a larger current flow, indicating that resistivity R2 is lower than resistivity R1. Due to divergence pattern of the currents away from the casing, depth of investigation is typically around 5-15 feet.
FIG. 2B shows an alternative system configuration, in which the fiberoptic cable 106 is replaced by an alternative fiberoptic cable 206 having a conductor or a conductive layer to transport an injected current 212 along the cable. The conductor may be a protective metal tube within which the fiberoptic cable is placed. Alternatively, the conductor may be a wire (e.g., a strength member) embedded in the fiberoptic cable. As another alternative, a metal coating may be manufactured on the cable to serve as the current carrier. Parts of the cable may be covered with an insulator 205 to focus the current dispersal in areas of interest. The optical fiber in cable 212 may act as a distributed sensor or, as in previous embodiments, localized sensors may be integrated into the cable. Because conductive layers can significantly attenuate certain types of electromagnetic fields, the sensors are designed to be operable despite the presence of the conductive layer, e.g., magnetic field sensors, and/or apertures are formed in the conductive layer to permit the EM fields to reach the sensors.
FIG. 2C shows another alternative system configuration. A conductor or conductive layer of fiberoptic cable 206 is electrically coupled to casing 104 to share the same electrical potential and contribute to the dispersal of current into the formation. Parts of the cable 206 and/or casing 104 may be covered with an insulator 205 to focus the current dispersal in areas of interest.
FIG. 2D shows yet another alternative system configuration. Rather than providing an injected current 202 from the surface as in FIG. 2A , the configuration of FIG. 2D provides an injected current 222 from an intermediate point along the casing 104 . Such a current may be generated with an insulated electrical cable passing through the interior of casing 104 from a power source 120 ( FIG. 1 ) to a tool that makes electrical contact at the intermediate point, e.g., via extendible arms. (An alternative approach employs a toroid around casing 104 at the intermediate point to induce current flow along the casing. The toroid provides an electric dipole radiation pattern rather than the illustrated monopole radiation pattern.)
FIG. 2E shows still another alternative system configuration having a first borehole 102 and second borehole 102 ′. Casing 104 in the first borehole 102 carries an injected current from the surface or an intermediate point and disperses it into the surrounding formations. The second borehole 102 ′ has a casing 104 ′ for producing hydrocarbons and further includes a fiberoptic cable 106 ′ with an integrated EM sensor array in the annular space around casing 104 ′. The EM sensors provide measurements of the fields resulting from the currents dispersed in the formations.
The sensor array may employ multiple fiberoptic cables 106 as indicated in FIG. 3A . With cables 106 positioned in parallel or at least in an overlapping axial range, the azimuthal arrangement of sensors 114 enables a multi-dimensional mapping of the electromagnetic fields. In some embodiments, the sensors are mounted to the casing 104 or suspended on fins or spacers to space them away from the body of casing 104 . If actual contact with the formation is desired, the sensors 114 may be mounted on swellable packers 302 as indicated in FIG. 3B . Such packers 302 expand when exposed to downhole conditions, pressing the sensors 114 into contact with the borehole wall. FIG. 3C shows the use of bow-spring centralizers 304 which also operate to press the sensors 114 into contact with the borehole walls. To minimize insertion difficulties, a restraining mechanism may hold the spring arms 304 against the casing 104 until the casing has been inserted in the borehole. Thereafter, exposure to downhole conditions or a circulated fluid (e.g., an acid) degrades the restraining mechanism and enables the spring arms to extend the sensors against the borehole wall. If made of conductive material, the spring arms may further serve as current injection electrodes, concentrating the measurable fields in the vicinity of the sensors. To further concentrate the fields, the spring arms outside the zone of interest may be insulated.
Other extension mechanisms are known in the oilfield and may be suitable for placing the sensors 114 in contact with the borehole wall or into some other desired arrangements such as those illustrated in FIGS. 3D and 3E . In FIG. 3D , the sensors are positioned near the radial midpoint of the annular region. In FIG. 3E , the sensors are placed in a spatial distribution having axial, azimuthal, and radial variation. Balloons, hydraulic arms, and projectiles are other contemplated mechanisms for positioning the sensors.
FIG. 4 shows an illustrative fixed positioning mechanism for sensors 114 . The cage 402 includes two clamps 403 A, 403 B joined by six ribs 404 . The fiberoptic cable(s) 106 can be run along the ribs or, as shown in FIG. 4 , they can be wound helically around the cage. In either case, the ribs provide each fiberoptic cable 106 some radial spacing from the casing 104 . Cable ties 406 can be used to hold the cable in place until cementing has been completed. The ribs can be made of insulating material to avoid distortion of the electromagnetic fields around the sensors.
In addition to providing support and communications for sensors 114 , the fiberoptic cable 106 may support electrodes or antennas for generating electromagnetic fields in the absence of current injection via casing 104 . FIG. 5A shows two electrodes 502 on cable 106 . A voltage is generated between the two electrodes 502 to create an electric dipole radiation pattern. The response of the electromagnetic sensors 114 can then be used to derive formation parameters.
Similarly, FIG. 5B shows a solenoid antenna 504 on cable 106 . A current is supplied to the solenoid coil to create a magnetic dipole radiation pattern. The response of the electromagnetic sensors 114 can then be used to derive formation parameters. In both cases the sensors are shown to one side of the source, but this is not a requirement. The source may be positioned between sensors 114 and/or one or more of the sensors may be positioned between multiple sources. The sensors 114 may even be positioned between the electrodes of a electric dipole source. Moreover, it is possible to tilt the sources and/or the sensors to provide improved directional sensitivity.
FIG. 6 provides a function block representation of an illustrative fiberoptic-based permanent monitoring system. The sensors 114 include electrodes, antennas, or other transducers 602 that convert a property of the surrounding electromagnetic field into a signal that can be sensed via an optical fiber. (Specific examples are provided further below.) An energy source 606 may be provided in the form of a pair of conductors conveying power from the surface or in the form of a powerful downhole battery that contains enough energy to make the device operate for the full life span. It is possible to use an energy saving scheme to turn on or off the device periodically. It is also possible to adjust the power level based on inputs from the fiber optic cable, or based on the sensor inputs.
A controller 604 provides power to the transducers 602 and controls the data acquisition and communication operations and may contain a microprocessor and a random access memory. Transmission and reception can be time activated, or may be based on a signal provided through the optic cable or casing. A single sensor module may contain multiple antennas/electrodes that can be activated sequentially or in parallel. After the controller 604 obtains the signal data, it communicates the signal to the fiberoptic interface 608 . The interface 608 is an element that produces new optical signals in fiberoptic cable 610 or modifies existing optical signals in the cable 610 . For example, optical signal generation can be achieved by the use of LEDs or any other type of optical source. As another example, optical signals that are generated at the surface can be modified by thermal or strain effects on the optical fiber in cable 610 . Thermal effects can be produced by a heat source or sink, whereas strain effects can be achieved by a piezoelectric device or a downhole electrical motor.
Modification can occur via extrinsic effects (i.e., outside the fiber) or intrinsic effects (i.e., inside the fiber). An example of the former technique is a Fabry Pérot sensor, while an example of the latter technique is a Fiber Bragg Grating. For optimum communication performance, the signal in the optical transmission phase may be modulated, converted to digital form, or digitally encoded. The cable is coupled to a receiver or transceiver 612 that converts the received light signals into digital data. Stacking of sequential measurements may be used to improve signal to noise ratio. The system can be based on either narrowband (frequency type) sensing or ultra wideband (transient pulse) sensing. Narrowband sensing often enables the use of reduced-complexity receivers, whereas wideband sensing may provide more information due to the presence of a wider frequency band.
Optionally, a power source 614 transmits power via an electrical conductor 616 to a downhole source controller 618 . The source controller 618 operates an EM field source 620 such as an electric or magnetic dipole. Multiple such sources may be provided and operated in sequence or in parallel at such times and frequencies as may be determined by controller 618 .
Multiple sensors 114 may be positioned along a given optical fiber. Time and/or frequency multiplexing is used to separate the measurements associated with each sensor. In FIG. 7A , a light source 702 emits light in a continuous beam. A circulator 704 directs the light along fiberoptic cable 106 . The light travels along the cable 106 , interacting with a series of sensors 114 , before reflecting off the end of the cable and returning to circulator 704 via sensors 114 . The circulator directs the reflected light to a light detector 708 . The light detector 708 includes electronics that separate the measurements associated with different sensors 114 via frequency multiplexing. That is, each sensor 114 affects only a narrow frequency band of the light beam, and each sensor is designed to affect a different frequency band.
In FIG. 7B , light source 702 emits light in short pulses. Each sensor 114 is coupled to the main optical fiber via a splitter 706 . The splitters direct a small fraction of the light from the optical fiber to the sensor, e.g., 1% to 4%. The sensor 114 interacts with the light and reflects it back to the detector 708 via the splitter, the main fiber, and the circulator. Due to the different travel distances, each pulse of light from source 702 results in a sequence of return pulses, with the first pulse arriving from the nearest sensor 114 , the second pulse arriving from the second nearest sensor, etc. This arrangement enables the detector to separate the sensor measurements on a time multiplexed basis.
The arrangements of FIGS. 7A and 7B are both reflective arrangements in which the light reflects from a fiber termination point. They can each be converted to a transmissive arrangement in which the termination point is replaced by a return fiber that communicates the light back to the surface. FIG. 7C shows an example of such an arrangement for the configuration of FIG. 7B . A return fiber is coupled to each of the sensors via a splitter to collect the light from the sensors 114 and direct it to a light detector 708 .
Other arrangement variations also exist. For example, multiple sensors may be coupled in series on each branch of the FIG. 7B , 7 C arrangements. A combination of time division, wavelength-division and/or frequency division multiplexing could be used to separate the individual sensor measurements.
Thus each production well may be equipped with a permanent array of sensors distributed along axial, azimuthal and radial directions outside the casing. The sensors may be positioned inside the cement or at the boundary between cement and the formation. Each sensor is either on or in the vicinity of a fiber optic cable that serves as the communication link with the surface. Sensor transducers can directly interact with the fiber optic cables or, in some contemplated embodiments, may produce electrical signals that in turn induce thermal, mechanical (strain), acoustic or electromagnetic effects on the fiber. Each fiber optic cable may be associated with multiple EM sensors, while each sensor may produce a signal in multiple fiber optic or fiber optic cables. Even though the figures show uniformly-spaced arrays, the sensor positioning can be optimized based on geology or made randomly. In any configuration, the sensor positions can often be precisely located by monitoring the light signal travel times in the fiber.
Cement composition may be designed to enhance the sensing capability of the system. For example, configurations employing the casing as a current source electrode can employ a cement having a resistivity equal to or smaller than the formation resistivity.
The sensors 114 referenced above preferably employ fully optical means to measure EM fields and EM field gradients and transfer the measurement information through optical fibers to the surface for processing to extract the measurement information. The sensors will preferably operate passively, though in many cases sensors with minimal power requirements can be powered from small batteries. The minimization of electronics or downhole power sources provides a big reliability advantage. Because multiple sensors can share a single fiber, the use of multiple wires with associated connectors and/or multiplexers can also be avoided, further enhancing reliability while also reducing costs.
Several illustrative fiberoptic sensor configurations are shown in FIGS. 8A-8C . FIG. 8A shows an atomic magnetometer configuration in which light from an input fiber 802 passes through a depolarizer 804 (to remove any polarization biases imposed by the fiber) and a polarizing filter 806 to produce polarized light. A gradient index (GRIN) lens 808 collimates the polarized light before it passes through an alkali vapor cell 812 . A quarter-wave plate 810 enhances optical coupling into the cell. A second GRIN lens 814 directs light exiting the cell into an output fiber 816 . The light passing through the cell consists of a pump pulse to polarize the alkali atoms, followed by a probe pulse to measure the spin relaxation rate. The attenuation of the probe pulse is directly related to the magnetic field strength.
FIG. 8B shows a sensor having a support structure 820 separating two electrodes 822 , 824 . A center electrode 826 is supported on a flexible arm 828 . The center electrode 826 is provided with a set charge that experiences a force in the presence of an electrical field between electrodes 822 , 824 . The force causes displacement of the center electrode 826 until a restoring force of the compliant arm 828 balances the force from the electrical field. Electrodes 824 and 826 are at least partially transparent, creating a resonant cavity 830 in the space between. The wavelengths of light that are transmitted and suppressed by the cavity 830 will vary based on displacement of center electrode 826 . Thus the resonant cavity shapes the spectrum of light from input electrode 802 , which effect can be seen in the light exiting from output fiber 816 . The electrodes 822 , 824 may be electrically coupled to a pair of spaced-apart electrodes (for electric field sensing) or to the terminals of a magnetic dipole antenna (for magnetic field sensing).
FIG. 8C shows a sensor having a support structure 840 with a flexible arm 842 that supports a mirror 846 above a window 844 to define a cavity 848 . The arm further includes a magnet 850 or other magnetically responsive material that experiences a displacing force in response to a magnetic field from a coil 852 . The coil's terminals 854 are coupled to spaced-apart electrodes (for electric field sensing) or another coil (for magnetic field sensing). Light entering the cavity 848 from fiber 840 reflects from mirror 846 and returns along fiber 840 to the surface. Displacement of the arm 842 alters the travel time and phase of the light passing along fiber 840 .
The foregoing sensors are merely illustrative examples and not limiting on the sensors that can be employed in the disclosed systems and methods. An interrogation light pulse is sent from the surface through the fiber and, when the pulse reaches a sensor, it passes through the sensor and the light is modified by the sensor in accordance with the measured electromagnetic field characteristic. The measurement information is encoded in the output light and travels through the fiber to a processing unit located at the surface. In the processing unit the measurement information is extracted.
FIG. 9 provides an overview of illustrative formation monitoring methods. A controlled electromagnetic field source generates a subsurface electromagnetic field. While it is possible for this field to be a fixed (DC) field, it is expected that better measurements will be achievable with an alternating current (AC) field having a frequency in the range of 1-1000 Hz. (In applications where shallow detection is desired, higher frequencies such as 1 kHz to 1 GHz can be used.) In block 902 , each of the sensors convert the selected characteristic of the electromagnetic field into a sensed voltage V i , where i is the sensor number. For energy efficiency, sensors can be activated and measurements can be taken periodically. This enables long-term monitoring applications (such as water-flood movements), as well as applications where only small number of measurements are required (fracturing). For further efficiency, different sets of sensors may be activated in different periods.
In block 904 , the voltage (or electric field or magnetic field or electric/magnetic field gradient) is applied to modify some characteristic of light passing through an optical fiber, e.g., travel time, frequency, phase, amplitude. In block 906 , the surface receiver extracts the represented voltage measurements and associates them with a sensor position d i . The measurements are repeated and collected as a function of time in block 908 . In addition, measurements at different times can be subtracted from each other to obtain time-lapse measurements. Multiple time-lapse measurements with different lapse durations can be made to achieve different time resolutions for time-lapse measurements. In block 910 , a data processing system filters and processes the measurements to calibrate them and improve signal to noise ratio. Suitable operations include filtering in time to reduce noise; averaging multiple sensor data to reduce noise; taking the difference or the ratio of multiple voltages to remove unwanted effects such as a common voltage drift due to temperature; other temperature correction schemes such as a temperature correction table; calibration to known/expected resistivity values from an existing well log; and array processing (software focusing) of the data to achieve different depth of detection or vertical resolution.
In block 912 , the processed signals are stored for use as inputs to a numerical inversion process in block 914 . Other inputs to the inversion process are existing logs (block 916 ) such as formation resistivity logs, porosity logs, etc., and a library of calculated signals 918 or a forward model 920 of the system that generates predicted signals in response to model parameters, e.g., a two- or three-dimensional distribution of resistivity. All resistivity, electric permittivity (dielectric constant) or magnetic permeability properties of the formation can be measured and modeled as a function of time and frequency. The parameterized model can involve isotropic or anisotropic electrical (resistivity, dielectric, permeability) properties. They can also include layered formation models where each layer is homogeneous in resistivity. Resistivity variations in one or more dimensions can be included. More complex models can be employed so long as sufficient numbers of sensor types, positions, orientations, and frequencies are employed. The inversion process searches a model parameter space to find the best match between measured signals 912 and generated signals. In block 922 the parameters are stored and used as a starting point for iterations at subsequent times.
Effects due to presence of tubing, casing, mud and cement can be corrected by using a-priori information on these parameters, or by solving for some or all of them during the inversion process. Since all of these effects are mainly additive and they remain the same in time, a time-lapse measurement can remove them. Multiplicative (scaling) portion of the effects can be removed in the process of calibration to an existing log. All additive, multiplicative and any other non-linear effect can be solved for by including them in the inversion process as a parameter.
The fluid front position can be derived from the parameters and it is used as the basis for modifying the flood and/or production profile in block 924 . Production from a well is a dynamic process and each production zone's characteristics may change over time. For example, in the case of water flood injection from a second well, water front may reach some of the perforations and replace the existing oil production. Since flow of water in formations is not very predictable, stopping the flow before such a breakthrough event requires frequent monitoring of the formations.
Profile parameters such as flow rate/pressure in selected production zones, flow rate/pressure in selected injection zones, and the composition of the injection fluid, can each be varied. For example, injection from a secondary well can be stopped or slowed down when an approaching water flood is detected near the production well. In the production well, production from a set of perforations that produce water or that are predicted to produce water in relatively short time can be stopped or slowed down.
We note here that the time lapse signal derived from the receiver signals is expected to be proportional to the contrast between formation parameters. Hence, it is possible to enhance the signal created by an approaching flood front by enhancing the electromagnetic contrast of the flood fluid relative to the connate fluid. For example, a high magnetic permeability, or electrical permittivity or conductivity fluid can be used in the injection process in the place of or in conjunction with water. It is also possible to achieve a similar effect by injecting a contrast fluid from the wellbore in which monitoring is taking place, but this time changing the initial condition of the formation.
The disclosed systems and methods may offer a number of advantages. They may enable continuous time-lapse monitoring of formations including a water flood volume. They may further enable optimization of hydrocarbon production by enabling the operator to track flows associated with each perforation and selectively block water influxes. Precise localization of the sensors is not required during placement since that information can be derived afterwards via the fiber optic cable. Casing source embodiments do not require separate downhole EM sources, significantly decreasing the system cost and increasing reliability.
Numerous other variations and modifications will become apparent to those skilled in the art once the above disclosure is fully appreciated. For example, this sensing system can be used for cross well tomography with EM transmitters are placed in one well and EM fields being measured in surrounding wells which can be drilled at an optimized distance with respect to each other and cover the volume of the reservoir from multiple sides for optimal imaging. It is intended that the following claims be interpreted to embrace all such variations and modifications where applicable.
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A formation monitoring system includes a casing. An array of electromagnetic field sensors is positioned in the annular space and configured to communicate with the surface via a fiberoptic cable. A computer coupled to the fiberoptic cable receives measurements from the array and responsively derives the location of any fluid fronts in the vicinity such as an approaching flood front to enable corrective action before breakthrough. A formation monitoring method includes: injecting a first fluid into a reservoir formation; producing a second fluid from the reservoir formation via a casing in a borehole; collecting electromagnetic field measurements with an array of fiberoptic sensors in an annular space, the array communicating measurements to a surface interface via one or more fiberoptic cables; and operating on the measurements to locate a front between the first and second fluids.
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BACKGROUND
In downhole industries such as hydrocarbon recovery, and Carbon Dioxide sequestration, for example, formation treatments such as “fracing” and “acidizing” are well-known parts of downhole processes designed to increase permeability in or stimulate a formation. In general, a fracing process includes the employment of hyperbaric pressures applied from a surface location and directed through ports in a tubing string. The increased pressure while it does indeed result in formation fracture does not necessarily fracture the formation in optimum or even very controlled locations. Acidizing is similarly less than optimumly targeted. Since fractures and acidizing points can dramatically improve the efficiency of a downhole completion, the art will well receive alternate formation treatment systems and methods.
SUMMARY
A formation treatment system includes an annulus spanning member having one or more openings therein; a tubular having one or more ports therein in fluid communication with the one or more openings; and a sleeve capable of isolating or communicating the one or more ports with an ID of the tubular.
A method for effecting precision formation treatment including setting an annulus spanning member in a formation to bring one or more openings in the annulus spanning member proximate a formation wall; revealing one or more ports in a tubular member; communicating a tubular ID to the one or more openings in the annulus spanning member; applying fluid through the tubular ID; and directing the fluid to the formation through the one or more openings.
A method for effecting precision formation treatment including deploying a plug member to a formation treatment system includes an annulus spanning member having one or more openings therein; a tubular having one or more ports therein in fluid communication with the one or more openings; and a sleeve capable of isolating or communicating the one or more ports with an ID of the tubular; setting the annulus spanning member in a formation to bring one or more openings in the annulus spanning member proximate a formation wall by pressurizing a chamber defined by the annulus spanning member and the tubular; revealing one or more ports in the tubular member by moving the sleeve pursuant to pressure upon the plug on a seat in the sleeve; communicating a tubular ID to the one or more openings in the annulus spanning member; applying a fluid through the tubular ID; and directing the fluid to the formation through the one or more openings.
BRIEF DESCRIPTION OF THE DRAWINGS
Referring now to the drawings wherein like elements are numbered alike in the several Figures:
FIG. 1 is a cross sectional view of a first embodiment of a formation treatment system as disclosed herein in a run in position;
FIG. 2 is the formation treatment system of FIG. 1 in a formation treatment position;
FIG. 3 is another embodiment of a formation treatment system in a run in position;
FIG. 4 is the formation treatment system of FIG. 3 in a setting position;
FIG. 5 is the formation treatment system of FIG. 3 in a formation treatment position;
FIG. 6 is an enlarged schematic view of a portion of a annulus spanning member with a nozzle opening.
DETAILED DESCRIPTION
Referring to FIGS. 1 and 2 , a first embodiment of a formation treatment system 10 as disclosed herein is illustrated. The system 10 includes an annulus spanning member 12 (in a run-in or resting position) that may be a deformable element and may in some embodiments also act as a seal. The member 12 includes one or more openings 14 through which at least pressure is transmittable at selected times. It may however be desirable to plug the one or more holes at one or more times during the life cycle of the system. More information will be provided on this point later in this disclosure. In one embodiment the member 12 will include pips 16 that extend radially outwardly of a body 18 of the member 12 regardless of the position of the member 12 . Member 12 is positioned radially outwardly of a tubular 20 that includes one or more ports 22 . Further is a sleeve 24 acting as a valve in combination with the tubular 20 . The sleeve includes one or more passageways 26 extending radially therethrough. The sleeve 24 is translationally supported within the tubular 20 such that the one or more passageways 26 are alignable and misalignable with the one or more ports 22 .
In use, a first action is to cause the annulus spanning member 12 to span an annulus 28 between the system 10 and a formation 30 in which the system 10 is disposed. This can be done in a number of ways, some of which result in a compressive load being placed axially of the member 12 , resulting in its deformation radially outwardly as shown in FIG. 2 . Also notable in FIG. 2 is that the embodiment illustrated includes pips 16 and those pips 16 are embedded in the formation. This serves to segregate an annular space 32 in fluid connection with the one or more openings 14 , the one or more ports 22 and the one or more passageways 26 to provide a fluid conduit from the formation 30 to an inside dimension (“ID”) of the system 10 . The pips, then, assist in directing fluid pressure to the target area. The segregation of the area is also useful for purposes such as matrix acidizing since due to the confined nature of application, less acid would be needed to effect the desired result of formation stimulation, for example.
Those of skill in the art will recognize the system will be a part of a string 34 and the “ID” will be fluidically accessible to surface for pressurization. As illustrated in FIG. 2 , the sleeve 24 has already been shifted to align the passageways 26 with the ports 22 and the openings 14 . It is to be assumed that somewhere downhole of the system 10 the ID is plugged so that applied pressure from uphole of the system 10 finds an exit from the string only at or at least primarily at the openings 14 . Because of this condition, applied pressure or acid is directed to a very small portion of the formation and fracture initiation is very likely to occur there and acid treatment will certainly be applied directly there. Accordingly, through use of the system and method hereof, great precision in fracture initiation or acidizing is effected.
In another embodiment, referring to FIGS. 3-5 , a system 110 is illustrated that is similar to that of FIGS. 1 and 2 but is configured for use in situations where one or more fractures are planned or areas for acid treatment along a borehole are planned. More specifically, the system 110 employs a ball or other droppable or pumpable plug member 140 can be used to plug a particular system 110 to treat a certain target spot and then another plug 140 can be used for a next target spot and so on for as many systems 110 as are employed in a particular borehole.
The system 110 includes a member 112 similar to the member 12 of FIGS. 1 and 2 but that is actuated differently. The member 112 is configured to create a chamber 142 with tubing 120 upon which the member 112 may slide. The member 112 and tubing 120 are sealed to one another by o-rings 144 or equivalent. An actuation port 146 is located through the tubing 120 to allow pressure to be increased in the chamber 142 for actuation of the member 112 .
The system 110 further includes in one embodiment a one way movement configuration 148 , which in one embodiment may be a body lock ring or other ratcheting type configuration. The configuration 148 functions between the member 112 and tubing 120 to allow for the member 112 to move downhole relative to the tubing 120 (as illustrated but it is to be understood that this could be configured oppositely). The purpose and function of the configuration 148 is to accept movement imposed by the chamber 142 and then deny movement of the member 112 to a relaxed position after the force imposed by the chamber 148 is withdrawn.
System 110 further includes one or more openings 114 and one or more ports 122 . The ports 122 and openings 114 are initially fluidly isolated from the ID of the system 110 by a sleeve 150 . In one embodiment, the sleeve 150 includes an optional plug seat 152 receptive of a plug 140 as illustrated. The sleeve includes seals 154 that straddle the ports 122 during a nonoperational position of the system 110 . Finally the system 110 includes a release mechanism 156 which in some embodiments may be a shear arrangement such as one or more shear screws.
It is to be appreciated that the one or more openings 14 and 114 in annulus spanning members 12 and 112 can form a jet of fluid therethrough simply because the openings are relatively small in dimension. An even more effective jet can be formed if individual openings are configured through the thickness of the material of the annulus spanning member in a conical manner. The openings so configured would then act to some degree as nozzles. An enlarged schematic view of such is included as FIG. 6 . Such a jet of fluid will aid in the initiation of a fracture by disrupting a surface of the formation through fluid erosion.
During use of the system 110 , the system is run to a target location in a borehole and then a plug 140 is dropped or pumped to the location of the system 110 . Upon seating in the seat 152 , the plug 140 prevents fluid in the ID of the string from flowing past the seat 152 . Referring to FIGS. 3 and 4 , fluid pressure accordingly builds on an uphole side of the plug 140 (could be reversed for downhole if desired but must be upstream of the fluid flow). Increasing pressure acts upon chamber 142 to increase a dimension thereof that is longitudinal of the system 110 . Increasing this dimension of the chamber 142 causes the member 112 to buckle radially outwardly toward and ultimately, in some embodiments, into contact with the formation 30 . Referring to FIG. 5 , once a threshold pressure is reached at which it is expected the member 112 will be fully deployed, the release member 156 releases and the sleeve 150 moves downhole (downstream) thereby opening the one or more ports 122 to allow the application of pressure to reach the openings 114 and the formation 30 . Note that a shoulder 160 is provided to stop movement of the sleeve 150 after the one or more ports 122 are revealed. At this point the pressure can be increased to fracing pressure and the fracture will tend to initiate between pips 116 as in the embodiment of FIGS. 1 and 2 (or as noted above, acid can be applied to the formation between the pips. The system 110 can work with other systems 110 further upstream since after the treatment occurs as stated, flow is restored sufficiently to land another plug 140 at a more uphole sleeve 150 and the process as described again is repeated.
While one or more embodiments have been shown and described, modifications and substitutions may be made thereto without departing from the spirit and scope of the invention. Accordingly, it is to be understood that the present invention has been described by way of illustrations and not limitation.
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A formation treatment system includes an annulus spanning member having one or more openings therein. A tubular having one or more ports therein in fluid communication with the one or more openings. A sleeve capable of isolating or communicating the one or more ports with an ID of the tubular. A method for effecting precision formation treatment is included.
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[0001] This application is a continuation-in-part of U.S. application Ser. No. 09/912,977, filed Jul. 25, 2001, which claims the benefit of U.S. Provisional Patent Application No. 60/221,413, filed Jul. 28, 2000.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to a drill device for a drilling a hole in the earth.
[0004] 2. Description of the Prior Art
[0005] U.S. Pat. Nos. 4,281,723, 4,953,638, 5,423,388, 5,490,569, 5,957,222, 6050,350, and 6,082,470 disclose drilling apparatus.
SUMMARY OF THE INVENTION
[0006] It is an object of the invention to provide a drill device for drilling a hole in the earth. The drill device comprises a body having a front end and a rear end with a central axis extending between the front and rear ends and being connectable to a rotatable means. At least one slot is formed in the exterior of the body which is located outward relative to the central axis and which extends between the front and rear ends. The slot has a lip extending from its front and rear ends respectively. A cutting means is provided for the slot with the cutting means comprising a connecting portion located in the slot and having a forward end and a rearward end. The connecting portion comprises a hook near its front and rear ends respectively for connection to the lips of the slot. A removable stop means is positioned to prevent longitudinal movement of the connecting portion of the cutting means relative to the slot.
[0007] In another aspect, the plurality of angularly spaced apart slots are formed in the exterior of the body each for holding one of the cutting means.
BRIEF DESCRIPTION OF DRAWINGS
[0008] [0008]FIG. 1 illustrates the top view of a drilling apparatus in the straight drilling mode.
[0009] [0009]FIG. 2 illustrates the side view of the drilling apparatus in the straight drilling mode.
[0010] [0010]FIG. 3 is a side cross sectional view of the parts of the apparatus that are locked longitudinally with the guide housings.
[0011] [0011]FIG. 4 is a top cross sectional view of the parts of the apparatus that are locked longitudinally with the guide housings.
[0012] [0012]FIG. 5 is a side cross sectional view of the parts of the apparatus that are locked longitudinally with the shaft.
[0013] [0013]FIG. 6 illustrates the top cross sectional view of the parts that are locked longitudinally with the shaft.
[0014] [0014]FIG. 7 is a cross sectional view of FIG. 1 taken along the lines 7 - 7 thereof.
[0015] [0015]FIG. 8 is a cross sectional view of FIG. 1 taken along the lines 8 - 8 thereof.
[0016] [0016]FIG. 9 is a top view of the drilling apparatus in the shifting mode.
[0017] [0017]FIG. 10 is a side view of the drilling apparatus in the shifting mode positioned in a curved hole.
[0018] [0018]FIG. 11 is a cross sectional view of FIG. 9 taken along the lines of 11 - 11 thereof.
[0019] [0019]FIG. 12 is the cross sectional view of FIG. 9 taken along the lines of 12 - 12 thereof.
[0020] [0020]FIG. 13 is a cross sectional view of FIG. 10 taken along the lines of 13 - 13 thereof.
[0021] [0021]FIG. 14 is a cross sectional view of FIG. 7 taken along the lines of 14 - 14 thereof.
[0022] [0022]FIG. 15 is a cross sectional view of FIG. 8 taken along the lines of 15 - 15 thereof.
[0023] [0023]FIG. 16 is a cross sectional view of FIG. 11 taken along the lines of 16 - 16 thereof.
[0024] [0024]FIG. 17 is a cross sectional view of FIG. 12 taken along the lines of 17 - 17 thereof.
[0025] [0025]FIG. 18 is a cross sectional view of FIG. 12 taken along the lines of 18 - 18 thereof when the clutch is in the neutral position.
[0026] [0026]FIG. 19 is a cross sectional view of FIG. 12 taken along the lines of 18 - 18 thereof, which is the same lines as FIG. 18 was taken from but when the shaft has been rotated in order to rotate the drilling apparatus.
[0027] [0027]FIG. 20 is a top view of the drilling apparatus in the major turn mode.
[0028] [0028]FIG. 21 is a side view of the drilling apparatus in the major turn mode.
[0029] [0029]FIG. 22 is a cross sectional view of FIG. 20 taken along the lines of 22 - 22 thereof.
[0030] [0030]FIG. 23 is a cross sectional view of FIG. 20 taken along the lines of 23 - 23 thereof.
[0031] [0031]FIG. 24 is a cross sectional view of FIG. 22 taken along the lines of 24 - 24 thereof.
[0032] [0032]FIG. 25 is a cross sectional view of FIG. 23 taken along the lines of 25 - 25 thereof.
[0033] [0033]FIG. 26 is a top view of the drilling apparatus in the minor turn mode.
[0034] [0034]FIG. 27 is a side view of the drilling apparatus in the minor turn mode.
[0035] [0035]FIG. 28 is a cross sectional view of FIG. 26 taken along the lines of 28 - 28 thereof.
[0036] [0036]FIG. 29 is a cross sectional view of FIG. 26 taken along the lines of 29 - 29 thereof.
[0037] [0037]FIG. 30 is a top view of the drilling apparatus in the partially pulled back mode.
[0038] [0038]FIG. 31 is a side view of the drilling apparatus in the partially pulled back mode.
[0039] [0039]FIG. 32 is a cross sectional view of FIG. 30 taken along the lines of 32 - 32 thereof.
[0040] [0040]FIG. 33 is a cross sectional view of FIG. 30 taken along the lines of 33 - 33 thereof.
[0041] [0041]FIG. 34 is an isometric view of the shifting cam.
[0042] [0042]FIG. 35 is 360-degree flat view of the exterior of the shifting cam
[0043] [0043]FIG. 36 is a 180-degree flat view of the shifting cam and the shifting cam follower in the straight drilling mode.
[0044] [0044]FIG. 37 is a 180-degree flat view of the shifting cam lug contacting the shifting cam groove intersection.
[0045] [0045]FIG. 38 is a 180-degree flat view of the shifting cam with the shifting cam followers in full rearward position.
[0046] [0046]FIG. 39 is a 180-degree flat view of the shifting cam with the shifting cam follower lug contacting an intersection of the shifting cam grooves.
[0047] [0047]FIG. 40 is a 180-degree flat view of the shifting cam with the shifting cam follower in transition between the full rearward position and the full forward position.
[0048] [0048]FIG. 41 is a 180-degree flat view of the shifting cam with the shifting cam follower in the fully forward position.
[0049] [0049]FIG. 42 is a 360-degree flat view of the shifting cam with the shifting cam follower lugs contacting an intersection of the shifting cam grooves.
[0050] [0050]FIG. 43 is a 360-degree flat view of the shifting cam with the shifting cam followers in transition between the major turn position and the rearward position before drilling straight.
[0051] [0051]FIG. 44 is a 360-degree flat view of the shifting cam with the shifting cam followers by-passing the by-pass groove of the shifting cam.
[0052] [0052]FIG. 44A is a 180-degree flat view of the shifting cam with the shifting cam follower lug stopped by the end of the shifting cam groove.
[0053] [0053]FIG. 44B is a 180-degree flat view of the shifting cam with the shifting cam follower lug contacting the intersection of the grooves in the shifting cam.
[0054] [0054]FIG. 44C is a 180-degree flat view of the shifting cam with the shifting cam follower in the straight position.
[0055] [0055]FIG. 44D is a 180-degree flat view of the shifting cam with the shifting cam follower contacting an intersection of the shifting cam grooves.
[0056] [0056]FIG. 44E is a 180-degree flat view of the shifting cam with the shifting cam follower in the full rearward position.
[0057] [0057]FIG. 44F is a 180-degree flat view of the shifting cam with the shifting cam follower lug contacting an intersection of the shifting cam grooves.
[0058] [0058]FIG. 44G is a 180-degree flat view of the shifting cam with the shifting cam follower's forward displacement halted in preparation to start the minor turn sequence.
[0059] [0059]FIG. 44H is a 180-degree flat view of the shifting cam with the shifting cam follower contacting an intersection of the shifting cam grooves.
[0060] [0060]FIG. 44(I) is a 180-degree flat view of the shifting cam with the shifting cam follower fully rearward in the minor turn sequence.
[0061] [0061]FIG. 44J is a 360-degree flat view of the shifting cam with the shifting cam followers in transition from the fully rearward position to the minor turn position.
[0062] [0062]FIG. 44K is a 360-degree flat view of the shifting cam with the shifting cam followers exiting the by-pass groove.
[0063] [0063]FIG. 44L is a 360-degree flat view of the shifting cam with the shifting cam followers heading toward the minor turn stop.
[0064] [0064]FIG. 44M is a 360-degree flat view of the shifting cam with the shifting cam follower lugs stopped by the minor turn stop.
[0065] [0065]FIG. 44N is a 180-degree flat view of the shifting cam with the shifting cam follower in transition between the minor turn and the rearward stop before going straight. This view shows the shifting cam follower missing the by-pass groove.
[0066] [0066]FIG. 44(O) is a 180-degree flat view of the shifting cam with the shifting cam follower in transition between the minor turn and the rearward stop before going straight.
[0067] [0067]FIG. 44P is a 180-degree flat view of the shifting cam with the shifting cam follower in the fully rearward position before going straight.
[0068] [0068]FIG. 45 is an isometric view of the clutch stop.
[0069] [0069]FIG. 45A is an enlargement of the clutch stop lug.
[0070] [0070]FIG. 46 is an isometric view of the front of the female clutch member.
[0071] [0071]FIG. 47 is an isometric view of the rear of the female clutch member.
[0072] [0072]FIG. 48 is an isometric view of the rear of the male clutch member.
[0073] [0073]FIG. 49 is a cutout section of the guide housing showing the clutch members in a relaxed position.
[0074] [0074]FIG. 50 is a cutout section of the guide housing showing the clutch members engaging each other.
[0075] [0075]FIG. 51 is a front view of the shaft retainer cut to hold the rotational cutting means.
[0076] [0076]FIG. 52 is a side view of the shaft retainer.
[0077] [0077]FIG. 53 is a rear view of the shaft retainer.
[0078] [0078]FIG. 54 is a cross sectional view of FIG. 52 taken along the line 54 - 54 thereof.
[0079] [0079]FIG. 55 is a side view of the assembled rotational cutting means.
[0080] [0080]FIG. 56 is a front view of the assembled rotational cutting means.
[0081] [0081]FIG. 57 is a rear view of the assembled rotational cutting means.
[0082] FIGS. 58 - 65 shows the coupling procedure of the rotational cutting means.
[0083] [0083]FIG. 66 is a cross sectional view of the front end of the drilling apparatus showing the magnetic displacement device in use.
[0084] [0084]FIG. 67 is a cross sectional view of FIG. 66 taken along the line 67 - 67 thereof.
[0085] [0085]FIG. 68 is an isometric view of the transmitter housing with magnetic sensitive wires positioned to indicate longitudinal displacement of the shaft.
[0086] [0086]FIG. 69 is a cross sectional view of the rear of the apparatus using a longer clutch means.
[0087] [0087]FIG. 70 is a top view of the drilling apparatus with a third housing attached.
[0088] [0088]FIG. 71 is a side view of the drilling apparatus with a third housing attached.
[0089] [0089]FIG. 72 is a cross sectional view of FIG. 70, using a standard transmitter, taken along the lines 72 - 72 thereof.
[0090] [0090]FIG. 73 is a cross sectional view of FIG. 70, using a Wireline transmitter, taken along the lines 73 - 73 thereof.
[0091] [0091]FIG. 74 is an illustration of the alternative drilling apparatus using a percussion type cutting means in the straight drilling mode.
[0092] [0092]FIG. 75 is an illustration of the alternative drilling apparatus using a percussion type cutting means in the shifting mode.
[0093] [0093]FIG. 76 is an illustration of the alternative drilling apparatus using a percussion type cutting means in the turning mode.
[0094] [0094]FIG. 77 is an illustration of the alternative drilling apparatus using a rotational type cutting means in the straight drilling mode.
[0095] [0095]FIG. 78 is an illustration of the alternative drilling apparatus using a rotational type cutting means in the shifting mode.
[0096] [0096]FIG. 79 is an illustration of the alternative drilling apparatus using a rotational type cutting means in the turning mode.
[0097] [0097]FIG. 80 is a cross sectional view of FIG. 74 and FIG. 77 taken along the lines of 80 - 80 thereof.
[0098] [0098]FIG. 81 is a cross sectional view of FIG. 75 and FIG. 78 taken along the lines of 81 - 81 thereof.
[0099] [0099]FIG. 82 is a cross sectional view of FIG. 76 and FIG. 79 taken along the lines of 82 - 82 thereof.
[0100] [0100]FIG. 83 is a cross sectional view of FIG. 79 taken along the lines of 83 - 83 thereof.
[0101] [0101]FIG. 84 is a 180-degree flat view of the alternative-shifting cam with the alternative-shifting cam follower in the fully forward position.
[0102] [0102]FIG. 85 is a 180-degree flat view of the alternative-shifting cam with the alternative-shifting cam follower contacting an intersection of the alternative shifting cam grooves.
[0103] [0103]FIG. 86 is a 180-degree flat view of the alternative-shifting cam with the alternative-shifting cam follower in transition between fully forward and fully rearward positions.
[0104] [0104]FIG. 87 is a 180-degree flat view of the alternative-shifting cam with the alternative-shifting cam follower in the fully rearward position.
[0105] [0105]FIG. 88 is a 180-degree view of the alternative-shifting cam with the alternative-shifting cam follower contacting an intersection of the alternative-shifting cam grooves.
[0106] [0106]FIG. 89 is a 180-degree flat view of the alternative-shifting cam with the alternative-shifting cam follower in transition between the fully rearward position and the straight position.
[0107] [0107]FIG. 90 is a 180-degree flat view of the alternative-shifting cam with the alternative-shifting cam follower in the straight position.
[0108] [0108]FIG. 91 is a 180-degree flat view of the alternative-shifting cam with the alternative-shifting cam follower in contact with an intersecting groove.
[0109] [0109]FIG. 92 is a 180-degree flat view of the alternative-shifting cam with the alternative-shifting cam follower in transition from the straight position to the fully rearward position.
[0110] [0110]FIG. 93 is a 180-degree flat view of the alternative-shifting cam with the alternative-shifting cam follower in the fully rearward position.
[0111] [0111]FIG. 94 is a 180-degree flat view of the alternative-shifting cam with the alternative-shifting cam follower contacting an intersection of the grooves.
[0112] [0112]FIG. 95 is a 270-degree flat view of the alternative-shifting cam with the alternative-shifting cam follower in transition between fully rearward and fully forward positions.
[0113] [0113]FIG. 96 is the rear view of a hole-opener body.
[0114] [0114]FIG. 97 is a cross sectional view of the hole-opener body taken along the lines 97 - 97 thereof.
[0115] [0115]FIG. 98 is a front view of the hole-opener body
[0116] FIGS. 99 - 104 shows the rotational cutting means being mounted on to the hole-opener body.
[0117] [0117]FIG. 105 shows the side view of the hole-opener body with the rotational cutting means mounted thereto.
[0118] [0118]FIG. 106 illustrates the hole opener device of FIG. 105 in use enlarging a hole.
[0119] [0119]FIG. 107 illustrates a single modified wing type cutting means installed in a single slot of a shaft retainer.
[0120] [0120]FIG. 108 illustrates a single roller cone but attached to a plate holding mechanism installed in a single slot of a shaft retainer.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0121] Referring to FIGS. 1 - 65 of the drawings, the apparatus comprises a shaft 101 having a rear end 101 R connectable to a drilling system 103 and a rotational cutting means 105 connectable to the front end 101 F. The shaft 101 extends through a front housing 111 and a rear housing 113 . The drilling system is a conventional system that can rotate and push the shaft 101 forward for drilling purposes and it can also pull the shaft 101 rearward. Additional stem members can be attached to the rear 101 R of the shaft 101 and to the drilling system 103 as the hole being drilled gets longer or deeper. The shaft 101 can rotate within each of units 111 and 113 , and can move forward a small distance to a drilling position and rearward a small distance to a shifting position relative to units 111 and 113 . Units 111 and 113 cannot rotate relative to each other, but they can bend or pivot lengthwise relative to each other, as shown in FIGS. 21 - 23 and 27 - 29 .
[0122] A front ball joint 115 with pivot pins 117 located at the front of unit 111 supports unit 111 on the front of the shaft 101 F. A middle ball joint 119 with a rear end 119 R connects the rear of unit 111 with the front of unit 113 . A rear ball joint 121 with pivot pins 121 A similar to the front ball joint 115 supports the rear of unit 113 on the rear of shaft 101 R.
[0123] A main cam 123 and a main cam follower 163 are employed in unit 113 to cause the apparatus to drill straight as shown in FIGS. 1 and 2 or to tilt or pivot units 111 and 113 relative to the shaft 101 as shown in FIGS. 21 - 23 and 27 - 29 to cause the front of the shaft 101 F to turn up, down, left, or right or any fraction thereof while drilling operations are being carried out. A shifting cam 145 is also located in unit 113 for the purpose of regulating the straight and turn drilling by regulating the amount of longitudinal displacement between the main cam 123 and the main cam follower 163 .
[0124] For reference, in the drawings, the top of the drilling apparatus is on the inside of the radius being drilled, such that if the hole is being turned up relative to the earth, the top of the drilling apparatus is up relative to the earth. Likewise if the bore is being turned downward relative to the earth, the drilling apparatus is turned upside down, and so on. Referring to FIG. 3 and FIG. 4, the front housing 111 has fixedly attached to it, a front socket 127 , a transmitter case 129 , a middle socket 131 , and a front wear pad 133 . The front socket 127 encases the front ball 115 so that the front housing 111 may pivot relative to the shaft 101 . The transmitter case 129 is accessible through a cutout 135 in the side of the front housing 111 . The door 129 D covers the transmitter 137 . The transmitter case 129 holds the compartment for the transmitter 137 employed by the drilling apparatus. The middle socket 131 encases the middle ball 119 so that the front housing 111 may pivot relative to the rear housing 113 . The middle socket 131 and the middle ball 119 are pinned together so that they cannot rotate relative to each other, such that the two housings 111 and 113 cannot rotate relative to each other. The front wear pad 133 is located on the bottom of the drilling apparatus, such that it pushes against the bore wall 179 to cause the drilling apparatus to turn. The rear of the middle ball 119 R is fixedly attached to the front of the rear housing 113 . The rear housing 113 has fixedly attached to it a main cam 123 , a stop plate 141 , a shiffing cam bushing 143 , a stop bushing 167 B, a clutch stop 147 , a rear socket 149 , and a rear wear pad 151 . The shifting cam bushing 143 supports a shifting cam 145 . The shifting cam 145 is free to rotate, but is locked longitudinally relative to the rear housing 113 . The clutch stop 147 is fixedly attached to the housing 113 and limits the rotational and forward movement of a female clutch member 153 . The rear socket 149 limits the rearward movement of the female clutch member 153 . The female clutch member 153 is free to rotate relative to the rear housing 113 only enough to allow the male clutch member 171 to engage with female clutch member 153 without regards to their starting rotational orientation.
[0125] Referring to FIGS. 5 and 6 the shaft 101 has attached to it a shaft retainer 155 upon which; in this case, a rotational cutting means 105 is mounted. The cutting means 105 may be a conventional rotary type as shown or it may be a hammering system that is commonly employed in harder strata and illustrated in FIGS. 74 - 76 . Behind the shaft retainer 155 are two sleeves 157 and 159 that rotate with the shaft 101 and hold the other components longitudinally in place. Behind the sleeves 157 and 159 are a thrust bearing 161 , a main cam follower 163 , a cam follower spacer 165 , a thrust bearing 169 , and a male clutch member 171 . The cam follower 163 and cam follower spacer 165 are free to rotate relative to the shaft 101 , but are tied longitudinally to the shaft 101 by the shaft retainer 155 , the two sleeves 157 and 159 , the thrust bearings 161 and 165 and the shoulder 101 S of the shaft 101 . The shaft 101 can rotate relative to the cam follower 163 and spacer 165 . Mounted on the rear of the shaft 101 R is a rearward cutter 173 . The rearward cutter 173 contains threads for accepting a thread adapter 175 that joins the drilling apparatus to the drill string and ultimately the drilling system 103 . Two shifting cam followers 177 A and 177 B are mounted 180 degrees from each other and 90 degrees from the cam follower lugs 163 S and 163 L on the outside of the cam follower 163 . The shifting cam followers 177 A and 177 B are free to pivot relative to the cam follower 163 , but are locked longitudinally to the cam follower 163 by pins 163 P. The shifting cam followers 177 A and 177 B are locked rotationally to the housing 113 but are free to move longitudinally relative to the housing 113 . The followers 177 A and 177 B cannot rotate relative to the housing 113 .
[0126] Referring to FIGS. 3 - 44 the main cam 123 has two slots cut into it, 180 degrees apart. The bottoms of the slots stay relatively parallel to each other. The bottom of the slots start out in the rear of the main cam 123 close to the bottom of the drilling apparatus and progress in several stages close to the top of the drilling apparatus as they progress to the front. The slots accept the main cam follower lugs 163 S and 163 L. The sides of slots keep the main cam follower 163 rotationally engaged to the rear housing 113 for rotation with the rear housing 113 as well as giving support for side loaded pressure placed on the drilling apparatus. The large cam follower lug 163 L is located on the bottom of the drilling apparatus, while the small cam follower lug 163 S is located on the top of the drilling apparatus. As the main cam follower 163 is displaced forward relative to the main cam 123 , the main cam follower lugs 163 S and 163 L follow the slots in the main cam 123 . This causes the front of the rear housing 113 and the rear of the front housing 111 to pivot downward away from the shaft 101 , such that the bore wall 179 is pushed on by the wear pad 133 and the drilling apparatus is caused to change directions. When the main cam follower 163 is displaced fully rearward, the front of the rear housing 113 and the rear of the front housing 111 are pivoted upward toward the shaft 101 . This causes the wear pad 133 to be pulled in as close as possible to the shaft 101 .
[0127] Referring to FIGS. 34 - 44 P, the shifting cam 145 and shifting cam followers 177 A and 177 B regulate the amount of longitudinal displacement that the main cam 123 and main cam follower 163 undergo. In FIGS. 35 - 44 P the exterior surface of the cam 145 is shown laid out flat. The two cam followers 177 A and 177 B are located 180 degrees apart. In FIGS. 35 , 42 - 44 , and 44 J- 44 M, 360 degrees of the cam is shown and in FIGS. 42 - 44 and 44 J- 44 M both cam followers 177 A and 177 B are shown. In FIGS. 36 - 41 , 44 A- 44 ( 1 ) and 44 N- 44 P only 180 degrees of the cam 145 is shown and only one cam follower 177 B is shown although it is to be understood that the complete cam of FIGS. 34 and 35 and both followers 177 A and 177 B will be employed. In FIGS. 36 - 44 P the horizontal arrows depict the direction of longitudinal travel of the followers 177 A and 177 B and the vertical arrows next to the cam 145 depict the direction of rotation of the cam 145 . In FIGS. 36 - 44 P, rearward movement of the followers 177 A and 177 B is to the right and forward movement of the followers 177 A and 177 B is to the left. The lugs 177 AL and 177 BL of the cams 177 A and 177 B can be moved between positions displaced fully rearward as shown by follower 177 B in FIG. 38 and to positions fully displaced forward as shown by follower 177 B in FIG. 41 and to intermediate positions. Grooves 145 A- 145 E are cut into the outside of the shifting cam 145 at an angle such that when the shifting cam followers 177 A and 177 B are displaced longitudinally they contact the walls of the grooves 145 A- 145 E, which rotate the shifting cam 145 . Furthermore, the lugs 177 AL and 177 BL on the shifting cam followers 177 A and 177 B are shaped in such away as to ride along the walls of the grooves 145 A- 145 E and to enter into an intersecting groove 145 AB- 145 DE when the appropriate displacement and rotational positioning is achieved.
[0128] [0128]FIG. 36 shows the shifting cam follower 177 B in the straight drilling position. In this position the shifting cam followers 177 A and 177 B, and thus the main cam follower 163 , cannot progress any further forward relative to the shifting cam 145 , and thus the main cam 123 , because the shifting cam follower lugs 177 AL and 177 BL are in contact with end of the shifting cam grooves 145 E. Displacing the shifting cam followers 177 A and 177 B rearward causes them to contact the next set of intersecting grooves 145 DE (FIG. 37). When the shifting cam followers 177 A and 177 B are displaced further rearward the shifting cam 145 is forced to rotate by the shifting cam follower lugs 177 AL and 177 BL pushing on the walls of the shifting cam grooves 145 D. The contact of the main cam follower lugs 163 S and 163 L and the stop ring 141 halt the rearward longitudinal displacement of the shifting cam followers 177 A and 177 B relative to the shifting cam 145 (FIG. 38 and FIG. 12). In this longitudinal position the clutch members 153 and 171 are engaged and the housing 113 may be rotated with the shaft 101 . When the desired rotational position is achieved, the shifting cam followers 177 A and 177 B can be moved forward relative to the shifting cam 145 until they contact the next set of intersecting grooves 145 AD (FIG. 39). As the shifting cam followers 177 A and 177 B are further displaced forward relative to the shifting cam 145 , the shifting cam follower lugs 177 AL and 177 BL push on the wall of the shifting cam grooves 145 A forcing the shifting cam 145 to rotate relative to the housing 113 (FIG. 40). The shifting cam followers 177 A and 177 B do not rotate relative to the housing 113 because they are held rotationally locked to the housing 113 by the shifting cam bushings 143 . The contact of the stop washer 167 and the stop bushing 167 B halts the further forward displacement of the shifting cam followers 177 A and 177 B relative to the shifting cam 145 as well as the forward displacement of the main cam follower 163 relative to the main cam 123 (FIG. 41 and FIG. 23). In this position the tightest radius is being drilled. Displacing the shifting cam followers 177 A and 177 B rearward causes them to contact yet another set of intersecting grooves 145 AC (FIG. 42). Further rearward displacement causes the shifting cam follower lugs 177 AL and 177 BL to push on the walls of shifting cam grooves 145 C, forcing the shifting cam 145 to rotate relative to the housing 113 (FIG. 43). FIG. 44 shows the shifting cam followers 177 A and 177 B moving passed the by-pass groove 145 B without entering it. This is possible by the widening of the grooves 145 C in this location. The contact of the end of the shifting cam grooves 145 C and the shifting cam follower lugs 177 AL and 177 BL stops the rearward displacement of the shifting cam followers 177 A and 177 B relative to the shifting cam 145 (FIG. 44A). In this embodiment the clutch members 171 and 153 are not engaged in this position, allowing the operator to know that upon pushing forward he will be drilling straight because the next intersecting groove leads to the straight position. Displacing the shifting cam followers 177 A and 177 B forward causes the shifting cam follower lugs 177 AL and 177 BL to contact the intersections of yet another set of shifting cam grooves 145 CE (FIG. 44B). Further forward displacement of the shifting cam followers 177 A and 177 B causes the shifting cam follower lugs 177 AL and 177 BL to push on the shifting cam groove walls, which causes the shifting cam 145 to rotate relative to the housing 113 . The contact of the shifting cam follower lugs 177 AL and 177 BL and the end of the shifting cam grooves 145 E stops the forward displacement of the shifting cam followers 177 A and 177 B relative to the shifting cam 145 and thus, the forward displacement of the main cam follower 163 relative to the main cam 123 (FIG. 44C). In this position the housings 111 and 113 are virtually parallel with the shaft 101 , thus causing zero effect on the direction of travel, which allows the drilling apparatus to drill straight. In this embodiment the clutch members 171 and 153 are not engaged, which allows the shaft 101 to rotate without rotating the housing 113 . While drilling straight the housings 111 and 113 slide through the bore being drilled. Rearward displacement of the shifting cam followers 177 A and 177 B causes them to contact the next set of intersecting grooves 145 DE (FIG. 44D). Further rearward displacement causes the shifting cam 145 to rotate relative to the housing 113 . Contact between the main cam follower lugs 163 S and 163 L and the stop plate 141 stops the rearward displacement between the shifting cam followers 177 A and 177 B and the shifting cam 145 (FIG. 44E and FIG. 12). Forward displacement of the shifting cam followers 177 A and 177 B causes the shifting cam follower lugs 177 AL and 177 BL to contact the next set of intersecting grooves 145 AD (FIG. 44F). Further forward displacement of the shifting cam followers 177 A and 177 B causes the shifting cam follower lugs 177 AL and 177 BL to push on the shifting cam groove walls causing the shifting cam 145 to rotate relative to the housing 113 . By halting the forward displacement of the shifting cam followers 177 A and 177 B relative to the shifting cam 145 before the shifting cam follower lugs 177 AL and 177 BL are displaced enough to enter the intersecting grooves 145 AC, but after they have passed the entrance of the by-pass grooves 145 AB, the operator has a choice to either drill straight or at least drill a lesser deviated hole (FIG. 44G). The forward displacement of the shifting cam followers 177 A and 177 B may be stopped by the operator or by the hard surface of the bore wall. For example, if the cutting means 105 or 247 is not activated, by either the rotation of the shaft or the supply of a compressed medium, such as air or water, after the main cam follower 163 is displaced forward enough to put sufficient pressure on the housing 113 to deflect it against the bore wall, the apparatus will not cut off to the side and thus the pressure from the wear pads 151 and 133 and the non-activated cutting means 105 or 247 will halt the forward displacement of the main cam follower 163 relative to the main cam 123 and thus the shifting cam followers 177 A and 177 B relative to the shifting cam 145 . Rearward displacement of the shifting cam followers 177 A and 177 B relative to the shifting cam 145 causes the shifting cam follower lugs 177 AL and 177 BL to contact the shifting cam groove walls causing the shifting cam 145 to rotate. This time the shifting cam 145 is rotating in the opposite direction from what it normally rotates. Further rearward displacement causes the shifting cam follower lugs 177 AL and 177 BL to contact the intersections of the bypass grooves 145 AB (FIG. 44H). Still more rearward displacement of the shifting cam followers 177 A and 177 B causes the shifting cam 145 to rotate in its normal direction. The contact of the main cam follower lugs 163 S and 163 L and the stop ring 141 halts the rearward displacement (FIG. 44(I) and FIG. 12). In this position the clutch members 153 and 171 are engaged and the housing 113 may be rotated if desired. Forward displacement of the shifting cam followers 177 A and 177 B causes the shifting cam follower lugs 177 AL and 177 BL to contact the next set of intersecting grooves 145 BA. Further forward displacement of the shifting cam followers 177 A and 177 B causes the shifting cam 145 to rotate in its normal direction (FIG. 44J and FIG. 44K). The shifting cam 145 is rotated until the shifting cam follower lugs 177 AL and 177 BL exit the by-pass grooves 145 B (FIG. 44L). The continued forward displacement of shifting cam followers 177 A and 177 B causes the shifting cam follower lugs 177 AL and 177 BL to enter into a set of short grooves 145 M, which stops the forward displacement of the shifting cam followers 177 A and 177 B relative to the shifting cam 145 (FIG. 44M). In this position the main cam follower 163 is displaced forward relative to the main cam 123 enough to deflect the housings 111 and 113 only part of their total deflection capabilities (FIGS. 27 - 29 ). If the operator chooses to drill forward the drilling apparatus will turn at a lesser degree than would otherwise be possible. If the operator chooses not to drill forward he can continue to manipulate the drill stem in order to position the drilling apparatus in the desired mode. Rearward displacement of the shifting cam followers 177 A and 177 B causes the shifting cam follower lugs 177 AL and 177 BL to contact the walls of shifting cam groove 145 C on the other side of the by-pass groove 145 B thus allowing the shifting cam 145 to be rotated in the normal direction (FIG. 44N). Further rearward displacement of the shifting cam followers 177 A and 177 B relative to the shifting cam 145 causes the shifting cam follower lugs 177 AL and 177 BL to push on the shifting cam groove wall, which causes the shifting cam 145 to rotate relative to the housing 113 (FIG. 44(O)). Contact between the shifting cam follower lugs 177 AL and 177 BL and the end of the shifting cam grooves 145 C stops the rearward displacement of the shifting cam followers 177 A and 177 B relative to the shifting cam 145 (FIG. 44P). Further longitudinal displacement causes this sequence to repeat.
[0129] Referring to FIGS. 1, 2, 7 , 8 and 36 , when the shifting cam followers 177 A and 177 B are stopped by shifting cam grooves 145 E the drilling apparatus is drilling with the main cam follower 163 only partially displaced relative to the main cam 123 , such that a straight bore is produced.
[0130] Referring to FIGS. 9 - 13 , 38 , 44 E, and 44 (l) when the shifting cam followers 177 A and 177 B are allowed to regress backward without hindrance from the shifting cam 145 the longitudinal displacement of the main cam follower 163 relative to the main cam 123 is stopped by the main cam follower lugs 163 S and 163 L and the stop plate 141 . In this position all of the parts of the drilling apparatus are rotationally locked by the engagement of the clutch means 171 and 153 .
[0131] Referring to FIG. 10 the bore illustrated is curved downwards while the drilling apparatus is in the shifting position and oriented to drill upwards. The rear of the front housing 111 and the front of the rear housing 113 are bent upward allowing the drilling apparatus to be rotated a full 360 degrees in a tighter radius bore than might otherwise be possible. This allows the drilling apparatus to be with drawn through a smaller radius bore without becoming stuck.
[0132] Referring to FIGS. 20 - 25 and 41 when the shifting cam followers 177 A and 177 B are allowed to progress forward unimpeded by the shifting cam 145 the forward displacement of the main cam follower 163 relative to the main cam 123 is stopped by the contact of the stop washer 167 and the stop bushing 167 B. In this position the drilling apparatus is producing the tightest turn possible.
[0133] Referring to FIGS. 21 - 23 and 27 - 29 the middle wear pad 133 is mounted on the rear of the front housing 111 such that when the rear of the front housing 111 is bent downward the wear pad 133 is forced against the bottom of the bore 179 , which pushes laterally on the drilling apparatus until the rear wear pad 151 hits the opposite side of the bore 179 , then the front of the drilling apparatus is pivoted toward the opposite side changing the direction of travel.
[0134] Referring to FIGS. 26 - 29 and 44 M, when the shifting cam followers 177 A and 177 B are stopped by shifting cam groove 145 M the drilling apparatus is drilling with the main cam follower 163 only partially displaced relative to the main cam 123 , such that a larger radius is drilled.
[0135] Referring to FIGS. 30 - 33 , 44 A and 44 P, when the shifting cam followers 177 A and 177 B are stopped by shifting cam groove 145 C the male clutch member 171 is halted from engaging the female clutch member 153 such that the housing 113 cannot be rotated when the shaft is rotated. This lets the operator know that upon pushing forward he will be drilling straight.
[0136] Referring to FIGS. 18,19 and 45 - 50 the clutch stop 147 has two lugs 147 L protruding toward the rear of the drilling apparatus. Each lug is identical. Each has a cam groove 147 C cutout that acts like a cam and a pin 147 P protruding radially outward. The pin 147 P is designed to hold the end of one of two elastic bands 153 R or 153 S whose other end is attached to one of two cam follower pins 153 P, that are attached to the clutch ring 153 . The elastic bands may be O-rings made from a suitable elastomer. The clutch ring 153 has two cutouts 153 C cut into its outer edge. Within these cutouts 153 C are mounted the two cam follower pins 153 P that act as cam followers. The interior of the ring 153 has teeth 153 T protruding toward the center. Each tooth 153 T has a beveled surface 153 B on its forward face. Cut radially around the clutch rings 153 outer edge is a groove 153 G that is wide enough and deep enough for the unobstructed acceptance of the elastic bands 153 R and 153 S. A male clutch member 171 is mounted fixedly on the shaft 101 . On the outer edge of the male clutch member are mounted teeth 171 T. Each tooth 171 T has a beveled surface 171 B facing rearward.
[0137] [0137]FIG. 49 shows the clutch assembly in a relaxed state. The housing 113 supports the clutch ring 153 and the clutch stop 147 . The male clutch member 171 is forward of the clutch ring 153 . The clutch ring 153 is positioned so that the lugs 147 L on the clutch stop 147 are located in and engaged with the cutouts 153 C on the clutch ring 153 . The cam pins 153 P are positioned in the cam groove 147 C. The elastic bands 153 R and 153 S are position so that one end is held by a cam pin 153 P and stretches through the groove 153 G to the pin 147 P that is mounted on the opposite lug 147 L. In this relaxed state, the elastic bands 153 R and 153 S keep the clutch ring 153 rotated clockwise as seen from the rear of the drilling apparatus. Being fully rotated clockwise the cam follower pins 153 P are positioned in the apex of the cam grooves 147 C and the clutch ring 153 is fully forward, resting against the face of the clutch stop 147 .
[0138] When the male clutch member 171 is pulled rearward, it will either enter into the clutch ring 153 without any interference, or the respective teeth 153 T and 171 T will hit. If the teeth 153 T and 171 T hit, the clutch ring 153 will be forced rearwards. This will cause the cam follower pins 153 P to contact the cam grooves 147 C, which will force the clutch ring 153 to rotate counter-clockwise as seen from the rear. As the counter clockwise rotation is taking place the elastic bands 153 R and 153 S are stretching and gaining potential energy. The rearward displacement of the clutch ring 153 is stopped when it contacts the rear ball socket 149 . By the time the clutch ring 153 has been displaced fully rearward the cam groove 147 C has exhausted its influence on the cam follower pin 153 P (FIG. 50). In this position the beveled surfaces 153 B and 171 B on the clutch rings teeth 153 T and the male clutch members teeth 171 T will be rotationally aligned so that any further rearward displacement of the male clutch member 171 relative to the clutch ring 153 will cause these surfaces 153 B and 171 B to push on each other, which will continue the counter-clockwise rotation of the clutch ring 153 relative to the clutch stop. The counter-clockwise rotation will stop when the clutch ring 153 and the male clutch member 171 are located such that each tooth 171 T is located between adjacent teeth 153 T.
[0139] In this position, the male clutch member 171 may be rotated in either direction to rotate the clutch ring 153 and hence the housing 113 in either direction. If it is rotated counter clockwise, the clutch ring 153 will be rotated relative to the housing 113 until the clutch stop lugs 147 L contact the edges of the cutouts 153 C on the clutch ring 153 . Further counter-clockwise rotation of the clutch ring 153 will rotate the housing 113 counter-clockwise. If the male clutch member 171 is rotated clockwise, the cam follower pins 153 P will contact the cam grooves 147 C, which will force the clutch ring 153 forward. The clutch ring 153 will stop being rotated relative to the housing 113 when the edges of the cutouts 153 C in the clutch ring 153 contacts the clutch stop lugs 147 L. In this position the clutch ring 153 is back in its starting position. Further clockwise rotation of the clutch ring 153 will rotate the housing 113 clockwise. If the male clutch member 171 has moved forward enough to disengage with the clutch ring 153 but has not rotated the clutch ring 153 clockwise enough to reposition the clutch ring 153 in its starting position, the elastic bands 153 R and 153 L will contract. This will rotate the clutch ring 153 clockwise causing the cam follower pin 153 P to contact the cam groove 147 C. As the cam follower pin 153 P is rotated clockwise it is being forced forward by the cam groove 147 C. The rotation and the forward travel relative to the housing 113 stop when the edges of the cutouts 153 C on the clutch ring 153 contact the clutch stop lugs 147 L. In this position the clutch ring 153 is in its starting position.
[0140] Referring to FIGS. 51 - 65 the rotational cutting means 105 are individual wings positioned on the shaft retainer 155 in radial positions to form a drill bit. Three slots 155 S are cut lengthwise into the shaft retainer 155 . On the front and rear of the shaft retainer 155 are cut six slots 155 LS perpendicular to the slots 155 S such that they leave behind a lip 155 L corresponding to the front and rear of each slot 155 S. Two dowel-pin holes 155 P are drilled perpendicular to each slot 155 S such that they are in a position to allow dowel-pins 155 D to lock the rotational cutting wings 105 in place. The dowel-pin holes 155 P are drilled so that the dowel-pins 155 D can be inserted and extricated from the direction of rotation such that upon rotation in the proper and common direction, the dowel-pins 155 D will not be pushed out of the dowel-pin holes 155 P. Smaller diameter hole portions are formed in the member 155 on the other side of each slot to allow the dowel-pins to be pressed out. On the front of the shaft retainer are three openings 155 H that allow water or other medium to escape from inside the shaft 101 . The individual cutting wings 105 have a section behind the actual cutting area 105 C that is called the shank 105 S. The shank 105 S is of a shape that will fit into one of the slots 155 S with little clearance. On the front is a front hook 105 F. On the rear is a rear hook 105 R. A second cutting surface 105 B faces toward the rear. Two dowel-pin holes 105 D are drilled in the middle of the shank 105 S. FIGS. 58 - 65 show the rotational cutting means 105 being mounted onto the shaft retainer 155 in steps. First the shank 105 S is held in line with the slot 155 S, then lowering the rear end of the shank 105 S so that the rear hook 105 R is engaged with the rear lip 155 L of the shaft retainer 155 . Then the rotational cutter 105 is rotated downwards into the slot 155 S until it comes to rest in the bottom of the slot 155 S. In this position the rotational cutting means 105 can be pulled rearwards. This engages the front hook 105 F with the front lip 155 L and lines up its dowel-pin holes 105 D with the dowel pin holes 155 P in the shaft retainer 155 . Then dowel-pins 155 D are inserted into each dowel-pin hole 155 P.
[0141] Referring to FIGS. 66 - 68 , a magnet 183 is magnetically isolated from but locked onto the shaft 101 in a position which allows it to pass longitudinally in the area of the transmitter case 129 when the shaft 101 is displaced longitudinally relative to the front housing 111 . The transmitter case 129 is made of non-magnetic material and has a number of magnetic conducting strips 185 isolated from each other. Each strip 185 has an end positioned in a different longitudinal position with its other end positioned in a different radial position around the transmitter cavity 135 . A special transmitter 137 B such as the Digitrac Eclipse produced by Digital Control Inc. has to be used. This transmitter 137 B is built with magnetically sensitive switches 187 that when activated send signals to the receiver to be viewed by the locator and ultimately by the operator Referring to FIG. 69 the female clutch member 153 and the clutch stop 147 of FIGS. 1 - 68 are replaced in the drilling apparatus by a longer female clutch member 153 L and a corresponding clutch stop 147 B. This makes the housings 111 and 113 of the drilling apparatus of FIGS. 1 - 68 rotate while the bore is being drilled straight as well as when it is in the shifting mode. The clutch will be disengaged when the drilling apparatus is in the turning mode.
[0142] Referring to FIGS. 70 - 72 a third housing 189 may be attached to the rear of the drilling apparatus via the rear ball 121 such that it is rotationally and longitudinally locked to the drilling apparatus. A third housing shaft 101 H is attach to the rear end of the shaft 101 R via a standard collar 191 such that the third housing's axis is parallel to the shaft 101 and the third housing shaft 101 H is fixedly attached to the shaft 101 . The rear of the third housing 189 is supported on the third housing shaft 101 H via a bearing compartment 189 B. The third housing 189 is designed to hold a larger transmitter 137 L than can be held in the normal transmitter compartment 135 , which is sometimes needed or preferred to produce a bore. One such transmitter is the Subsite produced by Charles Machine Works Incorporated.
[0143] Referring to FIG. 73 in the third housing 189 a ring collar 191 R can be used, instead of the standard collar 191 , to attach the rear of the shaft 101 and the front of the third housing shaft 101 H. On the inside of the ring collar 191 R is attached a wire 193 . The wire 193 is fed back through the shaft 101 H and ultimately to the drilling rig 103 and onto a receiver. The wire 193 is spliced and made longer upon the addition of each new drill stem. A brush 195 is provided to transmit a signal from a wireline transmitter 137 W that is housed in the third housing 189 . The brush 195 is touching but not solidly attached to the ring collar 191 R such that a constant connection is achieved even when the shaft 101 is rotating or moving longitudinally relative to the third housing 189 . Wireline transmitters are special but not uncommon for longer and/or deeper bores.
[0144] Operation
[0145] After the crew foreman has determined the bore path, the crew sets up the drill rig, in this case a Vermeer 24 / 40 produced by Vermeer Manufacturing Incorporated. With the lead drill stem already on the drill rig, the crew threads the drilling apparatus onto it. The crew will then insert transmitter 137 and calibrate it with the receiver located at the surface. The foreman has chosen to use a cutting means/wear pad ratio that would allow the drilling apparatus to rotate 360-degrees about its own axis when in the shifting position even in a curved hole. He could have chosen a number of different ratios, anywhere from barely turning for sewer bores, to a 1/1 ratio which would give him the tightest turn, but would not allow the drilling apparatus to rotate about its own axis in a curved hole. Although, rotating about it's own axis in a curved hole is not necessary to its operation, at times it can be handy. Starting at a 15-degree angle with the horizon and the drilling apparatus set to drill straight, the operator of the drill rig begins the bore.
[0146] Initially, the operator of the system will start out with the followers 177 A and 177 B in the groove positions 145 E as shown in FIG. 36 in order to drill straight. The operator drills straight until the drilling apparatus is about 4 ′ deep. At this time, he pulls back on the drill stem. This causes reactions in the drilling apparatus, 1) the clutch engages 171 to 153 , 2) the shifting cam followers 177 A and 177 B pull back spinning the shifting cam 145 , and 3) the cam follower lugs 163 S and 163 L slide rearward relative to the guide housings 111 and 113 .
[0147] The operator can now rotate the drilling apparatus to the desired orientation, in this case 12 : 00 . This places the front wear pad 133 on the bottom of the drilling apparatus and the rear wear pad 151 on the top of it. The operator can now push the drill stem forward. This causes 1) the clutch to disengage 171 from 153 , 2) the shifting cam followers 177 A and 177 B are pulled forward rotating the shifting cam 145 , and 3) the cam follower lugs 163 S and 163 L ride up the main cam 123 which causes the guide housings 111 and 113 to bend or pivot relative to each other and the shaft 101 so that the front wear pad 133 pushes against the bottom of the bore 179 , in the middle of the drilling apparatus, while the rear wear pad 151 pushes on the top of the bore. This reaction forces the cutting means 105 , located on the front of the drilling apparatus upward, changing the direction of travel. When the drilling apparatus has reached its full deflection using the chosen cutting means/wear pad ratio, the turning radius is approximately 110 feet. (Note: choosing other cutting means/wear pad ratios will change the radius of the bore.)
[0148] The operator can continue turning until he has achieved his desired degree of deviation or until he has to add another drill stem. While adding another drill stem, it is a good time for the crew's locator to check the position of the drilling apparatus, which includes its inclination, and its X, Y and Z position, with the receiver. For a consistent reading the drilling apparatus needs to be positioned in the same clock position every time. For the best reading, the drilling apparatus needs to be in a 3:00 rotational position, as indicated by the receiver. To do this the operator pulls back on the drill stem approximately 5 inches, then pushes forward approximately 2 inches, and finally pulls back approximately 3 inches. This causes the lugs of followers 177 A and 177 B to be located in the cam groove positions 145 C as depicted in FIGS. 44A, 145E, as depicted in FIGS. 44 C, and 145 D and as depicted in FIG. 44E respectively. In this position the clutch is engaged and the drill stem can rotate the drilling apparatus until the receiver indicates a 3:00 position. While the drill stem is being changed the locator can take his reading.
[0149] After adding a new drill stem and calculating his heading the foreman chooses to drill straight. To do this the operator needs to push forward approximately 2 inches and then pull back approximately 2 inches and then forward approximately 4 inches and then back ward approximately 2 inches. This causes the lugs of the cam followers 177 A and 177 B to be located in the cam groove positions 145 A as depicted in FIGS. 44G, 145B, as depicted in FIGS. 44 (I), 145 M, as depicted in FIGS. 44 M, and 145 C, and as depicted in FIG. 44P respectively. In this position he should be able to rotate the drill stem without rotating the drilling apparatus. This indicates that the next time he pushes forward he will be drilling straight. Then pushing forward, he can drill straight for as long as he wants. After drilling for a short distance he notices that the drilling apparatus has drifted slightly off course. Since he is installing steel casing and does not want a major bend in the bore where the pipe will be placed, he decides to use the minor turn feature of the drill head. To do this the operator moves the drill stem back approximately 2 inches, then forward approximately 1 inch, then backward approximately 1 inch, and then pushing forward he can start to drill. This locates the lugs of the followers 177 A and 177 B in the groove positions 145 D as depicted in FIGS. 44E, 145A, as depicted in FIGS. 44G, 145B, as depicted in FIGS. 44 (I), and 145 M, and as depicted in FIG. 44M respectively. This will cause the drilling apparatus to change directions, but not as quickly as when using the major turn feature.
[0150] By oscillating or moving the shaft 101 in and out relative to the drilling apparatus the operator has the choice of a major turning radius, a minor turning radius, or drilling straight. The foreman continues to manipulate the drilling apparatus to achieve his goal of installing steel casing in a directional bore. Furthermore, the foreman has control of the degree of turn that each turning radius gives him by adjusting the diameter of the cutting means in relation to the diameter of the front wear pad and/or the diameter of the rear wear pad before the bore is even started. In this embodiment, while the drilling is being carried out the housings 111 and 113 slide along the bore hole being drilled by the cutting means 105 .
[0151] FIGS. 74 - 83 refer to another embodiment of the invention. This embodiment has a single housing 201 . A shaft 203 passes through the housing 201 such that its forward end 203 F passes out of the front of the housing 201 and its rear end 203 R passes out of the rear of the housing 201 . On the shaft's front end 203 F is mounted a cutting means. The cutting means may be a rotary type 245 as shown in FIGS. 77 - 79 or a percussion type 247 as shown in FIGS. 74 - 76 . In this embodiment the housing 201 rotates with the shaft 203 while straight drilling is being carried out and the housing 201 does not rotate with the shaft while turn drilling is being carried out. The housing 201 is supported on both ends by bearings 205 and is sealed by seals 207 . The shaft 203 is free to rotate and move longitudinally relative to the housing 201 . The housing supports a front wear pad 209 and a rear wear pad 211 . The two wear pads 209 and 211 are 180 degrees from each other and on opposite ends of the housing 201 . The resulting central axis of the housing 201 is offset from the central axis of the shaft 203 which allows the wear pads 209 and 211 to influence the direction of travel by contacting the bore wall outside of the cutting diameter. The outside of at least one of the wear pads lies outside of the cutting diameter of the cutting means. On the outside of the housing 201 are three spring-loaded friction arms 219 that add resistance to rotation.
[0152] Inside of the housing 201 , from front to back, is a front housing support 213 , a transmitter housing 215 , a forward stop 217 , a rearward stop 221 , a shifting cam bushing 223 which supports a shifting cam 225 and ties the shifting cam follower 235 rotationally to the guide housing 201 , a female clutch member 227 , and a rear housing support 229 . All of these parts, except the shifting cam 225 , are fixedly attached to the housing 201 . The shifting cam 225 is longitudinally locked to, but is free to rotate relative to, the housing 201 . The cam 225 has grooves formed in its outer surface.
[0153] On the shaft is a front sleeve 231 , a front thrust bearing 233 , a shifting cam follower body 235 supported on the shaft by bearings 235 B, a rear thrust bearing 237 , a rear spacer 239 , and a male clutch member 241 . The shifting cam follower body 235 has two shifting cam follower arms 235 D and 235 A positioned 180 degrees from each other. The shifting cam follower lugs 235 L on the shifting cam follower arms 235 D and 235 A ride in the grooves 225 A- 225 D of the shifting cam 225 . All of the parts except the shifting cam follower body 235 which holds arms 235 D and 235 A are locked to the shaft 203 . The shifting cam follower 235 is longitudinally locked to the shaft 203 but is free to rotate relative to the shaft 203 . The shifting cam follower 235 is free to move longitudinally with the shaft 203 relative to the housing 201 but is tied rotationally to the guide housing 201 , such that it cannot rotate relative to the guide housing 201 .
[0154] FIGS. 84 - 95 show the shifting cam follower 235 being longitudinally displaced relative to the shifting cam 225 . Since the shifting cam follower 235 is locked rotationally to the housing 201 by the shifting cam bushings 223 , the shifting cam 225 is rotated by the lugs 235 L of the shifting cam follower 235 pushing on the walls of the shifting cam grooves 225 A- 225 D.
[0155] In FIGS. 84 - 95 , the exterior surface of the cam 225 is shown laid flat. The two cam followers 235 A and 235 D are located 180 degrees apart. In FIG. 95, 270 degrees of the cam 225 is shown and in FIG. 95 both cam followers 235 A and 235 D are shown. In FIGS. 84 - 94 , only 180 degrees of the cam 235 is shown and only one cam follower 235 D is shown although it is to be understood that the complete cam 225 and both followers 235 A and 235 D will be employed. In FIGS. 84 - 95 the horizontal arrows depict the direction of longitudinal travel of the followers 235 A and 235 D and the vertical arrows next to the cam 225 depict the direction of rotation of the cam 225 . In FIGS. 84 - 95 , rearward movement of the followers 235 A and 235 D is to the right and forward movement of the followers 235 A and 235 D is to the left. The lugs 235 L of the followers 235 A and 235 D can be moved between positions displaced fully rearward as shown by follower 235 D in FIG. 87 and to positions fully displaced forward as shown by follower 235 D in FIG. 84 and to intermediate positions.
[0156] [0156]FIG. 84 shows the shifting cam follower arm 235 D in the fully forward or turning position. Shifting cam follower arm 235 A is not pictured in any of the FIGS. 84 - 94 , but is understood to exist. In this position the clutch means is not engaged. Pulling back on the shifting cam follower arm 235 D causes it to contact the shifting cam groove intersection 225 AB (FIG. 85). Further rearward displacement causes the shifting cam 225 to be rotated by the shifting cam follower lugs 235 L pushing on the wall of the shifting cam groove 225 B (FIG. 86). Rearward displacement is stopped when the shifting cam follower body 235 contacts the rearward stop 221 (FIG. 87 and FIG. 82). In this position the clutch means is engaged. Forward displacement of the shifting cam follower arm 235 D causes the shifting cam follower lug 235 L to contact the shifting cam groove intersection 225 BC (FIG. 88). Further forward displacement of the shifting cam follower arm 235 D causes the shifting cam follower lug 235 L to push on the wall of the shifting cam groove 225 C (FIG. 89). This causes the shifting cam 225 to rotate. Forward displacement of the shifting cam follower arm 235 D is halted when the shifting cam follower lug 235 L contacts the end of the shifting cam groove 225 C (FIG. 90). This is the straight drilling position. In this position the clutch means is still engaged and the whole drilling apparatus, including the housing 201 , is being rotated as the hole is drilled (FIG. 80). Rearward displacement of the shifting cam follower arm 235 D causes the shifting cam follower lug 235 L to contact the shifting cam groove intersection 225 CD (FIG. 91). Further rearward displacement of the shifting cam follower arm 235 D causes the shifting cam follower lug 235 L to push on the wall of the shifting cam groove 225 D (FIG. 92). This causes the shifting cam 225 to rotate relative to the housing 201 . Again the rearward displacement of the shifting cam follower arm 235 relative to the shifting cam 225 is halted when the shifting cam body 235 C contacts the rearward stop 221 (FIG. 93 and FIG. 82). In this position the housing 201 can be rotated to a desired clock position in preparation for drilling a curved hole in the chosen direction. Forward displacement of the shifting cam follower arm 235 D causes the shifting cam follower lug 235 L to contact the shifting cam groove intersection 225 DA. Further forward displacement of the shifting cam follower arms 235 D and 235 A causes the shifting cam follower lugs to push on the walls of the shifting cam grooves 225 A (FIG. 95). This causes the shifting cam 225 to rotate. Forward displacement is halted when the shifting cam body 235 C contacts the forward stop 217 (FIG. 81 and FIG. 84). In this position the clutch means is disengaged and the housing 201 is held from rotating by friction on the walls of the bore. While the drill stem is rotating and thrusting forward the cutting means 245 or 247 , the drilling apparatus is drilling a curved hole. Further manipulations of the drill stems allow the operator to control the direction of travel.
[0157] When using a rotary type cutting means 245 with this embodiment, a hole-opener 243 is to be employed directly behind housing 201 . The hole-opener 243 is fixedly attached to the shaft 203 and is designed to enlarge the bore enough to allow the entire drilling apparatus to rotate around its own axis, even in a curved hole. If the drilling apparatus is not positioned in a sufficiently large void to allow the drilling apparatus to be rotated about its own axis without hindrance from the bore walls, undue strain and stress will be placed on the drilling apparatus. Furthermore the complete rotation of the drilling apparatus may not be possible in a non-enlarged bore, thus hindering the ability to control the path of the bore.
[0158] To use this embodiment with a percussion type cutting means 247 , the drilling crew would first thread the drilling apparatus onto the lead drill stem. Then they would mount the percussion head 247 on the front of the drilling apparatus. Next, the transmitter 137 would be inserted under the front wear pad 209 . With these things done the bore is ready to begin. Starting with the drilling apparatus in the straight drilling mode and the percussion bit 247 pressed up against the ground, the fluid medium usually either compressed air or water is switched on. This causes the bit 247 to vibrate in and out pulverizing even the hardest rock. As the drilling apparatus is advanced, it is rotated. This makes the bit 247 move in a circular motion with the center of the bore off center from the center of the bit 247 . The resultant bore diameter is larger than the cutting bit diameter. As long as the apparatus is moved forward and rotated with the percussion cutting means 247 activated it will drill relatively straight. When the operator wants to change direction, he pulls back on the drill stem. This causes the shifting cam follower 235 to rotate the shifting cam 225 . The rearward displacement ceases when the shifting cam follower 235 encounters the rearward stop 221 . The drill stem can now rotate the drilling apparatus to the desired rotational position. Once in the desired position, the drill stem can be pushed forward causing the shaft 203 to be forwardly displaced relative to the housing 201 . This disengages the clutch means 241 from 227 and causes the shifting cam follower 235 to rotate the shifting cam 225 . The forward displacement is halted when the shifting cam follower 235 hits the forward stop 217 . The bit 247 is pressed against the earth and the fluid medium is switched on. This causes the bit 247 to vibrate in and out pulverizing the rock. The drill stem can be rotated allowing the bit 247 to impact various spots on the face of the rock being drilled. The bit 247 is rotated about its own center. While turning, the housing 201 is held from rotating by the friction arms 219 that are contacting the wall of the bore. Since the housings wear pads 209 and 211 lay outside of the cutting radius of the percussion means 247 , they push on the wall of the bore which in turn pushes on the drilling apparatus moving the cutting means 247 in the opposite direction. The bore can be drilled in the turning mode as far as needed. To drill straight again the drill stem is pulled back. This causes the shifting cam follower 235 to rotate the shifting cam 225 and engages the clutch means 241 to 227 . The drill stem is then pushed forward causing the shaft 203 to be displaced relative to the housing 201 until the grooves 225 C (FIG. 90) in the shifting cam 225 stop the shifting cam follower 235 . In this position the clutch means 241 to 227 is still engaged such that when the drill stem rotates the shaft 203 , the entire drilling apparatus, including the housing 201 , is rotated. Since the curved hole that the drilling apparatus is now in, is too small to allow the rotation of the drilling apparatus about its axis at first, the percussion means 247 is activated and slowly rotated along with the housing 201 which enlarges the bore diameter. After one revolution, normal drilling can be resumed. The operator can choose between straight and curved drilling at any time. The operator knows that he is drilling straight when he is drilling and the transmitter is showing that the drilling apparatus is rotating. Likewise he knows when he is drilling a curved hole when he is drilling and the transmitter is showing that the drilling apparatus is not rotating.
[0159] To use this embodiment with a rotary type cutting means 245 . The drilling crew would first thread the drilling apparatus onto the lead drill stem. Then the crew would mount the rotary drill bit 245 on the front of the drilling apparatus. Next, the transmitter 137 would be inserted under the front wear pad 209 . Starting with the drill head in the straight drilling mode, the drill stem is rotated and then thrust forward. This makes the drilling apparatus, including the housing 201 , as well as the rotary drill bit 245 to do the same, which drills a straight hole.
[0160] When the operator wants to turn, he pulls back on the drill stem, which pulls back on the shaft 203 causing it to be displaced relative to the housing 201 . At the same time the shifting cam follower 235 rotates the shifting cam 225 . The drill stem can be rotated which rotates the shaft 203 , which in turn rotates the drilling apparatus until the desired rotational direction is reached. Then pushing forward the shifting cam follower 235 rotates the shifting cam 225 and the clutch means 241 is disengaged from 227 . The forward displacement is stopped when the shifting cam follower 235 hits the forward stop 217 . With the housing held rotationally in place by the friction arms 219 , the drill stem, the shaft 203 , and rotary drill bit 245 are rotated and thrust forward cutting the hole. Since at least one wear pad 209 and/or 211 lies outside of the cutting diameter of the rotary bit 245 , the protruding wear pad 209 and/or 211 contacts the wall causing the drilling apparatus to be deflected in the opposite direction. While the curved hole is being drilled a hole opener 243 on the rear of the drilling apparatus is enlarging the hole, which is also true when a straight hole is being drilled, but to a lesser extent, because a straight hole is bigger than a curved hole. The curved hole can be cut until the operator chooses to drill straight. When he does desire to drill straight, he pulls back on the drill stem for at least five feet, which positions the entire drilling apparatus in the enlarged hole. While pulling back the shaft 203 and shifting cam follower 235 are displaced relative to the housing 201 and the shifting cam 225 . This causes the shifting cam follower 235 to rotate the shifting cam 225 and the clutch means 241 and 227 to engage. The drill stem is then pushed forward which causes the shaft 203 , the shifting cam follower 235 and the male clutch means 241 to be displaced relative to the housing 201 , the shifting cam 225 and the female clutch member 227 . The shifting cam follower 235 hitting the grooves 225 C (FIG. 90) in the shifting cam 225 stops the forward displacement. In this position the clutch members 241 to 227 are still engaged which causes the housing 201 to rotate and the bore to be drilled straight. The drill stem is now thrust forward and rotated which causes the entire drilling apparatus to be rotated and thrust forward. The resulting bore is relatively straight and of a larger diameter than the diameter of the rotary drill bit 245 . The operator knows that he is drilling straight, if while he is drilling the transmitter is indicating that the housing 201 is rotating and conversely he is turning if the transmitter indicates that the housing 201 is not rotating.
[0161] After the bore has reach its destination the drilling crew may wish to enlarge the hole using a hole-opener. If so, they would use a system that attaches rotational cutting means to a hole-opener in a manner similar to the way the rotational cutting means 105 were attached to the shaft retainer 155 . (NOTE: the rotational cuffing means may be one or more of any style on the market, including roller cones and bullet teeth, with the only change being the mounting shank made special for this application.)
[0162] Referring to FIG. 106 the rotational cutting means 251 are individual wings positioned on the hole-opener body 249 in radial positions to form a hole-opener 255 . Four slots 249 S are cut lengthwise into the hole-opener body 249 . On the front and rear of the hole-opener body 249 are cut eight slots 249 LS perpendicular to the slots 249 S such that they leave behind a lip 249 L corresponding to the front and rear of each slot 249 S. Two dowel-pin holes 249 P are drilled perpendicular to each slot 249 S such that they are in a position to allow dowel-pins 253 to lock the rotational cutting means 251 in place. The dowel-pin holes 249 P are drilled so that the dowel-pins 253 can be inserted and extricated from the direction of rotation such that upon rotation in the proper and common direction, the dowel-pins 253 will not be pushed out of the dowel-pin holes 249 P. Smaller diameter hole portions are formed in the body 249 on the other side of each slot to allow the dowel-pins 253 to be pressed out. On the front of the hole-opener body 249 are four openings 249 H that allow water or other medium to escape from inside the hole-opener body 249 . The rotational cutting means 251 have a section behind the actual cutting area 251 C that is called the shank 251 S. The shank 251 S is of a shape that will fit into one of the slots 249 S with little clearance. On the front is a front hook 251 F. On the rear is a rear hook 251 R. Two dowel-pin holes 251 P are drilled in the middle of the shank 251 S. FIGS. 99 - 104 show the rotational cutting means 251 being mounted onto the hole-opener body 249 in steps. First the shank 251 S is held in line with the slot 249 S, then lowering the rear end of the shank 251 S so that the rear hook 251 R is engaged with the rear lip 249 L of the hole-opener 249 . Then the rotational cutting means 251 is rotated downwards into the slot 249 S until it comes to rest in the bottom of the slot 249 S. In this position the rotational cutting means 251 can be pulled rearwards. This engages the front hook 251 F with the front lip 249 L and lines up its dowel-pin holes 251 P with the dowel-pin holes 249 P in the hole-opener body 249 . Then dowel-pins 253 are inserted into each dowel-pin hole 249 P. With the rotational cutting means 251 attached to the hole-opener body 249 the hole-opener 255 is ready for use.
[0163] To use this hole-opener 255 the drilling crew would attach the hole-opener 249 body to the drill-string 175 D. Then the drill rig operator would rotate the drill string 175 D and begin to pull the hole-opener 255 through the previously bored hole 257 leaving behind an enlarged hole 259 . (NOTE: the hole-opener 255 can be mounted and used to be pulled through the previously bored hole or it can be mounted and used to be pushed through the previously bored hole.)
[0164] In hole-opener 255 , four slots 249 S were used and in the shaft retainer 155 three slots 155 S were used. If desired as few as only one slot 249 S maybe used in the hole-opener 255 and also only one slot 155 S may be used in the shaft retainer 155 . If only one slot 249 S is used in the hole-opener 255 or if only one slot 155 S is used in the shaft retainer 155 the single rotational cutting means 105 or 251 would cut the entire diameter when rotated in a complete revolution.
[0165] In the single slot shaft retainer 155 a different version of the rotational cutting means 105 may be more desirable. In this version the rotational cutting means 261 would extend across the desired diameter of the hole as in FIGS. 107 and 108. In FIG. 107 cutting edges are shown at and 273 and 155 A is the axis of rotation. In FIG. 108, a cutting edge own at 271 and member 275 is a roller cutting cone.
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The drill device has a body with a front end and a rear end and which is connectable to the shaft of a drilling apparatus. A plurality of angularly spaced apart slots are formed in the exterior of the device which extend between the front and rear ends. Each slot has a lip extending from each of its front and rear ends respectively. A cutting member is provided for each of the slots with each cutting member having a connecting portion located in one of the slots and having a forward end and a rearward. Each connecting portion has a hook near its front and rear ends respectively for connection to the lips of the slot in which it is located.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND
The present disclosure relates to a device for fastening a toilet seat.
DISCUSSION OF THE RELATED ART
A toilet seat generally comprises a seat and a lid which are hingedly assembled on a bowl. The back portion of the toilet seat may be fastened to the bowl by bolts having their nuts generally located under the seating portion. A disadvantage is that the fitting and the removal of the toilet seat, particularly for the maintenance thereof, requires unscrewing and screwing the bolts, which may be uneasily accessible, the bowl being generally placed in a narrow room. Another disadvantage is that the fitting and the removal of the toilet seat for maintenance requires manipulating the bolt and the back portion of the toilet seat, which may be relatively uncleaned parts due to their location.
There exist toilet seats where the seat and the lid of the toilet seat are pivotally mounted on a fastening device which is fastened on two pins attached to the toilet bowl by a locking device which may be released by pressing on a button located at the back or at the front of the toilet seat. A disadvantage is that the fitting and the removal of the toilet seat for the maintenance thereof generally requires manipulating the back portion of the toilet seat. According to a variation, a protrusion may be provided at the back of the seat to press on the unlock button when the seat is up. A disadvantage then is that the unlock button is actuated each time the seat is put up, which may cause an incidental unwanted removal of the toilet seat.
There exist toilet seats where the toilet seat comprises, at its back portion, a magnet which cooperates with a magnet provided on the bowl to fasten the toilet seat to the bowl. A disadvantage is that, to provide a good fastening of the toilet seat to the bowl, the attractive force of the magnets used should be relatively significant, whereby removing the toilet seat may require applying a significant force.
It would be desirable to be able to simply fit and/or remove a toilet seat, particularly for the maintenance thereof, with no excessive effort and without having to manipulate the back portion of the toilet seat.
SUMMARY
An object of an embodiment aims at overcoming all or part of the disadvantages of previously-described toilet seat fastening devices.
Another object of an embodiment is for the toilet seat to be able to be fitted or removed, particularly for the maintenance thereof, with no manipulation of the back portion of the toilet seat.
Another object of an embodiment is for the user to be able to simply and rapidly fit and remove the toilet seat, particularly for the maintenance thereof.
Another object of an embodiment is for the toilet seat to be able to be fitted or removed, particularly for the maintenance thereof, with no excessive effort.
Thus, an embodiment provides a device for fastening a toilet seat to at least one first elements fastened to a toilet bowl, comprising a first locking part and wherein, for each back and forth motion of the fastening device relative to the bowl, the locking part is capable of alternately displacing between a first position where the first locking part cooperates with the first element and a second position where the fastening device can be separated from the first element.
According to an embodiment, the device comprises a support, a first arm hinged with respect to the support and stressed at a first end by a spring and intended to be stressed by the first element at a second end, the first arm cooperating with a first cam hinged with respect to the support and capable of allowing the pivoting of the first hinged locking part relative to the support, for each back and forth motion of the fastening device relative to the bowl, alternately between a first position where the first locking part partly penetrates into a first groove of the first element and a second position where the first locking part does not penetrate into the first groove.
According to an embodiment, the first arm is hinged with respect to the support around a first axis and the first cam and the first locking part are hinged with respect to the support around a second axis different from the first axis.
According to an embodiment, the first cam comprises a first groove following a closed curve.
According to an embodiment, the device comprises a first finger attached to the first arm and penetrating into the first groove.
According to an embodiment, the second axis is outside of the first curve.
According to an embodiment, the first locking part comprises first stressing means capable of having the first locking part pivot against the first element.
According to an embodiment, the first stressing means comprise a first flexible tab.
According to an embodiment, the device comprises a second arm hinged with respect to the support and stressed at a third end by the spring and intended to be stressed by a second element of the bowl at a fourth end, the second arm cooperating with a second cam hinged with respect to the support and capable of allowing the pivoting of a second locking part hinged with respect to the support, for each back and forth motion of the fastening device relative to the bowl, alternately between a third position where the second locking part partly penetrates into a second groove of the second element and a fourth position where the second locking part does not penetrate into the second groove.
According to an embodiment, the first arm comprises a first toothed portion and the second arm comprises a second toothed portion, the first toothed portion meshing with the second toothed portion.
According to an embodiment, the second arm is hinged with respect to the support around a third axis and the second cam and the second locking part are hinged with respect to the support around a fourth axis different from the third axis.
According to an embodiment, the second cam comprises a second groove following a second closed curve.
According to an embodiment, the device comprises a second finger fastened to the second arm and penetrating into the second groove.
According to an embodiment, the fourth axis is outside of the second curve.
According to an embodiment, the second locking part comprises second stressing means capable of pivoting the second locking part against the second element.
An embodiment also provides a toilet comprising a bowl and a toilet seat, and a device, such as previously defined, for fastening the toilet seat to at least one first element fastened to the bowl.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other features and advantages will be discussed in detail in the following non-limiting description of specific embodiments in connection with the accompanying drawings, among which:
FIG. 1 is a perspective view of an embodiment of a toilet;
FIG. 2 is a cross-section view of an embodiment of a device for fastening a toilet seat to a toilet bowl;
FIGS. 3 and 4 are front views of parts of the embodiment of the fastening device of FIG. 2 ;
FIGS. 5A and 5B are front views of each side of another part of the embodiment of the fastening device of FIG. 2 ;
FIGS. 6A and 6B are front views of each side of another part of the embodiment of the fastening device of FIG. 2 ;
FIGS. 7A to 7E are cross-section views of the embodiment of the fastening device of FIG. 2 at successive steps during an operation of removing the toilet seat from a toilet bowl; and
FIGS. 8A to 8D are cross-section views of the embodiment of the fastening device of FIG. 2 at successive steps during an operation of fitting the toilet seat to a toilet bowl.
DETAILED DESCRIPTION
For clarity, the same elements have been designated with the same reference numerals in the various drawings and, further, the various drawings are not to scale. In the following description, expressions “substantially”, “around”, and “approximately” mean “to within 10%”. Further, adjectives “front”, “back”, “lower” and “upper” are used with respect to the usual orientation of a toilet.
FIG. 1 shows an embodiment of a toilet 10 comprising a bowl 12 having an internal cavity 13 and an edge forming a seating portion 14 . A toilet seat 15 is fastened to bowl 12 . Toilet seat 15 comprises a seat 16 , for example, made of a plastic material, pivotally assembled with respect to bowl 12 at the level of a fastening device 18 fastened to the back portion of bowl 12 so that seat 16 covers seating portion 14 when it is put down on bowl 12 . A lid 20 , for example, made of a plastic material, is also pivotally assembled with respect to fastening device 18 so that lid 20 covers seat 16 when it is put down on bowl 12 . When seat 16 and lid 20 are put down on bowl 12 , they close internal cavity 13 of bowl 12 .
FIG. 2 is a cross-section view of an embodiment of fastening device 18 in closed position. The cross-section plane is a vertical plane perpendicular to the horizontal direction oriented from front to back of toilet 10 . In FIG. 2 , seat 16 and lid 20 are not shown.
Fastening device 18 comprises a cylindrical tube 24 containing a locking device 26 having an axial symmetry relative to a vertical axis C. In the following description, the elements which are symmetrical with respect to axis C are designated with the same reference numeral followed by letter “A” when the element is totally or mainly located to the left of axis C in FIG. 2 , and followed by letter “B” when the element is totally or mainly located to the right of axis C in FIG. 2 .
Fastening device 18 is fastened to two elements 28 A, 28 B, for example, pins, attached to the bowl, not shown. The spacing between pins 28 A and 28 B is for example in the range from 10 cm to 25 cm. The diameter of tube 24 is a few centimeters, for example, from 2 cm to 3 cm. Locking device 26 comprises a support 29 fastened to the internal wall of tube 24 . Locking device 26 further comprises two arms 30 A, 30 B. Each arm 30 A, 30 B is mounted so as to pivot with respect to support 29 around an axis DA, DB, which is for example horizontal. Arms 30 A, 30 B are stressed by a spring 32 , for example, a helical spring, having one end maintained on a base 34 forming part of support 29 . A finger is fastened to each arm 30 A, 30 B, only finger 36 A being shown in FIG. 2 . Each finger 36 A cooperates with a cam 38 A, 38 B mounted so as to pivot with respect to support 29 around an axis EA, EB, which is, for example, horizontal. Each cam 38 A, 38 B may pivot a locking part 40 A, 40 B, mounted so as to pivot with respect to support 29 around axis EA, EB.
FIG. 3 shows pin 28 A. Each pin 28 A, 28 B comprises a base 42 A, 42 B resting on the bowl, a cylindrical body 44 A, 44 B extending along an axis parallel to axis C from base 42 A, 42 B and extending in a tapered end portion 46 A, 46 B. In locked position, each cylindrical body 44 A, 44 B penetrates into an opening 45 A, 45 B provided in tube 24 . A groove 47 A, 47 B is made in cylindrical body 44 A, 44 B at the junction between cylindrical body 44 A, 44 B and end portion 46 A, 46 B.
FIG. 4 shows arm 30 A. Each arm 30 A, 30 B comprises an end 48 A, 48 B capable of bearing against end portion 46 A, 46 B of pin 28 A, 28 B when fastening device 18 is in locked position. Each arm 30 A, 30 B comprises a toothed wheel sector 50 A, 50 B at the end opposite with respect to axis DA to end 48 A, 48 B comprising teeth 52 A, 52 B on two rows. Toothed wheel sector 50 A of arm 30 A permanently meshes with toothed wheel sector 50 B or arm 30 B, so that arms 30 A, 30 B simultaneously pivot around axes DA, DB, the clockwise or counterclockwise pivoting direction of arm 30 A being opposite to the pivoting direction of arm 30 B and the inclination angles of arms 30 A, 30 B permanently being, in absolute value, substantially identical. Each arm 30 A, 30 B comprises a portion 54 A, 54 B having one end of spring 32 pressing against it. Finger 36 A is fastened to arm 30 A, 30 B between axis DA, DB and end 48 A, 48 B.
FIGS. 5A and 5B show the two sides of cam 38 A. Each cam 38 A, 38 B comprises a guiding portion 55 A, 55 B comprising a groove 56 A having a finger 36 A capable of moving therein, only groove 56 A of cam 38 A being visible in the drawings. Groove 56 A follows a closed curve which successively comprises, in FIG. 5A in the counterclockwise direction, a first limiting upper position 58 A, a limiting outer position 60 A, a limiting lower position 62 A, a limiting inner position 64 A, a second limiting upper position 66 A, and a locking position 68 A. Guiding portion 55 A, 55 B is connected to a portion forming a pivot 70 A, 70 B by two connection portions 72 A, 72 B. Pivot-forming portion 70 A, 70 B comprises a cylindrical opening 71 A, 71 B of axis EA, EB. Rotation axis EA, EB of each cam 38 A, 38 B is located outside of groove 56 A. Pivot-forming portion 70 A, 70 B comprises a pin 74 A, 74 B. Each cam 38 A, 38 B comprises a flexible tab 76 A, 76 B for example extending from pivot-forming portion 70 A, 70 B and ending in a convex portion 78 A, 78 B which rubs against support 28 when cam 38 A, 38 B pivots around axis EA, EB.
FIGS. 6A and 6B show the two sides of locking part 40 A. Each locking part 40 A, 40 B comprises a pivot-forming portion 80 A, 80 B pivotally assembled with respect to support 29 around axis EA, EB. Pivot-forming portion 80 A, 80 B comprises a cylindrical portion 81 A, 81 B having cylindrical opening 71 A, 71 B of each associated cam 38 A, 38 B assembled thereto. Pivot-forming portion 80 A, 80 B extends in a head 82 A, 82 B. A recess 84 A, 84 B forming a stop is provided on one of the sides of head 82 A, 82 B. A flexible tab 86 A, 86 B extends from pivot-forming portion 80 A, 80 B.
Arms 30 A, 30 B and cams 38 A, 38 B may be made of polyamide. Fingers 36 A may be made of stainless steel. Locking parts 40 A, 40 B may be made of polyacetal.
FIG. 2 shows fastening device 18 in a locked position. In this position, finger 36 A maintained by each arm 30 A, 30 B is in the locking position 68 A of groove 56 A. Locking part 40 A, 40 B is maintained under the action of flexible tab 86 A, 86 B against pin 28 A, 28 B, head 82 A, 82 B of locking part 40 A, 40 B penetrating into notch 47 A, 47 B of pin 28 A, 28 B.
FIGS. 7A to 7E are views similar to FIG. 2 of the embodiment of locking device 18 at successive steps during a toilet seat removal operation. Only the rotating motions of arm 30 A, of cam 38 A, and of locking part 40 A are described, the rotating motions of arm 30 B, of cam 38 B, and of locking part 40 B being symmetrical with respect to axis C. Head 82 A, 82 B and groove 47 A, 47 B of pin 28 A, 28 B are shaped so that, while head 82 A, 82 B penetrates into groove 47 A, 47 B of pin 28 A, 28 B, head 82 A, 82 B remains locked in groove 47 A, 47 B in the case where tube 24 is removed from the bowl. Locking device 18 thus remains locked on pins 28 A, 28 B when only a traction is exerted on the toilet seat in vertical position.
FIG. 7A shows locking device 18 after a user has, with respect to the locked position shown in FIG. 2 , displaced tube 24 with respect to the seating portion downwards along direction C, tube 24 substantially coming into contact with bases 42 A, 42 B of pins 28 A, 28 B. This may be obtained by putting up the seat and the lid vertically and by exerting a pressure on the front portion of the seat and of the lid downwards along direction C. Head 82 A and groove 47 A of pin 28 A are shaped so that, when head 82 A penetrates into groove 47 A of pin 28 A, the efforts exerted by pin 28 A on head 82 A, when tube 24 is brought closer to the seating portion, cause the clockwise pivoting of locking part 40 A around axis EA in FIG. 7A until head 82 A comes out of groove 72 A. Once head 82 A has come out of groove 47 A, it keeps on sliding along cylindrical body 44 A of pin 28 A. Moreover, when tube 24 is brought closer to the seating portion, pins 28 A, 28 B exert a pressure on ends 48 A, 48 B of arms 30 A, 30 B. This causes a pivoting of arms 30 A, 30 B around axes DA and DB and compressing of spring 32 . Arm 30 A pivots clockwise in FIG. 7A . Finger 36 A displaces in groove 56 A of cam 38 A, 38 B from locking position 68 A to the first limiting upper position 58 A. This translates in FIG. 7A by a clockwise pivoting of cam 38 A around axis EA. The pivoting of locking part 40 A causes the deformation of flexible tab 86 A against tube 24 . For simplification, in FIGS. 7A, 7B, and 7C , deformed flexible tabs 86 A, 86 B are shown as crossing tube 24 .
As a variation, the removal of head 82 A from groove 47 A may be obtained by the pivoting of cam 38 A, which may cause a clockwise pivoting of locking part 40 A around axis EA in FIG. 7A to disengage head 82 A from groove 47 A, by the pressing of pin 74 A against stop 84 A of locking part 40 A.
FIG. 7B shows locking device 18 after the user has, with respect to the position shown in FIG. 7A , started taking tube 24 away from the seating portion by displacing it upwards along direction C. This may be obtained by exerting a traction on the front part of the seat and of the lid, in vertical position, upwards along direction C. As a variation, the action of spring 32 may be such that the user does not have to or only slightly has to pull on the toilet seat. Under the action of spring 32 , arm 30 A has pivoted around axis DA in the counterclockwise direction in FIG. 7B . Finger 36 A displaces in groove 56 A of cam 38 A from limiting upper position 58 A to a position closer to limiting outer position 60 A. Groove 56 A substantially follows, between limiting upper position 58 A and limiting outer position 60 A, an arc of a circle of axis DA. This translates in FIG. 7B as a maintaining substantially in angular position of cam 38 A around axis EA and also of locking part 40 A under the action of pin 74 A of cam 38 A bearing against stop 84 A of locking part 40 A. Head 82 A of locking part 40 A thus does not penetrate into groove 47 A of pin 28 A when, due to the relative displacement between pin 28 A and locking part 40 A, head 82 A is located opposite groove 47 A as shown in FIG. 7B .
FIG. 7C shows locking device 18 after the user has, with respect to the position shown in FIG. 7B , continued taking tube 24 away from the seating portion by displacing it upwards along direction C. Under the action of spring 32 , arm 30 A has pivoted around axis DA in the counterclockwise direction in FIG. 7C . Finger 36 A displaces in groove 56 A of cam 38 A all the way to limiting outer position 60 A. This translates in FIG. 7C as a maintaining substantially in angular position of cam 38 A and also of locking part 40 A under the action of pin 74 A of cam 38 A bearing against stop 84 A of locking part 40 A.
FIG. 7D shows locking device 18 after the user has, with respect to the position shown in FIG. 7C , continued taking tube 24 away from the seating portion by displacing it upwards along direction C. Under the action of spring 32 , arm 30 A has pivoted around axis DA in the counterclockwise direction in FIG. 7D . Finger 36 A displaces in groove 56 A of cam 38 A all the way to limiting lower position 62 A. This translates in FIG. 7D by a counterclockwise pivoting of cam 38 A around axis EA. Under the action of flexible tab 86 A, a counterclockwise pivoting of locking part 40 A around axis EA maintaining it stopped against pin 74 A of cam 38 A is obtained. Head 82 A, 82 B being located at the level of end portion 46 A, 46 B of pin 28 A, head 82 A, 82 B does not oppose the displacement of pin 28 A.
FIG. 7E shows locking device 18 after the user has, with respect to the position shown in FIG. 7D , kept on taking tube 24 away from the seating portion by displacing it upwards along direction C. Pins 28 A, 28 B have been totally removed from tube 24 . The toilet seat is then no longer fastened to the seating portion.
FIGS. 8A to 8D are views similar to FIG. 2 of the embodiment of locking device 18 at successive steps during a toilet seat fitting operation. Only the rotating motions of arm 30 A, of cam 38 A, and of locking part 40 A are described, the rotating motions of arm 30 B, of cam 38 B, and of locking part 40 B being symmetrical with respect to axis C.
When the toilet seat is not connected to the seating portion, fastening device 18 is in the configuration shown in FIG. 7E .
FIG. 8A shows locking device 18 after the user has introduced end portions 46 A, 46 B of pins 28 A, 28 B into openings 45 A, 45 B of tube 24 and has started bringing tube 24 closer to the seating portion by displacing it downwards along direction C. This may be obtained by exerting a downward pressure on the front part of the seat and of the lid, in vertical position, along direction C. FIG. 8A shows the time when end portions 46 A, 46 B of pins 28 A, 28 B come into contact with ends 48 A, 48 B of arms 30 A, 30 B.
FIG. 8B shows locking device 18 after the user has, with respect to the position shown in FIG. 8A , continued bringing tube 24 closer to the seating portion by displacing it downwards along direction C. When tube 24 is brought closer to the seating portion, pins 28 A, 28 B exert a pressure on ends 48 A, 48 B of arms 30 A, 30 B. This causes a pivoting of arms 30 A, 30 B around axes DA and DB and a compressing of spring 32 . Arm 30 A pivots clockwise in FIG. 8B . Finger 36 A displaces in groove 56 A of cam 38 A from limiting lower position 62 A to first limiting lower position 64 A. This translates in FIG. 8B as a counterclockwise pivoting of cam 38 A around axis EA. The sliding of head 82 A on end portion 46 A of pin 28 A causes a clockwise pivoting of locking part 40 A around axis EA in FIG. 8B . The pivoting of locking part 40 A causes the deformation of flexible tab 86 A against tube 24 . For simplification, in FIGS. 8B, 8C, and 8D , deformed flexible tabs 86 A, 86 B are shown as crossing tube 24 .
FIG. 8C shows locking device 18 after the user has, with respect to the locked position shown in FIG. 8B , continued bringing tube 24 closer to the seating portion by displacing it downwards along direction C, tube 24 substantially coming into contact with bases 42 A, 42 B of pins 28 A, 28 B. During the relative displacement between pin 28 A and locking part 40 A, head 82 A penetrates into groove 47 A, comes out of groove 47 A, and then continues sliding along cylindrical body 44 A of pin 28 A. Further, under the action of pin 28 A on end 48 A of arm 30 A, arm 30 A has pivoted clockwise around axis DA in FIG. 8C , further compressing spring 32 . Finger 36 A displaces in groove 56 A of cam 38 A all the way to the second limiting upper position 66 A. This causes a clockwise pivoting of cam 38 A.
As a variation, the shape of groove 56 A may be adapted so that cam 38 A is in a position which enables to prevent head 82 A of locking part 40 A from penetrating into groove 47 A of pin 28 A, due to the pressing of pin 74 A, 74 B of cam 38 A, 38 B against stop 84 A, 84 B of locking part 40 A, 40 B, during the relative displacement of pin 28 A relative to tube 24 .
FIG. 8D shows locking device 18 after the user has, with respect to the position shown in FIG. 8C , started taking tube 24 away from the seating portion by displacing it upwards along direction C. This may be obtained by exerting a traction on the front part of the seat and of the lid, in vertical position, upwards along direction C. Under the action of spring 32 , arm 30 A has pivoted around axis DA in the counterclockwise direction in FIG. 8D . Finger 36 A displaces in groove 56 A of cam 38 A from second limiting upper position 66 A to locking position 68 A. This translates in FIG. 8D as a clockwise pivoting of cam 38 A around axis EA. Under the action of flexible tab 86 A, a counterclockwise pivoting of locking part 40 A around axis EA is obtained, which makes head 82 A penetrate into groove 47 A of pin 28 A, pin 74 A allowing the pivoting of locking part 40 A. Fastening device 18 is then locked on pins 28 A, 28 B. As a variation, the action of spring 32 may be such that the user does not have to or only slightly has to pull on the toilet seat.
During a removal or fitting operation, convex portion 78 A, 78 B of flexible tab 76 A, 76 B of each cam 38 A, 38 B continuously rubs against support 29 . Thereby, each cam 38 A, 38 B remains substantially motionless and does not tilt under its own weight, for example, when finger 36 A supported by each arm 30 A, 30 B is in limiting lower position 62 A.
Specific embodiments have been described. Various alterations, modifications, and improvements will readily occur to those skilled in the art. In particular, flexible tabs 86 A, 86 B may be replaced with helical springs.
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A device for fastening a toilet seat to at least one first element of a toilet bowl, including a first locking part and wherein, for each back and forth motion of the fastening device relative to the bowl, the locking part is capable of alternately displacing between a first position where the first locking part cooperates with the first element and a second position where the fastening device may be separated from the first element.
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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 generally to the field of frames for openings and more specifically to a framing assembly for a window in a door.
BACKGROUND OF THE INVENTION
A door light is a window which is installed in an opening in a door to allow additional light to enter a room and to enhance the appearance of the door. In a typical door light, a pane of glass is sandwiched between frames attached to both sides of a hollow door.
Many known door lights have frames which extend beyond the outer surfaces of the door. However, if low profile panic hardware must be installed in order to comply with fire codes or other safety regulations, often the panic hardware or the surface of the door must be shimmed or modified to allow the panic hardware to be installed over the protruding frame. Moreover, full length door lights which have frames that extend beyond the outermost surfaces of the door may not comply with handicap codes because the frame may catch on the wheel of a wheel chair or other equipment.
In addition, many existing door lights have frames that cannot be installed without welding or other methods which adversely affect pre-finished surfaces, such as polished brass. Typically, pre-finished frames must be welded prior to applying the finish. This process is time and labor intensive and results in less flexibility to the consumer to customize the size and shape of the frame while increasing cost to tho consumer. Frames having finished surfaces which are designed for installation in a pre-existing door must be fabricated and finished at the frame factory prior to shipment. Although special welding machines are available for welding pre-finished surfaces without affecting the final appearance of the surface, the specialized welding machines are expensive and not readily available for installing window lights outside of a factory. Therefore, if the window frame does not fit the opening in a door, the frame cannot be re-welded at the installation site without ruining the appearance of the pre-finished surface.
Further, although some existing door lights can be installed so that the outer surface of the frames are flush with the outer surface of the skins, extensive preparation to bend or modify the skins of the door is required before the frame can be installed.
In view of the foregoing, there is a need for a framing assembly that can be installed so that the outer surface of the frame does not extend past the surface of the door without modifying or bending the door skins prior to installation. Further, a need exists for a framing assembly that can be fabricated economically from components having pre-finished surfaces such as polished or antiqued brass, stainless steel, chrome or similar materials.
SUMMARY OF THE INVENTION
The present invention overcomes these and other disadvantages of existing door lights by providing a framing assembly which does not extend past the outer surfaces of the door. Further, the framing assembly of the present invention can be installed in a door without any significant modification to the skins of a door prior to installation. Moreover, the present framing assembly can be fabricated with prefinished surfaces such as polished brass, since the exposed surfaces of the frames of the present framing assembly require no welding.
The present framing assembly typically is installed in a door which has a front skin and a back skin. Each of the front and back skins has an interior surface and an exterior surface. The front skin is spaced apart from the the back skin to define a hollow space between the interior surface of each skin. An opening is cut through each of the front and back skins. When referring to the opening, the terms front and back are arbitrarily assigned for purposes of clarity in the summary and the detailed description. However, the front and back openings arc typically identical.
The framing assembly of the present invention preferably includes a first frame, a second frame and a plurality of channel sections for securing the first and second frames to the door. The channel sections are recessed between the interior surfaces of the front skin and the back skin. In a preferred embodiment, at least a first frame is secured directly to the channel sections. A second frame may be secured to either the first frame or the channel section. The first and second frames surround the perimeter of the openings in the front and back skins. The outer surface of the first and second frames are flush with the front and back outer surfaces of the door after the frames are installed within the openings in the door.
Each channel section includes a web member and two flange members. The web member of each channel section is an elongated and substantially rectangular member having two long edges and two short edges. In a preferred embodiment, the flange members also are elongated substantially rectangular members having two long edges and two short edges. One long edge of each flange member is attached to or depends from one of each of the long edges of the web member to form a channel section having a U-shaped cross-section. The web member defines one or more guide grooves for receiving screws or other fastening means for fastening at least one frame to the channel section. Although each channel section includes at least a web member and two flange members, preferably each channel section is formed from a single sheet of metal or other suitable material.
The channel sections are inserted in the hollow space around the openings in the door. The channel sections are of a width sufficient to allow the flanges to contact the interior surface of each skin of the door. Each channel section is oriented within the hollow space so that the flanges extend into the hollow space away from the openings. The channel sections are secured to the skins around the openings by welding the channel to the interior surfaces of the skins of the door. Preferably, the channel sections are completely recessed within the hollow space so that the web members do not extend beyond the periphery of the openings.
The first frame of the present frame assembly is formed from a plurality of frame sections. Each first frame section includes a first leg, a second leg, an inclined member and a stop member. The first leg has a first long edge and a second long edge. A plurality of holes for receiving screws or other fastening means is positioned between the first and second long edges of the first leg. The second leg, inclined member and stop member each have first and second long edges and first and second short edges. A first long edge of the second leg is joined to a first long edge of the first leg to form a first frame section having a generally L-shaped cross-section.
A first long edge of the inclined member is joined to a second long edge of the second leg. The inclined member extends at an angle toward the center line of the web member so that the inclined member is positioned directly above and spaced apart from the first leg. A first long edge of the stop member is joined to the second long edge of the inclined member. Preferably, the stop member extends from the inclined member toward the first leg in a direction which is substantially perpendicular to the first leg. In a particularly preferred embodiment, the second long edge of the first leg of the first frame is configured to form a latch member for retaining a clip member which is formed from a long edge of the first leg of the second frame.
The first frame sections are secured to the channel sections around the front opening by positioning the first leg on the web member. The holes in the first leg are aligned with the guide groove in the web member so that the first frame section can be securely attached to the web member of the channel section by inserting self-tapping screws through the aligned holes or by any other sutiable fastening means. The second leg of the first frame section is positioned along the periphery of the front opening but does not extend beyond the front door skin.
Preferably, the latch member is formed from the first leg of the first frame by folding a portion of the first leg along a line parallel to the second long edge of the first frame to form a down-turned segment which projects toward the web member of the channel section. The second long edge of the first leg is positioned above the web member to form narrow space or slot for receiving a clip member from the first long edge of the first leg of the second frame section. The inclined members and the second legs of the first frame sections cooperate to form the visible portion of the first frame. The stop members of the first frame sections cooperate to form a glass retaining surface.
The second frame is assembled from a plurality of sections. Each second frame section is formed from a first leg, a second leg, an inclined member and a stop member. Each first leg, second leg, inclined member and stop member of the second frame have first and second long edges and first and second short edges. A first long edge of the second leg is joined to the second long edge of the first leg along two long edges to form a first frame section having a generally L-shaped cross-section. A first long edge of the inclined member is joined to the second long edge of the second leg. The inclined member extends at an angle toward the centerline of the web member so that the inclined member is positioned directly above and spaced apart from the first leg. A first long edge of the stop member is joined to the second long edge of the inclined member. Preferably, the stop member extends from the inclined member in a direction which is substantially perpendicular to the first leg. A plurality of holes for receiving screws or other fastening means may be disposed in the inclined member. In a preferred embodiment, the inclined member does not include holes for receiving screws or fastening means. Rather, the fastening means includes a clip member formed at the second long edge of the first leg. The clip member cooperates with the latch member formed with the first frame section to fasten the second frame sections into position without the need for screws.
The second frame sections are positioned on the channel sections around the back opening so that the first leg of the second frame section rests on the web member of the channel. The second leg is positioned along the periphery of the back opening but does not extend beyond the back door skin. The clip member formed at the second long edge of the first leg snaps in the narrow space formed between the down-turned segment of the latch member and the web member. The clip member typically is larger than the narrow space so that the clip member cannot be easily removed once inserted between the web member and the down-turned segment of the first frame section. The fold in the first leg of the first frame section forms a bend that rests against the second leg of the second frame section. The bend cooperates with the clip member and the latch member to prevent movement of the second frame section so that the second frame section is securely fastened in the back opening. The inclined members and the second legs of the second frame sections cooperate to form the visible portion of the second frame. The stop members of the second frame sections cooperate to form a glass retaining surface. The glass retaining surfaces of the first and second frames cooperate to hold a pane of glass securely within the opening.
The ends of each first and second frame sections have a miter or similar configuration so that adjoining frame sections fit together in an attractive manner. The visible portions of the first and second frames of the present door light require no welding to install the framing assembly of the present invention. Therefore, particularly preferred materials for the first and second frame include stainless steel, polished or antiqued brass, or similar metals that can support a pre-finished surface.
Preferably, the channel sections, first frame sections and second frame sections are each provided in eight to twelve foot lengths. The sections typically are fabricated in a range of widths to accommodate a variety of door sizes.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing aspects and other features of the present invention are explained in the following specification taken in connection with the accompanying drawings wherein:
FIG. 1a is a perspective view showing features of the framing assembly of the present invention;
FIG. 1b is a perspective view showing features of the framing assembly of the present invention;
FIG. 2 is a cross-sectional view of the framing assembly shown in FIG. 1 taken along line 2--2;
FIG. 3 is an enlarged view of a portion of the framing assembly shown in FIG. 2;
FIG. 4 is a cross-sectional view showing features of a preferred embodiment of the channel sections of the present invention;
FIG. 5 is a cross-sectional view showing features of a preferred embodiment of the first frame sections of the present invention;
FIG. 6 is a cross-sectional view showing features of a preferred embodiment of the second frame sections of the present invention;
FIG. 7 is a cross-sectional view showing channel sections of the present invention installed between the skins of a door;
FIG. 8 is a cross-sectional view showing features of a first alternate embodiment of the channel sections, first frame, and second frame of the present invention;
FIG. 9 is a side view of typical mitered ends of preferred embodiment of the first frame sections;
FIG. 10 is a top view showing typical installation procedures for the horizontal sections of the first frame and second frame of the present invention;
FIG. 11 is a side view showing typical installation procedures for the vertical sections of the first frame and second frame of the present invention;
FIG. 12 is a side view showing features of a second embodiment of the present framing assembly; and
FIG. 13 is a top view and end view showing features of the channel sections, first frame and second frame of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIGS. 1-3, the framing assembly of the present invention is designated generally as 1. The framing assembly 1 is installed in a door 3 having a front skin 7 spaced apart from a back skin 9. The front skin 7 has an interior surface 90 and an exterior surface 92. The back skin 9 has an interior surface 94 and an exterior surface 96. A hollow space 11 is defined between the interior surfaces 90 and 94 of the skins 7 and 9. A front opening 8 and a corresponding back opening 10 are cut in the front and back skins 7 and 9. The front opening 8 and back opening 10 typically define square or rectangular perimeters.
The present framing assembly 1 includes a first frame 19 and a second frame 21, and channel sections 17a, 17b, 17c, and 17d for securing the first 19 and second 21 frames to the door. The channel sections 17a, 17b, 17c, and 17d are recessed between the interior surfaces 90 and 94 of the front 7 and back 9 skins. The first frame 19 includes a plurality of sections 19a, 19b, 19c, and 19d that surround the perimeter of the front opening 8. Self-tapping screws 29 or other fastening means fasten the first frame sections to the channel sections. The second frame 21 includes a plurality of sections 21a, 21b, 21c, and 21d that surround the perimeter of the back opening 10. Self-tapping screws 29 or other fastening means fasten the second frame sections directly to the channel sections. Preferably, the sections of second frame 21 are secured around the back opening 10 by clip members 75 formed with the second frame sections as described in more detail below.
The detailed description and cross-sectional views depicting features of the channel section 17a, are typical for the remaining sections 17b, 17c, and 17d. Likewise, the detailed description and cross-sectional views depicting features of the first frame section 19a and second frame section 21a are typical for the remaining sections 19b, 19c, 19d and 21b, 21c, 21d.
As shown in FIGS. 3 and 4, channel section 17a includes a web member 54 and two flange members 51 and 52. The web member 54 is an elongated and substantially rectangular member having two long edges 66 and 68 and two short edges (not designated). In a preferred embodiment, the flange members 51 and 52 also are elongated and substantially rectangular members having two long edges 81 and 83 and two short edges (not designated). One long edge 83 of each flange member is attached to and depends from one of each of the long edges 66 and 68 of the web member 54 to form a channel section 17a having U-shaped cross-section. Preferably, flanges 51 and 52 include bevels 53 and 56 at the edges 66 and 68 of the web member 54.
The web member 54 includes a center portion 60 and curved segments 55 and 58 disposed on either side of the center portion 60. The center portion 60 defines three guide grooves 25, 26, 28 for receiving self-tapping screws or other fastening means. The guide grooves 25, 26. and 28 are preferably arcuate in shape so that self-tapping screws 29 can be easily threaded through the web member 54. The guide grooves 25, 26, 28 extend parallel to the flanges 51 and 52 along the length of the web member 54. Alternately, the guide grooves may be replaced by pre-drilled holes to receive fastening means such as rivets or bolts.
Referring to FIG. 7, the channel section 17a is inserted in the hollow space 11 between the skins 7 and 9. Preferably, the channel section 17a spans the distance between the front opening 8 and the back opening 10 so that the channel section 17a is positioned along one side of the perimeter of both the front opening 8 and the back opening 10. The flanges 51 and 52 contact the interior surfaces 90 and 94 of the door skins 7 and 9 and extend away from the openings into the hollow space 11. Preferably, the web member 54 of channel section 17a is completely recessed in the hollow space 11 so that the web member 54 does not extend past the perimeter of the front 8 or the back 10 openings.
Tack welds 13 secure the channel section 17a to the interior surfaces 90 and 94 of the door skins 7 and 9. When the optional bevels 53 and 56 are included between the flanges 51 and 52 and the long edges 66 and 68 of the web member 54, the bevels 53 and 56 cooperate with the interior surfaces 90 and 94 to form weld pockets 57 for the tack welds 13. The sections 17b, 17c, 17d are arranged in the remaining three sides of the openings and attached in the same manner as channel section 17a. The channel sections 17a, 17b, 17c, and 17d substantially circumscribe the openings 8 and 10.
Referring to FIG. 5, the first frame section 19a includes a first leg 41, a second leg 44, an inclined member 37 and a stop member 31. The first leg 41 has two long edges 46 and 48. A plurality of openings 27 for receiving self-tapping screws 29 are positioned between the edges 46 and 48 of the first leg 41. The first leg 41 preferably has a curved segment 45 for resting on the curved segment 55 of the web member 54. The second leg 44 has a first long edge 95 and a second long edge 96. The first long edge 95 of the second leg 44 is joined to the long edge 46 of the first leg 41 to form a first frame section 19a having a generally L-shaped cross-section.
The inclined member 37 also has a first long edge 97 and a second long edge 98. The first long edge 97 of the inclined member 37 is joined to the second long edge 96 of the second leg 44. The inclined member 37 extends at an angle toward the centerline of the web member 54 so that the inclined member 37 is positioned directly above and spaced apart from the first leg 41.
The stop member 31 has a first long edge 99 and a second long edge 100. The first long edge 99 of the stop member 31 is joined to the second long edge 98 of the inclined member 37. The stop member 31 extends from the inclined member 37 in a direction which is substantially perpendicular to the first leg 41.
The first frame section 19a is secured to the channel section 17a along the front opening 8 by positioning the first leg 41 on the curved segment 55 of the channel section 17a. As shown in FIG. 3, the curved segment 55 of the web member 54 corresponds to the shape of the curved segment 45 of the first leg 41 so the first frame section 19a nests on the web member 54 of the channel section 17a. The openings 27 in the first leg 41 align with the guide groove 25 so that the first frame section 19a can be securely attached to the channel section 17a by inserting self-tapping screws 29 through the aligned openings 27. The first frame section 19a is oriented so the second leg 44 of the first frame section 19a preferably contacts, but does not protrude past, the interior surface 90 of the front door skin 7.
In a particularly preferred embodiment, the long edge 48 of the first leg 41 is configured to form a latch member 47 for retaining a clip member 75 formed at an edge 82 of the first leg 43 of the second frame section 21a. The latch member 47 is formed by folding a portion of the first leg 41 along a line parallel to the long edge 48 of the first frame section 17a to form a down-turned segment 73 which projects toward the web member 54 of the channel section 17a. The portion of the first leg 41 at the fold forms a bend 91 for resting against the second frame section 21a. The long edge 48 of the first leg 41 is positioned above the web member 54 to form a narrow space 101. The clip member 75 of the second frame section 21a is held in the narrow space 101 between the long edge 48 and the web member 54 is the second frame section 21a is securely fastened within the back opening 10.
First frame sections 19b, 19c, 19d are oriented in a similar manner around the front opening 8 to form the first frame 19 of the present invention. The inclined members 37 and the second legs 44 of the first frame sections form the visible portion of the first frame 19. Further, the stop members 31 cooperate to form a glass retaining surface (not shown) for installing a pane of glass 23.
Referring to FIG. 6, the second frame section 21a is formed from a firs t leg 43, a second leg 49, an inclined member 39 and a stop member 33. The first leg 43 has two long edges 78 and 82 with a curved segment 80 disposed between the edges 78 and 82. The second leg 49 has a first long edge 102 and a second long edge 103. The first long edge 102 of the second leg 49 is joined to the long edge 78 of the first leg 43 to form a second frame section 21a having a generally L-shaped cross-section.
The inclined member 39 also has a first long edge 104 and a second long edge 105. The first long edge 104 of the inclined member 39 is joined to the second long edge 103 of the second leg 49. The inclined member 39 extends at an angle toward the centerline of the web member 54 so that the inclined member 39 is positioned directly above and spaced apart from the first leg 43. The stop member 33 has a first long edge 106 and a second long edge 107. The first long edge 106 of the stop member 33 is joined to the second long edge 105 of the inclined member 39. The stop member 33 extends from the inclined member 39 in a direction which is substantially perpendicular to the first leg 43.
The second frame section 21a is installed around the back opening 10 by positioning the first leg 43 of the second frame section 21a on the web member 54 of the channel section 17a. As shown in FIG. 3, the curved segment 58 of the web member 54 corresponds to the shape of the curved segment 80 of the first leg 43 so the second frame section 21a nests on the web member 54 of the channel section 17a. The second frame section 21a is oriented so the second leg 49 contacts, but does not extend beyond, the interior surface 94 of the back door skin 9.
Referring to FIG. 11, a plurality of openings 71 for receiving self-tapping screws 29 may be disposed in the inclined member 39. The screws 29 are inserted in the openings 71 and advanced through the guide groove 28 to attach the second frame section 21a to the channel section 17a. In this embodiment, the latch member 47 of the first frame section 19a is omitted because the latch member 47 conceals the guide groove 28. In a particularly preferred embodiment, the latch member 47 is provided along with a clip member 75. The clip member 75 is formed at the edge 82 of the first leg 43. The clip member 75 is preferably formed by a fold at the edge 82. However, any configuration will suffice that provides an enlarged segment at the edge 82.
The clip member 75 snaps securely in the space 101 formed by down-turned segment 73 of the latch member 47 and the web member 54. The second leg 49 of the second frame section 21a rests against the bend 91 of the first frame section 19a. The bend 91 assures a snug fit between the second leg 49 and the interior surface 94 and prevents the frame section 21a from moving.
Second frame sections 19b, c, d are oriented in a similar manner around the back opening 10 to form the second frame 19 of the present invention. The inclined members 39 and the second legs 49 of the second frame sections form the visible portion of the second frame 21. Further, the stop members 33 cooperate to form a second glass retaining surface (not shown). The first and second glass retaining surfaces secure a pane of glass 23 between the first 19 and second 21 frames.
A first alternate embodiment of the present framing assembly 1 is shown in FIG. 8. The elements of the first alternate embodiment generally correspond to those previously described. The changes reside primarily in the shape of the various features. For instance, a channel section 117a has a web member 154 with flat segments 155 and 158 in lieu of curved segments 55 and 58. A single guide groove 125 is defined by the web member 154 and preferably extends the length of the channel section 117a.
Similarly, a first frame section 119a has a first leg 141 having a substantially flat segment 145. A latch member 147 and a down-turned portion 173 are also both substantially flat. Finally, a second frame section 121a has a first leg 143 having a flat segment 180.
To install a preferred embodiment of the present framing assembly 1, the openings 8 and 10 are cut by a computer numerically controlled punch (not shown). Alternately, the openings 8 and 10 can be cut in the field by a hand-held reciprocating saw or similar tool (not shown). Any burrs or rough spots in the opening are removed with a grinder, rasp or similar tool. The door skins 7 and 9 do not require bending or further modification to install the present framing assembly 1.
Channel sections 17a, b, c, and d are cut to length according to the height and width of the openings. Next, each section is inserted in the hollow space 11 between the openings 8 and 10. The flanges 51 and 52 of each section are disposed between the front skin 7 and the back skin 9 and extend away from the opening 5. Welds 13 are placed in the weld pockets 57 to secure the channel sections to the front door skin 7 and back door skin 9.
Next, the first frame sections 19a, b, c, d are cut into four sections according to the height and width of the openings 8 and 10 and mitered at the ends as shown in FIG. 9. Generally, the first frame sections 19a, b, c, d are inserted around the front opening 8. Preferably, the two sections of first frame 19 that form the vertical components and are cut shorter than the height of the front opening 8. The horizontal components of first frame 19 are cut longer than the width of the front opening 8. Referring to FIG. 10, the horizontal sections are installed first. The ends of the horizontal sections slip behind the front door skin 7 and contact the interior surface 90.
Referring to FIG. 11, the vertical sections are installed next. The ends of the vertical sections do not slip behind the front door skin 7 since the sections are shorter than the height of the front opening 8. However, the ends of the vertical sections extend over the horizontal sections to provide a mitered appearance at the corners. Each section of the first frame 19 is attached to the channel 17 by inserting the self tapping screws 29 through the openings 27 and threading the screws 29 through the guide groove 25 of the channel sections.
The pane of glass 23 is installed between the first frame 19 and the second frame 21. As is well known in the art, a gasket or adhesive 35 or any other type of similar glass installation apparatus may be used to secure the pane of glass.
Next, the second frame sections 21a, b, c, d are cut to length and mitered at the ends as shown in FIG. 10. Preferably, the two sections of second frame 21 that form the vertical frame are cut shorter than the height of the back opening 10. The horizontal sections of the second frame 21 are cut longer than the width of the back opening 10. Using the preferred lengths of second frame sections, the horizontal sections are installed first. The ends slip behind the back door skin 9 and contact the interior surface 94. Referring to FIG. 11, the vertical sections are installed next. The ends of the vertical sections do not slip behind the back door skin 9 since the sections are shorter in length than the height of the back opening 10. However, the ends of the vertical sections extend over the horizontal sections to provide a mitered appearance at the corners.
Preferably, each section of the second frame 21 is installed by pushing the clip member 75 of each second frame section between the catch 47 and the web member 54 of each first frame section until the second frame sections snap into place around the back opening 10. Alternately, self-tapping screws 29 are inserted through the openings 71 in the second frame 21 and tapped through the guide groove 28 of the channel 17.
Alternately, the channel 17 is installed in the hollow space 11 so the web member 54 is substantially even with the perimeter of the front 8 and back 10 opening. When the first and second frames 19 and 21 are cut and installed, they are positioned on the web member 54 of the channel sections so the second legs 41 and 43 do not contact the interior surfaces 90 and 94 of the door skins 7 and 9. Rather, the second legs 41 and 43 are flush with the exterior surfaces 92 and 96 of the door skins 7 and 9. If the present framing assembly 1 is installed in an exterior door, caulk or a similar sealant may be applied at all exposed joints and mating surfaces to prevent moisture from entering the door.
The present framing assembly 1 allows panic hardware to be installed without shims or other modification to the door or panic hardware. Further, the frames 19 and 21 of the present framing assembly 1 does not protrude past the face of the door to cause problems with compliance with handicap codes.
Although FIGS. 1-13 illustrate a frame having four sides, the framing assembly of the present invention may be installed in openings having three or more sides or in openings having circular or curved perimeters. The channel sections, first frame 19, and second frame 21 of the present invention may fabricated to a variety of lengths. In a preferred embodiment, the components are roll-formed from a single sheet of metal and fabricated in eight to twelve foot lengths as shown in FIG. 13. The channel sections, first frame 19 and second frame 21 may further be provided in a variety of widths to fit in a hollow door of any width. As the foregoing illustrates, the visible portions of the frames of the present framing assembly require no welding. Therefore, particularly preferred materials include stainless steel, polished or antiqued brass, or similar metals that can receive a pre-finished surface.
The present invention is not limited to doors, but can be installed in any hollow panel having a front and back door skin. While the present invention has been described with reference to the accompanying drawings, it is understood that various modifications or alterations may be made to the described embodiments. Therefore, the scope of the present invention is defined by the following claims.
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A framing assembly for a door light which includes a first frame, a second frame, and a plurality of channel sections. The first and second frames are formed from a plurality of frame sections. The channel sections are disposed within the hollow space defined by the two skins of a door panel. The first frame sections are attached to the channel sections by any conventional fastening means. The first frame sections are provided with integral latch members and the second frames are provided with integral clip members which cooperate to retain the second frame member within the opening in a hollow door panel without the use of any visible external hardware. The framing assembly of the present invention may be provided with pre-finished surfaces and can be installed in pre-existing doors without the need for special welding equipment or extensive modification to the door panel prior to installation.
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PRIORITY STATEMENT & CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority from co-pending U.S. Patent Application No. 61/533,357, entitled “Apparatus and Method for Heating Ground” and filed on Sep. 12, 2011, in the name of Dale Befus; which is hereby incorporated by reference for all purposes.
TECHNICAL FIELD OF THE INVENTION
[0002] The present disclosure is related to the field of ground heating equipment, in particular, radiant heaters used for heating ground and for thawing frozen ground.
BACKGROUND OF THE INVENTION
[0003] Much construction in modern economies lie in building, installing, and maintaining surface and subsurface structures such as roads, water distribution, drainage systems, pipelines, barriers, fences, electrical transmission infrastructure, telecommunication infrastructure, and the like. In cold climates, frost persists in the ground for much of the year rendering summertime equipment for penetrating the surface (e.g., digging, trenching, ploughing, filling, sealing, and the like) ineffective without first thawing the ground. This circumstance is particularly pronounced in the urban environment where frost is typically much deeper and precise dimensionality of subsurface penetration much more critical. Many construction techniques are available for thawing the top 10 centimetres of ground fairly efficiently. However few services are buried at such depths and many services are situated deep within the frost zone. Consequently, controlling the dimension of the thaw has become increasingly important as too little thawing at the required dimension and depth leads to difficulty moving the earth as desired while too much thawing may cause problems such as wasted energy or sloughing of the adjacent terrain.
[0004] Concurrently with the proliferation of subsurface structures that has occurred in the past 60 years, there has been an evolution of regulations and standards in the construction industry arising from improved understanding in the engineering, occupational safety, environmental, urban-planning, fire-safety, and allied fields. Meeting these regulations is often challenging and expensive. In order to achieve operating profitably within these evolving limitations contractors have had to investigate new ways to achieve their ends
[0005] Heat transfer for thawing is typically accomplished by a combination of conduction, convection, and radiation. Conventionally, ground heating or thawing is typically undertaken by 1) piping heated fluids (e.g., glycerol) through hoses having a serpentine configuration disposed under thermal blankets or soil, 2) heating enclosed air over a construction site, 3) placing a portable heating enclosure over the target ground or 4) burning materials (usually a coal-straw mixture) over the ground to be thawed.
[0006] Serpentining piping filled with heated fluids under thermal blankets (e.g. Grochoski, U.S. Application No. 2003/0124315) or within mats (e.g., Albert, U.S. Application No. 2010/0119306) are designed mainly for surface heating and curing of concrete. For trenching, pipes or tubes are sometimes buried to gain the transmission and insulating effects. For curing of concrete, the blankets absorb significant amount of the heat output providing a relatively uniform lateral heat distribution for the air under the blankets. When used for deep thawing, the downward radiation and conduction is a relatively small part of the energy output; thus, the technique can be slow and may result in uneven thawing at target depths. Moreover, this technique can lead to significant loss of energy over the length of the hoses or pipes, especially when the heat source is far from the thaw zone. Also, while thaw zones are characteristically targeted as right angular plans, hoses are typically of different size than the target zone and must be laid out in hairpins to approximate the layouts of these planned construction zones. Uneven distances between these conduits may also result in uneven heating throughout the target thaw zone. At any given construction site, one or more of these limitations may result in difficulty in planning or meeting schedules.
[0007] Similarly, when one heats an indoor air environment inside of shrouding or a canopy, the working environment may comfortable and enclosed surfaces compliant to best practices for curing, sealing and the like but ground thawing is superficial and normally not dimensionally compliant to the enclosure at depth. The shape of the subsurface thaw will also be deepest in the middle while achieving very little thawing at the edges of the thaw zone. Investigators have tried to use general-purpose construction heaters for blowing radiant heat to warm the air (e.g., Schmidt, U.S. Pat. No. 4,682,578) or canopies with suspended heating devices (e.g., Nielson et al., U.S. Application No. 2005/0103776) achieved some thawing but had difficulty with deep thawing. These methods are sometimes even impotent for frost deeper than 20 cm. This result may be magnified in harsh conditions as the susceptible to the elements of weather wherein colder or faster moving air absorbs the energy the contractor wants focused on the target ground. Again, any of these complications may result in a contractor having difficulty planning or meeting schedules.
[0008] As an alternative, certain devices are sold that provide a propane burner with a case or outer housing. U.S. Pat. No. 5,033,452 (issued to Carriere) theorizes that liquid water on the ground surface is a major impediment to ground thawing and that removal is an improvement in efficiency. Carriere discloses a thawing device having a thermally insulated housing and a single undivided fire tube mounted within the housing. The fire tube has a first end connected to one port in the housing and a second end connected to another port in the housing. A burner is mounted outside the housing in the first end of the fire tube, that tube running along the ground surface, and a flue for exhausting the combustion gases is connected adjacent the second end. Heat transmitted from the fire tube directly into the ground and interior of the housing serving to evaporate water. The housing includes a steam vent to provide egress for the moisture. Carriere does not concern himself with the evenness of the thaw within the device or how his devices may be used in collaboration to achieve an intended result.
[0009] Another ground thawing-device, called “Frost Hog,” is manufactured by Leric Holdings, Ltd., of Lloydminster, Alberta, Canada. The device includes a heavy trailer-mounted housing and a fire tube extending through the housing from one port to another port. A burner is positioned in the first port and a vertical flue for exhausting the combustion gases is positioned adjacent the second port. Because of its size and trailer mount, the unit is difficult to place between structures (for example between a garage and a fence) and cannot be used in contiguous arrays that would thaw ground for contiguous underground structures such as gas or electrical service.
[0010] Yet another ground-thawing device, called the “Thaw Dawg”, is manufactured by Ground specialties Incorporated of Minneapolis, Minn., U.S.A. The device comes with a 36″×48″ case with an open bottom and provides a burner attached to one of the 48″ sides of the case. The external burner limits its use near building structures and trees and results in the production of waste heat. Even though the burner is relatively close to all parts of the enclosure, in our hands, the heat and thawing is most intense directly below the burner and thawing underground occurs in an inverted, non-circular, conical fashion. Accordingly, this device does not predictably allow trenching of the entire dimension of the case footprint in a period less than 48 top 72 hours. Moreover, if placed end to end to enable the digging of a 48″ wide trench, for example, the external burner box and inverted conical thawing at depth would result in intermittent segments where there is difficult digging in frozen ground.
[0011] Consequently, for many years trenching contractors almost universally burned mixtures of coal and straw laid out along a trench-line to thaw terrain for digging on subsequent days. This technique was not without drawbacks. When temperature dropped rapidly overnight, the inability to capture heat and direct the heat downward often resulted in incomplete thawing within the production schedule. This technique also suffered from intermittent loss of ignition by vandalism, rain, snow, melt water or discontinuities in fuel as well as pollution through emission of smoke, cinders, and odor. Accordingly, contractors needed to employ personnel for monitoring the burn over extended periods of time. Even with monitoring, the combination wind and cinders, left an ever-present fire hazard. Accordingly, this technique was particularly unsafe for use near construction equipment, buildings, as well as in dry fields, or wooded areas. If there were delays between burning and trenching, the local microenvironment was uncontrolled resulting in the potential for refreezing. For these fire and environmental reasons, using unattended burning materials for ground preparation is a practice now banned in many jurisdictions. Nonetheless, this method forms the “gold standard” for efficacy against which all other methods are measured.
[0012] Accordingly, all conventional deep-thawing practices suffer the common problem of scheduling reliably. Under well-controlled conditions, the method of burning a straw-coal mixture along a trench-line typically achieved a centre-line deep thaw of approximately 3 feet or 1 meter in 72 hours where there has been a successful burn. Depending on the outside air temperature, the use of construction heaters in a tarped-in or canopied area may achieve one half of that depth in a similar period along the centre-line of the structure. Using hydronic heaters with insulating blankets would typically achieve a thawing result somewhere between these two methods. Efficacy of various portable inventions is highly variable depending upon the task assigned. None of the above-mentioned methods reliably leave a dimensionally uniform thaw zone at a predictable time. Accordingly, the more spatially complex the target thaw zone becomes, the more refractive scheduling becomes for any given subsurface construction activity.
[0013] It is, therefore, desirable to provide an apparatus and method for thawing frozen ground that overcomes the shortcomings of the prior art.
SUMMARY OF THE INVENTION
[0014] In some embodiments, a deep-ground-thawing method is provided that can 1) repeatably and 3-dimensionally heat or thaw the ground commensurate with the length, width, and depth of the task; 2) accomplish the task predictably within the 4th dimension, i.e., within a known time period; 3) be energy efficient, 4) be safe with respect to humans, animals and surrounding structures in conformance with modern fire, environmental, and occupational health regulations; and 5) use means that are adaptable to complex construction environments. For the purposes of this specification and the claims herein, the term “ground” means natural earth, sod, loam, peat moss, marl, muskeg, rock, sand, gravel, silt, clay and the like as known to those skilled in the art in addition to man-made compositions such as asphalt, concrete and other engineered or geotechnical soil construction compositions and materials used in civil engineering projects as known to those skilled in the art.
[0015] In some embodiments, the apparatus and method presented herein can provide means for efficiently providing heating and deep thawing in a modern construction environment. In some embodiments, dimensionally fixed, unitized heaters are provided that can collaborate in arrays to evenly thaw a surface in a desired dimension in a timely manner. Accordingly, these unitized heaters can be used like “building blocks” and positioned to achieve the individual and collaborative thaw patterns desired. In some embodiments, individual arrays of the heaters can collaborate to achieve very complex thaw patterns.
[0016] In some embodiments, infrared radiant heaters can be used alone or in conjunction with other components and techniques for achieving more uniform heating or thawing. Such components and techniques can include increasing the surface area of radiating conduit by such strategies as double tubing. In some embodiments, the heaters can be enclosed with highly reflective material in order to scatter the reflected radiant energy over the entire target ground surface. In some embodiments, fans or blowers can be provided to help ensure that the heat is more efficiently and evenly radiated within the heater enclosure.
[0017] In some embodiments, the apparatus and method presented herein can achieve a similar or better heating or thaw depth with superior dimensionality to other conventional methods within comparable heating or thawing times over a broad range of climatic conditions. To achieve these goals, the apparatus, in some embodiments, can be configured to collaborate in arrays. In contrast to the conventional ground-heating methods wherein heat energy is produced in one location and transported to the zone of interest by gas or fluid, the apparatus presented herein can be configured such that each part of the overall spatial dimension of ground to be heated can be supplied with a heat source of predictable heat or thaw dimension. In some embodiments, each heater can provide more uniform deep heating or thawing within its footprint on the surface on the ground without loss to distal heating or thawing. When placed adjacent to other heating devices of defined dimension, the unitized fixed-form heating devices can overlay the heat or thaw areas as defined in construction plans similar to the concept to of setting out building blocks. By this method, the heaters can collaborate to provide maximal heat for deep heating or thawing within the dimension of the array of devices and heating or thawing of unnecessary ground is minimized. No energy is lost from transporting heat from an external energy source (e.g. a furnace or boiler) to the heat or thaw zone as used in other conventional prior art heating apparatuses and methods.
[0018] In some embodiments, the apparatuses and methods described herein can be used to heat or thaw buried flow-lines that carry produced substances from a well, such as water, oil, gas and the like. In cold weather conditions, any water in the produced substances can freeze and block the flow-line. In addition, a flow-line can become “waxed off”; meaning that wax can build up in a flow-line carrying oil and block the flow-line. The apparatuses described in this specification can be placed on the ground over the flow-line and heat the ground to either thaw the water frozen in the flow-line or to melt the wax built up in the flow-line so as to clear the blockage in the flow-line and allow produced substances to flow once again.
[0019] In some embodiments, the apparatuses and methods described herein can be used to pre-heat the ground for a construction activity. One example can include pre-heating asphalt around a pothole on a road to enable new asphalt used to fill the pothole to bond to the surrounding asphalt and thus produce a better repair of the pothole. Other examples can include heating the ground prior to adding new or additional ground material where heating the ground improves the adhesion of the new or additional ground material to the existing ground material.
[0020] Broadly stated, in some embodiments, a ground-heating apparatus is provided, comprising: a frame configured to sit or be placed on the ground; a heat exchanger disposed in the frame, the heat exchanger configured to emit heat energy; and a heater assembly, the heater assembly operatively coupled to the heat exchanger, the heater assembly configured to convey heated air or gas through the heat exchanger.
[0021] Broadly stated, in some embodiments, a system is provided for heating ground, comprising at least one heating apparatus, each at least one heating apparatus comprising: a frame configured to sit or be placed on the ground; a heat exchanger disposed in the frame, the heat exchanger configured to emit heat energy; and a heater assembly, the heater assembly operatively coupled to the heat exchanger, the heater assembly configured to convey heated air or gas through the heat exchanger.
[0022] Broadly stated, in some embodiments, a method is provided for heating ground, the method comprising the steps of: providing at least one heating apparatus, each at least one heating apparatus comprising: a frame configured to sit or be placed on the ground, a heat exchanger disposed in the frame, the heat exchanger configured to emit heat energy, and a heater assembly, the heater assembly operatively coupled to the heat exchanger, the heater assembly configured to convey heated air or gas through the heat exchanger; placing the at least one heating apparatus on an area of frozen ground; and operating the at least one heating apparatus to emit heat energy wherein at least a portion of the ground is heated.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] FIG. 1 is a perspective view depicting one embodiment of an apparatus for thawing ground where reflector assembly 1 , frame 2 , and burning enclosure 3 are visible.
[0024] FIG. 2A is a side elevation view depicting the apparatus of FIG. 1 wherein reflector assembly 1 , frame 2 , burning enclosure 3 , and piping assembly 4 are visible.
[0025] FIG. 2B is a top plan view depicting the apparatus of FIG. 1 wherein reflector assembly 1 , frame 2 , burning enclosure 3 , and piping assembly 4 are visible.
[0026] FIG. 3 is a an end elevation view depicting the apparatus of FIG. 1 wherein the piping assembly is secured by 4 hex bolts as represented by 5 , 6 , and 7 .
[0027] FIG. 4 is a perspective view depicting the burning enclosure of the apparatus of FIG. 1 .
[0028] FIG. 5A is a perspective view depicting the reflector unit of the apparatus of FIG. 1 .
[0029] FIG. 5B is an end elevation view depicting the reflector unit of the apparatus of FIG. 1 .
[0030] FIG. 5C is a side elevation view depicting the reflector unit of the apparatus of FIG. 1 .
[0031] FIG. 5D is an end elevation view depicting the reflector unit of the apparatus of FIG. 1 .
[0032] FIG. 6A is a left elevation view depicting the burner assembly of the apparatus of FIG. 1 .
[0033] FIG. 6B is a rear elevation view depicting the burner assembly of the apparatus of FIG. 1 .
[0034] FIG. 6C is a right elevation view depicting the burner assembly of the apparatus of FIG. 1 .
[0035] FIG. 6D is a front perspective view depicting the burner assembly of the apparatus of FIG. 1 .
[0036] FIG. 6E is a rear perspective view depicting the burner assembly of the apparatus of FIG. 1 .
[0037] FIG. 7A is a front elevation view depicting the burner assembly of FIG. 6 with its enclosure removed.
[0038] FIG. 7B is a rear elevation view depicting the burner assembly of FIG. 6 with its enclosure removed.
[0039] FIG. 8 is a perspective view depicting the rigid exoskeleton frame of the apparatus of FIG. 1 .
[0040] FIG. 9A is a top plan view depicting the piping assembly of the apparatus of FIG. 1 .
[0041] FIG. 9B is a side elevation view depicting the piping assembly of the apparatus of FIG. 1 .
[0042] FIG. 10 is a block diagram depicting an array of rectangular embodiments of the apparatuses of FIG. 1 for thawing frozen ground.
[0043] FIG. 11 is a block diagram depicting an array of rectangular and triangular embodiments of the apparatuses of FIG. 1 for thawing frozen ground.
DETAILED DESCRIPTION OF THE INVENTION
[0044] An apparatus and method for thawing frozen ground is provided herein. In some embodiments, the apparatus and method can comprise one or more unitized thawing devices, means for transporting the devices, and means for controlling the devices as well as the components for the system.
[0045] For the purposes of this application, the following terms are defined as follows.
[0046] “Array”—means devices arranged for heating thawing the ground in dimensional conformance with all or part of an existing or planned surface or subsurface structure. These devices may share one or more energy sources to achieve a desired collaborative effect. Where the surface target is not rectangular, placing a group of rectangular arrays or sub arrays adjacent to each other can form a thawing system. In the alternative, combinations of devices including non-rectangular shaped devices can be employed.
[0047] “Device” means a unitized fixed-form ground-heating device configured for heating or thawing the ground in dimensional conformance with all or part of an existing or planned ground surface or subsurface structure. When used herein to refer to a member of an array, the words “unit” and “device” are used interchangeably.
[0048] “Heat-transfer plane” means a plane covered by one or more unitized fixed-form ground-heating device that can provide a plane through which heat energy can be dimensionally transferred to the target ground surface. With devices comprising infrared heaters, this plane can allow energy to directly travel to the ground without any obstruction.
[0049] “Low emission device” means a low emission device that meets applicable standards for indoor or outdoor air quality depending upon the circumstances. In general, a low emission device for indoor use would also be a low emission device for outdoor use.
[0050] “Thawing system” means a system that can comprise the asset management, transport, fuel supply, and control of devices whether employed as one or as a plurality of devices configured in arrays collaborating to achieve a thawing task.
[0051] In some embodiments, a device can comprise an infrared radiation heat source. In some embodiments, the source of infrared heat can comprise an infrared tube heater. In these embodiments, a burner control box can ignite a gas-air mixture and fan the hot gases into a radiant tube assembly. As the gases pass through the tube assembly, the tube assembly is heated and can emit infrared radiation at intensity levels proportional to the temperature of the tube. In some embodiments, the device can emit heat towards the ground directly or indirectly by a reflector configured to reflect emitted heat towards the ground. The ground within the targeted surface can absorb this radiation and can further re-radiate it as secondary infrared radiation.
[0052] In some embodiments, a plurality of devices can be configured into an array for thawing an area of frozen ground larger than the footprint of a single device. In some embodiments, the devices can be unitized such that each device can be self-contained and can provide the heat necessary for dimensionally heating the ground directly below it. In other embodiments, the devices can be shaped in a fixed form to conform to standard sizes of thaw zones, as they would be encountered on a construction site. When used in collaboration in an array, the unitized fixed-form devices can afford the ability for all devices of a given array to complete their task at or about the same time, regardless of the complexity of the dimensions of the thaw zone.
[0053] In some embodiments, the devices can be aligned over the dimensions of a planned construction activity, connected to a fuel source, and turned on. In some embodiments, the heat output from each device can be set so that the surface can be readied according to a construction timetable. In some embodiments, the heat output from each device in an array can be set so that the ground surface under the array can be readied at the same time. In some embodiments, the heat output from each device in an array can be set so that portions of the surface under the array can be readied sequentially according to a construction timetable.
[0054] In some embodiments, each device can be equipped to uniformly distribute heat to the dimension of its footprint. In other embodiments, uniform distribution of heating can be accomplished by combining infrared radiant heating and reflectors that can focus this energy evenly within the footprint of the device. In some embodiments, each device can be equipped with a means of forcing heated air through at least one radiating conduit. In other embodiments, uniform distribution of heating can be accomplished by combining infrared radiation heating, reflectors, and forced air to focus this energy evenly within the footprint. In some embodiments, forced air can be impelled from burner assembly 49 by fan or blower 34 , as shown in FIG. 7A . In some embodiments, a plurality of radiating conduits can be employed to distribute heat energy evenly within the footprint. In one aspect, conduits can be connected in parallel. In some embodiments, a plurality of radiating conduits can be connected sequentially to distribute energy evenly within the footprint. In a representative embodiment, a plurality of radiating conduits can be sequentially connected by double tubing 66 , 67 , as shown in FIG. 9 , to distribute energy evenly within the footprint.
[0055] In some embodiments, the method can comprise warming and/or clearing ice from a surface to provide passage of surface traffic. In some embodiments, the method can comprise heating and/or drying a target ground surface to the degree needed for a repair of the surface. In some embodiments, the method can comprise heating the target ground to a degree needed to eliminate contaminants disposed in the ground. In some embodiments, the method can comprise heating the target ground to a degree needed to thaw frost up to six feet down. In some embodiments, the method can comprise heating the target ground is heated to a degree needed to thaw frost up to 3 cm/hour.
[0056] In some embodiments, arrays of devices can be used spatially or temporally in collaboration with conventional methods to heat a target frozen ground zone. In some embodiments, insulating blankets canopies, tarps or other protection from the wind and cold can be employed with the devices. In some embodiments, conventional construction heaters can be employed in combination with the devices to heat the protected environment. In some embodiments, hydronic heaters can be used in combination with arrays of devices to accomplish specific portions of a thawing task. In some embodiments, conventional heaters can be used concurrently with arrays of devices. In some embodiments, conventional heaters can be used sequentially with arrays of devices. In some embodiments, conventional heaters can be used prior to the use of arrays of devices in preparation for deep thawing. In some embodiments, conventional heaters can be used after the use of arrays of devices to maintain deep thawing of frozen ground.
[0057] Referring to FIG. 1 , one embodiment of a heating device is shown. In some embodiments, the shape of unitized heater 1 can be formed by supporting frame 2 that, in turn, can support a heating unit comprising an infrared heating unit further comprising burning enclosure 3 . Such heaters 1 can be set out adjacent to each other in almost any combination to collaborate in the thawing of a zone with almost any desired shape. In some embodiments, heater 1 can comprise a radiant heating conduit disposed under a reflective surface.
[0058] Referring to FIGS. 2A and 2B , piping assembly 4 can be suspended within burning enclosure 3 . In some embodiments, piping assembly 4 can be centered in a reflector to maximize the amount of primary and reflected energy reaching the ground. In other embodiments, the reflector can comprise at least one surface made from a reflective material. In some embodiments, the reflector can be shaped to direct energy in a downward direction. In some embodiments, the reflecting surface can be integral to the reflector structure. In other embodiments, the reflective material can further comprise physical or mechanical means such as coating, deposition, or a securing means such as rivets or screws. In some embodiments, the reflective material can comprise a corrosion-resistant material. In another preferred embodiment the reflective material is coated with corrosion-resistant protection means. In some embodiments, the reflective material can acts as an infrared mirror. In some embodiments, the reflective material can comprise one or more corrosion-resistant materials from the group consisting of stainless steel, silver, aluminium and gold. In some embodiments, the reflector can be coated with an insulating paint. In some embodiments, the insulating paint can comprise ceramic micro-spheres.
[0059] In some embodiments, piping assembly 4 can be secured at one end of burning enclosure 3 by a securing means. As shown in FIG. 3 , in some embodiments, piping assembly 4 can be secured by one or more hex bolts to provide easy removal when replacement or maintenance is called for. In this embodiment, the piping assembly 4 is secured at the other end by attachment to burning enclosure 3 by a securing means. In some embodiments, burner wall 8 , burner wall 9 , burner bracket 10 , and air diffuser 11 can enclose the burner as shown in FIG. 4 . This burner enclosure may take many forms but its primary function is to provide for the safe ignition of the fuel used. In some embodiments, piping assembly 4 can comprise a U-shape, as shown in FIG. 2 .
[0060] In some embodiments, piping assembly 4 can comprise a radiant conduit formed from steel. In some embodiments, the steel can comprise alloy elements that do not exceed the following limits: 1% carbon, 0.6% copper, 1.65% manganese, 0.4% phosphorus, 0.6% silicon, and 0.05% sulphur. In some embodiments, the conduit can be formed from AISI 1022 grade steel. In some embodiments, the conduit can be constructed from 4″ tubes formed from AISI 1022 steel. In some embodiments, the radiant conduit can be formed from 4″×106.69″ tube made from AISI 1022 steel, as shown as 66 and 67 in FIG. 9 . In some embodiments, an exhaust system can be provided from materials of similar metallurgic properties. In some embodiments, the exhaust system can comprise tubes 70 , 72 and an elbow 73 . In some embodiments, tubes 70 and 72 can be comprised of 2″ steel tube.
[0061] In some embodiments, each device can comprise a low emission device.
[0062] In some embodiments, the device can comprise an instrument panel. Referring to FIGS. 6A-E and 7 A-B, panel 18 can comprise enclosure wall 19 , enclosure wall 20 , burner box centralizer 21 , enclosure lid 22 , nozzle shield 23 , light 24 , flanged inlet receptacle 25 , transformer 26 , hole 27 , hour meter 28 , ON/OFF switch 29 , plug button 30 , and borosilicate glass 31 . In yet another preferred embodiment the components of each device are organized in a modular fashion for ease of repair, inspection, and possibly replacement. In some embodiments, the device can comprise an infrared tube heater. In some embodiments, the burner box assembly, the piping assembly, and the control assembly can be configured that they can easily be removed as single units.
[0063] In some embodiments, the exhaust system can release exhaust gas in a manner that affords safe collaboration of devices. In some embodiments, the exhaust gas can be ported to the environment directly or through a hose or a pipe assembly. In some embodiments, the exhaust gas can pass through a diffuser or other protective devices to prevent workers from being inadvertently burned by hot gases. In some embodiments, the exhaust can be ported such as to not create an operating hazard for neighbouring devices of the array or nearby structures. In some embodiments, the diffuser can be attached to the frame to allow heat from the gas to be absorbed and conducted by the frame. In some embodiments, all or part of the exhaust gas can be ported through the frame to capture and passively diffuse residual heat. In some embodiments, exhaust gas can be released vertically as shown in FIGS. 9A and 9B .
[0064] In some embodiments, a means to focus energy on the target ground assigned to the unit can be provided. In infrared tube heater devices, a reflective surface can be provided above and to the sides of the radiant heating conduit. In some embodiments, the reflector can extend over, to the sides, and for the entire length of the heating conduit. In some embodiments, the reflector can be shaped like reflector 13 as shown in FIG. 5C . As illustrated in FIGS. 5A , 5 B, 5 C and 5 D, reflector 13 can be surrounded by outer case 12 , and attached to reflector end walls 14 , 15 as well as pipe support bracket 16 , and reflector end cover 17 .
[0065] In some embodiments, the heat can be produced by converting energy from sources including electricity and hydrocarbon fuels. In some embodiments, the hydrocarbon fuel can be selected from one or more from the group consisting of natural gas, one of its components, e.g. methane, propane, etc., gasoline, kerosene, diesel fuel, heating oil, and other suitable hydrocarbons as well known to those skilled in the art. If an infrared tube heater is used, propane can be used as the fuel in some embodiments. In some embodiments, the heat each device in an array can produce can be controlled by the regulation of the fuel supply to each device.
[0066] The size and shape of the device used in an array are important for the array to conform to the size and shape of the target zone for heating. In some embodiments, an array can be comprised of devices sized and shaped to conform to all or part of the intended surface or subsurface structure. Examples of target zones for heating include graves, walls, trenches, pipelines, electrical utilities, telecommunication utilities, water utilities, footings, and basements. In some embodiments, the device can be rectangular in shape. In some embodiments, the device can be round or ovoid in shape. In some embodiments, the device can be shaped for thawing ground for planned footings or post holes. In some embodiments, the device can be round and sized to thaw a bell hole. In some embodiments, the device can be shaped to match the width of a planned trench. In some embodiments, the device facing the ground can be quadrangular or polygonal in shape. In some embodiments, the device can be circular or elliptical in shape. In some embodiments, the device can comprise a shape that is a combination of one or more polygonal, circular and elliptical shapes. In some embodiments, an array of identically shaped devices can be utilized. In some embodiments, the device can be rectangular and shaped to match the width of a trench and can be 2 to 10 times longer than it is wide. In some embodiments for thawing the ground for trenches less than 30 inches wide, the surface dimension of the device can be approximately 24 inches×120 inches. In some embodiments for thawing the ground for trenches less than 30 inches wide, the dimension of the device (including the frame) can be approximately 26″(w)×23″(h)×120″(l). For wider trenches, larger devices or side-by-side array configurations can be employed. In some embodiments, the device can be used in a planned construction activity, such as installing artificial turf, landscapes, roads, sidewalks, curbs, parking lots, gutters, rail lines, utility junctions, runways, concrete slabs, or patios. In some embodiments, the planned construction activity can comprise the repairing of a ground or surface defect. In some embodiments, the planned activity can comprise the curing or drying of a material.
[0067] In some embodiments, an array can comprise a device shaped such that the plane facing the ground surface has a shape selected from the group consisting of: triangular, quadrangular, pentangular, sextantular, septangular, octangular and polygonal. In some embodiments, the array can comprise one or more devices whose surface footprint is rectangular.
[0068] In some embodiments, the device can comprise a rigid frame configured to conform to the shape of the target ground to be heated. In some embodiments, a rigid frame is provided to support and protect the heating unit of the devices during operation. In some embodiments, the rigid frame can be configured to be stacked on one another for storage in the off-season. In some embodiments, the frame can be configured for manual or machine positioning within an array. In some inventions, the rigid frame can provide means for securing multiple devices during transportation. In some embodiments, the rigid frame can be configured for interlocking a device with adjacent devices. In some embodiments, the rigid frame can be configured for of securing additional insulation or protection thereto for protection from the elements. In some embodiments, the device can comprise one or more thermal blankets to cover all or part of the frame. In some embodiments, the array can be laid out within a canopied or tarped-in enclosure.
[0069] In some embodiments, the frame or case of a device can be used to focus environmentally available energy on the function of the device. In some embodiments, the device (frame or case) can be painted or shrouded in black to incorporate or absorb passive solar heat or energy to assist in the heating function. In some embodiments, the device (frame or case) can be configured with solar cells or windmill means to generate electricity for device function through solar or wind power. In some embodiments, material can be applied or attached to the target thaw zone to enhance the absorption and re-radiation of heat energy.
[0070] In some embodiments, devices in an array can be oriented by spatially adjacency without a mechanism of interlocking. In some embodiments, the devices can be interlocked to one another. In further embodiments, devices can be interlocked to prevent theft. In some embodiments, an array of devices can be set out end-to-end to collectively form a snake shape over the length of the planned trenching activity. In some embodiments, certain sections of the snake-like array can be lined up perpendicular to a trench-line to accommodate digging a structure such as a bell hole. In some embodiments, the array of devices can be comprised of non-identically shaped devices.
[0071] In embodiments, devices can be set up to operate individually. In some embodiments, a plurality of devices can be arrayed in a pattern conformable in shape to the warming task at hand. In some embodiments, devices can be aligned to cooperate in ground thawing of a predefined pattern. In some embodiments, the array can comprise a 1×1 array. In other embodiments, the array can comprise a 1×n linear array. In further embodiments, the individual devices can be arrayed in any m×n pattern. In some embodiments, devices can be arrayed to cover and thaw an area in need of repair. In other embodiments, devices can be arrayed in a pattern consistent with the application of a construction material such as sealant, concrete or asphalt. In further embodiments, devices can be arrayed in a pattern that can permit drainage. In yet other embodiments, the array can be configured to permit boring under a structure. In some embodiments, devices can be arrayed linearly over a trench-line or fence-line scheduled for excavation. In some embodiments, devices can be arrayed in a plurality of rows to permit the digging of a basement.
[0072] In some embodiments, the pattern can be established in reference to surface and aboveground structures. In some embodiments, the structures can be permanent structures such as buildings. In some embodiments, the aboveground structures can be mechanical or mobile. In some embodiments, the structures can be one or more of the group consisting of rubber-tired construction vehicles, tracked vehicles, trailers, sleds, and vehicles comprising a boom. In some embodiments, members of the array can be held by a crane or rough-terrain forklift.
[0073] In some embodiments, the device can comprise a fixed-form device. In some embodiments, the device can comprise an adjustable frame. In some embodiments, the device can comprise a rigid frame suitable for storage and transportation. In some embodiments, the frames for the devices can be configured to permit safe and efficient stacking of the devices in both storage and transportation.
[0074] In some embodiments, a device can be used to heat frozen ground. In some embodiments, a device can be used to heat snow- or frost-covered ground. In some embodiments, one or more devices can be used to thaw frozen ground. In some embodiments, one or more devices can be used to thaw ground frozen more than 10 cm from the surface. In some embodiments, one or more devices can be used to thaw ground frozen more than 20 cm from the surface.
[0075] In some embodiments, a device can reliably thaw targeted ground in conformance with a production schedule. In some embodiments, the device can have the ground ready when the crew and equipment are ready to engage in the target task. In some embodiments, the device can thaw the targeted ground in 72 hours. In other embodiments, within 48 hours. In further embodiments, within 24 hours. In yet other embodiments, within 12 hour. In yet further embodiments, within 8 hours.
[0076] In some embodiments, a device for deep thawing of the ground can employ electromagnetic energy radiated from an energy source. In some embodiments, the device can employ infrared radiation. In some embodiments, the electromagnetic radiation emitted can be optimized in the range of about 0.7 μm to about 1 mm. In some embodiments, all or part of the infrared radiation can be directed at the ground to be thawed by a reflective means. In some embodiments, the device can additionally cause thawing by combining a means for emitting radiation with a means for heating by conduction and/or convection. In some embodiments, the ground can be covered with a substrate to reduce the reflective index of the ground and assist the absorption of energy emitted by the device.
[0077] In some embodiments, the thawing device can be portable. In some embodiments, a device can be positioned manually without machine assistance. In some embodiments, the device can be equipped with wheels or a site for attaching a wheeled manual transportation carriage. In some embodiments, the device can be positioned with the assistance of machinery such as a crane or forklift. In some embodiments, two adults without machine assistance can position a device. In some embodiments, a device can comprise a weight in the range of 100 lbs to 500 lbs.
[0078] In some embodiments, a device and or a system of devices can be configured to be used safely over dirt, gravel, asphalt, concrete, or other non-flammable construction materials. In some embodiments, the system or device can be configured to be used safely in close proximity to man-made structures. In some embodiments, a device can be configured to be used over ground polluted by hydrocarbons. In some embodiments, a device can be configured to be used in proximity to trees or shrubs.
[0079] In some embodiments, a device and or a system of devices can be configured to generate less pollution as compared with conventional heating methods. In some embodiments, the device will not exhaust cinders, ash, smoke, odor, noise or toxic fumes. In some embodiments, the device can exhaust minimal heat energy into the atmosphere. In some embodiments, the device can have sufficiently low emissions so that it may be used indoors.
[0080] In some embodiments, the apparatuses described herein can further comprise sensors configured to monitor operating parameters of the apparatus. These parameters can include, but are not limited to, whether the heater is functioning or not, fuel remaining, temperature of the heated air or gas, temperature of the heat exchanger, exhaust gas temperature, and any other parameter of the apparatus that can be monitored as known to those skilled in the art. In some embodiments, the apparatuses can further comprise GPS sensors or transceivers that can be used to monitor and track the location of the apparatuses as part of an inventory control management system.
[0081] Although a few embodiments have been shown and described, it will be appreciated by those skilled in the art that various changes and modifications might be made without departing from the scope of the invention. The terms and expressions used in the preceding specification have been used herein as terms of description and not of limitation, and there is no intention in the use of such terms and expressions of excluding equivalents of the features shown and described or portions thereof, it being recognized that the invention is defined and limited only by the claims that follow.
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An apparatus and method is provided for preparing frozen ground for construction-type work includes using arrays of heat sources placed over the surface to be heated. The apparatus can warm the surface in preparation for the construction activity with energy penetrating into the ground affording efficient thawing of materials below 20 centimeters of depth. Heat sources used in the array can include emitted infrared radiation.
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[0001] This invention relates to an improved tool or plug for use in hydrocarbon wells having a modified segmented back up ring to restrain deformation of a seal.
BACKGROUND OF THE INVENTION
[0002] There are many well tools that incorporate a sealing member that is deformed into sealing engagement with a casing string. Typically such tools are called plugs, one species of plugs being packers. Many plugs are designed to be soluble, meltable or drillable, i.e. they incorporate a modest amount of materials that not easily drillable and are typically mostly made of composites, polymers, aluminum, brass and the like which are easily removed from a well in any of a variety of ways.
[0003] These type tools usually incorporate slips that grip the interior of a casing string, an expansion device or devices to expand the slips into gripping engagement with the casing string and a deformable or resilient seal member that is compressed during actuation of the plug so it expands more-or-less radially into sealing engagement with the casing string. An element often used in such devices is known as a back up ring, a support ring, a back up shoe, a gage ring or the like, the purpose of which is to restrain axial expansion of the deformable seal so it is directed radially against the casing string. In other words, these devices are anti-extrusion devices which minimize or prevent extrusion of the malleable seal axially along the tool and thereby minimize or prevent leakage past the seal.
[0004] Disclosures of some interest relative to this invention are found in U.S. Pat. Nos. 3,554,280; 4,397,351; 4,730,835; 5,024,270; 5,540,279; 6,739,491; 7,578,353; 8,066,065 and 8,336,616.
SUMMARY OF THE INVENTION
[0005] As disclosed herein, a plug has a collapsed or running in position so it an be run in a well, such as a hydrocarbon well, and an expanded or operative position where a deformable seal is pressed against the inside of a casing string or well bore in the case of an open hole packer. Such plugs include the deformable seal, slips that anchor the plug in a desired position, some way allowing manipulation of the tool so it can be expanded from the running in position to the operative position and a back up ring to restrain deformation of the seal so it efficiently expands against the casing string.
[0006] Many current generation plugs are used during completion of wells and are designed to be readily drilled up in order to minimize completion costs. Current generation back up rings are made of composite material and are segmented so that when the plug is set or expanded, the segments flare out against the casing string in much the same manner as flower petals opening and thereby prevent extrusion of the deformable seal axially. This directs the deformable seal radially toward the casing string. It has been learned that current model segmented back up rings sometimes fail in laboratory tests of extended reach plugs such as shown in U.S. application Ser. No. 13/737,223, filed Nov. 8, 2011, the disclosure of which is incorporated herein by reference. Although such back up rings often fail during laboratory tests, no field failures have yet been seen which is not surprising because down hole failures are unusual and because the cause is almost never known.
[0007] Extensive tests are run by Magnum Oil Tools, Ltd. on many different types of plugs. On extended reach plugs where the tool, in its running in condition, is relatively small compared to its expanded condition and necessarily undergoes considerable expansion, it is common for the petals of back up rings to fracture and detach from the main part of the ring during testing.
[0008] The failure rate of back up rings has, by use of the construction disclosed herein, has so far fallen to zero. This is accomplished, as disclosed hereinafter, by moving the connection between the segment or petal and the ring body toward the exterior of the back up ring.
[0009] It is an object of this invention to provide an improved segmented back up ring and a plug incorporating the same.
[0010] Another object of this invention is to provide an improved segmented back up ring that allows flaring of the segments without fracturing the segment from the body to which it is attached.
[0011] These and other objects and advantage of this invention will become more fully apparent as this description proceeds, reference being made to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a partial vertical cross-sectional view of a plug equipped with a segmented back up ring;
[0013] FIG. 2 is a cross-sectional view of a conventional segmented back up ring;
[0014] FIG. 3 is a cross-sectional view of an improved segmented back up ring;
[0015] FIG. 4 is an end view of the segmented back up ring of FIG. 3 ;
[0016] FIG. 5 is an exploded view of an improved segmented back up ring, as in FIG. 3 , in conjunction with a separate additional annular support;
[0017] FIG. 6 is a schematic view of the relationship between a segment of a conventional back up ring and a casing string which it abuts in an expanded condition of the plug; and
[0018] FIG. 7 is a view similar to FIG. 6 illustrating the relationship between a segment of an improved back up ring and the casing string.
DETAILED DESCRIPTION OF THE INVENTION
[0019] As used herein, upper refers to that end of the tool that is nearest the earth's surface, which in a vertical well would be the upper end but which in a horizontal well might be no more elevated than the opposite end. Similarly, lower refers to that end of the tool that is furthest from earth's surface. Although these terms may be thought to be somewhat misleading, they are more normal than the more correct terms proximal and distal ends.
[0020] Referring to FIGS. 1 , a plug 10 may comprise, as major components, a body or mandrel 12 having a passage 13 therethrough, one or more sets of slips 14 , 16 , one or more wedge sections 18 , 20 , a rubber or packing element 22 and an anti-rotation device or mule shoe 24 . The body 12 may include an upper section 26 and a lower section 28 connected together in a suitable manner, such as by threads 30 . The tool 10 is illustrated as of a type that can be converted between a bridge plug, a flow back plug, a check valve plug or otherwise by installing or removing a component in an insert 32 such as shown in U.S. Pat. No. 8,307,892, the disclosure of which is incorporated herein by reference. The component may be a plug, a valve ball, a soluble ball or the like as shown in U.S. patent application Ser. No. 12/317,497, filed Dec. 23, 2008, the disclosure of which is incorporated herein by reference.
[0021] The insert 32 may be attached to the upper body 26 by suitable threads 34 and may include internal threads 36 for connection to a conventional setting tool (not shown) connected to a wire line extending to the surface. The setting tool (not shown) may act in a conventional manner by pushing down on the top of a collar 38 and pulling up on the threads 36 . This shears a pin (not shown) and allows the collar 38 to move downward relative to the slips 14 , 16 thereby expanding the slips 14 , 16 into gripping engagement with the casing 40 .
[0022] The slips 14 , 16 , the wedges 18 , 20 and the packing element 22 may be of a conventional type as shown in U.S. patent application Ser. No. 12/317,497, filed Dec. 23, 2008 so the tool is set in a conventional manner. During setting of the tool 10 , the slips 14 , 16 ride along the wedges 18 , 20 to expand the slips 14 , 16 and fracture them into a number of segments in gripping engagement with the interior of a casing string 40 which may be cemented in a well bore (not shown). At the end of the setting of the tool 10 , the insert 32 fails or breaks at a neck 42 thereby detaching the threads 36 and the setting tool (not shown) so the setting tool and wire line may be removed from the well.
[0023] The anti-rotation device 24 acts to minimize or prevent rotation of the tool when it is being drilled up by interacting with a subjacent tool. This may be accomplished in a number of ways, one of which is to provide angled faces 44 , 46 on the bottom of a body 48 of the anti-rotation device 24 .
[0024] The plug 10 may also include one or more back up rings 50 , 52 which may be part of the wedges 18 , 20 or may be separate members. In addition, the back up rings 50 , 52 may abut the packing element 22 or may abut an intermediate annular support as discussed hereinafter which may be a drillable material, soluble material or meltable material such as a drillable metal, polymer or composite. As shown in FIG. 2 , a conventional wedge or expander 18 may be of conventional shape and can comprise a body 54 having a central passage 56 , a tapered exterior or conical section 58 and one or more set screw passages 60 for securing the lowermost wedge 20 to the body 12 . Pulling up on the insert 32 causes the lowermost wedge 20 to rise relative to the uppermost wedge 18 thereby setting the slips 14 , 16 and expanding the seal 22 .
[0025] The back up rings 50 , 52 may be part of the bottom of the wedges 18 , 20 and may include a series of tapered segments 62 extending circumferentially around the passage 84 . The segments 62 can act like flower petals and flare out against the casing 40 during setting of the plug 10 and thereby constrain movement of the seal 22 into generally radial movement into sealing engagement with the casing 40 . In drillable plugs, the back up rings 50 , 52 may preferably be of a conventional composite material or polymer. Current composite or polymer materials are rigid at room temperature but become somewhat pliable or flexible at typical temperatures found in hydrocarbon wells. To promote the flexibility of the segments 62 , an exterior notch 64 has been provided. Those skilled in the art will recognize the plug 10 as being of a type commercially available from Magnum Oil Tools International of Corpus Christi, Tex.
[0026] Some fraction of laboratory tests with the conventional back up rings 50 , 52 in plugs similar to the plug 10 have experienced failure of the segments 62 , i.e. a fracture or complete break sometimes develops in the joint 66 between the end of the notch 64 and the central passage 56 as represented by the jagged line 68 . When a segment 62 detaches from the body 54 , this allows the seal 22 to expand axially into the gap left by the detached segment 62 thereby reducing the ability of the seal 22 to move radially into sealing engagement with the casing 40 thereby reducing the ability of the seal 22 to seal against the casing 40 . No field failures have yet been reported even though several thousand plugs with the design of FIG. 2 have been run and set in hydrocarbon wells, have sustained fracing pressures when the wells were fraced and have then been drilled up. The absence of reported field failures may be simple good luck, it may be that a small seal leak is not consequential in light of the high volume pumped during frac jobs or it may be that frac sand bridges off the plug, even if it is leaking. In any event, it is desirable to provide a back up ring that does not fail by fracturing at the joint between the segment 62 and the body 54 .
[0027] To this end, the segmented back up ring 80 is provided. The back up ring 80 may be integral with the wedges 18 , 20 or may be separate, as illustrated in FIG. 3 , from an expander dome (not shown) which may be affixed to the back up ring 80 by suitable threads or other means. Integral and separate segmented back up rings are illustrated in U.S. application Ser. No. 13/373,223, filed Nov. 8, 2011, which is incorporated herein by reference. The back up ring 80 may comprise a body 82 having a cone (not shown) on the upper end or an integral cone which acts to fracture or expand the slips 14 , 16 in a conventional manner. A passage 84 through the back up ring 80 allows the back up ring 80 to be received on the body 12 . Instead of the groove 64 on the outside of the back up ring, a groove 86 on the inside of the back up ring 80 opens into the passage 84 and imparts some flexibility to the petals or segments 88 at reservoir temperature. As in the prior art, the segments 88 are separated by a gap or kerf 90 which may be formed in any suitable manner, as by cutting with a saw.
[0028] The back up ring 80 accordingly provides a connection or joint 92 between the segments 88 and the body 82 . The outside of the junction 92 may be on the outside diameter of the body 82 or adjacent the outside diameter of the body 82 or, in any event, is closer to the outside diameter than to the inside diameter. The back up ring 80 may be made of a soluble, meltable or drillable material such as aluminum, brass, a composite material or polymer either by machining, injection molding or otherwise. The kerfs 90 separating the segments 88 may preferably extend through the junction 92 and separate it into segments. Thus, kerfs in the junction 92 may be coplanar with kerfs through the segments 88 .
[0029] As suggested in FIG. 1 , the back up ring 80 may abut the packing element 22 or may abut an intermediate annular support or second back up ring 94 as shown in FIG. 5 which is in load transferring relation between the back up ring 80 and the packing element or seal 22 . The annular support 94 may be a soluble, meltable or drillable metal, plastic or composite material. The annular support 94 may comprise a rim or body 96 having a passage 98 therethrough from which depend segments 100 resembling the segments 88 of the back up ring 80 . The segments 100 may be separated by kerfs or slots 102 and may flare outwardly to nest in a cavity 104 in one end of the back up ring 80 . It will be seen that the back up ring 80 is in force transmitting relation with the seal 22 , either in direct contact as in the embodiment of FIG. 3 or in indirect contact through the annular support 94 as in the embodiment of FIG. 5 .
[0030] Lab tests of plugs incorporating the improved back up ring 80 show that the connection or joint 92 does not fracture or fail under conditions where the segments 62 of the prior art back up ring 50 are prone to fail. There appear to be several reasons. One reason may be the junction 92 between the segments 88 and the body 82 , being on or adjacent the outside diameter of the body 82 , is necessarily longer and therefore has more material than a comparably thick junction on the inside diameter, as in FIG. 2 .
[0031] Second, it may be that the geometry of the segments 88 is more favorable than the geometry of the segments 62 , i.e. the junctions 66 , 92 act analogously to a pivot about which the petals 62 , 88 rotate. Because the junction 66 is further from the inside wall of the casing 40 , the base of the petals 62 have to undergo more movement than the base of the petals 88 in order for the tips of the petal to reach the I.D. of the casing 40 . This is shown by a comparison of FIGS. 6 and 7 .
[0032] Third, the thickness of the junction 92 may be thicker than in the prior art for reasons which are not immediately apparent. It may be that the segments 88 have to move so much less, as discussed above, that a thicker junction 92 can still allow sufficient flexibility. One would think that the junction 66 of the prior art might be thickened but the depth of the notch 64 is needed to provide the necessary flexibility of the segments 62 .
[0033] In FIG. 6 , a conventional segment is connected to the body of the back up ring at a junction 66 and basically pivots about a point 106 from a solid line position 108 to a dashed line position 110 to engage the inside of the casing string 40 upon expansion of the plug 10 . The solid line position 108 represents the centerline of the unstressed segment 62 and the dashed line position 110 represents the centerline of the stressed segment 62 when it abuts the casing 40 . The angle 112 is accordingly defined by the length of the solid line 108 and the distance between the pivot point 106 and the inside of the casing string 40 .
[0034] In FIG. 7 , a segment of the improved back up ring 80 is connected to the body at a junction 92 and basically pivots about a point 114 from a solid line position 116 to a dashed line position 118 to engage the inside of the casing sting 40 upon expansion of the plug 10 . The solid line 116 represents the centerline of the unstressed segment 88 and the dashed line represents the centerline of the stressed segment 88 when it abuts the casing 40 . The angle 120 is accordingly defined by the length of the solid line 116 and the distance between the pivot point 114 and the inside of the casing string 40 . The angle 120 will be found to be smaller than the angle 112 and is necessarily smaller than the angle 112 . The same idea can be visualized by extending one's arm slightly away from one's body and asking: is the angle between the arm and the side of the body smaller than the angle between the arm and the centerline of the thigh.
[0035] It will be seen that a preferred location of the pivot point 114 may be as close as possible to the outer diameter of the tool 10 represented by the line 120 in FIG. 7 but some advantages accrue as the pivot point is moved from the inner diameter of the tool toward the outer diameter. In other words, a preferred location of the outside of the junction 92 may be the outer diameter of the tool 10 .
[0036] Although this invention has been disclosed and described in one of its preferred forms with a certain degree of particularity, it is understood that the present disclosure of the preferred form is only by way of example and that numerous changes in the details of operation and in the combination and arrangement of parts may be resorted to without departing from the spirit and scope of the invention.
[0037] represents the centerline of the stressed segment 88 when it abuts the casing 40 . The angle 120 is accordingly defined by the length of the solid line 116 and the distance between the pivot point 114 and the inside of the casing string 40 . The angle 120 will be found to be smaller than the angle 112 and is necessarily smaller than the angle 112 . The same idea can be visualized by extending one's arm slightly away from one's body and asking: is the angle between the arm and the side of the body smaller than the angle between the arm and the centerline of the thigh.
[0038] It will be seen that a preferred location of the pivot point 114 may be as close as possible to the outer diameter of the tool 10 represented by the line 120 in FIG. 7 but advantages accrue as the pivot point is moved from the inner diameter of the tool toward the outer diameter. In other words, a preferred location of the outside of the junction 92 may be the outer diameter of the tool 10 .
[0039] Although this invention has been disclosed and described in one of its preferred forms with a certain degree of particularity, it is understood that the present disclosure of the preferred form is only by way of example and that numerous changes in the details of operation and in the combination and arrangement of parts may be resorted to without departing from the spirit and scope of the invention.
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A down hole tool or plug includes a segmented back up ring acting to minimize extrusion of a seal in an axial direction thereby promoting radial expansion of the seal into engagement with the internal diameter of a casing string. The segments of the ring are joined to a ring body having a passage thereby by a junction having, as its outer dimension, the outside diameter of the tool and an inside dimension provided by a groove opening into the passage.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention generally relates to portable restrooms, and more particularly to a system for servicing portable restrooms located upon various levels in a multistory building.
[0003] 2. Background Information
[0004] Portable restrooms are a convenience of the modern world. They provide individuals the ability to have a contained and sanitary location for urinating and defecating and provide a health benefit in that these restrooms contain and treat this waste with a liquid that prevents potentially pathogenic bacteria from proliferating. These devices are used at sporting events, weddings, construction sites, and in other locations where traditional permanent plumbing has not been made available. Sometimes these devices are provided simply for convenience, while in other circumstances they are mandated by law to provide sanitation.
[0005] A typical portable restroom is made up of four walls, a roof, a door, a seat, and a holding container. This holding container is configured to hold a quantity of waste that is deposited within the restroom by those persons utilizing the portable restroom. Over time these holding containers fill and must be emptied or serviced. This servicing is typically done by a pair of service personnel who drive a tank truck to the location where the portable restrooms are located. These trucks have tanks that are configured to hold a quantity of waste and a vacuum pump that is configured to draw the liquid out of the holding containers in the portable restrooms. They then pump this waste into the tank on the trucks. To perform this feat, the two persons servicing the restrooms typically drive the tank truck to a location and connect a hose or conduit to the pump. Additional hoses are then interconnected by T-valve combinations until sufficient length has been achieved so as to allow the hoses to reach from the tank to the portable restroom to be serviced.
[0006] Once the hose has been connected to achieve this length, one operator places one end of the hose into the holding container in the portable restroom and then signals the other operator at the truck to engage the vacuum pump. The pump then engages and pumps the material out of the holding container connected to the portable restroom, through the conduit, and into the holding tank. Once all of the material has been pumped out of the holding container, the person at the end of the hose signals the operator at the vacuum pump that the portable restroom has been emptied and after the conduit has been emptied, the pump is shut off. The two individuals operating the device then go to another location and repeat this process. Through this process, the individuals work to empty the various portable restrooms in a single location.
[0007] Portable restrooms may be utilized in situations and circumstances where the access to these portable restrooms by a service team is more difficult. One of those situations occurs when the portable restroom is located in an elevated position as compared to the position of the vacuum truck. In the prior art, this same system is utilized wherein one person drags the hose up to a higher level, places one end of the hose within the container to be emptied, signals his companion to engage the pump, and empties out the holding container.
[0008] In using such systems on buildings having multiple floors, a variety of problems arise. One of these problems is that the vacuum truck has insufficient suction capabilities to pump waste from high elevations and in distant locations to the pump truck. As a result of these flow problems, sludge and waste can clog and plug the device thus making the tank emptying process difficult. In addition, in some instances these devices are simply unable to pull material out of the holding tanks and into the trucks themselves. Another problem that arises is that the pumps overheat and must be turned off frequently in order to prevent damage to the pumps themselves and to prolong the life of these pumps. Most pumps in the industry will simply burn up if left running for prolonged periods of time. To do this, typically two individuals must be utilized to service a building. One individual sits in the vacuum truck and operates the vacuum tank motor by alternatively turning the motor off and on to effectuate the removal of the waste from the containers, while at the same time preventing the vacuum pump from overheating. He does this while the other individual services the various floors. This incurs substantial cost.
[0009] What is needed is a system or device for servicing portable restrooms, particularly those on multiple levels, which also provides increased pumping capabilities. What is also needed is a tower service system that prevents clogging or obstruction of the system by waste in the line. What is also needed is a device for servicing of portable restrooms that has increased functional capabilities as compared to the devices in the prior art. Another necessity is a system that allows a single user to both operate the truck and service the various floors without the requirement of two employees. Another needed item is to provide a device with increased suctioning capabilities for performing these services.
[0010] Accordingly, it is an object of this invention to provide a system or device for servicing portable restrooms, particularly those on multiple levels, which provides increased pumping capabilities. It is another object of the invention to provide a tower service system that prevents clogging or obstruction of the system by waste in the line. Another object of the present invention is to provide a device for servicing of portable restrooms that has increased functional capabilities as compared to the devices in the prior art. Another object of the invention is to provide a system with the aforementioned capabilities that further allows a single user to both operate the truck and service the various floors without the requirement of two employees.
[0011] Additional objects, advantages and novel features of the invention will be set forth in part in the description which follows and in part will become apparent to those skilled in the art upon examination of the following or may be learned by practice of the invention. The objects and advantages of the invention may be realized and attained by means of the instrumentalities and combinations particularly pointed out in the appended claims.
SUMMARY OF THE INVENTION
[0012] The present invention is a system for servicing restrooms on the upper floors of a high-rise building. The system is comprised of sections of vacuum hose that are interconnected by specially designed T-valves. Each of these T-valves is configured to provide a user the ability to shut off the flow of material in either a vertical direction, in a horizontal direction, or both. These vacuum hoses are then connected to a liquid cooled pump connected to a vacuum tank. The vacuum hoses are temporarily mounted on the side of the building and sections of hose are added on, as the building grows higher and higher.
[0013] At each floor, a T-valve made up of a horizontal valve and vertical valve is positioned and connected. The vertical valve shuts off the vacuum to the upper side of the building while the horizontal valve opens the vacuum to the hose that vacuums out the portable restrooms. The vertical valve remains closed the entire time that the operator is using the horizontal valve on that particular floor. Connected to the horizontal valve is a hose that extends to the service area and the operator is able to use a valve service hose at the restroom. When the valve service hose is activated, the waste from the restroom can travel into the hose and down the hose to the vacuum truck at the base of the building. The vertical valve prevents the entire system from becoming vacuumized and enables the waste or liquid to flow freely down the conduit to the vacuum truck.
[0014] The present invention can be utilized with either a traditional air cooled pump, as is common in the art, or a liquid cooled vacuum pump, as is utilized in the preferred embodiment. In the preferred embodiment, the liquid cooled vacuum pump and the vacuum truck are positioned at the base of the building. This liquid cooled pump is more durable than the air-cooled pump and allows the pump to run all day long without wearing out prematurely. This configuration of a durable pump and dual horizontal and vertical valves to open and close the flow of material through the hose, enables a single operator to service restrooms alone, thus increasing the efficiency and decreasing the costs to the user.
[0015] The purpose of the foregoing abstract is to enable the United States Patent and Trademark Office and the public generally, especially the scientists, engineers, and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection, the nature and essence of the technical disclosure of the application. The abstract is neither intended to define the invention of the application, which is measured by the claims, nor is it intended to be limiting as to the scope of the invention in any way.
[0016] Still other objects and advantages of the present invention will become readily apparent to those skilled in this art from the following detailed description wherein I have shown and described only the preferred embodiment of the invention, simply by way of illustration of the best mode contemplated by carrying out my invention. As will be realized, the invention is capable of modification in various obvious respects all without departing from the invention. Accordingly, the drawings and description of the preferred embodiment are to be regarded as illustrative in nature, and not as restrictive in nature.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 shows a slide perspective view of the present system in a first preferred embodiment.
[0018] FIG. 2 is a detailed view of the embodiment shown in FIG. 1 demonstrating a connection between the vacuum truck and the vertical conduit.
[0019] FIG. 3 is a detailed embodiment of the T-valves shown in FIG. 1 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0020] While the invention is susceptible of various modifications and alternative constructions, certain illustrated embodiments thereof have been shown in the drawings and will be described below in detail. It should be understood, however, that there is no intention to limit the invention to the specific form disclosed, but, on the contrary, the invention is to cover all modifications, alternative constructions, and equivalents falling within the spirit and scope of the invention as defined in the claims.
[0021] Referring now to FIGS. 1-3 , several views of the preferred embodiment of the present system is shown. As shown in FIG. 1 , the present system 10 is shown in use upon a building 2 having a plurality of floors 4 , 6 , and 8 . Located on each of these floors is a portable restroom. While the present embodiment is shown as having three floors, it is to be distinctly understood that the present invention can be variously embodied to reach heights of up to 700 feet and/or buildings of up to fifty stories. The present system is configured to service these portable restrooms and is comprised of a vacuum tank 12 positioned upon a vacuum vehicle 16 , typically a truck, which enables the vacuum tank 12 to be taken to a variety of locations. A vacuum pump 14 is operatively connected to the vacuum tank 12 and is configured to create a vacuum sufficient to pull material through various conduit sections 18 , 20 , 30 into the vacuum tank 12 .
[0022] In this preferred embodiment, the vacuum pump 14 is a liquid cooled pump 14 that is integrally connected and wired for use with the truck itself. Preferably, this pump 14 has sufficient capacity to pump approximately 350 cfm. However, various other sizes and modifications may be made to the pump 14 as well. It is to be distinctly understood, however, that this example is merely illustrative and is not to be considered limiting in any manner.
[0023] This pump 14 is connected to tank 12 , which typically has a capacity of 500 gallons. However, tanks of other capacities can also be utilized. This tank 12 is connected to a first conduit 18 in a manner that allows the connection to be held in a leak-proof and tight connection, while also being easily removable and replaceable. In the preferred embodiment, this is accomplished by connecting the first conduit 18 to a three-inch full flow ball valve 38 connected to a three-inch female aluminum coupler 40 , which is connected to a three-inch to two-inch male-to-male reducer 36 that is configured to connect to a first conduit 18 . A more detailed view of this connection is shown in FIG. 2 .
[0024] The first conduit 18 is a vacuum hose like the other hoses 20 , 30 also referred to as horizontal 30 or vertical 20 conduits that are used in the present invention. The conduits are vacuum hoses in the preferred embodiment being two inch 390 SD 100-psi hoses having a 300 psi burst rating and a twenty-nine inch vac. Each of these hoses is sectioned into appropriate lengths having female couplers on each end. In the preferred embodiment, the hoses are configured so that the first hose is approximately thirty-six feet in length and is configured to reach from the vacuum truck 16 to a second floor 4 of a building 2 to be serviced. Lengths of hose of approximately twenty-eight feet are then used to span from the second floor of the building being serviced to the fourth floor of the building being serviced and from the fourth floor of the building being serviced to the sixth floor being serviced. From the sixth floor, each additional piece of hose is approximately twenty feet in length. The system can be configured for use on a building up to fifty stories in height and an over a length of about 700 feet. While the dimensions of the various hoses and their method of connection in the preferred embodiment are set forth above, it is to be distinctly understood that this configuration is meant for illustrative purposes only and many various alternative configurations are also envisioned within the spirit and scope of this invention.
[0025] These hoses 18 , 20 , 30 , are interconnected by T-valve combinations 24 , which are made up of vertical valves 28 and horizontal valves 26 . A detailed view of a preferred T-valve combination is shown in detail in FIG. 3 . A first vertical hose 20 is connected to an open portion of a T-valve combination 24 and a second vertical hose 20 ′ is connected to the upper portion of a vertical valve 28 . This second conduit then extends to another T-valve combination wherein it is connected in a similar fashion until a desired height has been achieved. In the present embodiment, both the vertical valve 28 and the horizontal valve 26 are two inch full flow ball valves, which are configured to allow full flow of material through the T-valve combination 24 valve itself. These ball valves are connected to a two-inch T-shaped conduit by male couplers. Preferably, these two-inch male couplers are made of aluminum and allow the valves 26 , 28 to connect to the T-shaped conduit.
[0026] In use, the vertical conduit 20 is secured to a building in such a way that the hoses are generally vertically aligned in a straight up and down orientation. Preferably, these hoses are tied to the building in order to secure them. However, a variety of other types of devices that also secure these hoses to the building may also be utilized. These vertical hoses 20 are positioned so that a T-valve combination 24 is positioned approximately three feet above the level of the floor, upon the floor that is to be cleaned. A horizontal hose 30 is connected to the horizontal valve 26 and extended toward the restroom. In a preferred embodiment, the restrooms to be cleaned are positioned within twenty feet of the T-valve sets which may be connected either to the outer portions of the building or placed within the plumbing crawl spaces where the permanent water and plumbing will ultimately be positioned. This positioning allows a single horizontal hose to reach from the T-valve combination 24 to the restroom to be cleaned. However, depending upon the necessities of the user, multiple horizontal hoses 30 may be utilized to reach the desired location. Preferably, each of the horizontal hoses 30 is a typical service hose that contains a wand that is configured to be inserted inside the holding container of the restroom to be cleaned and a service valve that allows material to be suctioned through the device. This service hose 30 assists in facilitating the passage of sewage or sludge from the holding container to the vacuum truck.
[0027] Once the system is connected as described, it is utilized by engaging the pump 14 . Since the pump 14 is a liquid cooled pump and since the invention allows the vacuum pressure to be utilized solely in those locations where the pressure is needed, a single user can simply turn on the pump 14 , lock the truck, and go into the building to service the restrooms. At the first floor to be cleaned, the user closes the vertical valve 28 on the T-valve combination 24 and opens the horizontal valve 26 on this same T-valve combination 24 . By doing this, the user prevents the remaining parts of the system from having a vacuum applied to them and allows the maximum amount of vacuum through the horizontal conduit 30 . The horizontal conduit 30 is then placed within a container that is to be cleaned and the waste is sucked out. When all of the various restrooms on this level have been cleaned and serviced, the user closes the horizontal valve 26 and opens the vertical valve 28 on the T-valve combination 24 . The user then goes up to the next floor and repeats these same steps. This process is then repeated until all of the restrooms in a particular building have been cleaned.
[0028] This invention provides a significant number of advantages over the inventions shown in the prior art. First, by closing the vertical valve 28 above the floor to be cleaned, the user ensures that only those portions of the system that must have vacuum pressure within them are open and thus focuses the vacuum pressure upon the waste that is being sucked through the device. Second, this system prevents clogs in the vacuuming system from forming because the vacuum pressure is always contained and controlled. Third, because this system utilizes a liquid cooled pump, the pump 14 can be run continuously, thus allowing a single person to utilize the invention and increasing the efficiency and cost effectiveness of the invention itself.
[0029] While there is shown and described the present preferred embodiment of the invention, it is to be distinctly understood that this invention is not limited thereto but may be variously embodied to practice within the scope of the following claims. From the foregoing description, it will be apparent that various changes may be made without departing from the spirit and scope of the invention as defined by the following claims.
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A system and method for servicing restrooms on the upper floors of a high rise building. The system is comprised of sections of vacuum hose that are interconnected by T-valves each T-valve is configured to provide a user with the ability to selectively shut off the flow of material in a vertical or horizontal direction or both. These vacuum hoses are then connected to a liquid cooled pump, which is connected to a vacuum tank. The system operates by selectively opening and closing the vertical and horizontal valves to focus vacuum force in areas to be cleaned and prevent vacuum in non-desired areas.
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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 the construction of a base unit for a cabana of the type used for portable outdoor-type restroom facilities, with the base functioning as a shipping container for restroom facility components, a waste receptacle for toilet and sink units contained in the facility and, upon becoming filled with waste, a ballast for stabilizing the facility.
Portable standard cabanas housing toilets and sinks function as restroom facilities at outdoor public gatherings, construction sites and other locations where such facilities would otherwise be unavailable. Conventional cabanas typically include walls constructed from relatively large, thin sheets of thermoplastic material such as polyethylene-type plastic, secured to a base to define both the height and the width of the cabana enclosure. One wall panel typically includes a door frame with a door hingedly connected thereto for providing access to the interior of the cabana.
Conventional portable cabanas of the type generally described above vary widely in shape and size. Examples of such cabanas are disclosed in the following patents to Richard Leach Tagg: U.S. Pat. No. 5,550,960 for a “Portable Toilet Cabana”, U.S. Pat. No. 5,500,962 for a “Portable Toilet Cabana”, and U.S. Design Pat. Des. 360,471 for a “Portable Toilet Cabana”.
Conventional portable toilet cabanas are designed to provide maximum interior volume. However, toilets, waste-holding tanks, sinks, fresh water holding tanks, and/or other restroom facility components typically installed within the cabana interior occupy a portion of the cabana interior. Typically, an integrated toilet and waste-holding tank are arranged upon the top of a pallet base or skid, as for example is illustrated in U.S. Pat. No. 3,835,480 to Harding for a “Chemical Toilet Cabana”. However, such a design utilizes a significant portion of the cabana interior volume, thereby minimizing the available room for additional restroom components such as sink units and fresh water supplies.
In addition, conventional outdoor restroom facilities are not designed for use as either an Asian style toilet unit, which is essentially a unit built directly into the floor surface, or a Western style toilet unit of the type typically used in the United States, and shown in U.S. Pat. No. 5,550,960 referenced above.
Shipping these portable restroom units in a knock-down condition is costly, given their sizes and the numerous components that must be assembled. As with shipping of any bulky goods having numerous unassembled components, separate boxing of these components increases the probability of the components being either lost or misplaced during shipment.
Further, the waste-holding tanks that have been used with these portable restroom units are normally arranged along one of the inner walls of the cabana. When these tanks are substantially filled, they create an unbalanced weight distribution in the cabana. The unbalanced weight distribution problem increases the ease of tipping the cabana over by wind forces or by vandalism. Further, in conventional outdoor toilet facilities, the waste tanks must be emptied through an interior access port, such as through the toilet unit itself. This required interior access increases the difficulty of removing waste from the unit.
SUMMARY OF INVENTION
The invention contemplates a multi-function base unit for an outdoor portable toilet or restroom cabana that is molded from a plastic material to form a combined cabana floor, a waste-holding tank, and pallet for support and for forklift access. The unit includes a hollow base that forms a holding tank and is shaped for forklift access thereunder. The holding tank is also a storage unit for facility components therein when the toilet cabana is in a knock-down state, a waste storage unit during cabana use, and a ballast for stabilizing the cabana as the holding tank is filled.
The structure of the present invention increases the space available within the cabana when compared to conventional outdoor restroom cabanas. The base unit also functions as a shipping container for the restroom facility components, such as the toilet and the sink unit, thereby minimizing shipping costs and the probability of components becoming separated or lost during shipment. In addition, the base unit functions as a ballast to stabilize the restroom facility as the waste-holding tank of the base unit becomes filled, thereby minimizing the chance of the cabana being tipped over. Also, the base unit is designed with a floor on which either an Asian style or Western style toilet unit may be positioned, with or without flushing capabilities.
An object of this invention is to provide a base unit for a modular portable outdoor cabana structure, with the base unit being molded to include a waste-holding tank beneath the base unit floor, thereby increasing the available volume within the cabana structure.
Another object of this invention is to provide a base unit for a modular portable outdoor cabana, with the base unit being molded to include a waste-holding tank beneath the base unit floor that functions as a ballast for the structure, thereby minimizing the chance of the structure being tipped over.
Yet another object of this invention is to provide a base unit for a modular portable outdoor structure, with the base unit being molded to include a waste-holding tank beneath the base unit floor that functions as a chassis for ensuring correct assembly of wall panels and other components of the structure.
An object of the present invention is to provide a base unit for a portable outdoor structure that is molded from a plastic material to include skids for forklift access.
A further object of the present invention is to provide a base unit for a portable outdoor restroom facility that includes a waste-holding tank that doubles as a shipping container for storage and shipment of facility components when the facility is disassembled.
Also, an object of the present invention is to provide a base unit for a portable outdoor restroom facility that is molded from a plastic material to include a waste-holding tank below a substantially planar floor that is designed for use with either Asian or Western style toilet units, with or without flushing capabilities.
Yet another object of this invention is to provide a base unit for a portable stand-alone restroom facility that may be retrofit on existing restroom facilities, thereby minimizing implementation costs associated therewith.
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 an outdoor toilet cabana restroom facility, including a floor or base that includes skids and a waste-holding tank, according to a preferred embodiment of the present invention;
FIG. 2 is an exploded view of the cabana and the base unit according to the present invention;
FIG. 3 is a schematic side elevational view of the cabana base unit;
FIG. 4 is a schematic front elevational view of the base unit of FIG. 3;
FIG. 5 is an exploded view of the interior components of the cabana and shows both Western style and Asian style toilet components which may be used alternatively;
FIG. 6 is a perspective view with a portion of the outdoor cabana walls being removed to show the components arranged within the cabana;
FIG. 7 is a perspective view with a portion of the cabana walls being cut away to show an alternative, Asian style, toilet embodiment.
FIG. 8 is a schematic cross-sectional view of the Asian style toilet bowl shown in FIG. 5; and
FIG. 9 is a schematic cross-sectional view of the Asian style toilet bowl shown in FIG. 5 indicating the section of the bowl to be trimmed if the bowl is to be used in a direct drop application.
DETAILED DESCRIPTION
Referring to the drawings, a portable stand-alone toilet facility 10 is shown in FIG. 1 . The facility includes a four-sided cabana 12 . The cabana includes a hollow multi-function base or floor unit 14 that functions as a waste-holding tank, a storage unit for restroom facility components during shipping of the components and, as the base unit becomes filled, as a ballast to prevent tipping or undesired movement of the restroom facility from its placement location. In addition, the base unit 14 functions as a chassis to facilitate correct insertion and placement of all the restroom or toilet components that form the toilet facility. The structure and function of the restroom facility 10 will be discussed in more detail below.
Referring to FIG. 2, an exploded view of the outer structure of the restroom 10 is shown. The cabana 12 includes two molded side panels 16 , a molded rear panel and frame shown generally at 18 , and a door 20 pivotally connected to door frame 22 . The cabana is enclosed by a molded roof 24 . The restroom facility cabana is of the type generally disclosed in the above referenced patents.
Referring to FIGS. 2-4, the base unit 14 is preferably formed by rotationally molding a high-density plastic material such as polyethylene. As an example of size, the base unit may be formed so as to define a waste-holding tank 25 having a capacity of approximately 400 liters, which is almost double the approximate 200 liter capacity of typical commercially available units. The bottom of the base unit is formed with parallel skids 26 , between which is a forklift access area 30 (See FIG. 4 ). Base unit 14 also includes outer peripheral walls 32 that define the outermost dimensions of the base unit. For example, the base unit can be about 47″ square. The base unit has a peripheral ledge 34 and secondary peripheral walls 36 which extend upwardly from the peripheral ledge 34 . The walls define a floor perimeter rim 37 upon which a floor panel 38 is placed. The floor panel is preferably formed from thick plastic board, as for example 0.5 inches thick. The inner peripheral walls 36 also have sockets 40 that receive floor joists 42 which engage and extend beneath the lower surface of the floor panel. These joists increase the structural integrity of the base unit and reinforce the floor panel 38 in supporting loads placed thereon.
The base unit itself, including the floor panel 38 , may be, for example, approximately 14 inches in height. When fully assembled, the cabana 12 , including the base unit 14 , has approximately 2.10 meters in internal headroom and an external height of about 2.5 meters. The base unit therefore does not significantly increase the height of the facility.
As shown in FIG. 2, a recess 44 including hinge receptacles 46 is formed in the front of the base unit for facilitating hinging of a step 50 to the front of the base unit 14 , upwardly. The sides of the step are hinged by hinges, such as those shown at 51 , to the base unit so that it may be pivoted upwardly. into the cabana interior space defined by the panels 16 , 18 , the door 20 and the roof 24 , and indicated generally at 52 . The step 50 may be pivoted into the cabana interior 52 during movement of the cabana to minimize the chance of damage to the step and to reduce the floor space needed on a vehicle used to move the cabana.
Still referring to FIG. 2, the peripheral ledge 34 has threaded receptacles 56 , at a pair of opposite corners. The receptacles threadably receive rings or eye-type plugs 60 . The plugs form tie points or rings 60 to which cables can be attached for lifting the cabana by an overhead boom, such as used on delivery trucks or a crane lift. In addition, the peripheral ledge 36 includes an external waste removal port 62 that opens into the interior of the base to allow waste to be removed from the base unit without the necessity for accessing the waste tank through the toilet as is conventional. This represents a significant improvement over conventional restroom facilities, whose waste must typically be removed by inserting a pipe into the waste-holding tank through the toilet opening. A cap, such as a screw type cap, can be used to cover the port.
Referring to FIGS. 2 and 5, the floor panel 38 has a waste water port 64 for draining waste water or dispensing of gray water from a sink unit 70 (FIG. 5 ). The floor panel also has a vent stack port 71 for communication of a vent stack 72 (FIG. 5) with the base unit holding tank 25 to allow noxious vapors to escape to the outside of the restroom facility. The floor panel also includes a pump port 74 in which a conventional foot pump 76 is placed. The foot pump 76 is connected via hydraulic lines (not shown) to a fresh water holding tank 78 arranged within the sink unit 70 to facilitate flushing of a toilet unit, if desired. By way of example, the holding tank 78 is designed to hold approximately 110 liters of fresh water, with a depth from the front side to the rear side of the tank, being, for example, 12 inches at the location of the sink and 6-8 inches at the counter. Such dimensions allow the entire unit 70 to be fitted within the holding tank defined by the base unit 14 along with other unit components for storage and shipping. The floor panel also includes toilet port 80 over which a toilet unit, such as a Western style toilet shown generally at 82 , or an Asian style toilet shown generally at 84 , is placed and through which the toilet 82 or 84 communicates with the waste-holding tank 25 .
Referring again to FIG. 5, the Western style toilet unit includes an outer. carrier 90 , an inner bowl 92 , a support 94 , a toilet seat 96 , and a toilet lid 98 , all of which are made of conventional materials well known in the art. The toilet unit also includes a flap 100 which is used to seal the toilet unit port 80 during periods of non-use of the toilet unit.
Alternatively, an Asian style toilet unit 84 may be used with the base unit 14 of the present invention. The Asian style toilet unit is typically a direct drop, non-flush toilet unit including an Asian bowl 104 and an outer peripheral rim 106 , both of which are raised only slightly above the plane of the floor panel 38 . If the Asian toilet unit 84 is of the flushing type, the unit also includes a flap 110 of the type similar to the flap 100 associated with the Western toilet unit 82 .
It is contemplated that either the Western style toilet unit 82 or the Asian style toilet unit 84 may be used with the base unit 14 of the present invention. Either of the units may be used either in a flushless, direct drop mode or in a flush mode. For flush type use, a flush foot pump 74 is operatively connected by a water line from the sink unit holding tank 70 to the toilet in a conventional manner, such that two foot strokes of the pump dispense about one-half liter of water into the toilet for flushing purposes. In final assembled form, the Western facility interior in which the Western style toilet is installed is shown generally at 110 , in FIG. 6, while a restroom facility in which an Asian style toilet unit is installed is shown at 112 in FIG. 7 .
Depending upon the particular type of Asian style toilet unit desired, it is contemplated that either a direct drop or a water flush Asian toilet bowl can be manufactured utilizing a single mold. As shown in the cross-sectional views in FIGS. 8 and 9, a flush type Asian style bowl is shown having a peripheral lip 120 to accommodate a spigot (not shown) and running water to prevent the running water from overflowing onto the floor panel 38 . If a direct drop type Asian style toilet bowl is desired, the flush-type bowl is trimmed accordingly to the height indicated by the dotted line at 126 . Thus, only a single mold need be manufactured for both types of Asian bowls.
It is also contemplated that the sink unit 70 , toilet unit 82 or 84 , and all associated components thereof are of dimensions that allow the components to be stored within the waste holding tank formed by the base unit. When placed within the holding tank as such, floor panel 38 may be placed over the tank, and the holding tank thus functions as a shipping container for the restroom facility components. Thus, the base unit 14 serves not only as a waste holding tank during utilization of the restroom facility, but also as a storage/shipping container during storage/shipping of the restroom facility and its associated components.
Additionally, it should be appreciated that the holding tank formed by the base unit, through its design, tends to uniformly distribute waste deposited from toilet and the sink unit 70 . This is a significant improvement over prior art outdoor restroom facilities, as waste deposited in prior art units was typically deposited in a holding tank which was located at rear wall of the cabana, thereby resulting in an uneven weight distribution toward the end of the usage period. Such uneven weight distribution made such prior art facilities prone to tipping over due to natural forces such as wind, or as a result of vandalism. The base unit 14 , through its design, functions as a ballast for the cabana, thereby making the facility more stable as the facility and its sink unit and toilet are used.
As compared to prior outdoor restroom cabana designs, the base unit 14 increases available space within the facility interior, and at the same time provides additional stability to the cabana. In addition, the multi-function base unit of the present invention increases the waste-holding capacity as the waste-holding tank is formed without concern about using space within the interior of the cabana. Further, the base unit of the present invention acts as a chassis for easy assembly and disassembly of wall panels attached thereto. In addition, the base unit of the present invention may be retrofitted onto existing restroom facility cabana configurations, to replace older existing base units and skids. That is, the walls, roof and interior toilet and service components of prior types of cabana installations can be disassembled from the prior floor or support pallet used and reassembled upon the base of this invention, to convert two prior facilities into the improved construction provided by this base unit. Further, the bottom of the base unit is molded to form skids, thereby facilitating ease of access to the underside of the base unit for moving the assembled restroom facility, or the base unit itself, by forklift or other automated means. Finally, the holding tank formed within the base unit of the present invention functions as a shipping container for storage and/or shipment of components used within the restroom facility, thereby minimizing chance of misplacement or loss of these components during the shipping process.
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. Having fully described an operative embodiment of this invention,
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A multi-function base unit for an outdoor portable restroom cabana that is molded from a plastic material to form a combined cabana floor, waste-holding tank, and pallet skids for support and for forklift access. The unit includes a base that defines a holding tank and a pallet that supports the cabana. The base includes a top floor panel enclosing the base holding tank. The panel may be removed for storing restroom components therein when the toilet cabana is in a knock-down state, and for storing waste when the cabana is assembled and used, and for stabilizing the cabana as the holding tank is filled. The base unit is designed with a floor on which either an Asian style or Western style toilet unit may be mounted with or without flushing capability.
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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 takes priority from U.S. patent application Ser. No. 60/093,714 filed Jul. 22, 1998.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to oil well completion strings and more particularly to a hydrostatically-balanced open hole gravel pack system wherein hydrostatic pressure is maintained on the formation throughout the gravel packing operations.
2. Description of the Art
To obtain hydrocarbons from earth's subsurface formations, wellbores or boreholes are drilled into hydrocarbon-bearing formations or producing zones. After drilling a wellbore to the desired depth, a completion string containing various completion and production devices is installed in the wellbore to produce the hydrocarbons from the production zone to the surface. In one method, a fluid flow restriction device, usually containing one or more serially connected screens, is placed adjacent the production zone. Gravel is then packed in the space or annulus between the wellbore and the screen. No casing is installed between the screens and the wellbore. Such completions are called “open hole” completions and the systems used to gravel pack are called open hole gravel pack systems.
In commercially used open hole gravel packing system a completion string is frequently utilized for gravel packing. The completion string usually includes a screen near its bottom (or the downhole end), at least one packer or packing element above the screens, and a mechanism above the packer that allows gravel slurry to flow it from the surface to the annulus between the screens and the wellbore, and the clean fluid to return from the completion string to the surface. To gravel pack the annulus between the formation and the completion string, packer is set to form a seal between the completion string and the wellbore, the packer prevents the hydrostatic pressure from being applied to the formation, which prevents, for a period of time, maintaining the hydrostatic pressure above the formation pressure (the “overbalanced condition” or “overburdened condition”) during the gravel pack operation. Thus, the formation pressure can exceed the hydrostatic pressure, which can cause hole damage or well collapse and damage to the filter cake.
A substantial number of currently drilled wellbores are highly deviated or horizontal. The horizontal wellbores are extremely susceptible to damage if the overbalanced conditions are not maintained throughout the gravel pack operations or during any other completion operation. Maintaining the wellbore under overbalanced condition throughout the gravel packing, especially in highly deviated and horizontal wells is very desirable. The present invention provides a gravel pack system and method which maintains the pressure on the formation above the formation pressure throughout the gravel packing operation. The present system also is simpler and easier to use, thereby reducing the overall completion or gravel pack operations time and cost.
SUMMARY OF THE INVENTION
The present invention provides apparatus and method for gravel packing open holes wherein hydrostatic pressure on the formation is maintained above the formation pressure throughout the gravel pack process. In one embodiment, the gravel pack apparatus includes a completion string which contains a fluid flow restriction device, a crossover device uphole of the fluid flow restriction device and a packer above and below the crossover device. The completion string is conveyed in the wellbore to position the flow restriction device adjacent the producing formation while maintaining the wellbore under overburdened conditions. The upper packer and the crossover device are set while maintaining the wellbore under overburdened condition. This allows the gravel fluid to pass to the annulus and return through the completion string. The returning fluid crosses over to the annulus above the upper packer. After gravel packing, the lower packer is set. The portion of the completion string above the lower packer, which includes the crossover device and the upper packer are retrieved from the wellbore, thus leaving the fluid flow restriction device and the lower packer in the wellbore. In this particular embodiment, setting the lower packer after the gravel packing process has been completed enables maintaining the hydrostatic pressure on the formation throughout the gravel packing process.
Examples of the more important feature of the invention 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
For detailed understanding of the present invention, reference 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:
FIGS. 1A-1D show a schematic diagram of a gravel pack string for placement in the wellbore and the wellbore fluid flow path to hydrostatically balance the formation.
FIGS. 2A-2D show a schematic diagram of the gravel pack string with the upper or service packer set and the fluid flow path which enables maintaining the hydrostatic pressure on the formation.
FIGS. 3A-3D show the gravel pack system of FIGS. 1A-1D with the service packer set for a reverse circulation flow path.
FIGS. 4A-4D show the gravel pack system of FIGS. 1A-1D after the Run-in tool and the service packers have been removed, leaving the screen and the liner packer in the wellbore.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIGS. 1A-1D, 2 A- 2 D, 3 A- 3 D, and 4 A- 4 D show a gravel pack system 10 according to one embodiment of the present invention in various stages of gravel pack operations.
Referring to FIGS. 1A-1D, the system 10 includes a fluid flow restriction device 100 having a number of serially disposed screen assemblies 110 a - 110 c . The fluid flow restriction device 100 terminates at the bottom end of the string 10 with a plug 112 and a casing joint 114 . Each screen assembly, such as assembly 110 a , includes an outer shroud 120 and an inner sand screen 122 . The shroud 120 protects the internal parts of the screen assembly 110 a from direct impact of the production fluid 202 , while the screen 122 prevents gravel, sand and other small solid particles from penetrating into the flow restriction device inside 116 . The screen 122 , however, maintains the string inside 116 in fluid communication with the formation 200 . Any fluid 40 supplied from the surface into the opening 116 at a pressure greater than the pressure of the formation 200 travels downhole to the plug 112 . This fluid then returns uphole (return fluid 42 ) via an opening 124 at the casing joint 114 . The returning fluid 42 passes through the screen assemblies 110 a - 110 c (as shown by arrows 43 ) to the annulus 204 between the flow restriction device 100 and the wellbore 201 and travels uphole via the annulus 204 , as shown by arrows 44 . The purpose of the flow restriction device 100 is to prevent solids present in the production fluid 202 to pass into the opening 116 of the string 10 . It also prevents passage of any gravel though the screens 122 into the completion string inside 116 that is supplied to the annulus 204 from the surface.
A liner packer 150 is disposed uphill of (above) the flow restriction device 100 . A casing nipple 160 and a knock-out isolation valve 165 are serially coupled between the liner packer 150 and the flow restriction device 100 . A running tool 140 in the liner packer 150 is used to convey the liner packer 150 and the flow restriction device 100 into the wellbore 201 . An end 140 a of the running tool couples a swivel sub 162 in the casing nipple 160 . The swivel sub 162 allows the tool portion above or uphole of the swivel sub 162 to rotate while maintaining stationary the tool portion 163 below the swivel sub.
The liner packer 150 includes setting slips 151 and one or more packing elements 152 . A liner packer setting dog (not shown) when moved downhole, causes the packer elements 152 to set, i.e., extend outward to the wellbore inside walls. Seals 144 in a junk bonnet 145 at the top of the liner packer 150 allow a polished stinger 143 to maintain seal. In the above-described configuration, the running tool 140 is attached to the section of the completion string that includes the liner packer assembly 150 and the flow restriction device 100 (referred to herein as the “bottom hole assembly” or the “BHA”). This allows an operator to rotate and release the running tool 140 from the bottom hole assembly to pull out the upper section of the completion string 100 out of the wellbore 201 , leaving behind the BHA in the wellbore 201 .
A crossover port assembly or device 170 is coupled uphole of the liner packer assembly 150 through the stringer 143 . The crossover port assembly 170 includes a port 172 which is initially closed off by a sleeve 174 . When the port 172 is closed, as shown in FIG. 1C, fluid supplied under pressure from the surface flows down to an opening 176 in the crossover port assembly 170 and continues to flow through the liner packer assembly 150 and the flow restriction device 100 as show by arrows 40 . When the sleeve 174 is moved downward, i.e., downhole, the port 172 opens. If the flow path below the port 172 is blocked, then any fluid supplied to the completion string 10 above the port 172 will flow through the port 172 and into the annulus 204 and eventually return uphole through the central bore 116 along the completion string 10 length. In the particular embodiment of FIGS. 1A-1D, a gravel pack kit 185 and a service packer 180 are disposed uphole of the crossover device 170 .
The service packer 180 can be hydraulically set to block or restrict fluid flow through the annulus 204 uphole of the crossover device 170 . The gravel pack kit 185 includes a port 186 that allows the fluid to flow from a reverse fluid flow path 179 in the service packer 180 to the annulus 204 above the service packer 180 as more fully explained below. The service packer 180 includes slips 181 and a plurality of packing elements 183 . Thus, the gravel pack system or completion string 10 shown in FIGS. 1A-1D includes in a substantially serial relation a flow restriction device 100 , a liner packer 150 above the flow restriction device 100 , a crossover port assembly tool 170 , and a service packer 180 uphole of the crossover device 170 . The gravel packing around the flow restriction device 100 while maintaining the hydrostatic pressure above the formation pressure will now be described while referring to FIGS. 1-4.
The completion string 10 shown in FIGS. 1A-1D is conveyed into the wellbore 201 to a desired depth to position the flow restriction device 100 adjacent the producing formation 200 . A wellbore fluid 40 is pumped from a source thereof at the surface (not shown) into the completion string 10 . The fluid flows through the string 10 as shown by the arrows 40 and returns to the surface via the annulus 204 as shown by the arrows 43 . The fluid in the wellbore maintains the hydrostatic pressure over the formation 200 , i.e., maintains the wellbore under overburdened condition.
Once the string 10 is correctly positioned in the wellbore 201 , the running tool 140 is released (or disengaged) from the liner packer 150 by rotating the pipe or the work string (attached above the string 10 ), which rotates the string 10 above the swivel sub 162 . The work string is then moved up or uphole, which causes the slips 181 of the service packer 180 to move over members 182 , which sets the packer elements 183 of the service packer 180 (See FIGS. 2 A- 2 D). Setting of the service packer 180 blocks any fluid flow through the annulus 204 around the packer elements 183 . Since the fluid in the string 10 remains in fluid communication with the formation 200 , it maintains the hydrostatic pressure on the formation 200 .
After setting the service packer 180 , a ball 190 is dropped into the completion string 10 , which moves the sleeve 174 , thus opening the port 172 . The ball 190 seats in position in the crossover assembly 170 and prevents fluid flow through the crossover assembly 170 past the ball 190 . The movement of sleeve 174 also opens a reverse fluid flow path 177 in the crossover port assembly which is further in fluid communication with fluid path 179 in the service packer assembly 180 . Thus, activating or setting the crossover assembly 170 causes any fluid supplied from the surface to flow through the string 10 to the port 172 and then over to the annulus 204 via the port 172 . The fluid then flows downhole through the annulus 204 and passes through the screens 110 a - 110 c and then into the string opening 116 as shown by arrows 50 (FIGS. 2 A- 2 D). The fluid then flows uphole through the opening 116 in the flow restriction assembly 100 and then through openings 117 and 118 respectively in the liner packer 150 and the crossover tool 170 . The fluid then crosses over to the line or opening 179 through the service packer via crossover opening 177 . The fluid from line 179 passes into the annulus 204 above the packer 180 via port 186 in the crossover kit 195 . The downhole fluid flow path after the setting of the crossover assembly 170 is depicted by arrows 50 , while the uphole fluid flow path of the returning fluid is shown by arrows 52 . Thus, during the setting of the crossover assembly 170 to establish fluid flow below the service packer via the annulus 204 , the fluid in the wellbore 201 remains in fluid communication with the formation 200 , thereby maintaining the hydrostatic pressure on the formation 200 .
Still referring to FIGS. 2A-2D, once the service packer 180 has been set, fluid 188 with gravel or sand 189 (also known in the art as “propant”) is pumped into the string 10 from a source at the surface (not shown). The gravel fluid 188 flows to the annulus 204 around the flow restriction device 100 . The flow restriction device 100 prevents the gravel 189 from entering into the tool inside 116 . The gravel 189 deposits or settles in the annulus 204 while the filtered fluid enters the opening 116 and travels uphole as shown by arrows 52 . The supply of the gravel fluid is continued until the annulus 204 around the flow restriction device 100 is packed with the gravel 189 .
Referring to FIGS. 3A-3D, after the desired amount of gravel 189 has been packed around the flow restriction device 100 , the work string is picked-up, which opens bypass 220 in the service packer 180 . Clean fluid 222 is pumped downhole, along the annulus fluid flow path shown by arrows 55 and returns uphole though the flow opening 224 via the port 172 . This reverse circulation removes any excess sand or gravel from the work string.
The junk bonnet 144 is then sheared off. The packer setting dog sub 154 is then removed. The liner packer 150 is then set and the string above the bottom hole assembly is pulled out of the wellbore 201 . The work string, the gravel pack kit 185 , the service packer 180 and the crossover device 170 are replaced by production tubing 230 (FIGS. 4 B- 4 D).
It should be noted that in the particular method of this invention described herein, the liner packer 150 is set after the gravel pack operation has been completed, which allows maintaining the hydrostatic pressure on the formation throughout the gravel pack operations, thus, maintaining overbalanced or over burdened condition during all stages of the gravel packing operations. This system 10 also requires no gravel pack ports in the hook-up. Full inner dimensions or diameter is available throughout the operations. This method causes no swabbing or disturbance of the open hole filter cake.
The gravel pack system described herein above may utilize an combination of devices or any configuration that allows maintaining the hydrostatic pressure on the formation throughout the completion operations, such as gravel pack operations described above. The devices, such as packers, run-in tools, flow restriction devices described herein above are known in the oil field and thus are not described in great detail.
While the foregoing disclosure is directed to the preferred embodiments of the invention, various modifications will be apparent to those skilled in the art. It is intended that all variations within the scope and spirit of the appended claims be embraced by the foregoing disclosure.
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The present invention provides apparatus and method for gravel packing open holes wherein hydrostatic pressure is maintained above the formation pressure (“overburdened condition”) throughout the gravel pack process. The apparatus includes a completion string which contains a flow restriction device, a crossover device and a packer each above and below the crossover device. The string is set in the wellbore with the flow restriction device adjacent the producing formation. The upper packer and the crossover device are set, which allows the gravel fluid to pass to the annulus, and return through the string. After gravel packing, the lower packer is set. The crossover device and the upper packer are retrieved from the wellbore leaving the flow restriction device and the lower packer in the wellbore. The system maintains the wellbore under overburdened condition throughout the gravel packing process.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
FIELD OF THE INVENTION
[0001] The present invention pertains to the field of subterranean excavation. More particularly, the present invention pertains to devices used to stabilize material forming the walls, roof, and pillars of a tunnel, room, or other subterranean excavation to prevent collapse of the material into the excavated space.
BACKGROUND OF THE INVENTION
[0002] Coal mining in the United States is a major industry, reaching an all-time high in the production in 2008 at 1.17 billion short tons being mined in 25 states. Coal accounts for approximately half of all electricity produced in the United States, and provides 40% of the world's electricity needs.
[0003] Mining has always been a very dangerous activity, although in recent years improvements in technology have decreased the number of fatalities and accidents. Still, many fatalities and accidents occur due to a collapse of a tunnel roof or the collapse of a tunnel rib. A rib is defined as the side wall of a tunnel. Tunnels are developed in an engineered layout so that sufficiently sized pillars are left in place to support the overall mining system. Roofs have been supported by various means, and to various degrees, for the history of mining. In 2007, areas of the Crandall Canyon Mine in Utah collapsed due to pillar failures. A second collapse ultimately trapped and killed six miners, and a third collapse killed three would-be rescuers. Given the prevalence of mining worldwide, coupled with the desire to reduce mining deaths, further improvements to safety will remain a primary and overarching concern.
[0004] Surface control of the tunnel roof and ribs is an important concern of the mining business during the development of the tunnels and while men and material are transported through these tunnels. Once the mined material is exposed, the surfaces comprising the roof and ribs are commonly referred to as “the skin”. Ideally, the skin of the roof is supported by a primary support system, usually consisting of resin bolts installed on an approved pattern. Secondary systems are also applied when conditions are less than favorable. This secondary supporting system is responsible for controlling local skin failures, defined as mined material and loose rock that slip away from the surface of the rib or roof. This mined material and loose rock that fall from the roof and ribs are responsible for many accidents and deaths.
[0005] Most surface control problems (rib skin failures) of the ribs result from the separation of mined material due to anomalies in the mined material, such as fracture planes, allowing the mined material to fall to the mine floor, possibly injuring anyone near.
[0006] To minimize these skin failures and the associated accidents and issues, several product styles have evolved: Pans (“Mine Safe Draw Rock Shields”), Mesh/Geogrid, Mats, Boards, and Channel. Each product style is designed to help create and aid in the secondary support system. The variety of styles reflect the different and unique properties of the rib and roof to which they are applied, and thus the products styles are neither necessarily interchangeable, nor is selection of a particular product style purely a matter of preference. The different product styles thus reflect differences in equipment, time, and skill required to install the products, the characteristics of the material forming the rib and roof, as well as the cost of the actual product itself.
[0007] Pan systems involve the use of a pan and a plate machine bolted into the skin. The pan system stiffens the skin, and thus helps prevent skin failures. The term pan, as commonly used in the industry, is a bearing plate bolted directly against the skin to stabilize the skin, and is usually used in conjunction with a support plate, which is a smaller plate sandwiched between the pan and the bolt, effectively further stabilizing the through hole of the pan. Pan products are advantageous due to their fast installation, the limited expertise and specialized equipment need for such installation, their relatively small size for ease of handling by installers, and versatility in terms of placement location, resulting in a competitively priced product compared to other systems. A typical pan, such as that detailed in U.S. Pat. No. 7,284,993 B2, features a through hole for receiving a bolt, and a square, planar central surface immediately surrounding the through-hole, with one or more continuous channels circumscribing the through-hole. Another typical pan is the so-called spider plate made by Minova http://www.minovausa.com/pdfs/Products/SpiderPlate.pdf, featuring a plurality of “legs” or channels extending from the center of the pan to the perimeter or outer boundary of the pan. The '933 (Jenmar) pan, as well as other pans, are not fail-proof, and their small design size requires a greater number of pans be used in any given area to create surface control. Given the high cost of skin failures, further improvements in safety products is highly desirable.
[0008] What is needed is a pan that overcomes deficiencies in the prior art pan category of skin controlling products, specifically a pan that allows a mine operator or others performing subterranean excavation, the flexibility of placement, simple installation, and increased skin stabilization per installed pan.
DISCLOSURE OF INVENTION
[0009] Accordingly, the invention provides for an oval bearing plate or pan having a largely convex central portion existing in a first horizontal plane, and a planar peripheral portion or edge portion existing in a second horizontal plane below the first horizontal plane, the convex central portion joined to the peripheral portion by an outermost edge of the central portion angling downwards from the central portion to meet the innermost edge of the peripheral portion. The central portion further includes a plurality of parallel rib members held in spaced apart relationship, the rib members configured as a series of concave channels oriented so as to span the narrowest width of the oval pan. The invention further provides for an oval pan comprised of either galvanized metal or plastic. The invention still further provides for a pan system in which the installed pan becomes largely concave in shape.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The features and advantages of the invention will become apparent from a consideration of the subsequent detailed description presented in connection with accompanying drawings, in which:
[0011] FIG. 1 is a top view of the pan according to the invention.
[0012] FIG. 2 a is a cross-sectional side elevational view of the pan shown in FIG. 1 cut along lines A-A, showing the convex shape of the central portion and the concave profile of the rib members.
[0013] FIG. 2 b is a cross-sectional side elevational view of the pan shown in FIG. 1 , cut through the narrowest diameter of the pan parallel with the rib members, showing the convex shape of the central portion.
[0014] FIG. 2 c is a cross-sectional side elevational view of a rib member shown in FIG. 2 a at circle 2 c.
[0015] FIG. 3 is a perspective view of a pan system according to the invention, showing the pan, a support plate, and a bolt in a typical installation on a rib or roof, and a perspective view of a prior art pan system as installed adjacent to the pan system according to the invention.
[0016] FIG. 4 a is a top view of one side of the pan according to the invention.
[0017] FIG. 4 b is a partial view of FIG. 4 a taken at circle 4 b, showing the outermost edge of the central portion and the peripheral portion.
[0018] FIGS. 4 c - ce show embodiments of the pan according to the invention.
[0019] FIG. 5 a is a cross-sectional, side elevational view of the pan according to the invention, in a typical installation on a rib or roof, showing the concave shape of the installed pan.
[0020] FIG. 5 b is a perspective view of the pan according to the invention, showing the generally convex shape of the unistalled pan.
[0021] FIG. 6 is a perspective view of two different sized pans according to the invention, showing optional through bores or apertures in addition to the through bore located in the center of the pan, and additionally highlighting the varying number and spacing of the rib members.
DRAWINGS LIST OF REFERENCE NUMERALS
[0022] The features and advantages of the invention will become apparent from a consideration of the subsequent detailed description presented in connection with accompanying drawings, in which:
10 bearing plate or pan 12 through-bore 12 a first aperture 12 b second aperture 14 pan edge portion or peripheral portion 14 a innermost edge of peripheral portion 14 b second edge of peripheral portion 16 transition point 18 rib member 18 a length of first rib member 18 b length of second rib member 18 c length of third rib member 18 d length of fourth rib member 18 e diameter of through-bore 18 f width of rib member 18 g angle or rise of rib member 18 h height of rib member 18 j width of pan edge 18 k radius of pan edge 18 l true radius of pan edge 18 m width of rib crest 20 central portion 20 a outermost edge of central portion 20 b first diameter of central portion 20 c second diameter of central portion 30 support plate 40 bolt 50 skin (roof and/or rib) 60 prior art pan system 100 pan system
DETAILED DESCRIPTION
[0053] Now referring to FIGS. 1-6 , a bearing plate or pan 10 according to the invention is comprised an oval shaped, single piece of embossed or stamped metal, or alternatively, out of plastic, such as thermo-plastic. The pan 10 is comprised of a standard sized 1⅜ inch through-bore 12 cut into the center of a central portion 20 of the pan 10 , the through-bore 12 sized and shaped to receive a bolt 40 (as shown in FIGS. 3 and 5 ). The central portion 20 includes a first diameter 20 b and a second diameter 20 c, the first diameter spanning the shortest width of the oval shaped central portion 20 and existing in a first horizontal plane. The first diameter 20 b ranges from about 14 inches to about 18 inches. The second diameter 20 c ranges from about 20 inches to 24 inches. The central portion 20 is defined by an outermost edge 20 a curving downwards below the first horizontal plane in which the central portion 20 lies. Two additional apertures 12 a 12 b in spaced apart relation and on opposite sides of the through-bore 12 are formed in the central portion 20 , and may be used to further secure the pan to a skin (rib and/or roof) 50 by each aperture receiving one bolt 40 , as necessary when a typical installation using the central through-bore 12 is not possible, or as desired, in lieu of or in addition to installation using the central through-bore 12 (see FIG. 6 ).
[0054] A plurality of parallel rib members 18 , in spaced apart relation, are embossed or stamped onto the central portion 20 , each rib member 18 further comprising a concave channel spanning the first diameter 20 b of the central portion 20 . The central portion 20 is largely convex in shape, with the area upon which the rib members 18 are embossed lying in the first horizontal plane, parallel to the first diameter 20 b and to one another. The rib members 18 have at least two and in some embodiments, three different lengths. In a typical embodiment, shown in FIG. 1 , a pair of first rib member lengths 18 a are about 8 inches long each, each one of four second rib member lengths 18 b is about 12 inches long, and each one of four third rib member length 18 c is about 14.5 inches long.
[0055] The central portion's outermost edge 20 a meets an innermost edge 14 a of a pan edge portion or peripheral portion 14 at a transition point 16 , the peripheral portion 14 and the transition point 16 lying in a second horizontal plane, as shown more clearly in FIGS. 2 a and 2 b . The uninstalled pan 10 is thus largely convex in shape, as shown more clearly in FIG. 5 b , with the peripheral portion 14 being flat, the entire pan 10 somewhat resembling a flattened bowler hat resting on its brim. The peripheral portion 14 is thus defined by the innermost edge 14 a and a second edge 14 b, the second edge 14 b being the perimeter or outermost limit around the pan 10 .
[0056] The pan 10 according to the invention, in a typical embodiment as shown in FIGS. 1-6 , features a surface area of approximately 24×18 inches, when compared to the prior art pans results in a larger surface area of the pan 10 contacting the skin 50 when the pan is part of an installed pan system 100 . The pan 10 has about 30% greater surface area than the 18×18 inch and 17×17 inch square prior art pans, allowing an operator of a coal mine greater flexibility in its roof and rib plan, and importantly, better safety due to the larger surface area controlled by the pan system 100 , as shown more clearly in FIG. 3 , where a prior art pan system 60 is comprised of a square prior art pan and support plate bolted to a rib, and the pan system 100 including the pan 10 according to the invention bolted to the same rib and adjacent to the prior art pan system 60 . The single most critical characteristic of a skin control product such as the pan 10 is its ability to contact the surface of the mining tunnel skin with adequate stiffness characteristics which help eliminate progressive roof and rib failures. The oval shape of the pan 10 as well as the large, planar peripheral portion 14 allows for easier handling of the pan 10 during installation (no sharp edges or points), as well as superior strength derived from the oval and generally convex shape of the pan.
[0057] When the pan 10 is used in the pan system 100 and installed on the skin 50 , as shown more clearly in FIGS. 3 and 5 a , the convex central portion 20 is pushed towards the skin 50 by a support plate 30 and the bolt 40 , causing the central portion 20 to dimple and become concave in shape, pushing the pan 10 tightly against the skin 50 . When the pan system 100 is installed, pressure from the bolting machine transfers load energy to the transition point 16 causing a “riveting” process to occur. This energy “pops” the pan 10 tightly into place. Further, the planar peripheral portion 14 has a greater surface area for better load strength and allows the installed pan 10 to more tightly grip the skin throughout the life of the pan.
[0058] FIG. 2 a shows a side elevational cross section of the pan 10 according to the invention. The rib members 18 are arranged in parallel, spaced apart relation, each rib member 18 having a concave cross section so as to form a channel in the central portion 20 . Each rib member has a greater depth than the average rib member of the prior art. In a typical embodiment according to the invention, shown in FIGS. 2 a and 2 c , each rib is about 0.125 inches deep 18 h, with a diameter or width 18 f of about 0.84 inches. Other embodiments of the pan 10 are provided with dimensions for the rib members ranging from depths 18 h of 0.55 inches to 0.17 inches and diameters 18 f from 0.75 inches to 0.84 inches. The width of the rib crest 18 m is about 0.13 inches wide in a typical embodiment. The outermost edge 20 a has a range of varying dimensions, the width 18 j of the peripheral portion 14 ranging from about 0.9 inches to about 1 inch, and the radius 18 k ranging from about 2 inches to 3 inches, with a true radius 181 of about 2.3 inches in a typical embodiment. The angle or rise of the rib member 18 h, as shown in FIG. 2 c , in a typical embodiment is about 22 degrees.
[0059] The arrangement and number of rib members 18 per pan 10 provide approximately five times the strength of the prior art pans. The rib members 18 provide strength, and as load-weight is exerted onto the pan 10 , the energy expands onto the convex central portion 20 , the rib members 18 pushing the load energy to the outer edges of the pan, thus aiding in surface tension control. FIG. 1 shows 10 total rib members 18 , however it should be noted that the number of rib members 18 per central portion 20 may vary, and at least two rib members 18 are needed per pan 10 .
[0060] The pan 10 is typically made of galvanized steel, G-90 and/or G-60 galvanized hot dipped processed steel (see FIG. 6 ) to resist rust formation and deterioration of the pan. Plastic pans 10 are made of thermo-plastic or other suitable plastic materials. The metal pan 10 is typically stamped, guaranteeing the tolerances of the pan 10 are consistent during the manufacturing process. Plastic pans 10 are created using a thermo forming process using a tool.
[0061] It should be noted that the present invention is not only useful for roof and wall stabilization in mining, but can also be used for any tunneling or other subterranean excavation, such as for placement of utilities beneath the surface.
[0062] Finally, it is to be understood that the above-described arrangements are only illustrative of the application of the principles of the present invention. Numerous modifications and alternative arrangements may be devised by those skilled in the art without departing from the scope of the present invention. For instance, in some embodiments (not shown), two or more pans 10 may be stacked and used together to form a pan system, with or without the use of the support plate 30 , and plastic pans 10 may be used in combination with metal pans 10 , either side by side in a pan system 100 or stacked together. The dimensions and shape of the pan 10 may also be modified to have a rectangular peripheral portion but retaining an oval shaped pan central portion, and the dimensions may be larger or smaller than 24×18 inches, as desired. A square support plate 30 is shown in FIG. 3 , however any style support plate can be used in the pan system 100 and FIG. 3 should not be regarded as requiring solely the use of square support plates. Also, use and installation of the pan 10 or of the pan system 100 to the rib or to the roof is identical, and hence references to rib or roof, or rib and roof, or collectively to the skin are not meant to indicate different uses or installations of the pan 10 and/or the pan system 100 . These are just a few possible modifications and alternative arrangements, and the appended claims are intended to cover such modifications and arrangements.
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A pan ( 10 ) and a pan system ( 100 ) for surface control of wall and/or roof material in a subterranean tunnel or room, the oval pan ( 10 ) having a convex central portion ( 20 ) held at an angle above a horizontal plane and an outermost edge angling downwards and meeting a planar pan edge portion ( 14 ) lying in the horizontal plane, both edges meeting at a transition point ( 16 ). The central portion includes a plurality of parallel concave rib members ( 18 ) arranged to span the shortest width of the pan. In use as a system ( 100 ), a bolt ( 40 ) drilled though a support plate ( 3 ) and the pan secures the pan system to the wall or roof. The force exerted onto the bolt transfers to the pan results in a dimpling of the central portion, allowing for a tighter application of the pan to the wall or roof.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF INVENTION
1. Field of the Invention
This invention is for multiple safety valves for location within an oil or gas well that can be activated to open or close and thus prevent, or permit upward flow of fluids within the well for example in case of an emergency.
2. Description of Related Art
Downhole safety valves are known that include a housing, a flapper valve and a remotely controlled actuator for closing the normally open valve in case of an emergency. See for example U.S. Pat. No. 7,392,849. Also serially arranged valves in a downhole tool are also known. Examples of such are shown in U.S. Pat. Nos. 6,394,187; 7,673,689; 4,846,281; 4,605,070; and 6,152,229. These valves are complicated in design and are not compact as is critical in the art. Furthermore the internal flow passage for the fluids are not of a single diameter and many contain obstruction shoulders or changes in diameter that result in turbulent flow or pressure drops.
Threaded joints are in common use in hydrocarbon producing wells. During design qualification of subsurface safety valves, a body joint must be designed qualified and verified which is an expensive process, because of the consequences of a leak in a valve of this type. Typical solutions would be to provide valves with two body joints and a pup joint between which adds two additional body joints. The present invention reduces the number of body joints in an integral valve to four or five and utilizes the same body joint.
BRIEF SUMMARY OF THE INVENTION
The invention disclosed and claimed in this application is for subsurface multiple stage safety valves that are highly reliable, compact, simple to manufacture and include at least two complete, separately functioning safety valves. In accordance with another aspect of the invention, dual control lines are provided which allows for individual operation of each safety valve. This allows the operator the option of operating one valve and keeping the other as a stand-by or operating both valves simultaneously. The principles of the invention can be applied to pressure equalizing or non-pressure equalizing closing systems. Due to the internal design of the valve, the internal flow path is substantially of uniform diameter thus eliminating turbulence and pressure drops due to internal obstructions and irregularities. Furthermore the exterior diameter of the tool is substantially constant. The tool includes a minimum of body joints which increases the reliability of the tool and simplifies construction.
Another advantage of the valve is the reduction of body joints necessary for its construction. Reducing the number of body joints reduces potential leak paths of hydrocarbons from the inside. Fewer joints also reduces the cost of the body joint.
Another embodiment of the present invention is to operate both valves with a single control line, which controls the sequence of openings and closures.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)
FIG. 1 is a longitudinal sectional view of an embodiment of the invention.
FIGS. 2 a and 2 b are cross sectional views of an embodiment of the multiple stage safety valve in the closed position.
FIGS. 3 a and 3 b are cross sectional views of an embodiment of the multiple stage safety valve in the open position.
FIGS. 4 and 5 are cross sectional views of an example of a piston operated sleeve.
FIG. 6 is a cross sectional view of the safety valve having a single surface control line.
FIG. 7 is a view similar to FIG. 6 showing a flow restrictor in the control line branch going to the first valve.
FIG. 8 is a cross-sectional view of a second embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
Initially, in order to better understand the invention, the prior art will be discussed. Currently in order to provide redundancy, two valves are simply joined together by a pup joint. The upper valve is connected to production tubing by a threaded connection and the lower valve is connected to lower production tubing by a threaded connection. This results in six body joints. As discussed above these body joints increase the likelihood of leak passages and increase the cost of fabrication.
Referring to FIG. 1 , an embodiment of the present invention is illustrated. The integral multiple stage safety valve includes five tubular sections 11 , 12 , 13 , 14 and 15 connected to each other by any suitable known methods such as internal and external threads. Upper connection body 11 may be connected to any tubular to be placed within the well. A first spring housing 12 is connected at one end to the upper connection body and at the other end to an integral chamber housing 13 which interconnects the two separate safety valves 60 and 70 as shown in FIGS. 2 a and 2 b according to an embodiment of the invention. Housing 13 includes an interior flow path 57 of substantially constant diameter and generally equal to the interior diameter of sleeve 19 . Second spring housing 14 is connected to a reduced diameter portion 52 of the integral chamber housing 13 by threads as an example. Lower connection body 15 is attached by any known manner to a reduced diameter portion 39 of second spring housing 14 at one end and may be connected to a tubular at its lower end 63 . This design results in four body joints.
As shown in FIGS. 4 and 5 , each safety valve includes a piston 18 , a sleeve 19 with an enlarged connection portion 34 , a flapper valve element 33 pivotably connected at 32 to the spring housing, a coil spring 38 that biases the flapper valve element against a valve seat 31 and a coil spring 20 that surrounds sleeve 19 .
As shown in FIG. 4 , a conventional mechanism for operating each safety valve includes a piston 18 having a seal 55 on its outer surface. Piston 18 at its lower end is received by an enlarged connection portion of sleeve 19 . Spring 20 abuts a shoulder 56 on the sleeve 19 and is captured at its other end within spring housing 12 as shown at 61 in FIG. 5 .
Pressurized hydraulic fluid may be introduced above piston 18 at inlets 51 by separate conduits that extend to the surface. Fluid introduced above piston 18 will cause piston 18 to move downwardly as shown in FIG. 1 , while compressing spring 20 as shown in FIG. 3 a . The lower end of sleeve 19 will push open flapper valve 33 . Conversely, a decrease in the pressure will cause sleeve 19 to move upwardly by the force of the compressed spring which will cause flapper valve 33 to close thereby preventing any upward flow of fluid through the central passageway 16 of the safety valve. As discussed above safety valves 60 , 70 may be independently operated by providing separate hydraulic lines for inlets 51 .
FIG. 5 illustrates an example of a typical flapper valve that may be utilized with the invention. Lower portion 39 of spring housings 12 and 14 are provided with a valve seat 31 . Flapper valve members 33 are pivotably connected at one side to the spring housings 12 and 14 . The pivot 32 includes a coil spring 38 or the like which biases the valve member 33 against valve seat 31 as is known in the art.
As shown in FIG. 6 , both valves may be activated by a single control line 80 that extends to the surface. A branch line 83 may extend to the inlet 51 of the upper valve 60 while line 80 connects to inlet 51 of lower valve 70 . A flow restrictor 82 may be located in either branch line 83 or in flow line 80 downstream of branch line 83 as shown in FIG. 7 and FIG. 6 respectively. The positioning of flow restrictor 82 will delay opening of the valve as pressure is applied through control line 80 . In the configuration shown in FIG. 6 , valve 60 will open first followed by valve 70 and in the configuration shown in FIG. 7 valve 70 will open first followed by valve 60 .
As pressure in the control line is reduced, the valve having the flow restrictor in its control line will close second while the other will close first.
FIG. 8 illustrates a second embodiment of the invention which includes two independent safety valves similar to those disclosed in FIG. 1 Each safety valve may include an actuator piston, a flow sleeve, a flapper valve element and a coil spring.
In this embodiment, the safety valve includes six tubular sections 111 , 112 , 113 , 116 , 117 and 118 . First tubular section 111 has an upper portion which may be threadably connected to production tubing in a known manner.
The lower portion of first tubular member includes a piston chamber in which piston 136 is received. Fluid under pressure is introduced into the piston chamber via an inlet 127 . Piston 112 acts on a flow sleeve 129 to open flapper valve 115 in the manner discussed above.
The second tubular section 112 is connected to tublar section 111 at a threaded joint 120 . A third tubular section 113 is connected to second tubular section 112 at a threaded joint 121 .
A fourth tubular section 116 also has a piston chamber in which is mounted a piston 126 which is adapted to move flow sleeve 131 which will open flapper valve 125 in the same manner as discussed above. A fifth tubular section 117 carries flow sleeve 131 and spring 132 and is connected to the fourth tubular section 116 by a threaded joint as shown it 123 . Hydraulic lines 127 and 114 are connected to a source of hydraulic fluid under pressure at the well head.
A sixth tubular member 118 is connected to the fifth tubular section 117 at a threaded joint shown at 124 . The lower portion of the sixth tubular member includes a threaded female connector adapted to receive a threaded portion of a production tubular.
Third tubular member 113 and fourth tubular member 116 in this embodiment form a chamber housing that consists of two tubular members.
The tubular members are connected together in a similar manner at 120 , 121 , 122 , 123 and 124 . Each joint includes a female threaded portion of the tubular member at its upper portion and a male threaded member at its lower end which is threadably connected to the female portion of the tubular member below it.
The outside diameter of the tubular members in the embodiments of FIGS. 1 and 8 are substantially the same as are the diameters of the inner flow passages. This embodiment results in five tubular joints.
Although the present invention has been described with respect to specific details, it is not intended that such details should be regarded as limitations on the scope of the invention, except to the extent that they are included in the accompanying claims.
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An integral multistage safety valve is designed to provide a second level of protection should a first stage fail. The valve may be used in oil and/or gas wells. The interior portion of the multiphase safety valve is designed so as to reduce turbulence and pressure loss through the valve when the valve is in an open position. The valves may be independently operable, or operable with a single control line. The multi-stage valve reduces the number of body joints required to construct two identical valves thereby reducing cost and potential leak paths and increasing reliability of the system.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
This invention relates to a drilling arrangement wherein there is included a reciprocating piston hammer effecting a hammering against a drill bit.
BACKGROUND OF THE INVENTION
The invention has particular application to a hydraulic down-the-hole piston hammer assembly directly acting against a drill bit which in turn is mechanically rotated and which is adapted to use the hydraulic fluid to. recover at least in part cuttings resulting from the actions.
The problem to which this invention is directed relates to the situation where the reciprocating piston hammer is driven by a fluid at pressure and the impacting faces between the hammer and the drill bit are within the fluid.
Conventionally the fluid is water.
The problem is that where the hammer is caused to strike a first end of the drill bit, upon removal of the striking face of the hammer, there will be caused, in view of the rapidity of the action, some cavitation which in turn will cause, upon collapsing of voids, significant stress forces in the localised vicinity of the impacting faces.
Such an effect has the capacity to effect significant and relatively rapid removal of parts of the material of the impacting surfaces.
BRIEF DESCRIPTION OF THE DRAWINGS
An object of this invention is to provide an arrangement which has the ability to reduce this problem.
According to this invention there is a drilling arrangement of a type using fluid for driving a reciprocating piston hammer, with respective impacting surfaces between the hammer and the drill characterised in that at least one of the surfaces includes at least one channel.
In preference but not essentially, the surface opposite the surface containing the channel, includes a protrusion located so as to be coincident with the location of the channel.
In preference but not essentially, the channel is located in the surface of the first end of the drill bit so as to define therebetween two annular faces and the piston hammer has a correspondingly located outer surface with a correspondingly located circular protrusion located so as to be located when the two impacting surfaces are together, in the channel shape.
In preference but not essentially, the surfaces impacting one against the other are planar across their impacting faces except for the channel and protuberant shapes and the orientation of the respective planar surfaces is at right angles to the direction of relative movement between the two parts.
It is thought that the effectiveness of this described feature arises from the factor that as the faces are impacted together, there is some trapped fluid within the channel shape which as it is caused to be compressed, will cause some fluid to escape past the surfaces coming together and that such action will significantly retard the force of the piston hammer as it approaches the surface of the bit to the extent that most of the impact will be effected through the medium of the fluid acting as an interface between the respective surfaces.
The part of the piston hammer protruding has the effect of additionally forcing fluid at the last moment at a more rapid rate through the closing gap to assist this effect.
In preference, but not essential, the fluid is water.
Ideally, the actual surfaces do not contact directly so that when the surfaces are then drawn away, there is a film of fluid already existing so that the restoration of fluid behind the retreating surface is effected with much less negative pressure and minimal cavitation.
For a better understanding of this invention it will now be described with reference to an embodiment it being emphasised that this is illustrative and not intended to be a limiting explanation of any aspect of the invention.
Accordingly, the embodiment will be described with the assistance of drawings in which:
FIG. 1 is a cross sectional view of an assembly including a reciprocating piston hammer and a drill bit,
FIG. 2 is an enlargement of a part of the view in FIG. 1,
FIG. 3 is a plan view of the impact surface of the inner side of the drill bit, and
FIG. 4 is a plan view of the impact surface of the impacting piston.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring in detail to the drawings the down-the-hole assembly 1 includes a drill bit 2 and an impacting piston 3.
The drill bit 2 and the piston 3 each have a central channel shown respectively at 4 and 5 providing a return path for the fluid which in this case is an aqueous fluid.
Other features within the assembly include an appropriate valving arrangement shown typically at 6 and elsewhere such that fluid at pressure coming through an annular channel 7 will cause the piston 3 to reciprocate and thereby effect a repetitive hammering against the lowermost face shown at 8 which in turn hits the inner surface 9 of the piston 3. Remaining features within this description include a pressure relief system including a helical spring 10 controlling piston 11 which has a lower surface at 12 connected through channel 13 to the high pressure side of the fluid.
The system and assembly as a whole is intended to work down-the-hole and is thereby supported by an appropriate stem assembly not shown which is connected at the upper end shown at 14.
In this arrangement, some of the fluid at pressure is used to cause the piston 3 to reciprocate, and the remainder is directed through channels 15 in such a way that the fluid is caused to pass around the outside of the drill bit head and return through the return passages 18 in the head.
The problem however to which this description is specifically directed relates to the impacting surfaces between the piston 3 and the inner surface of the drill bit 2 which is illustrated at 9.
The respective surfaces are substantially of annular shape and have substantially coincident external and internal diameters and surfaces that impact against each other or are intended to be closest at impact, recalling that it is expected that the aqueous fluid will stay to some extent between the two surfaces, are in each case planar and are aligned in their planar orientation so that they are at right angles to the cylindrical central axis of the piston which in turn defines the reciprocating direction.
The problem is of course that when the piston 3 impacts against the drill bit 2, there will be the two surfaces which having been impacted together with substantial and repetitive forces so that these will be closely aligned in shape and would therefore be normally expected to have excluded effectively any fluid.
As soon as the piston then is caused to return for the next cyclic impact, it has to break apart the respective surfaces and because this will have to be done very quickly, it is expected that this will conventionally pull a momentary vacuum in the sense of cavitation which will thereafter collapse causing effective momentary very high forces within the very localised vicinity transmitted through the fluid.
In order to minimise this, there is accordingly located an annular channel 16 which is located substantially midway between the inner and outer circular peripheries of the piston 2 and which is of constant cross sectional shape and size throughout its path with its path being coaxial with respect to the axis of the drill bit. The channel being a depression within an otherwise planar face.
Further, located on the other side namely the impacting surface of the piston 3 there is a downwardly protruding annular protuberance 17 the location of which is coincident with the medial alignment of the channel 16 the protuberance being of a constant cross sectional shape and size throughout its path with its path being coaxial with respect to the axis of the drill bit. The protuberance extending out from an otherwise planar face.
The drawings 1 and 2 illustrate the presence, size and shape of these cooperating shapes.
The invention however, is not intended to be limited necessarily to this very specific illustration.
However, with this particular illustration, by trapping some water within one of the faces which will normally be the surface which is upwardly facing so that the channels have an uppermost opening so that these will naturally retain the aqueous fluid therein, is such that as the piston 3 presses down on the surface 9, the trapped aqueous fluid within the channel 16 will be slightly compressed. This effect will be slightly magnified by reason of the protuberance 17 with the result that there will be increased squeezing pressure of the fluid to escape. Insofar that the time allowed for this is very small, considering the viscosity of the fluid, there will be some liquid remaining between the respective surfaces.
With such remaining fluid, the result is that as the piston 3 retracts, the effect will not be so severe in terms of cavitation because of the thin film of water still remaining between the respective surfaces and hence a reduction of potential material removal between the impacting surfaces from this effect.
Alternative arrangements including a plurality of channels and an inclusion of an external skirt so as to provide some retardation of exuding water are considered to perhaps assist the action but are not the preferred techniques presently being used.
The use of the coaxial channel and protuberance allows for relative rotational orientation of one of the elements as compared to the other.
Using the invention as described has resulted in significantly reduced cavitational corrosion in the application to the extent that there has been negligible corrosion observed in test examples thus far trialed.
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A drilling arrangement is provided having a reciprocating piston hammer which hammers a drill bit for hydraulic down-the-hole piston hammer drilling. The drilling arrangement uses a liquid for driving the reciprocating piston hammer with respective impacting facing surfaces between the hammer and the drill. The respective impacting facing surfaces are formed such that at the moment of impact some of the liquid is forced between the impacting surfaces. This substantially reduces if not eliminating altogether the cavitation which might otherwise develop.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
TECHNICAL FIELD
This invention relates to a strong, light weight accordion shutter system that increases strength while decreasing weight, and is especially resistant to hurricane force winds and flying objects when used to cover doors, windows or openings. More specifically, this invention relates to a shutter system comprising a plurality of connectable subsystems of shutters that are connected via a shutter mating system which provides sufficient strength to obviate the need to drill locking holes during installation and connection. This accordion shutter system also offers a unique ability to secure doors, windows and openings of any size from forced entry and enables operation from either side of the shutter system.
BACKGROUND OF THE INVENTION
In coastal and non-coastal areas subjected to high winds and flying objects from wind and rain storms, tornadoes, hurricanes or typhoons, accordion shutters traditionally have been used that lacked the strength to resist flying objects like a 9 pound 2×4 traveling at 34 M.P.H. while resisting hurricane force winds in excess of 155 M.P.H. on an 8 feet tall shutter, installed on a one story residence. Some accordion shutters are much larger in blade width, and component thickness, while actually being weaker. Others are very heavy and bulky causing considerable difficulty in operation, have large protrusions from the wall when stacked and difficulty walking over the wide bottom track when used across doorways and are extremely expensive and unattractive. Further, as a plurality of separate systems must be connected when covering larger areas due to installation and transportation difficulties of large single systems, prior accordion systems required that locking pins be custom drilled to provide for adequate strength in the connecting areas. Also, accordion shutters have historically required two or three guide pins per blade, with one or two rows of these guide pins following the outside of a top and bottom guide track while another rides in a groove.
There has been a need for accordion shutters built for wide openings to be manufactured in sections that can be assembled in the field. Further, when leaving the accordion shutters in an open position, there has heretofore been no convenient method of securing the contracted shutters in the open position. By providing a securing clip an effortless securing means has been provided for. This invention addresses the shortcomings of previous accordion shutters by providing resistance to high winds and protection from a 9 pound 2×4 traveling at 34 M.P.H. Further, it has a very low weight per square foot of deployed shutter system and is easy to operate. It has minimal protrusion from the wall when stacked at edges of the opening and the system provides for ease of maintenance for the guide pins, trolley and blade replacement and the capability of the accordion shutter to be assembled from factory assembled smaller sections, in the field, by the unique gate locking system hereinafter described. This facilitates the installation of very wide shutters without undue weight problems for the installer.
SUMMARY OF THE INVENTION
The shutter system of the present invention provides a unique accordion shutter system wherein a plurality of subsystems can be combined via a unique shutter mating system. The system comprises a top, single mounting flange guide pin track and a bottom mounted guide pin track. Hinged vertical blades, are supported therebetween at every other knuckle by a top dual wheeled trolley with guide pin and screw assembly. For attaching separated segments of blades is included a very unique connecting or shutter mating system which enables the accordion shutter system to be assembled with greater ease, while decreasing the weight of the system significantly and still conforming with the 1994 South Florida Building Code and the 1994 Standard Building Code. It is an object of this invention to provide an easy to install, strong accordion system that can protect nearly any size opening by providing a shutter mating system which connects a plurality of subsystems. It is another object of this invention to enable each subsystem to be locked in the open position.
These and other objects, features, and advantages of the present invention may be more clearly understood and appreciated from a review of the following detailed description of the disclosed embodiments and by reference to the appended drawings and claims.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
FIG. 1 is an elevation of the deployed accordion shutter system, with the unique shutter mating system shown in the middle and as an option, at the far end. Additionally, an open position holding clip is depicted.
FIG. 2 is a cross sectional view of an extruded, trap mounted header for the shutter system.
FIG. 3 is a cross sectional view of an extruded, wall mounted, built out header for the shutter system.
FIG. 4 is a cross sectional view of an extruded, wall mounted built out sill for the shutter system.
FIG. 5 is a cross sectional view of an extruded, trapped mount or wall mount two piece adjustable sill which is used when varying the distance between the header and sill is required.
FIG. 6 is a cross section view of an extruded, wall mounted, 180° degree starter strip.
FIG. 7 is a cross sectional view of an extruded, wall mounted, 90° degree starter strip.
FIG. 8 is a typical cross section of an extruded blade with a male end and a female end. Each end makes up one half of the hinge mechanism.
FIG. 9 depicts the female end of the two piece shutter mating system of the present invention.
FIG. 10 depicts the male end of the two piece shutter mating system of the present invention.
FIG. 11 illustrates the latch receiving member of the shutter mating system of the present invention.
FIG. 12 depicts the latch member of the shutter mating system of the present invention.
FIG. 13 depicts the securing clip member, which is secured to the header and sill, used to secure the blades when in the open or stacked position.
FIG. 14 is a profile cross section of the accordion shutter system of the present invention.
FIG. 15 is a plan view of the of locking action of individual blades and the shutter mating system of the present invention.
FIG. 16 is an is a plan view of the locking action of individual blades and the shutter mating system of the present invention as well as 180° degree and 9° degree wall connections and locking handle.
FIG. 17 depicts the accordion shutter system of the present invention in the open position with the securing posts fitting snugly into their respective retaining clips on either side of the header and sill.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The accordion shutter system of the present invention is made up of a top built out guide pin track that mounts to a wall surface with fasteners and a bottom, single flange built out guide pin track mounted to a wall surface. The top and bottom guide pin tracks alternatively can be attached directly to a ceiling or floor. It is understood that any combination of header and sills is possible. The hinged vertical blade, is supported at every other knuckle by a top dual wheeled trolley with a guide pin and screw assembly. A guide pin and screw are used in the remainder of the top blade knuckles that align with the top guide track. A bottom guide pin and screw is installed in each knuckle that aligns with the groove in the bottom track.
The knuckles that do not align with the groove in the track can receive optional screws and washers to secure the connection of the male and female edges of the blade, but do not receive guides. These trolleys and guides follow their respective top and bottom guide tracks for operation. The blade is substantially rectangular in appearance and when viewed as an elevated cross section, the blade has female and male ends. The female end comprises an integrally formed greater than 180° degrees hollow, partial cylinder which forms the outside of the hinge or knuckle. The outside of this knuckle is smooth while the inside has two internal hooks or stops protruding inward from the inside surface of the female partial cylinder.
The male end is a smaller in diameter partial cylinder with one outward protruding hook or stop that fits inside one female section. A second hook or stop protrudes from an offset connection arm integrally connected to the blade. The placement of this protrusion on the arm as opposed to the outer circle allows for greater shear strength. The male end is also the end of the blade that receives the dual trolley wheels or guide pin. The male end of the blade is especially shaped to allow for an external interlock at the knuckle. The use of both locking mechanisms limits the blade opening to approximately 100° degrees.
The shutter members, when deployed, are arranged in a continuous v pattern (sinusoidal in appearance), which follows the header and sill grooves. The edge portions of adjacent shutter members are connected so as to allow each blade to rotate with respect to the adjacent blades.
In order to provide for ease of installation, manufacture and transport of the shutter system, the system comprises a plurality of sub-systems which are combined using the shutter mating system of the present invention. These subsystems may be connected to a wall, column, structural stop and then to each other. The present invention utilizes a unique connecting means for attaching a plurality of sections of accordion storm shutters described in detail herein. Mechanical locks may be added to the shutter mating systems to provide for security. These locks utilize a hook and stop system to maintain strength.
On each end of the shutter subsystems are starter strips FIG. 16, 1605 and 1620, FIG. 6, 600 and FIG. 7, 700 that allow the shutter to be attached to a wall, column or mullion. This starter strip has a 180° degree FIG. 6 or a 90° degree FIG. 7 flat mounting surface on one side, while offering the same female cylindrical section as found on the blades on the other side. This facilitates the attachment of the blade to a wall, column or mullion.
Wall mounted headers FIG. 3 are rectangular sections with a flange at one top end and parallel continuous grooves and a continuous notch in the center of the bottom that receives the wheels of the trolley assembly and a guide pin. The wall mounted headers that receive the pin/trolley/blade assembly are designed to be mounted from this single flange on top of the wall header.
Ceiling mounted headers, FIG. 2, are a substantially rectangular section with a continuous notch in the center of the bottom that receives the wheels of the trolley assembly and a guide pin. The ceiling mounted headers, FIG. 2, that receive the pin/trolley/blade assembly are designed to be mounted from the top. The headers may include receivers (not shown) for felt strips on either side of the notch that receives the pin or trolley assembly. These strips allow easier and quieter operations.
The wall mounted sill of FIG. 4 is basically an angular cross section with notch or groove configuration setting on top of the angle to receive the guide pin assemblies. The wall mounted sill can be mounted from a singular flange positioned below the shutter for ease of access. This flange can be wall mounted in the desired vertical location to effect the proper blade clearances for optimum performance and operation.
The adjustable sill of FIG. 5, is a two piece receiver for the guide pin assemblies. Each piece is shaped in a channel configuration. The top piece 500 has a notch or groove formed into the wide part of the horizontal part of the channel section and this top piece fits into the bottom piece 520 with overlapping vertical sections 515 and 530 that allow the top section to be raised as needed to achieve the proper blade to sill clearances for optimum shutter performance and operation. When proper clearances are determined and the part adjusted, screws or rivets may be used to secure the relative positions of the two components of this adjustable sill. The adjusted and fastened adjustable sill assembly now has a rectangular appearance with the long flat bottom section anchored to the floor directly or it can utilize an equal angle at the back for optional track anchorage or for a removable track capability (See FIG. 14).
A frontal view of the accordion shutter system which embodies this inventions is shown in FIG. 1. The accordion shutter system is made up of a plurality of interlocking blades 10 and shutter subsystems 50, 60 riding in and guided by an elongated header 15 and an elongated adjustable sill assembly 20. It is appreciated that although two connected subsystems are depicted in FIG. 1, there is no limit as to the number of subsystems that can be connected utilizing the shutter mating system of the present invention and the number used is based entirely on the size of each subsystem and the area desired to be covered. The system includes an optional, 90° degree starter strip 25 at one side and an optional, 180° degree starter strip 30 on the other side. The shutter system is held together by a unique shutter mating system comprising a male mate 35 and a female elongated and interlocking mate 40 held together by a mechanical lock 45, more clearly illustrated infra.
FIG. 2 is a cross section view of the continuously extruded header 200 used in a trapped mounting condition as shown in FIG. 14, 1405. The trolley wheel seats 205 and 210 are symmetrical about the vertical centerline of header 200. The "V" shaped protrusions 215 and 220 are also located symmetrically about the vertical centerline of header 200. These help maintain alignment of the trolley wheels when they are rolling. The sides 225 and 230 are tapered for maximum strength while minimizing weight and therefore cost. Mounting is accomplished by a fastening means such as screw 1410 being placed through the top horizontal member 235, into the horizontal surface to be attached to 1415.
FIG. 3 is a cross section view of the continuously extruded built out header 300 used in a wall mounting condition. The trolley wheel seats 305 and 310 are symmetrical about the vertical centerline of header 300. The "V" shaped protrusions 315 and 320 are also located symmetrically about the vertical centerline of the top portion of header 300. These help maintain alignment of the trolley wheels when they are rolling. The sides 325 and 330 are tapered for maximum strength while minimizing weight and therefore cost. Mounting is accomplished by a fastening means such as screws being placed through the vertical connecting member 335 to the vertical surface to be attached to.
FIG. 4 clearly defines a built out wall mounted sill 400. This component is a continuous extrusion and acts as a guide way for the lateral movement of the shutter array via u-shaped canal 410. This built out sill 400 has a single mounting flange 415 turned down for easy, quick and economical installations. Mounting flange 415 is attached to a vertical surface by a fastening means such as screws placed through the single mounting flange 415 to the vertical surface it is to be attached to.
FIG. 5 clearly defines the two component adjustable sill 500. This sill is made up of a continuously extruded top section 510 and a continuously extruded bottom section 515 wherein the top section 510 slides up or down in the interior 520 of bottom section 515. Interconnection is further depicted in FIG. 14, 1425, with the two sections 510 and 515 finally secured with tek screws or rivets as depicted in FIG. 14, 1420. A U-shaped canal 525 in the top section provides the guideway for the lateral movement of the shutter array, FIG. 14, 1425.
Shown generally as 600, the 180° degree starter strip component is a continuous extrusion with female hinge portion 610 at one extremity that allows the shutter array to be attached to a wall at one end and to the blade members at the other. The 180° degree starter strip is shown connected in FIG. 16, 1605 to a wall with a tek screw 1610. This configuration enables the shutter assembly to be immediately adjacent and on the interior of a connecting wall.
FIG. 7 illustrates the 90° degree starter strip 700. In contrast to the 180° degree starter strip, the 90° degree starter strip possesses an integrally attached and substantially perpendicular connecting member 710 enabling connection to the front portion of a wall with a frontal offset. Shown as 1620 of FIG. 16, the 90° degree starter strip's perpendicular member 710 is rigidly attached via a connecting means such as a masonry screw anchor 1615. The amount of frontal offset from the connecting wall is determined by strength requirements and the length of the 90° degree starter strip. As with the 180° degree starter strip, the 90° degree starter strip component is a continuous extrusion with female hinge portion 720 at one extremity that allows the shutter array to be attached to a wall with a frontal offset at one end and to the blade members at the other.
An elevated cross section of a continuously extruded accordion shutter blade is shown generally as 800 in FIG. 8. This component has a male end 810 and a female end 805 which allows the shutter to interlock forming a hinge depicted more clearly in FIG. 15, 1510. This hinge is made up of a male section with one exterior hook 815 on the outside of the greater than 180° degree cylindrical member engaging portion 810 and one protrusion 820 integrally connected to the offset arm on the side opposite the exterior hook 815. The female section is a greater than 180° degree formed cylindrical member with one interior hook 825 offset from the end portion of the 180° degree formed cylindrical member so as to form a receiving notch 830 for engaging said male exterior notch 820. A second interior hook 860 is located at the end of the opposite side of the 180° degree formed cylindrical member of the female end forming an acute angle in relation to the interior of said circle for engaging said interior hook of said male end 815 when the hinge mechanism is in the extended position. As can be seen in FIG. 8, in order to decrease weight while maintaining sufficient strength, a unique taper and expand structure has been devised. Tests have shown that when force has been applied to the prior shutter systems, the failure point is predominantly located in the connecting joints such as in 835 and 840. By tapering the blade in non-failing areas such as in the center of the blade 850 and expanding the thickness of the blade in failing areas such as 835 and 840, significant weight saving can be accomplished without sacrificing strength.
The female section of the unique shutter mating system of the present invention, illustrated in FIG. 9, obviates the need for drilling locking holes and placement of locking pins, which heretofore have been required due to strength requirements. By obviating the need for locking pins, the manufacture, installation and operation of the storm shutters of the present invention is far simpler. The female section of the shutter mating system 900, depicted in the connected state in FIG. 15, 1515, and FIG. 16, 1635 provides enhanced structural support by providing a triple U-lock. The exterior U-lock 910 has an upper member 915, lower member 920 and vertical member 925 all integrally and substantially perpendicularly connected to form the U-shape of said exterior U-lock 910. The upper member of said U-lock has an integrally connected, inwardly facing substantially perpendicular L member 930 positioned sufficiently before the end of said upper member 915 so as to provide for an upper extension member 940. The lower member of said U-lock has an integrally connected, inwardly facing substantially perpendicular L member 935 also positioned sufficiently before the end of said lower member so as to provide for a lower extension member 945 wherein in combination with upper extension member 940 another U-lock is formed. L members 930 and 935 are positioned opposite each other so that the base of said L members form an inwardly facing, interior U-lock themselves 980, which will rest in clip member 1100 notch's 1115 and 1120 described in detail infra. Upper L-member 930 has an integrally connected substantially perpendicular member 950 offset from said extension member 940. A plurality of protrusions 965 are located thereon to provide for greater surface area and therefore greater support. Lower L-Member 935 has an integrally connected substantially perpendicular member 955 offset from said lower member 945. On said lower perpendicular member 955 are a plurality of protrusions 960 to provide for greater surface area and therefore greater support. Upper perpendicular member 950 and lower perpendicular member 955 together form a third U-lock in the triple U-lock structure.
To provide for connection of the U-lock mechanism with the blades of the shutter system, a male end of hinge 810 is integrally connected to said female U-lock shown as 970. Further, as another novel aspect of this shutter mating system, a shutter-open-securing device 975 is located at the corner angle formed by the male end of hinge 810 which is integrally connected to said female U-lock shown as 970 and the upper member 915 of exterior U-Lock 910. This is shown connected to a blade in FIG. 17, 1735. Said shutter-open-securing device 975 comprises a greater than 180° degree formed cylindrical member wherein is placed a screw or similar securing structure whereon a plastic spacer is placed. As clearly shown in FIG. 17, said plastic spacer 1710 is inserted into a clip member 1715 thus securing the shutter blades when in the open position.
The male section of the unique shutter mating system of the present invention illustrated in FIG. 10 also obviates the need for drilling locking holes and placement of locking pins, which heretofore have been required due to strength requirements. The male section of the gate locking system 1000, depicted in the connected state in FIG. 15, 1515, has an exterior U-lock 1010 which is smaller than its male counterpart so as to fit snugly into the female exterior U-lock 910 and has an upper member 1015, lower member 1020 and vertical member 1025 all integrally and substantially perpendicularly connected to form the U-shape of said smaller exterior U-lock 1010. The upper member of said U-lock 1015 has an integrally connected, inwardly facing substantially perpendicular L member 1030 positioned sufficiently before the end of said upper member 1015 so as to provide for an upper extension member 1035 facing the gap of the exterior U-lock 1010. Further extending from the end of said upper extension member 1035 is a second L member 1040 with the base also facing the gap 1050 of the exterior U-lock. The lower member of said U-lock has an integrally connected, inwardly facing substantially perpendicular L member 1045 positioned sufficiently before the end of said lower member 1020 so as to provide for a lower extension member 1055 facing the gap 1050 of the exterior U-lock 1010. Further extending from the end of said lower extension member 1055 is a second L member with the base also facing the interior gap 1050 of the exterior U-lock 1010. Further, to provide for connection of the male section of the U-lock mechanism with the blades of the shutter system, a male end of hinge 810 is integrally connected to said male U-lock shown as 1060. As with the female section, the male section includes a shutter-open-securing device 1065 which is located at the corner angle formed by the male end of hinge 810 and the upper member 1015 of exterior U-lock 1010. This is also shown connected to a blade in FIG. 17. 1730. Said shutter-open-securing device 1065 comprises a formed greater than 180 degree cylindrical member wherein is placed a screw or similar securing structure, whereon a plastic spacer is placed. Again, as clearly shown in FIG. 17, said plastic spacer 1720 is inserted into a clip member 1725, thus securing the shutter blades when in the open position.
All L-shaped members are sized so as to snugly fit in each corresponding female U-lock. When inserted as shown in FIG. 15, 1515, the dual sided triple U-lock provides great resistance to impact wind forces.
FIG. 13, 1300 depicts a clip member utilized in the preferred embodiment of the present invention. A base portion 1305 to the clip member connects directly to the header 15 with a fastening means such as rivets or tek screws. An integrally connected receptor portion 1310 protrudes from said base portion and forms a bottleneck portion 1315 wherein said bottleneck is sized to be be slightly smaller than said plastic spacer so as to lock said spacer in place when the shutter subsystems are in the open position.
Inserted into the female end of the gate locking system, FIG. 9, immediately adjacent said interior facing U-lock 940 is a latch receiving member shown expanded in FIG. 11 as 1100. Said clip member 1100 is further depicted in its integrated state in FIG. 15, 1520 and FIG. 16, 1615. Latch receiving member 1100 comprises a rigid base member 1110 with two notches spaced therein 1115 and 1120, and facing the U-locking mechanism such that the notches 1115 and 1120 correspond to the distance between the two L-shaped members of the interior facing U-lock 940, wherein said L-shaped members 940 fit snugly into said notches 1115 and 1120 thereby providing further structural support. Further, integrally connected to said base member on the opposite side of said notches 1115 and 1120 are substantially parallel guide prongs 1125 and 1130. These guide prongs form a gap therein to allow for a latching mechanism, FIG. 12, 1200 to fall therebetween. The latching mechanism 1200 comprises connecting member 1210 integrally connected to a hooking member 1215. Said hooking member 1215 in the latched position fits snugly over said base member 1110 of said latch receiving member 1100 and between said guide prongs 1125 and 1120, thus providing very strong resistance to transverse forces tending to break a connection between two adjacent shutter systems.
An aft opening 1220 in said connecting member 1210 allows for a handle protrusion, FIG. 16, 1625, to fit therethrough. Said handle protrusion 1625 is rigidly and integrally connected to a handle member 1630 such that when a user rotates said handle member 1630 it cause a rotational force to be applied to said latching mechanism 1200 to remove the hooking member 1215 from its snug position over said base member 1110 of said latch receiving member 1100 thereby allowing for separation of separate shutter subsystems.
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This invention relates to a strong, light weight accordion shutter system that increases strength while decreasing weight, and is especially resistant to hurricane force winds and flying objects when used to cover doors, windows or openings. More specifically, this invention relates to a shutter system comprising a plurality of connectable subsystems of shutters that are connected via a shutter mating system which provides sufficient strength to obviate the need to drill locking holes during installation and connection. This accordion shutter system also offers a unique ability to secure doors, windows and openings of any size from forced entry and enables the user to operate from either side of the shutter system.
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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 generally to gas lift valves for the artificial production from oil and gas wells and, more particularly, to gas lift valves capable of operating at high differential pressures.
[0003] 2. Description of Related Art
[0004] Gas lift valves have been used for many years to inject compressed gas into oil and gas wells to assist in the production of well fluids to the surface. The valves have evolved into devices in which a metal bellows, of a variety of sizes, converts pressure into movement. This allows the injected compressed gas to act upon the bellows to open the valve, and pass through a control mechanism into the fluid fed in from the well's producing zone into the well bore. As differential pressure is reduced on the bellows, the valve can close. Two types of gas lift valves use bellows. The first uses a non-gas charged, atmospheric bellows and requires a spring to close the valve mechanism. The other mechanism uses an internal gas charge, usually nitrogen, in the bellows and volume dome to provide the closing force for the valve. In both valve configurations, pressure differential on the bellows from the injected high pressure gas opens the valve mechanism.
[0005] In the case of the non-gas charged bellows, the atmospheric pressurized bellows is subjected to high differential pressures when the valve is installed in a well and exposed to high operating gas injection pressure. The nitrogen charged bellows is subject to high internal bellows pressure during setting and prior to installation. Once installed, the differential pressure across the bellows is less than in a non-gas charged bellows during operation of the valve. High differential pressure across a bellows during operation reduces the cycle life of the bellows. The existing gas lift valves and bellows are not designed to operate with set pressures or in operating pressures in excess of 2000 psig without severe failure risks. Some existing valve bellows do have some fluid and/or mechanical protection for overpressure due to operating pressures in the fill open position. However, none provide for protection from differential overpressure from the set pressure in the bellows.
SUMMARY OF THE INVENTION
[0006] The present invention comprises a gas-charged gas lift valve wherein the bellows of the gas lift valve are protected from high differential pressure. A piston is disposed in a central bore of a sleeve in the bellows. The piston separates a hydraulic damping reservoir in the interior convolutions of the bellows from the upper gas volume chamber containing the gas charge. The piston can only travel a pre-set distance in the internal bore between two stops. When operating pressure exerted on the bellows from the injected gas exceed the pressure of the gas charge in the upper gas chamber, the piston is pushed to contact the upper stop. More of the hydraulic dampening fluid is allowed to exit the interior of the bellow convolutions and move into the central bore of the internal sleeve. This allows the pressure from the injected gas to move the bellows into a contracted position to open the valve. Once the piston has reached the top position, the incompressible nature of the hydraulic fluid protects the bellows from any further increase in external pressure as well as further contraction due to that pressure. When the operating pressure of the injected gas drops below the pressure of the upper gas chamber, the gas in the upper gas chamber pushes the piston to the lower stop. This forces more of the hydraulic dampening fluid in the interior of the bellow convolutions, extending the bellows and closing the valve. Once the piston reaches the bottom position, the incompressible nature of the hydraulic fluid prevents the bellows from further extension and prevents a large pressure differential across the bellows.
[0007] The bellows design in the disclosed invention provides a fluid dampened hydraulic balance across the bellows convolutions in both the open and closed positions of the valve. It also preferably eliminates pressure differentials in excess of the natural spring rate of the bellows materials and any small compression resistance of the nitrogen charged gas in the dome/bellows volume. Since this new device prevents high differential pressure across the convolutions of the bellows, the valve can preferably be charged with any pressure up to the limits of the materials and can be run in any operating pressure up to the limits of the materials, without overstressing the bellows. This can provide a long lived bellows operation, approaching the life cycle ratings of the bellows manufacturer under low stressed conditions. The new bellows device can also preferably be retrofitted into existing gas lift valve configurations.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The apparatus of the invention is further described and explained in relation to the following figures wherein:
[0009] FIG. 1 is a cross-sectional view of a typical wire line retrievable high pressure gas lift valve of the preferred embodiment;
[0010] FIG. 2 is a cross sectional view of the upper chamber of the preferred embodiment illustrated in the fully extended position with the piston located at the lower travel stop;
[0011] FIG. 3 is a cross sectional view of the upper chamber of the preferred embodiments from FIG. 1 , illustrated in the fully contracted condition with the piston located at the upper travel stop.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0012] Various aspects and relationships of a preferred embodiment of the current invention will be described in the context of what is commonly known to the industry as a casing sensitive one inch wire line retrievable gas lift valve. It is within the scope of this patent to apply the present invention to other sizes and configurations of gas lift valves, both wire line retrievable and tubing retrievable gas lift valves and both injection pressure operated (IPO) or production pressure operated (PPO) valves.
[0013] FIG. 1 illustrates a gas lift valve 11 into which the present invention has been adapted. The valve 11 consists first of an upper chamber 1 , which includes a tail plug 2 , a sealing gasket 3 , a core valve 4 , and a set of external seals 34 employed to pack off the valve in the upper seal bore of an appropriate side pocket gas lift mandrel common to the industry and not illustrated herein. The upper chamber 1 is attached by means of a threaded connector or other suitable means to the improved metal bellows assembly 5 of the present invention, and is enclosed by a ported bellows housing 23 .
[0014] The improved metal bellows assembly 5 of the present invention consists of a metal bellows 6 , an upper bellows adaptor 7 , a lower bellows adaptor 8 , an internal ported sleeve 9 , a piston 10 , an adjustment screw 19 , and a stem adaptor 12 , to which is attached a stem 35 . The metal bellows 6 is attached to the upper bellows adaptor 7 and the lower bellows adaptor 8 by any of the means of soldering, brazing, or welding to produce a strong hermetic seal between the metal bellows 6 and the upper and lower bellows adaptors 7 , 8 . The improved metal bellows assembly 5 is sealed to the upper chamber 1 by the use of O-rings 36 or any other suitable means.
[0015] The internal ported sleeve 9 has a small fluid port 13 through which hydraulic fluid is able to communicate from the annulus 15 created by the internal ported sleeve 9 and the interior of the metal bellows 6 to the internal seal bore 16 of the internal ported sleeve 9 , and to act upon the piston 10 . The piston 10 having external resilient seals 17 is located in the internal seal bore 16 of the internal ported sleeve 9 and is allowed to travel between the upper travel stop 18 and the lower travel stop 19 . Lower travel stop 19 can optionally be an adjustment screw. The use of an adjustment screw as travel stop 19 allows the range of movement of piston 10 to be limited and thus the amount of extension of bellows 6 . The internal ported sleeve 9 also has external seals 20 to seal it to the internal seal bore 21 of the upper bellows adaptor 7 , an upper travel stop shoulder 22 , and is allowed to travel within the upper adaptor 7 within travel limits imposed by the upper travel stop shoulder 22 and the piston's lower travel stop 19 .
[0016] Upper chamber 1 contains compressed gas, typically nitrogen, in chamber 37 that exerts a downward force upon the piston 10 . This pushes the piston 10 downward forcing the incompressible hydraulic fluid located in the internal seal bore 16 below the piston 10 in an external direction through the small fluid port 13 and into the annulus 15 created by the internal ported sleeve 9 and the interior surface of the metal bellows 6 . Increased hydraulic fluid in annulus 15 causes the metal bellows 6 to extend. FIG. 2 will illustrate this condition. Compressed gas 38 from the casing-tubing annulus (not illustrated) injected from the surface wellhead provides a counteracting force on the external surface of the metal bellows 6 . When the force of compressed gas 38 is larger than the downward force upon the piston 10 of the compressed gas located in chamber 37 , the metal bellows 6 contract. FIG. 3 will illustrate this condition.
[0017] The gas lift valve 11 of the preferred embodiment further comprises a stem adapter 12 secured to the lower bellows adapter 8 . Stem 35 is secured in stem adapter 12 and is positioned proximate to seat 32 . Upon extension of bellows 6 , lower bellows adapter 8 , and thus stem adapter 12 , and stem 35 are translated toward seat 32 . When bellows 6 are fully extended, stem 35 is seated in seat 32 , thereby preventing injection gas 38 from passing through opening 40 . This represents the ‘closed’ position of valve 11 . Upon contraction of bellows 6 , lower bellows adapter and thus stem adapter 12 and stem 35 are translated away from seat 32 . This allows injection gas 38 to pass through opening 40 and out through nose cap 25 of valve 11 . This represents the ‘open’ position of valve 11 .
[0018] As shown in FIG. 1 , the gas lift valve 11 of the preferred embodiment further consists of a check valve assembly 24 common to the industry. Check valve assembly 24 comprises a nose cap 25 , and back check dart 26 , a spring 27 , a resilient seal 28 , a seal support washer 29 , and a back check adaptor 30 . The valve further consists of a lower packing adaptor 31 , in which is also located a seat 32 and a retaining ring 33 to capture the seat in the lower packing adaptor, and on which is located a set of external seals 34 employed to pack off the valve in the lower seal bore of an appropriate side pocket gas lift mandrel common to the industry and not illustrated herein.
[0019] FIG. 2 illustrates the upper chamber 1 and improved metal bellows assembly 5 of the present invention with the bellows 6 in the fully extended condition and the internal piston 10 located against the lower travel stop 19 . Optionally, the lower travel stop 19 may be an adjustable screw to provide additional control over the distance that the piston 10 can move in internal sleeve 9 . The fully extended condition of the improved metal bellows assembly 5 is obtained when the pressure exerted upon the internal surfaces of the metal bellows 6 exceeds the pressure exerted upon the external surfaces of the metal bellows 6 .
[0020] The pressure of the compressed gas in the chamber 37 acts upon the area of the external seals 20 on the internal sleeve 9 and the external resilient seals 17 on the piston 10 to provide a downward force that tends to extend the metal bellows 6 and move the piston 10 downward. As the piston 10 travels downward in the internal seal bore 16 of the internal ported sleeve 9 , it forces the hydraulic fluid in the internal seal bore 16 through the small fluid port 13 and into the annulus 15 created by the exterior of the internal ported sleeve 9 and the interior surface of the metal bellows 6 . The pressure transferred to the internal surface of the metal bellows 6 by the displaced hydraulic fluid 14 causes the metal bellows 6 to extend. When the piston 10 travels to and is stopped by the lower travel stop 19 in this embodiment, no further hydraulic fluid 14 may be displaced into the annulus 15 created by the internal ported sleeve 9 and the interior surface of the metal bellows 6 , thereby protecting the metal bellows 6 from any further increase in internal pressure, and thus also from any further extension or increased internal forces which would otherwise overstress the metal bellows 6 .
[0021] When the improved metal bellows assembly 5 is in the fully extended position, less a small predetermined distance, and the piston 10 is within the same small predetermined distance from the lower travel stop 19 , stem 35 first contacts and seals to the seat 32 , thereby preventing injected gas 38 from passing through the valve 11 . The inherent diametric flexibility of the metal bellows allows the piston 10 to continue until it contacts the lower travel stop 19 . Once the piston 10 contacts the lower travel stop 19 any further extension of the metal bellows 6 is restricted due to the incompressibility of the contained hydraulic fluid in annulus 15 .
[0022] FIG. 3 illustrates the preferred embodiment of the present invention in the fully contracted condition, with the upper travel stop shoulder 22 of the internal ported sleeve 9 against the upper bellows adaptor 7 and the internal piston 10 located against the upper travel stop 18 . The fully contracted condition of the improved metal bellows assembly 5 is obtained when the pressure of injected gas 38 exerted upon the external surfaces of the metal bellows 6 exceeds the pressure exerted upon the internal surfaces of the metal bellows 6 from the compressed gas in chamber 36 . This would occur when the pressure of the injected gas 36 is raised above a certain threshold.
[0023] When the pressure of the injected gas 38 is above the threshold, it forces the metal bellows 6 to contract, thus displacing the hydraulic fluid 14 from the annulus 15 created by the exterior of the internal ported sleeve 9 and the interior surface of the metal bellows 6 and into the internal seal bore 16 of the internal ported sleeve 9 . The increased amount of hydraulic fluid 14 in the internal seal bore 16 forces the piston 10 in an upward direction, until it reaches the upward travel stop 18 . The contraction of the metal bellows also moves internal sleeve 9 upward until a shoulder 22 on internal sleeve contacts upper bellows adapter 7 . This raises stem 35 off of seat 32 , thereby allowing injected gas 38 to pass through the valve. Upon reaching the upward travel stop 18 , the piston 10 creates an impassable barrier for the hydraulic fluid in internal seal bore 16 . The incompressible hydraulic fluid remaining in annulus 15 thereby protects the bellows from any further increase in external pressure, and thus also from any further contraction or increased external forces which would otherwise overstress the metal bellows 6 .
[0024] The above descriptions of certain embodiments are made for the purposes of illustration only and are not intended to be limiting in any manner. Other alterations and modifications of the preferred embodiment will become apparent to those of ordinary skill in the art upon reading this disclosure, and it is intended that the scope of the invention disclosed herein be limited only by the broadest interpretation of the appended claims to which the inventor is legally entitled.
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A unique gas lift valve bellows assembly in which an internal piston incorporated within the bellows provides over travel prevention and over pressure protection during valve operation, independent of the set or operating gas pressures exerted on the gas lift valve. The piston separates a hydraulic damping reservoir in the interior convolutions of the bellows from the upper gas volume chamber. The piston travels a pre-set distance between two stops to provide a fluid dampened hydraulic balance across the bellows convolutions in both the open and closed positions of the valve. This results in a long lived bellows valve that can operate with any pressure up to the limits of the material, without overstressing the bellows.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is the § 371 National Stage Entry of International Application PCT/IB2013/055428, filed on Jul. 2, 2013, which claims the benefit of United Kingdom Patent Application Serial No. GB 1212092.9, filed on Jul. 6, 2012, the contents of which applications are herein incorporated by reference in their entirety.
FIELD OF THE INVENTION
[0002] This invention relates to collapsible ladders and more specifically to increasing the stability of a extendible ladders when erected.
BACKGROUND OF THE INVENTION
[0003] Collapsible ladders are utilised because of the convenience they provide. They may be transported easily, such as in the boot of a car, and may be carried and erected by one man. It is beneficial for such ladders to collapse to the smallest possible size, whilst still allowing them to be erected to a useful height.
[0004] Reducing the physical dimensions to produce the smallest collapsed size has the downside of reducing the width of the footprint when the ladder is erected. A narrower footprint reduces the stability of the ladder, the degree of instability is more noticable the taller the ladder.
[0005] Previous solutions to this include the provision of removable feet located at the bottom of each stile which serve to widen the foot print of the ladder, but these are cumbersome to attach or remove each time the ladder is collapsed or erected dor transport.
SUMMARY OF THE INVENTION
[0006] With a view to mitigating the foregoing disadvantage, the present invention provides an improved extendable ladder. According to an embodiment of the present invention, an extendable ladder has a collapsed mode and an extended mode. When the ladder is transformed from the collapsed mode to the extended mode, at least one ground stabiliser extends laterally from the ladder to widen the footprint of the ladder.
[0007] Preferably, the stiles of the ladder may extend telescopically.
[0008] The at least one one ground stabiliser may be urged laterally outwards by a spring.
[0009] The at least one ground stabiliser may be retained in a retracted position by a pin engaged within a hole when the ladder is in a collapsed mode.
[0010] The pin may be resiliently biased towards the hole in the ground stabiliser.
[0011] The pin may be supported by one of the telescopic stiles of the ladder such that when the stiles slide relative to one another as the ladder is extended the pin is pulled out of the hole, releasing the ground stabiliser.
[0012] Preferably, at least two ground stabilisers may extend coaxially from each of the two stiles of the ladder.
[0013] The two ground stabilisers may extend from a hollow floor rung and are biased apart by a spring contained within the rung.
[0014] Preferably the motion of the ground stabiliser is damped.
[0015] Alternatively a podium may be provided comprising a rectangular platform and a ladder as described above, hingedly attached to each of two opposing sides of the platform.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The invention will now be described further by way of example with reference to the accompanying drawings in which:
[0017] FIG. 1 shows a sectional view of the lower most rung of a collapsed ladder embodying the present invention, with its ground stabilsers in a retracted position, and
[0018] FIG. 2 shows a sectional view of the lower most rung of a partially extended extended ladder embodying the present invention, with its ground stabilsers in an extended position.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0019] Turning now to FIG. 1 , a collapsible ladder embodying the present invention is shown. In this example a telescopic ladder 10 of the type described in U.S. Pat. No. 5,495,915. The dotted line to the right of the figures represents a vertical line of symmetry. The description provided here should be assumed to be duplicated about this line.
[0020] The ladder is formed of individual rungs 12 having two ends (one end 14 of each rung shown). Each end 14 is connected to and associated with a corresponding hollow stile section 16 . The stile sections 16 associated with a first rung 14 are larger in diameter than the stile sections 18 associated with a second rung 20 immediately above. As a result, the ladder 10 may be collapsed by sliding the stile sections 16 , 18 inside one another resulting in the collapsed ladder having rungs 12 , 20 which rest directly on top of one another.
[0021] To extend the ladder the rungs 12 , 20 are separated causing the stile sections 16 , 18 to slide telescopically apart. They continue to slide until a spring biased pin 22 , 24 arranged inside the ends 14 , 26 of each rung 12 , 20 engages with a hole 28 , 30 in the circumference of the stile section of the rung immediately above.
[0022] The spring biased pins 22 , 24 lock the stile sections 16 , 18 at the separation predetermined by the position of the holes 28 , 30 . Typically the rungs are separated starting with the bottom two rungs 12 , 20 and then working up the ladder 10 towards its top. This allows the height of the ladder to be chosen depending on the extension required.
[0023] As stability is increased by widening the foot print of the ladder, or increasing the distance between the outermost points of the foot of the ladder, the present invention is provided with extendable feet or ground stabilisers 32 .
[0024] These protrude at the outer circumference of the stiles 34 of the ladder where they meet the floor 36 . The stiles 32 are each provided with a curved high grip rubber foot 38 inserted into the hollow stile 32 to provide a better purchase on the ground 36 regardless of the angle of the ladder 10 . These feet define the width of the foot print of a standard ladder.
[0025] In the present invention, the ground stabilisers 32 may themselves be in either a retracted ( FIG. 1 ) or extended ( FIG. 2 ) position. In the retracted position, the ground stabilisers of the preferred embodiment increase the width of the foot print of ladder in the preferred embodiment, when compared to a ladder not so equipped. In some applications this may be undesirable and so is considered optional.
[0026] In an alternative embodiment, the ground stabilisers 32 may be integral to the outer circumference of the stiles 34 immediately adjacent the ground 36 such that when retracted the ground stabilsers 32 sit flush with the circumference of the largest diammeter stile portion at the foot of the ladder.
[0027] For ease of transportation, the ground stabilisers 32 are best maintained in the retracted position as shown in FIG. 1 . The stabilisers each consist of a cylinderical support tube 40 supported for axial movement within a transverse apertures 42 in the lowermost stile section. In an alternative embdiment, the stabiliser 32 may be supported within a plastic attachment including a foot portion to be attached the bottom of each stile 34 . In this preferred embodiment, the apertures 42 for supporting each tube of each ground stabiliser are coaxial and joined by a hollow ground tube 44 .
[0028] The stabilisers 32 are urged outwards by means of a resilient member 46 such as a spring acting between the inner most ends 48 of both ground stabilisers 32 . The resilient member 46 is retained within the hollow ground tube 44 running at almost ground level between the stiles 34 . It is raised slightly from the ground to allow the ladder to be used on uneven ground without the ladder 10 rocking on the ground tube 44 .
[0029] The ground stabilisers 32 are retained in their retracted position against the force of the resilient member 46 in a similar manner to the way in which the stiles of the ladder are locked in the ladder's extended position. The support tube 40 of each ground stabiliser 32 is provided with a hole 50 in the upper most section of its circumference such that each is aligned with the axis of the respective stile 34 .
[0030] A resiliently biased pin 52 extending from stile section 18 of rung 20 , mates with the hole 50 preventing the resilient member 46 from forcing the ground stabiliser 32 outwards.
[0031] When the ladder is extended ( FIG. 2 ) and the rungs ( 12 , 20 ) separated, the stile section 18 carrying the resiliently biased pin 52 is moved upwards and clear of the hole 50 causing the ground stabilisers 32 to extend laterally.
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An extendable ladder having a collapsed mode and an extended mode, characterised in that when the ladder is transformed from the collapsed mode to the extended mode, at least one ground stabiliser extends laterally from the ladder to widen the footprint of the ladder.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an architectural block containing holes which are filled with a heat-insulator and moisture-proof material and to a structure constructed with said blocks.
2. Description of the Prior Art
In conventional architectural blocks, it is well known to construct these blocks with chambers or holes in the center thereof. The blocks are generally made of a material such as concrete or other porous type material. One of the disadvantages with these types of blocks is that they do not provide adequate that insulation or moisture-proofing. Thus, when these blocks are used in constructing a structural member such as a wall, it is generally necessary to cover the surface with some sort of a sealing film to prevent moisture from seeping through and also to cover a surface with a layer of insulating material to prevent heat transfer through the structure. The necessity for the water-proofing and heat insulating materials not only increases the cost of the block, but also significantly increases the cost of construction, since it is necessary to spend additional time applying these materials.
SUMMARY OF THE INVENTION
The present invention overcomes the disadvantages of the prior art blocks by providing a block which has chambers formed therein and filling these chambers with a foaming agent which comprises a light-weight heat insulator and moisture-proof material. This material is merely placed in the chamber portion of the block and then allowed to foam thereby taking on its heat insulator and moisture-proof characteristics. Thus, it is unnecessary to apply the additional layers to the exterior of the blocks.
Another important feature of the present invention is the formation of grooves on one edge of each partition of the blocks. These grooves allow the insertion of a pipe through the block so that the end of the pipe can be positioned within each chamber. Thus, the invention includes the structure necessary to provide a very simple technique for filling the chambers with the light-weight insulator and moisture-proof material.
Still another feature of the disclosed invention is the provision of a pipe in the groove in the partitions of the block. This pipe is of a larger diameter than the pipe which is used to insert the heat insulator and moisture-proof material in the chambers, and thus, the insertion pipe is inserted into the pipes in the groove. The pipe in the groove prevents the insertion pipe from contacting the periphery of the groove and possibly damaging the periphery of the groove.
Thus, the present invention provides an architectural block which includes the necessary structure for permitting the insertion of a foaming agent comprising a light-weight heat insulator and moisture-proof material into chambers formed within the block. This overcomes the disadvantages in prior art blocks which require layers of moisture-proof material and heat insulator material on the exterior thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is the plan of principal block 1, according to the present invention.
FIG. 2 is the fragmentary elevation along line II--II in FIG. 1.
FIG. 3 is a cross sectional view along line III--III of FIG. 1.
FIG. 4 is a perspective view thereof.
FIG. 5 is a cross-sectional view of an accessory block having a cover plate.
FIG. 6 is a cross-sectional view of an accessory block having through holes therein.
FIG. 7 is a partial plan of a structure (wall or floor) composed of principal blocks jointed in series.
FIG. 8 is a partial longitudinal cross-sectional view of the structure constructed of the blocks of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings, the blocks are generally incorporated together with concrete and have the form of a square box. As shown in FIGS. 1-4, a principal block 1 is so formed that the space between two lateral walls 2, 3 is divided by a plurality of partition walls 4 having the same height as said lateral walls to define compartments or chambers 5 passing through from the top to the bottom of said block. Both lateral sides of said block having projected end portions 2a, 2b and 3a, 3b of said lateral walls 2, 3, the projected end portions forming grooves or recesses 6 and 7. The top surfaces of said partitions are provided with a linear groove 8 and a pipe 9 fixed in groove 8. The pipe 9 has a length of substantially the same length as the thickness of said partition. As shown in FIG. 1, the vertical grooves 6, 7 on the both lateral sides are penetrated by reinforcement steel bars 13 and filled with mortar. Furthermore, they are preferably penetrated with prolonged pipes 9'. Numerals 11 and 12 in FIGS. 5 and 6 denote accessory blocks. A block 11 in FIG. 5 has a structure similar to that of said principal block 1 but is partitioned with a wall having no groove 8. One side of chamber 16 has a cover plate 15 of the bottom. A block 12 in FIG. 6 has a structure similar to that of said principal block 1 but is partitioned by a wall 17 without a groove 8. Hole 18 passes through the block.
Among the blocks as described above, the principal block 1 and accessory block 11 are necessary for the construction of an architectural structure, but the accessory block 12 in FIG. 6 is occasionally employed in a convenient combination according to the structure.
FIGS. 7 and 8 show the portions for forming the walls and floor of structure 10 constructed with these blocks. FIG. 7 is a plan view of the foundation structure of combined blocks, while FIG. 8 is the longitudinal view thereof, which foundation structure is employable both for wall and floor. As shown in FIG. 7, the structure is so built that the chamber 5 may be positioned vertical or jointed horizontally as shown in FIG. 2 to construct the base for the fundamental structure, and then, as shown in FIG. 8, blocks 12 are placed over and under the principal block 1 so that the chamber 18 of block 12 may pass through on the both sides of the chamber 5 of block 1. When further the blocks 11 having cover plates 15 are overlaid jointly, the chambers of three blocks are covered with said cover plate 15 to define a chamber 21. This chamber may also be covered with a block plate 19 in place of said block 11 having the cover plate 15. When a chamber 21 has been defined in this manner, the injection pipes 30 are inserted, as shown in FIGS. 1-4, into different pipes 9 disposed along linear lines in different partitions 4 of block 1.
The composition 20 comprising a blowing agent-containing synthetic resin mixed with glass fiber, asbestos and other inorganic lightweight insulating and moisture-proof materials is injected from said injection pipe 30 by an air stream. After one chamber is filled, the injection pipe 30 is withdrawn and inserted into another chamber to inject the composition.
For the purpose of injection, an injection pipe may be placed directly in a groove 8 whether or not a pipe 9 is used, but the pipe 9 may preferably be employed because the grooved walls may be broken and the smooth insertion of the injection pipe could be interrupted.
After the whole cavity of said block is filled with said composition, the blowing agent in the composition generates foam owing to the natural drying, and the expanded mass containing the insulating and moisture-proof materials fills the chambers of each block. A piece of string is attached to the end of injection pipe 30 and kept outside the block. The string is pulled after the complete withdrawal of injection pipe 30 and is pulled out after the insertion of injection pipe 30. Thus, the expanded mass if bored to form an orifice, which serves to aerate the expanded foam and to prevent it from hardening. The outmost orifice is usually closed with a stopper. When the effectiveness of expanded mass has been reduced after the use of a long period, the injection pipe 30 may be pulled through to let the fresh composition set up the expanded mass. The vertical grooves 6, 7 are penetrated by a reinforcing bar 13 and filled with mortar 24, thus being reinforced. An oblong cover plate 22 is mounted to the end of the reinforcement portion.
According to the present invention, since the hollows in the blocks are filled with heat insulator and moisture-proof material, the structures constructed with said blocks maintain coolness in summer and warmth in the winter within the interior.
The present invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The presently disclosed 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 the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore to be embraced therein.
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The present invention provides an architectural block which comprises two opposed side walls and at least two parallel partitions positioned between the side walls perpendicular thereto. The partitions and side walls define chambers within the block, and a groove is formed in one edge of each of the partitions. The chambers are filled with a foaming agent comprising a lightweight heat insulator and moisture-proof material.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND
[0001] The statements made herein merely provide information related to the present disclosure and may not constitute prior art, and may describe some embodiments illustrating the invention.
[0002] It is known that in drilling some wells, sections of casing are run down a borehole, often with a float shoe at the lower end which is equipped with a double valve enabling the casing to fill with drilling mud both while the casing is moving down and also while it is stationary. Within the casing is a baffle collar which defines a socket for a latching dart carried by a plug. The plug and dart are driven down to the collar, when the pumping of cement into the casing has been completed, by a launching dart which also closes the passageway through the plug. U.S. Pat. No. 4,664,192.
[0003] Also known are well liner running shoes which include ports for discharging cement into the well annulus between the liner and the wellbore wall, a check valve to prevent reverse flow of fluid up through the interior of the liner and the workstring, receiver means for receiving a cement plug or “dart” and receiver means for receiving a running tool which may be disconnected from the shoe after the liner has been set in its predetermined position. U.S. Pat. No. 5,277,255.
SUMMARY
[0004] In some first embodiments, an apparatus includes a tubular subject to a first pressure value at a distal end and a second pressure value at a proximal region within the tubular, a shoe disposed within the distal end of the tubular, a sealable valve disposed within the proximal region within the tubular, and a cement composition contained within a medial region of the tubular formed between the distal end and the proximal region. In some cases the tubular is a casing disposed in a wellbore penetrating a subterranean formation.
[0005] The surface of the subterranean formation may be located undersea, or on land. Also, the first pressure value may be greater than or equal to the second pressure value, and vice versa. The sealable valve may be a ball valve, a sleeve valve, flapper valve, butterfly valve, multiple flapper valves, multiple checks valves, or any other suitable valve arrangement known to those with skill in the art. Alternatively, in some cases the apparatus does not include a check valve in the shoe.
[0006] In some other embodiments, methods are provided which include introducing a casing into a wellbore penetrating a subterranean formation, the casing forming an annulus with the wellbore surface, where the casing is subject to a first pressure value at a distal end and a second pressure value at a proximal region within the casing, and where a shoe is positioned at the distal end of the casing. Then, placing a sealable valve within the proximal region of the casing, injecting a first cement composition into the casing, through the sealable valve and shoe, and into the annulus, and the placing a second cement composition in a medial region of the tubular formed between the distal end and the proximal region. Afterward, the sealable valve is closed.
[0007] For these embodiments, in some cases the tubular is a casing disposed in a wellbore penetrating a subterranean formation. The surface of the subterranean formation may be located undersea, or on land. Also, the first pressure value may be greater than or equal to the second pressure value, and vice versa. The sealable valve may be a ball valve, a sleeve valve, flapper valve, butterfly valve, multiple flapper valves, multiple checks valves, or any other suitable valve arrangement known to those with skill in the art. Alternatively, in some cases the apparatus does not include a check valve in the shoe.
[0008] In yet some other embodiments, methods are provided which include introducing a tubular into an open hole wellbore penetrating a subterranean formation, the tubular forming an annulus with the open hole wellbore surface, where the tubular is subject to a first pressure value at a distal end and a second pressure value at a proximal region within the tubular, and where a shoe is positioned at the distal end of the tubular; placing a sealable valve within the proximal region of the tubular; injecting a cement composition into the casing, through the sealable valve and shoe, and into the annulus; and, closing the sealable valve.
[0009] Again, in some cases the tubular is a casing disposed in a wellbore penetrating a subterranean formation. The surface of the subterranean formation may be located undersea, or on land. Also, the first pressure value may be greater than or equal to the second pressure value, and vice versa. The sealable valve may be a ball valve, a sleeve valve, flapper valve, butterfly valve, multiple flapper valves, multiple checks valves, or any other suitable valve arrangement known to those with skill in the art. Alternatively, in some cases the apparatus does not include a check valve in the shoe.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The manner in which the objectives of some embodiments and other desirable characteristics may be obtained is explained in the following description and attached drawings in which:
[0011] FIG. 1 illustrates an apparatus having a shoe with a check valve at the very bottom of the string, a casing joint, and a float collar with a check valve.
[0012] FIG. 2 illustrates an apparatus having a shoe with a check valve at the very bottom of the string, a casing joint with cement composed therein, a sealable valve thereabove, and a float collar with a check valve.
DESCRIPTION
[0013] At the outset, it should be noted that in the development of any such actual embodiment, numerous implementation—specific decisions must be made to achieve the developer's specific goals, such as compliance with system related and business related constraints, which will vary from one implementation to another. Moreover, it will be appreciated that such a development effort might be complex and time consuming but would nevertheless be a routine undertaking for those of ordinary skill in the art having the benefit of this disclosure. In addition, the composition used/disclosed herein can also comprise some components other than those cited. In the summary of the invention and this detailed description, each numerical value should be read once as modified by the term “about” (unless already expressly so modified), and then read again as not so modified unless otherwise indicated in context.
[0014] Some embodiments relate to methods of cementing, prior to perforation, a wellbore with casing disposed therein. Some embodiments of the invention incorporate the concept of a “hard bottom” into the production casing string. The term “hard bottom” means a sealing component with high pressure integrity, and not necessarily easy to drill out. The pressure integrity is obtained by adding valves to the bottom of the production casing or production liner. These valves allow the casing to be cemented in the well but after cementing, seal the bottom of the production casing mechanically and with high pressure integrity. The valves (not cement) keeps the formation fluids from coming into the well bore through the shoe. The cement trapped between shoe and ball valve in the illustration above can now be a redundant seal.
[0015] In some instances, the concept is to add a reliable barrier. In current practice, if all proceeds as planned, the cement between shoe and float collar provides a good barrier. However, in some embodiments, a technique to incorporate an additional barrier is used as a contingency in case all does not proceed as planned in the operation, such as the instance where cement is over displaced. This can be a critical well control issue and adding a sealable valve, such as a ball valve, further ensures a reliable barrier.
[0016] Some embodiments disclosed are casing or liner cementing methods including positioning lower and upper wiper plugs having elastomer cups that are inwardly compressed in an open-bottomed tubular basket near the top of the liner, the basket having an outer diameter that is less than the inner diameter of the liner to permit cement to flow therebetween, the basket having a tubular body extending upwardly therefrom; providing a push rod in the body that can move longitudinally thereof and which has a lower end engaging the upper plug, pumping a first piston or dart down into engagement with the upper end of the rod and then applying pressure to the dart to force the rod downward a selected distance to expel the lower plug from the basket and out into the liner where said cups expand to engage the liner walls and provide a separation between the lower end of a column of cement and the drilling fluids, pumping a certain volume of cement slurry into the liner with said lower plug moving downward at the lower end of the cement, pumping a second piston or dart down into engagement with the first dart, and then applying pressure to force both of the darts and the rod further downward another selected distance to expel the upper plug from the basket and out into the liner where its cups expand to provide a separation between the upper end of the column of cement and the displacing fluids. The cement and plugs then are pumped on down the liner, and when the lower plug seats against a float collar or float shoe, a passage is opened through the plug to enable the cement to flow into the annulus. When the upper wiper plug engages the lower one, the displacement is complete. The basket and body assembly then is retrieved to the surface so that the inside of the liner is unobstructed. Apparatus in accordance with this includes a tubular body having a cylindrical, open-bottomed basket mounted on its lower end. Lower and upper elastomeric wiper plugs are force-fitted into the basket, which temporarily reduces their respective outer diameters. A push rod is mounted for longitudinal movement in the body with its lower end in engagement with the upper plug. The upper end of such rod is adapted to be engaged by a first dart or piston that is pumped down the running string and into the body in order to drive the rod and both wiper plugs downward until the lower plug is expelled from the basket. Upon expulsion, the plug expands radially outward to its relaxed diameter where the outer edges of its cups engage the inner walls of the liner. This plug then moves ahead of a column of cement which is being pumped down the running string and out of lateral ports in the body above the rod. From there the cement flows through the annular space between the basket and the inner wall of the liner. At the appropriate time a second dart or piston is pumped down into the body and engages the first dart. Fluid pressure then is applied to drive the two darts and the rod further downward until the upper wiper plug also is expelled from the basket and launched into the liner at the upper end of the column of cement. This plug expands like the first one to provide a moving seal that prevents contamination of the upper end of the cement column. When the cementing is complete, means are provided to enable the body, the basket, the drive rod and the darts to be retrieved to the surface. U.S. Pat. No. 5,890,537.
[0017] In general, there are three possible locations where formation fluid can enter the well bore in a cemented casing prior to perforating; at the shoe, at the top of the liner or casing and through a ruptured casing. The leak at the shoe is thought to be the most likely and some embodiments address improvements to the pressure integrity of the completion in the shoe area.
[0018] As discussed, at least in part above, typical hardware at the end of a casing string or liner allows cement to be pumped down the casing inner diameter and back up the wellbore through the annulus formed between the casing and the wellbore. This hardware arrangement typically has check valves which keeps the cement from re-entering (u-tubing) back into the casing at the end of the cementing operation, when pump pressure is removed or reduced. This equipment is typically designed and built to be easily drillable with plastic and aluminum interior parts that are often cemented or held with epoxy. Components of this type arrangement are illustrated in FIG. 1 .
[0019] As shown in FIG. 1 , the casing shoe 110 has a check valve and is at the very bottom of the string. Next, a casing joint is commonly used followed by the float collar 100 . The float collar may also have a check valve 120 . Also, as shown in FIG. 1 , a check valve in the shoe and a check valve in a float collar re spaced typically 20-40 ft apart. After the cementing operation, the 20-40 ft of cement can become the barrier and is pressure testable when the cement is cured.
[0020] In one embodiment, during the cementing operation, a casing wiper dart is pumped on top of the last cement going in the well and a pressure spike indicates the wiper has hit bottom or “bumps”. Below the wiper is expected to be a good column of cement between the shoe and float collar. This cement column is expected to be the long term barrier to keep formation fluids from entering the well bore from the bottom. A primary purpose for these check valves is to keep cement from u-tubing, but these check valves can also provide a barrier to formation fluid entering the well bore at the shoe.
[0021] Cementing a liner or a casing string back to the wellhead is typically done the same way in any onshore, or offshore formation, notwithstanding water depth. A casing hanger or liner hanger is on top of the casing string and attaches to a workstring (in most cases, the available drill pipe). The workstring inner diameter (ID) is smaller than the casing so there are actually two cement wiper darts used. The casing wiper is commonly pre-assembled below the liner hanger and has a hollow ID. The smaller workstring wiper dart is launched from the surface at the end of the cement. This smaller dart wipes the workstring ID and lands inside the casing wiper dart and seals. Pressuring up, shears some screws and releases the casing wiper dart. Systems have wiper darts before and after the cement column.
[0022] If the operation is performed and results according to plan, the wipers are effective and bump at the end on cement column, and subsequently, a non contaminated volume of cement cures in the casing joint between shoe and float collar. But there are several things that can compromise the long term cement seal at the bottom of the casing. Some of the things that can go wrong are:
1. Wipers plugs do not “bump” 2. Wipers are damage and allow contamination 3. Contaminates on ID of drill string or casing are swept off the surface by wiper dart and contaminates last feet of cement 4. Wiper is damaged and allows over displacement and a wet shoe 5. Cement does not cure sufficiently before a pressure test 6. Weak cement 7. Check valves leak and contaminated cement u-tubes back into bottom of casing 8. Contaminated cement does not cure, does not develop sufficient strength or has channels
[0031] In some embodiments of the invention, a ball valve is incorporated where the float collar is installed. The ball is closed when all the cement or nearly all of the cement is pumped past ball valve. The ball valve will allow an immediate pressure test (both positive and negative) up to full casing rating regardless of the condition of the cement. Additionally, reliance on cement to provide a long term seal at the bottom of the production casing string is avoided.
[0032] Additionally, if the ball valve or valves are used without check valves, the casing will “auto fill” while running in the hole. This eliminates the need to top fill. If top filling is not done frequently, well control issues could arise.
[0033] Referring now to FIG. 2 , which shows a casing show 210 and float collar 200 , in some embodiments, when the ball valve 220 is closed, it can create a “hard bottom” which may be more difficult to drill. There are two common cases when drilling out the bottom is desired. The first case is if the production casing did not get close to the proper depth and is cemented high in the hole. The bottom would then be drilled out and a smaller liner would be run through this casing. The second case is a planned temporary bottom where the well would be produced for a period of time and then the well bore lengthened to produce from a deeper zone. However, a drillable shoe on the production casing string is not perceived as bringing much value in some instances. The drillable shoe on the intermediate casing and everything larger is optimum and is just repeated on the production casing. If a well with a hard shoe does need to be deepened, the well can be drilled by side tracking. The arrangement in FIG. 2 also includes a sealable valve 230 , such as a flapper valve, and the cement 240 located in a medial region of the tubular formed between the distal end and the proximal region.
[0034] Some methods which may be used to close the ball valve proximate the shoe include, but are not limited to, bumping of the wiper dart, a ball dropped before the cement wiper dart, a temperature profile based on the cooling effect of pumping cement and then warming back to or near reservoir temperature, RF tags in cement passing through ball valve, RF signal in wiper dart or other device pumped or drop in well at end of the cement column but does not pass through valve, pressure pulse signal, electromagnetic signal, acoustic signal, seismic signal, or the like.
[0035] Alternative to the ball valves described above, the functionality of the ball valve could be duplicated with other sealable valves such as a sleeve valve, multiple flapper valves (facing opposite directions) held open during cementing, multiple checks (facing opposite directions) held open during cementing, and the like.
[0036] The foregoing disclosure and description of the invention is illustrative and explanatory thereof and it can be readily appreciated by those skilled in the art that various changes in the size, shape and materials, as well as in the details of the illustrated construction or combinations of the elements described herein can be made without departing from the spirit of the invention. 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 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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Methods include introducing a casing into a wellbore penetrating a subterranean formation, the casing forming an annulus with the wellbore surface, where the casing is subject to a first pressure value at a distal end and a second pressure value at a proximal region within the casing, and where a shoe is positioned at the distal end of the casing. Then, placing a sealable valve within the proximal region of the casing, injecting a first cement composition into the casing, through the sealable valve and shoe, and into the annulus, and the placing a second cement composition in a medial region of the tubular formed between the distal end and the proximal region. Afterward, the sealable valve is closed.
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This is a division of application Ser. No. 83,871, filed Oct. 11, 1979 and now U.S. Pat. No. 4,279,443.
BACKGROUND OF THE INVENTION
The present invention relates to a shearer for use in coal or metal mining and suitable for effecting the long wall mining method. More particularly, the present invention relates to a shearer provided with a device for detecting the position of a lower cutting drum according to the height which the long wall face or coal or metal mine is cut by another upper cutting drum so as to always keep the mining height constant.
Ranging drum shearers are well known as conventional coal mining machines and the shearers of this kind can be divided in to two groups, one of which is a single ranging drum shearer provided with a ranging arm only at one end of shearer and having a cutting drum, while the other is a double ranging drum shearer provided with ranging arms at both ends of the shearer having cutting drums.
Since the single ranging drum shearer has only one cutting drum, generally speaking, it is difficult to cut the whole height of the seam by one pass of said shearer. Accordingly, it is necessary to reciprocate the shearer along the pit face changing the height of the shearer every pass along the pit face.
On the other hand, the double ranging drum shearer has ranging arms provided at the front and back ends of the shearer, each ranging arm having one cutting drum. Therefore, the preceding drum is positioned high to function as a drum for cutting the pit face at the side of the mine roof and the other succeeding drum is positioned low to function as another drum for cutting the pit face at the side of the mine floor, thus enabling the shearer to cut the entire seam height at one time.
In order to cut the pit face using the double ranging drum shearer, the operator must judge by himself whether or not the cutting operation is correct by viewing the top of the cutting drum arranged at the side of the mine roof and the bottom of another cutting drum arranged at the side of the mine floor. The cutting operation of the drum arranged at the side of mine roof provides no problem since the top of the drum can be easily viewed. However, the cutting operation of another drum arranged at the side of the mine floor depends on the skill of the operator since the bottom of the drum cannot be easily viewed because of the presence of coal previously cut by the preceding cutting drum and scattered on the mine floor and also because of the presence of a conveyor arranged on the mine floor along the pit face. Therefore, when the shearer is operated by an unskilled operator, the mine floor is either made uneven having wave-formed concave convex portions, or the distance between the mine roof and floor, i.e., the mining height, is either exceeded by the maximum height of self-advancing supports or made lower than the minimum height of self-advancing supports, so that the working operation at the pit face is hindered and the mining efficiency is lowered.
In order to overcome the above-mentioned drawbacks, the inventors of the present invention previously disclosed a new technique in their publicly opened Japanese Patent No. 958,841. This technique comprises attaching a sensor to the head of a ranging arm of a cutting drum arranged at the side of the mine roof, said sensor to use the change in the elasticity of a spring or oil pressure by the pantograph or diaphragm manner and arranged to contact and follow the mine roof surface to detect the change in the shape of the mine roof surface. Accordingly, the other cutting drum arranged at the side of the mine floor is raised or lowered responding to the signals transmitted from the sensor to thereby keep the mining height constant. However, according to this technique, the succeeding lower cutting drum is raised or lowered responding to the changes in the mine roof height detected by the sensor arranged to the preceding upper cutting drum, and the mining height is therefore not maintained accurately, because the preceding and succeeding cutting drums are arranged at both ends of the shearer body with a certain space interposed therebetween and the succeeding lower cutting drum is raised or lowered instantly responding to the information detected by the sensor which is arranged to the upper cutting drum several meters ahead of the succeeding lower cutting drum. In addition, the sensor is affixed to the head of the ranging arm. Therefore, when the ranging arm is raised or lowered, the sensor is also raised or lowered at the same time, so that the sensor is slanted, causing the measurement by this slanted sensor to have errors. Further, the sensor employed by this technique is arranged to contact and follow the mine roof surface. However, it is difficult to cause the sensor to contact and follow the concave-convex surface of the mine roof accurately. In addition, an accident can easily happen in this case.
SUMMARY OF THE INVENTION
The present invention is intended to eliminate the above mentioned drawbacks. Accordingly, an object of present invention is to provide a coal mining machine wherein a sensor for measuring the distance to the mine roof is arranged to a cutting drum arranged at the side of the mine floor, whereby the mining operation can be effected keeping the mining height accurately constant.
Another object of present invention is to provide a coal mining machine provided with a device for detecting the position of a cutting drum to cut the lower portion of the coal seam, said device comprising a sensor arranged to move parallel in the vertical direction without rotating even when the ranging arm to which the sensor is attached is raised or lowered, whereby the measurement errors caused by the conventional slanted sensor are eliminated.
A further object of present invention is to provide a coal mining machine provided with a device for detecting the position of a cutting drum, said device which serves to function as a sensor for measuring the distance to the mine roof comprising a means for projecting a ray or fluid whereby the distance to the mine roof can be accurately measured and the occurrence of accident is eliminated.
A still further object of present invention is to provide a coal mining machine provided with a device for detecting the position of a cutting drum capable of easily keeping the mining height constant, so that a machine operator can easily operate the cutting drum to cut a lower portion of the coal seam by observing a cross point shown on a surface of the mine roof by rays or fluids projected from the projectors.
A still further object of present invention is to provide a coal mining machine provided with a device for detecting the position of a cutting drum wherein said device includes a parallel link means which includes a board to which the sensor for measuring the distance to the mine roof is attached and a ranging arm as two sides thereof, to prevent the sensor from being rotated or slanted whereby said device can be accurately operated even when the violent vibration of the coal mining machine or the impact of crumbling lumps or scattering pieces of coal is imparted to said device.
A still further object of present invention is to provide a coal mining machine provided with a device for detecting the position of a cutting drum wherein the board to which the sensor is attached is pivoted on the axial line of a drum rotating shaft of a ranging arm whereby the board is precisely moved upwardly or downwardly according to movement of the cutting drum.
These and other object as well as the merits of the present invention will be apparent from the following detailed description with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front view showing an embodiment of present invention.
FIG. 2 is a partly broken isometric view showing the embodiment shown in FIG. 1.
FIGS. 3 through 5 are explanatory views illustrating the function of detecting devices of present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIGS. 1 and 2 show an example in which the present invention is applied to the double ranging drum shearer. Numeral 1 represents a shearer body, which is mounted on conveyors 2 with skids 3 interposed therebetween. In the shearer body 1, a means for driving cutting drums or the like is housed which will be described later. Numerals 4 and 5 represent ranging arms of which bottom ends are attached to both ends of shearer body 1, respectively. Numerals 6 and 7 denote ranging jacks, which serve to rotate the ranging arms 4 and 5. Numerals 8 and 9 denote cutting drums each being attached to the foremost end of the corresponding ranging arm through a rotating shaft 10.
Numeral 11 represents a bearing housing by which the rotating shaft 10 is held. Numeral 15 denotes a device for detecting the position of a cutting drum, said device comprising a means 15A, 15B for projecting a ray or fluid. The detection device 15 is arranged on a board 12, which is freely rotatably mounted on the bearing housing 11 of foremost end of ranging arm 5. Numeral 13 represents a fixing plate erected on the shearer body 1 in front of the bottom end of ranging arm 5. Numeral 14 denotes a link bar, one end of which is pinned at a point to the upper end of fixing plate 13 and the other end of which is pinned at a point D to the board 12. Points A, B, C and D are in the following positional relation. Namely, line A-B is equal in length and parallel to line C-D, and line A-C is equal in length and parallel to line B-D, thus forming a parallelogram. In this embodiment, lines A-C and B-D are always kept vertical. As apparent from above, a parallel link mechanism is formed by the ranging arm 5, fixing plate 13, link bar 14 and board 12. Accordingly, even when the jack 7 is operated to change the slant angle of ranging arm 5, the board 12 on which the detection device 15 is arranged is changed in an angle relative to the ranging arm 5 always keep line B-D vertical. In other words, the board 12 is vertically moved corresponding to the extent to which the cutting drum 9 is raised or lowered.
Though the positions of points A, B, C and D can be freely changed so far as these points occupy any of a apexes of parallelogram, it is desirable that the moving direction and amount of point D are equal to those of the center of the cutting drum 9. When point B is replaced in the direction of point A to form a parallelogram, the moving direction and amount of points B and D are not equal to those of the center of cutting drum 9, and therefore, it becomes necessary to add to the detection device 15 a complicated circuit or the like for correcting the measurement values. The above mentioned parallel link means of the present invention includes a kind of link means which does not form a parallelogram such as the present invention, but has equal function as the same as a parallel link in allowed measurement errors.
In the present invention, the detection device 15 comprises a sensor for measuring the distance to the mine roof which is attached to the board 12. This sensor 15 includes a projectors 15A, 15B for projecting a ray, fluid, for example water, colored air, powdered or grained material or the like, to the mine roof. The projector of this kind is publicly well known and the operation principle thereof is also publicly well known. Therefore, construction of the projector 15A and 15B employed in the present invention will be not described in detail but may be attached to the board 12 as described below.
The sensor 15 consists of at least one pair of the projectors 15A and 15B, each of which is mounted on the board 12 with desired projection direction and distance, with rays projected from the projectors 15A, 15B appearing as a cross point on surface of the mine roof. Because mining height occasionally changes according to condition of the coal or metal seam, therefore it is necessary to arrange a mechanism by which the cross point of the two projected rays is moved upwardly and downwardly. For this technical object, it is desired that at least one projector 15A or 15B is movably mounted on the board 12 to change projection direction or mounted point thereof.
Furthermore, more than two pairs of the projector may be mounted on the board 12. To prevent the projected ray from being intersepted by a part of the shearer, self-advancing support or materials around the projector 15A, 15B, many sets of the projector are separately mounted in different directions and mounted positions.
To project a visible ray of light, a flood light projector is used for the projector 15A, 15B. If fluid similar to water is projected, a nozzle continued to a water pump or the like through hoses is used for the projector. In case the projector projects visible aerial material similar to coloured air, a nozzle is continued to a source of supply of aerial material as an air compressor. Further, if the projector projects powdered or grained materials, a nozzle is jointed with a source of supply of said materials.
For example, if a flood light projector projecting visible ray is used for the projector 15A, 15B, each of projector 15A and 15B may projects rays in different color, and then the cross point of said rays is shown in mixture color.
In addition to the above, in this invention it is unnecessary that the cross point O is indicated literally as a small point. Said cross point may be indicated as a sectioned portion having some square measurements.
The function of the sensor of the present invention constructed above will now be described.
In FIG. 3, a level a is regulated for a desired cutting face of a lower portion of the coal or metal seam, when the mine roof is provided in level L1. Before beginning the coal mining, a position of the cutting drum 9 used to cut the lower portion of the coal or metal seam is previously set by moving the arm 5 upwardly or downwardly in the level so that a bottom face of said drum 9 is on the level a. At the same time, two projectors 15A, 15B are regulated to cause visible rays or fluid projected from said projectors to cross on the surface of the mine roof L1. Accordingly an operator operates the shearer at the same time that he detects through his eyes the cross point O of rays shown on the surface of the mine roof.
Next, while the shearer continues to cut the coal or metal mine, as shown in FIG. 4, when a level of the mine roof changes into a level L2 which is higher than the level L1, a cross point of the rays projected from the projectors 15A and 15B is not shown on the surface of the mine roof, because first level L1 of the mine roof is moved to new level L2. Accordingly, the cutting drum 9 should be raised to a level so that the cross point of the rays projected from the projectors 15A and 15B is shown on the surface of the mine roof. This operation is done by the shearer operator in the manner of operating a valve 16A, for example an electromagnetic valve, to raise a jack 7 of the cutting drum 9. At this time, the board 12 is also raised equal to the raised extent of the cutting drum 9 to come closer to the mine roof. When a new cross point of the rays become visible on new level L2 of the mine roof, the operator closes the valve 16A to stop raising of the jack 7, and the cutting drum 9 is regulated at the desired level.
Further cutting is continued, and when the level of the mine roof changes into a lower level as shown at L3 in FIG. 5, the cross point disappears, and two points of the light now appear separately on the level L3. At this time, the shearer operator opens a valve 16B to lower the jack 7 and cutting drum 9. And just then, because the board 12 is mounted on the cutting drum 9, said board 12 is also lowered equal to the lowered extent of the cutting drum 9 to come nearer to the coal floor. In a short time, the board 12 is lowered, and a new cross point of the rays appears on the new surface of the mine roof. When the operator detects the above new cross point, he closes the valve 16B to stop unwanted movement of the cutting drum 9. Through this operation, the cutting drum 9 is regulated according to new level L3 of the mine roof, and said cutting drum 9 shears a lower portion of the coal or metal seam according to an imagined lower level c.
By repeating the above operation regardless of the height of the mine roof changing irregularly, coal or metal mining height is kept at desired constant height.
Though the present invention has been described in detail, it includes the following other embodiments:
(1) In the shearer having one ranging arm 5, two cutting drums 9 are provided between which the sensor attaching board 12 is mounted. The cutting drums are arranged on the shaft at the side of mine floor.
(2) In the double ranging drum shearer as shown in FIG. 1, the device for detecting the position of a cutting drum according to the present invention is also arranged to the ranging arm 4 to which the cutting drum to be arranged at the side of mine roof is attached, so that either of cutting drum 8 and 9 can be used as the lower cutting drum reciprocating the shearer body 1 along the long wall pit face.
(3) The shearer is a single ranging one having no ranging arm 4 to which the cutting drum to be arranged at the side of mine roof is attached as shown in FIG. 1.
(4) Point (B) is not positioned on the drum rotating shaft 10, but is replaced a little to the side of point (A) on a line connecting points (B) and (A), and correction of measured values is made by a controller, not shown.
(5) Lines connecting points (A), (B), (C) and (D) do not form a correct parallel link means, but a quasi-parallel link means capable of keeping the measurement errors of the sensor smaller than several centimeters, preferably five centimeters.
(6) As disclosed in the Japanese Patent Publication No. 53-4043, the shearer has a main ranging arm to which a sub-ranging arm is attached, and two cutting drums are attached to both ends of the sub-ranging arm. In this case, two parallel links are formed as shown in FIG. 5 and the sensor attaching board 12 is mounted on the shaft to which the cutting drum to be arranged at the side of mine floor is attached. When either the main or sub-ranging arm is fixed, it is enough to form one parallel link.
(7) A plurality of sensors 15 are attached to the board 12 and the average of values measured by these sensors 15 is employed to represent the distance to the mine roof.
(8) One end of link bar 14 is pivoted to the shearer body 1.
(9) A plurality of position detection devices are arranged to prevent the ray or wave from being intercepted by any obstacle at the mining site.
It is thought that the present invention can be applied as follows: Instead of board 12 and parallel link means employed in the present invention, other publicly well-known levels which use the surface of liquid or a float, or are of hanging or swinging weight type, or of gyro-type for example, are employed and the sensor 15 is attached to one of these levels.
The coal mining machine according to the present invention and having such arrangements as described above can be operated as follows
When the shearer body 1 is moved along the long wall pit face in the direction shown by an arrow in FIG. 1, the ranging arm 4 is turned in the upper direction to determine the position of cutting drum 8 which is intended to cut the coal seam at the side of mine roof, and then the coal seam at the side of mine roof is cut by the cutting drum 8. The coal seam at the side of the mine floor is cut by the following lower cutting drum 9 in such a way that the sensor 15 measures the distance to the mine roof as described above, namely the distance to the roof of the coal seam which has been cut by the preceding upper cutting drum 8, and the cutting drum 9 is manually or automatically raised or lowered according to the height of the mine roof. Accordingly, the mining height can be always kept constant.
Since the present invention can provide the above mentioned arrangements and operational functions, the objects of present invention can be attained. Namely, since the sensor for measuring the distance to the mine roof is arranged to the lower cutting drum, the distance to the mine roof can be accurately measured at the time of cutting the coal seam at the side of mine floor. Since the sensor is attached to the board which is kept moving in the vertical direction even if the ranging arm is rotated in the upper or lower direction, measurement errors are not caused because the sensor is not slanted as the conventional sensors are. Since the parallel link means is employed as a means to keep the sensor attaching board level, the sensor can be accurately operated even if violent vibration and impact of crumbling lumps and scattering pieces of coal are imparted to the shearer at the mining site. In addition, since the ray or fluid projector is employed as the sensor, the distance to the mine roof can be accurately measured even if the distance between the mine roof and the lower cutting drum is great, and accidents can be substantially reduced as compared with the conventional sensors which are designed to contact and follow the mine roof.
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The present invention is directed to a method for regulating position of a mining apparatus comprising the steps of transmission of a plurality of signals from a position detection device, interception of said signals at an edge of a mine at a distance away from the position detection device, and adjustment of the position of the mining apparatus to form an intersection between at least two signals at the edge of the mine.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of complete application Ser. No. 11/251,990, filed Oct. 17, 2005, entitled “Reinforced Supporting Connectors for Tubular Grab Railings” (U.S. Pat. No. 7,967,522) and incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
This invention relates to railings and more particularly to safety railings that are commonly referred to as grab bars and to connectors therefor.
BACKGROUND OF THE INVENTION
Because of safety concerns, particularly in bathrooms and showers which may have wet floors that make it possible for a person to fall, and concern for physically impaired individuals, it has become common to provide safety railings often called grab bars in bathrooms and around showers and bathtubs. Grab bars are particularly helpful and are frequently required by building codes to aid physically impaired individuals. Applicable building codes include stringent strength requirements. Consequently, grab bar systems now in use are formed from metal such as stainless steel or aluminum in order to have the strength needed to meet code requirements and accordingly are relatively expensive and have decorative and aesthetic limitations. While plastic grab bars have been previously proposed, e.g., formed from a plastic polymer as described, for example, in U.S. Pat. No. 5,690,237, it is difficult or impossible for plastic to meet the strength requirements set by building codes and they weaken with age. In addition, the patented device is not suited for use with commercially available tubing. Another problem is the difficulty associated with drilling holes and inserting grab bar mounting screws through a mounting flange often in a location that is beneath or behind the horizontally extending portions of the grab bar support unit. Thus, when a workman attempts to mount a grab bar support unit, he must drill holes and mount screws that are beneath or almost beneath the horizontal part of the grab bar support. This is time consuming, labor intensive, and often results in screws that are cocked to one side.
In view of these and other deficiencies of the prior art, it is one object of the present invention to provide a grab bar mounting assembly that exhibits outstanding performance, is easy to install, is rugged in construction and provides the appealing visual qualities of plastic, yet has the strength of steel so as to meet or exceed building codes, regulatory agency, and industry requirements.
Another object of the invention is to provide improved grab railing mounting hardware that can be readily manufactured from injection molded, thermo-formed or thermo-set plastic resin in any color and yet has the strength of steel.
A further object is to provide an improved mounting assembly for tubular grab railings of modular construction with interchangeable parts that can be readily assembled on site to meet dimensional and design requirements of any particular installation job.
Still another object is to provide a mounting system for tubular grab railings that has a more appealing appearance and better decorative possibilities than grab railings now in commercial use.
Another object is to provide a mounting connector assembly for tubular grab railings that will work with various kinds of commercially available metal or plastic tubing.
Another object is to remove stress on plastic parts and find a way to eliminate the possibility of catastrophic failure due to fracture or cracking of plastic components caused by aging, over-tightening screws or other causes.
Yet another object is to effectively prevent rotation of the tubing sections that extend between the connector assemblies so that the user will have secure support while at the same time facilitating rapid assembly during installation.
A further object is to make a connector assembly easier to clean as well as having a more attractive, yet less expensive cover for the base.
These and other more detailed and specific objects of the present invention will be better understood by reference to the following Figures and detailed description which illustrate by way of example but a few of the various forms of the invention within the scope of the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be described below with reference to the accompanying drawings wherein the same numerals represent like structures in the several Figures and wherein:
FIG. 1 is perspective view of a grab railing mounted for use on the walls of a building by way of example to show several tubing connectors embodying the invention for supporting different numbers of tubes.
FIG. 2 is a perspective view of a straight connector 14 of FIG. 1 shown on a larger scale.
FIG. 3 is an exploded view of the connector of FIG. 2 .
FIG. 4 is a vertical sectional view taken on line 4 - 4 of FIG. 2 .
FIG. 5 is an exploded view of an adjustable connector 20 of FIG. 1 in accordance with the invention on a larger scale.
FIG. 6 is a plan view of the adjustable connector of FIG. 5 when assembled.
FIG. 7 is a vertical cross-sectional view taken on line 7 - 7 of FIG. 6 .
FIG. 7A is a left end view of the connector of FIG. 7 .
FIG. 8 is a side elevational view of the connector of FIGS. 5-7 .
FIG. 9 is a perspective view of the adjustable connector 20 of FIGS. 5-8 on a slightly smaller scale.
FIG. 10 is a perspective view of an end fitting connector 12 of FIG. 1 showing its reinforcing plate in exploded position.
FIG. 11 is a perspective view of an L connector 16 of FIG. 1 in accordance with the invention showing its reinforcing plate in exploded position.
FIG. 12 is a perspective view of a T connector 18 in accordance with the invention showing its reinforcing plate in exploded position.
FIG. 13 is an X connector 19 in accordance with the invention showing its reinforcing plate in exploded position,
FIG. 14 is a tubular elbow railing section 24 in accordance with the invention,
FIG. 15 is an exploded view showing an end cap extension,
FIG. 16 is a side elevational view partly in section of another form of reinforced connector assembly in accordance with the application,
FIG. 16A is an exploded vertical sectional view of the connector assembly of FIG. 16 ,
FIG. 17 is a transverse sectional view taken on line 17 - 17 of FIG. 16 ,
FIG. 18 is an end view of a section of steel tubing to be placed between the connector assembly components as it appears before being installed on the connector assembly,
FIG. 19 is an end view of the tubing support of the connector assembly taken on line 19 - 19 of FIG. 16 with a section of the tubing of FIG. 18 installed over a boss at one end of the connector assembly showing the lateral deflection of the sidewalls of the tubing,
FIG. 20 is a perspective view of the deep drawn metal reinforcing member of the base shown in FIGS. 16 , 16 A and 21 that is used to secure the connector assembly of FIGS. 16-19 and 21 to a wall or floor, and
FIG. 21 is a side elevational view of an end fitting connector similar to that shown in FIG. 10 but embodying the mechanical construction shown in FIGS. 16 and 16A .
SUMMARY OF THE INVENTION
Briefly, the present invention provides a reinforced supporting connector and a tubular grab railing. The connector comprises an upper tubing support or fitting that is aligned with the grab railing during use and a lower mounting base portion that is attached to the tubing support and is fastened a wall, floor, or other surface as a pedestal for the tubing support. The tubing support can be split or otherwise provided with an opening extending longitudinally which contains a reinforcing member extending longitudinally of the tubing support. The tubing support has at least one boss that is constructed and arranged to engage and support one end of a section of the grab railing tubing. The invention thus provides a composite connector assembly for supporting a section of grab railing; the composite connector being formed from dissimilar structural materials comprising an outer plastic resinous supporting element that is exposed to view and tactile contact by the user and a hidden typically metal reinforcing member which is recessed therein. Each boss is constructed and arranged to engage one end of a section of the tubular grab railing. The reinforcing member can be a metal plate that extends through the support to provide reinforcement for the tubing support including the boss as well as the tubing itself and can have exposed ears on each side that frictionally engage and distend the tubing to prevent it from rotating during use. A supporting base is attached to the tubing support to fasten the connector to a wall, floor, or other surface. The metal plate is held in direct contact with the base. The invention also provides an adjustable connector including two pivotally related portions with a joint between them to permit adjustment on site for establishing the desired angle of intersection between two adjoining grab bar railing sections and a section of elbow tubing with a right angle bend that can be used for inside or outside railing corners as well as end extensions, and a screw cover.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to the Figures and particularly FIG. 1 , a tubular grab railing and supporting connectors in accordance with the invention is indicated generally by the numeral 10 . The supporting connectors, all of which embody the invention, must, as in any railing system, support different members of railing sections at various angles and accordingly are provided with different numbers of tubing support members. FIG. 1 shows by way of example, connectors embodying the invention can be used with different numbers of tubes and include the following: three end connectors designated 12 , one straight connector 14 , one L connector 16 , one T connector 18 , one X connector 19 , and one adjustable connector 20 . Mounted between the connectors 12 - 20 are sections of commercially available metal or plastic tubing 22 which may be pre-cut or cut to length by workmen on site during installation. A section of tubing 24 having a right angle bend that can be used as an inside or outside elbow is shown at the right in FIG. 1 in a position mounted between the connectors 12 and 14 . Tubing 22 can also be metal having a plastic outer sheath or a coating of paint.
The straight connector 14 will now be described in more detail by reference to FIGS. 2-4 . The connector 14 includes an upper split connector assembly portion 30 and a lower upright mounting base portion 32 that is connected to the upper portion by a suitable fastener such as a bolt, pin, screw, rivet, or the like, all for convenience referred to herein simply as a fastener. In this case, the fastener is a bolt 34 that is attached to the base 32 by a nut 36 which is welded to the metal reinforcing base. The upper tubing support 30 is split longitudinally along a separation line 38 into upper and lower halves 40 and 42 with cooperating recesses 44 and 46 confronting one another that are of the appropriate size to receive a metal reinforcing plate 48 which is bored or has a punched opening 49 at the center and at each end at 49 a for the bolt 34 and for screws 50 respectively which join the upper and lower halves of the tubing support 30 . Plate 48 can be flat as shown or, if desired, can be corrugated or embossed. The central opening 49 for the bolt 34 is larger than the peripheral openings 49 a for the screws 50 . The reinforcing plate 48 is preferably a metal stamping formed from steel which extends through a pair of bosses 56 and 58 from one end of the upper portion 30 to the other. It can be seen that the fastener 34 secures the halves 40 and 42 together and at the same time fastens the upper portion 30 rotatably to the base 32 . A socket 52 is provided in the top half 40 for the bolt 34 which following assembly is covered with a security cap 54 that is non-removable or only removable with a special tool (not shown). The tubing support 30 is elongated laterally and in this case includes two opposed bosses 56 and 58 which could be circular in cross-section but are most preferably of oval configuration, i.e., out of round to receive and support the ends of grab rail tubing sections 22 as shown in FIG. 1 . The bosses are constructed and arranged to have a sliding fit within the ends of the tubing sections 22 . If standard commercially available tubing is used by the installer, the ends of each tube section can be given an oval shape, e.g., by striking each end lightly with a hammer after being cut to size to fit the bosses 56 and 58 . In this way the tubing sections 22 will be unable to rotate on the bosses 56 and 58 so as to provide firm, secure, and reliable support for a person using the grab railing 10 .
The upper and lower halves 40 and 42 of the tubing support 30 are formed from a plastic resinous material of any suitable composition, e.g., polypropylene, nylon, PVC, polyester, polystyrene, Plexiglas, or other resin which has appealing visual qualities and is warm to the touch because of its relatively low thermal conductivity. The reinforcing plate 48 can be formed from any suitable material of high tensile strength such as steel.
The base 32 comprises a hollow body 60 formed from plastic resin with a horizontal mounting flange 62 at its lower end that is bored at 64 for mounting screws 67 used to attach the base 32 to a wall, floor, or other surface. Inside the plastic body 60 is a tubular or deep drawn metal reinforcing member 66 with an upper horizontal end wall 68 to which the nut 36 is bonded or welded, and a lower radially extending mounting flange 70 that has bored openings 72 which are aligned with the openings 64 . After the screws 67 have been installed, an optional thin walled cover 74 formed from metal or plastic may be placed over the hollow plastic body 60 to hide the mounting screws 67 . Cover 74 is held in place by the tubing support 30 which the installer attaches to the base 32 by bolt 34 after the cover 74 has been put in place as shown in FIG. 4 . The upright base 32 serves as a pedestal for tubing support 30 which can rotate about the center of the bolt 34 so that it can be moved during installation to any desired angle for placing the grab railings in the position required by the specifications for that installation. Once the location of each base 32 is established, the mounting screws 67 can be placed in any convenient position because the bosses are not in place when the base is mounted. However, even if they were, the tubing support 30 is able to be turned in either direction to position the railings so that the screw holes will not be covered by the bosses 56 , 58 , thus facilitating installation.
Refer now to FIGS. 5-9 which illustrate the adjustable connector 20 in more detail. The base 32 which serves as a pedestal for the adjustable connector 20 is the same modular base 32 described above and shown in FIGS. 2-4 . The same modular base 32 is used in all of the connectors to be described as a pedestal for rotatably supporting the tubing support at its upper end by means of the bolt 34 or other suitable fastener. The tubing support 30 of FIGS. 5-9 is also split longitudinally into upper and lower halves, which in this case are designated 80 and 82 at the left and 84 and 86 at the right with upper and lower halves 84 and 82 overlapping and in contact along a horizontal bearing surface 88 ( FIG. 5 ) to define a joint for enabling the boss 80 , 82 at the left to be pivoted with respect to a boss 84 , 86 about a vertical axis 88 at the center of bolt 34 which acts as a pivot pin. In this case, a longitudinal recess 84 a is provided in the lower surface of member 84 to accommodate a flat reinforcement plate 90 and the lower tubing support half 82 is provided with an upwardly opening recess 92 to receive a steel reinforcing plate 94 having a bored opening 96 aligned with a similar opening 98 in plate 90 for the bolt 34 . Plate 90 overlaps plate 94 as best seen in FIG. 7 . During installation, the base 32 is mounted first as described above in the correct position required for each particular railing installation. The tubing support 30 is then attached to base 32 by means of the bolt 34 which is secured to the nut 36 that is bonded or welded inside the base 32 . Once the plates 90 and 94 have been positioned, the screws 50 can be screwed in place or, optionally, this can be done at the factory. The cap 54 is then placed over the bolt 34 . The oval, i.e., out of round configuration of the boss 80 , 82 is clearly shown in FIG. 7 a . This feature prevents the tubing sections 22 from turning or rotating on the supporting bosses during use, thus providing secure support for the user.
Refer now to FIGS. 10-13 which show, respectively, an end connector 12 with a single boss in FIG. 10 , an L-shaped connector 16 in FIG. 11 , a T connector 18 in FIG. 12 , and an X connector 19 in FIG. 13 ; all with identical modular bases 32 that serve as a pedestal for holding the tubing support on a wall or other surface. In each of FIGS. 10-13 , the tubing support is similar to that described in FIGS. 2-4 except that in FIG. 10 there is only one boss 56 and the metal reinforcing plate shown in an exploded view in FIG. 10 at 48 a is of the appropriate length to fit between the halves of the end connector 12 which like connector 14 is split along longitudinal separation line 38 and includes a recess for plate 45 a , the left end of which can be seen in FIG. 10 . Like the metal reinforcing plate 48 in the support 12 of FIG. 3 , the plate 48 a which is recessed within support 30 at separation line 38 as in FIGS. 3 and 4 is bored at 49 to receive the bolt 34 (not shown in FIG. 10 ) the lower end of which is screw-threaded into the nut 36 of the base 32 . The tubing supports 30 in all of FIGS. 10-13 are similarly constructed, the bolt 34 securing the tubing support assembly 30 to base 32 in each case as shown in FIGS. 3 and 4 so that it is free to rotate on the base 32 about the axis of the bolt 34 .
In FIG. 11 the tubing support 16 is L-shaped as is the metal reinforcing plate 48 b located at the separation line 38 . In FIG. 12 the tubing support assembly 18 has a T-shaped configuration. The metal reinforcing plate 48 c is similarly shaped to fit between the upper and lower halves of the support 30 which separate along longitudinally extending separation line 38 . In FIG. 13 , the tubing support assembly 19 has an X configuration, as does the metal reinforcing plate which is designated 48 d . Each of the tubing support assemblies of FIGS. 11-13 are provided with recesses designated 45 , 47 , and 49 , respectively, which are shaped in each case to receive the corresponding metal reinforcing plate shown and described. Thus in summary, the tubing support of FIGS. 2-4 has two aligned bosses 56 , 58 , the tubing support 30 of FIG. 10 has a single boss 56 , the L-shaped tubing support 16 of FIG. 11 has a pair of bosses 56 and 58 that are at right angles to one another, the T-shaped support 18 of FIG. 12 has two aligned bosses 56 and 58 and an intermediate boss 59 at right angles thereto while the tubing support 19 of FIG. 13 has aligned bosses 56 and 58 similar to those described in FIG. 2-4 and another pair of bosses 59 and 61 at right angles to the first pair.
Refer now to FIG. 14 which shows the section of tubing 24 of FIG. 1 with a right angle bend to provide an inside or outside elbow that can be connected between any of the tubing supports described. To provide the appropriate strength and to simplify installation, the elbow 24 is provided with a rectangular metal reinforcing plate 47 at each end similar to plate 48 that are positioned at right angles to one another and are normal to the plane of the elbow. Each of the reinforcing plates 47 is bonded, e.g., by spot welding or other suitable welding method to the interior surface of the elbow 24 and each is provided with a punched opening 47 a that is appropriately positioned so that the bolt 34 can pass through it when the elbow is mounted on the boss of one of the tubing supports 30 of any of FIGS. 2-13 . The location of the elbow 24 after being installed can be seen in FIG. 1 . One of the bolts 34 shown in FIGS. 3 and 4 passes through each of the bored openings 47 a to secure the elbow 24 in place between connectors 12 and 14 ( FIG. 1 ).
In the event that one of the tubing supports such as 18 in FIG. 1 has bosses which do not require tubing sections 22 , the bosses can be covered by end extensions 100 that are held in place in any suitable manner, e.g., by retaining screws extending the grip surface beyond the mounting base by about 4″ per end. Tubing sections 22 can be made of metal or plastic and can be cut from any commercially available stock, thereby reducing installation and production costs.
The end extensions 100 will now be described in more detail in connection with FIG. 15 in which the same numerals refer to corresponding parts already described. First, a metal tube 102 that is typically 3″ or 4″ long is placed over the boss 30 . A metal or plastic end cap 104 of cylindrical shape sized to fit into the open end of the tube 102 is inserted into the free end of the tube. The end cap 104 includes a circular rim or bead 106 near its outer end for limiting insertion of the end cap into the tube 102 . In the center of the end cap 104 is a bore 108 which extends partially through the end cap 104 and includes openings for a pair of retaining screws 110 that are threaded into a slot 112 in the end of the boss 30 . Once the screws 110 are in place, they are covered by a plug 54 which is the same plug 54 that is used at the center of each fitting. The plug is held by friction within the bore 108 . The tubular extension 102 is properly dimensioned to fit over any of the bosses of any of the plastic fittings described herein above.
An important advantage of the invention is the variety of decorative possibilities provided by the plastic surfaces of the tubing support units 30 , yet the invention has more than enough strength to meet code and industry requirements. The invention can be installed more easily than previously because the invention allows workmen to install the mounting screws 67 before attaching the tubing support 30 so that none of the screws or screw holes are located beneath or concealed by the ends of the tubing 22 . Because the tubing support assembly is able to pivot about a vertical axis that is perpendicular to the wall or floor surface on which the connector is mounted at the center of bolt 34 , minor angular adjustments in the grab tubing can easily be made if needed thereby facilitating the installation process. The invention is therefore appealing from an aesthetic viewpoint both visually and tactilely because when the connector assemblies and interconnected tubing sections are made of plastic resin, they will be warm to the touch while being rugged in construction, strong enough to meet all building codes, and can at the same time be installed with greater precision and less effort than prior tubular grab railings. Tubing sections 22 can be made of metal or plastic and can be cut from any commercially available stock, thereby reducing production costs.
In a modified form of the invention which is also contemplated, the separation line 38 is eliminated and the metal reinforcing plate 48 is molded in situ so that the upper and lower halves of the tubing support 30 are integral with one another. In that case, the plate 48 is positioned between upper and lower molding dies (not shown) prior to injecting plastic resin into the mold as will be understood by those skilled in the art.
Refer now to FIGS. 16-22 wherein the same numerals refer to corresponding parts previously described.
With particular reference to FIGS. 16 , 16 A and 17 , the numeral 200 designates a reinforce connector assembly in accordance with another embodiment of the invention that includes a tubing support 202 which is attached to an upright base indicated generally at 204 (see FIG. 20 ) by means of a fastener 206 to be described more fully below. The tubing support 202 includes an upper portion 208 and a lower portion 210 that in the embodiment illustrated are separate components located on the upper and lower sides of a reinforcing member which can have any suitable shape, but which in this instance comprises an elongated reinforcing plate 212 extending substantially from one end 215 to the other end 216 of the reinforced connector assembly 200 . In the form of the invention shown in the figures, the upper portion of the tubing support 202 comprises an upper half having a generally planar downwardly facing surface 220 including a downwardly opening recess 222 ( FIG. 19 ). The lower portion comprises a lower half having an upper generally planar surface 224 with an upwardly opening recess 226 therein. Each recess has the same shape and dimensions as the reinforcing plate 212 so that the plate 212 fits securely therein as shown in FIGS. 17 and 19 . Plate 212 is provided with apertures 212 a and 212 b to receive a second fastener means comprising a pair of screws 230 and 232 which pass through openings 208 a and 208 b ( FIG. 16A ) and are screw-threaded into the bottom portion 210 through threaded openings 210 a and 210 b to securely hold the reinforcing plate 212 between the upper and lower half of the tubing support 202 thereby forming a sandwiched structure comprising the upper half 208 , the lower half 210 with the reinforcing plate 212 held between them by the second fastener means 230 and 232 . As described hereinabove, the upper and lower portions 208 and 210 of the tubing support 202 can be formed from a suitable plastic resinous material such as polystyrene, polymethylmethacrylate or other resin and if desired can be solid structures as shown in FIG. 16A or if injection molded optionally hollow with anti-sink webbing (not shown) in the form of transverse or diagonal plastic plates extending centrally from the outer surface of each half in any suitable known arrangement.
In the same manner described hereinabove, the tubing support 202 includes at least one and in the case of FIGS. 16-17 a pair of bosses 211 and 213 each located at one end of the tubing support and dimensioned so that each boss is constructed and arranged to have a sliding fit within a separate section 22 of metal tubing that is not a part of the connector assembly 202 itself. Since most commercial steel tubing 22 has a longitudinal weld flash 22 a that extends inwardly, each of the bosses 211 , 213 is provided with a longitudinally extending groove 210 e to accommodate the weld flash 22 a . The rigid tubing 22 which can be obtained from any suitable commercially-available source is adapted to enclose each of the bosses 211 and 213 so as to thereby enclose and help confine the sandwiched structure formed by the upper and lower portions of the tubing support with the reinforcing plate 212 held securely between them. In this way, the reinforcing plate absorbs the bending moment due to forces applied by persons using the grab bar thereby preventing the portions 208 and 210 which can be plastic from bending, cracking or fracturing during use.
The lower half 210 of the tubing support includes a centrally located integral hollow cylindrical base cover 210 c that extends downwardly from the lower portion 210 of the tubing support so as to fit concentrically around the base 204 as best seen in FIGS. 16 and 16A . Its lower end is in alignment with a confronting upper edge of a screw cover 207 which will be described more fully below.
The base 204 described with reference especially to FIG. 20 includes a tubular reinforcing member that can be formed from steel or brass or other suitable metal with upper and lower ends 204 a and 204 b and having a laterally extending flange 204 c at its lower end. Flange 204 c has a plurality of apertures 204 d for the insertion of screw fasteners 205 to attach the reinforcing connector assembly 200 to a supporting surface such as a wall or a floor. After the screws 205 are in place, they are enclosed beneath an annular screw cover 207 with a decorative outer surface such as polished brass or chrome plating.
As best seen in FIGS. 16 and 16A , the tubing support 202 is attached to the base 204 by the fastener 206 which in this case comprises a bolt having a head at its upper end within a socket or opening 208 c extending entirely through the upper portion of the tubing support between the bosses and covered by a security cap 209 which can have a decorative upper surface held frictionally in the socket 208 c . In assembling the reinforced connector assembly 200 , once the plate 212 is in place, the bolt 206 is inserted through a central aperture 212 c ( FIG. 17 ) in plate 212 and is passed through an aperture 203 a in a horizontal upper wall 203 of the base 204 . After adjusting the position of the tubing support 202 by pivoting the tubing support about the central vertical axis of the fastener 206 as required, the aperture 212 c which can be threaded or a nut 206 a placed on the fastener is tightened to securely lock the tubing support in the desired position about the axis of the fastener 206 to line it up with the other parts of the complete railing. A passage 210 d in the lower half of the tubing support extends all the way through to its upper surface to provide an opening ( FIG. 16A ) so that the top wall 203 of the base can be located coplanar with the surface of recess 226 ( FIG. 19 ) enabling the top wall 203 of the base to be positioned in direct face-to-face contact with the reinforcing plate 212 to assure that the metal reinforcing elements are touching one another. In this way, the fastener 206 is able to maintain a secure metal-to-metal connection between the tubing support 202 and the base 204 by fastening the reinforcing plate 212 directly to the top wall 203 of the base 204 to reduce or eliminate stresses otherwise placed on the plastic resin from which the tubing support 202 is formed.
The reinforcing plate 212 will now be described more fully with reference to FIGS. 16 , 16 A, 17 and 19 . It can be seen in FIGS. 16 and 16A that the recesses 222 and 226 ( FIG. 19 ) are provided on each side with laterally disposed ports 250 and 252 that open out through the sidewall near each end of the tubing support and communicate interiorly with the recesses 222 and 226 . The reinforcing plate 212 has a pair of laterally extending ears 212 d at one end and 212 e at the other end, each ear being positioned to extend out through one of the ports 250 , 252 by a distance that can typically be about 0.020 inch (0.079 mm). In this way the ears project outwardly beyond the outer surface of the boss so as to engage and expand the overlying tubing section 22 as shown best in FIG. 19 . In this way the ears distort the tubing section 22 slightly and provide enough frictional engagement to prevent the tubing section from rotating on the boss over which it is placed. While the bosses can be oval in cross section, they can also be round. Likewise, each tubing section can be round in cross-section and does not have to be specially formed before being mounted since it will assume an oval shape as seen in cross-section as it is slid into place ( FIG. 17 ) with the ears 212 d and 212 e distending and preventing rotation of the tube. It will be seen that the ears 212 d and 212 e comprise laterally aligned wing-like projections that are coplanar with the reinforcing plate 212 on opposite side edges of the plate. As best seen in FIG. 17 , the ears have outer edges for engagement with the tubing that include portions 260 which taper inwardly proceeding toward each end of the tubing support and terminate in a flat section 262 at the centermost end of each ear with parallel tube-engaging surfaces 262 that scrape against the inner surface and distend the tubing section that is placed on each boss.
Refer now to FIG. 21 which shows a side elevational view of an end fitting connector 200 A with mechanical features that are similar to FIGS. 16-20 but having only one boss 213 like that of FIG. 10 which is used to secure the endmost railing section to a supporting surface such as the wall of a building. The same numerals refer to corresponding parts already described,
In the end connector 200 A, the reinforcing plate 212 terminates at 211 since only one boss 203 is needed. To securely hold the plate 212 in place at its inner end, a retaining screw 205 is preferably passed through an opening in the plate and screwed into the upper portion 208 of the connector assembly as shown in FIG. 21 to provide a secure attachment. Stresses applied to a tubing section 22 placed on the boss 213 are transferred through the upper and lower plastic portions of the tubing support to the plate 212 which in turn transmits the applied force through the base 204 to the wall or other supporting surface thereby virtually eliminating stress on the plastic components. Rotation of the overlying tubing 22 is prevented by the engaged ears as described above.
Many variations of the present invention within the scope of the appended claims will be apparent to those skilled in the art once the principles described herein are understood.
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A reinforced connector assembly for a tubular grab railing has an upper tubing support that is aligned with the grab railing during use and a lower base portion bolted directly to the tubing support fastened to a wall or floor. The tubing support has an opening that divides it into upper and lower halves with a reinforcing plate hidden between them to form a three layer sandwich structure with at least one boss confined during use within the tubing. The connector assembly is a composite formed from an outer plastic resinous connector element and the hidden reinforcing plate which can be formed from steel. The reinforcing plate which provides reinforcement for the plastic components can include exposed ears on each side that frictionally engage and distend the tubing to prevent it from rotating during use. An adjustable connector assembly has two pivotally related portions to permit angular adjustment on site. A corner elbow, an end connector and an end extension are provided.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. application Ser. No. 08/662,070, filed on Mar. 26, 1996, the disclosure of which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to expandable and collapsible window coverings and, more particularly, to expandable and collapsible window coverings having a cellular construction. In addition, the present invention relates to methods for making such window coverings.
BACKGROUND OF THE INVENTION
[0003] Expandable and collapsible cellular window coverings have enjoyed considerable success as a result of their pleasing aesthetic appearance and their insulating qualities. Conventionally, two types of these window coverings have been available. One type includes a plurality of elongated cells aligned one on top of the other in a single row. In one method for making a window covering of this “single cell” type, disclosed in U.S. Pat. No. 4,603,072 to Colson, a plurality of individual strips are folded into a tubular configuration and adhered together, one on top of the other, to form longitudinally extending cells. In another method, disclosed in U.S. Pat. No. 4,288,485 to Suominen, a plurality of strips of material are stacked and adhered together along spaced bands to form a curtain having a plurality of cells in a honeycomb arrangement. The curtain may be cut between the bands to provide a single row of cells aligned on top of one another. Yet another method for forming window coverings of this type is disclosed in U.S. Pat. No. 5,205,891 to Neff, in which the opposed pleats in two pleated sheets are joined together to form a single row of aligned cells. The foregoing methods suffer from significant drawbacks which primarily relate to the need to align and adhere together multiple strips of material, the need to align and adhere together multiple sheets of material, or the need to accurately align the pleats in one sheet with those in another.
[0004] Another type of expandable and collapsible window covering includes a plurality of elongated cells arranged in at least two rows of partially overlapping cells. Methods for forming this “double cell” type of window covering, such as disclosed in U.S. Pat. No. 5,160,563 to Kutchmarek et al. and U.S. Pat. No. 5,106,444 to Corey et al., generally involve folding a continuous sheet of material upon itself in alternating fashion and adhering adjacent folds together. These methods utilize significantly greater amounts of material than the methods for forming a single row of aligned cells, and therefore have a greater material cost for each square foot of window covering.
[0005] There therefore exists the need for an improved method for forming expandable and contractible window coverings having a single row of aligned cells which will overcome the problems associated with handling and aligning multiple sheets or strips of material, yet which will not use the lengths of material associated with the formation of “double cell” window coverings from a single continuous sheet of material.
SUMMARY OF THE INVENTION
[0006] The present invention addresses these needs.
[0007] One aspect of the present invention provides methods of making an expandable and collapsible, single-cell product for window coverings or the like from a single web of foldable material. In accordance with one method, a continuous length of material is pleated to form a plurality of first creases projecting toward a first side of the material and a plurality of second creases projecting toward a second side of the material. The first and second creases are interconnected by panels having a first face facing generally toward the first side and a second face facing generally toward the second side. Opposing second faces are then bonded along first bond lines at a spaced distance from the first creases in order to form a series of enclosed cells bounded by the first creases and the first bond lines. Opposing first faces are then bonded along second bond lines between the first creases and the first bond lines in order to form a second series of enclosed cells bounded by the second creases and the second bond lines.
[0008] The first creases are then removed from the material, opening the first series of enclosed cells. The first creases may be removed by abrading, and more specifically by first abrading with a coarse media, and then abrading with a fine media. The second series of enclosed cells remains connected by the first bond lines.
[0009] The bond lines may be applied so that the distance between the first creases and the second bond lines is less than the distance between the second creases and the first bond lines. Preferably, the first bond lines are about equidistant between the second creases and the second bond lines. The first bond lines may include at least two parallel connecting lines separated by a predetermined distance.
[0010] In accordance with another method, an expandable and collapsible product is produced by starting with a web of accordion folded material having a series of panels united in alternate succession along creased folds. The panels are unfolded, and adhesive is applied to an alternating side of each panel in a band parallel to and spaced from the preceding creased fold. The panels having adhesive applied thereto are then refolded along the creased folds, the band of adhesive being applied to adjacent panels joined by the creased fold. The creased folds on one side of the product are then removed, forming a plurality of aligned cells bounded by the other creased folds and bands of adhesive on one side of the panels. The plurality of aligned cells are connected to one another by bands of adhesive on the other side of the panels.
[0011] In yet another method, an expandable and collapsible product is produced by folding a web of material widthwise alternately in opposite directions along creased folds disposed at first and second sides of the web. This forms a series of normally flat panels of uniform width that are united in alternate succession along respective folds. The panels are then unfolded, and adhesive is applied on the second side of the web to one of each pairs of panels that are united along a creased fold. The adhesive is applied in a band parallel to and spaced from the creased fold. Adhesive is also applied to the first side of the web to one of each pair of panels that are united along a creased fold. That adhesive is applied in a band parallel to and spaced from that creased fold.
[0012] The pairs of panels are then refolded along the associated creased folds into contiguous relation to adhesively bond adjacent panels together along a band spaced from the associated creased folds. The creased folds on the first side of the web are then removed from the web to form a plurality of aligned cells bounded by the remaining creased folds and the bands of adhesive applied on the first side of the web. The plurality of aligned cells are connected to one another by bands of adhesive applied on the second side of the web.
[0013] In a still further method, an expandable and collapsible product is produced by coating portions of both faces of a continuously fed web with an adhesive bonding substance in a predetermined bonding pattern. The bonding pattern comprises a plurality of narrow parallel stripes extending transversely the length of the web. The web is then transversely creased at predetermined locations relative to the bonding pattern to establish a pleat pattern on the web. The creases extend parallel to the adhesive bonding stripes.
[0014] The coated and creased web is then folded along the transverse creases and upon itself in alternating opposite directions. A stack of alternatingly directed pleats is accumulated to form an array of tubular cells. Each cell extends transversely the length of the web, with adjacent cells being joined together by the adhesive bonding stripes. Finally, one of the creases is removed from the web. This opens a first series of tubular cells, while a second series of tubular cells remains connected to one another by the adhesive bonding stripes.
[0015] In yet a further method, an expandable and collapsible product is produced by coating portions of both faces of a continuously fed web with an adhesive bonding substance in a predetermined bonding pattern. The bonding pattern comprises a plurality of narrow parallel stripes extending transversely the length of the web. The web is then transversely creased at predetermined locations relative to the bonding pattern to establish a pleat pattern on the web. The creases extend parallel to the adhesive bonding stripes and establish, upon subsequent folding of the web at the creases, a desired registration of adhesive stripes.
[0016] The coated and creased web is then folded along the transverse creases and upon itself in alternating opposite directions to thereby bring selected pairs of adhesive bonding stripes into face-to-face contact.
[0017] A stack of alternatingly directed pleats is accumulated to form an array of tubular cells each extending transversely the length of the web. Adjacent cells are joined together at selected pairs of adhesive bonding stripes. Certain of the creases are removed from the web, opening a first series of tubular cells, while a second series of tubular cells remain connected to one another by selected pairs of adhesive bonding stripes.
[0018] In another aspect of the invention, an expandable and collapsible product for window coverings and the like is provided. The product comprises a plurality of strips of material having first and second longitudinal edges. Each strip of material has a creased fold extending parallel to the longitudinal edges, dividing the strip of material into first and second panels having opposed faces. A tab is formed by joining the opposed faces together along the longitudinal edges. Each strip of material then defines an elongated cell having the creased fold projecting toward a second side of the cell and the tab projecting toward a first side of the cell. A bond line joins the first panel of each cell to the second panel of the next adjacent cell intermediate the creased folds and the tabs.
[0019] The tabs may have a width between about 0.030 inches and about 0.250 inches. The bond lines may comprise at least two parallel strips of adhesive spaced apart by a predetermined distance.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] A more complete appreciation of the subject matter of the present invention and the various advantages thereof can be realized by reference to the following detailed description in which reference is made to the accompanying drawings in which:
[0021] FIG. 1A is a highly schematic end view of a partially expanded pleated material for forming the window covering of the invention;
[0022] FIG. 1B is a highly schematic end view of the pleated material of FIG. 1A after adhesive has been applied;
[0023] FIG. 1C is a highly schematic end view of the pleated material of FIG. 1A after bonding;
[0024] FIG. 1D is a highly schematic end view of the bonded pleated material of FIG. 1C after the first creases have been removed to form a single cell body;
[0025] FIG. 1E is a highly schematic end view of the single cell body of FIG. 1D after drilling;
[0026] FIG. 2 is a highly schematic perspective view of a fixture used in the step of removing the first creases in the method of the invention;
[0027] FIG. 3 is a cut-away perspective view of the expandable and collapsible window covering of the invention;
[0028] FIG. 4 is an enlarged partial perspective view of a tab in accordance with one embodiment of the window covering of the invention; and
[0029] FIG. 5 is an enlarged diagrammatic end view showing the positions of the bond lines relative to the creases.
DETAILED DESCRIPTION
[0030] The present invention relates to a pleated single-cell product for window coverings and the like, and a method of making such a product from a single web of foldable material. The method is an improvement over the method disclosed in U.S. Pat. No. 5,160,563, to Kutchmarek et al., the disclosure of which is hereby incorporated by reference herein. That patent discloses, a process for manufacturing a double cell or a multi-cell product for window coverings; i.e., a product having cells partially or completely displaced horizontally from one another. The present invention is addressed to a single-cell product; i.e., a product in which all cells are aligned vertically.
[0031] To manufacture an expandable and collapsible product that may be used as a window covering according to one method of the present invention, a continuous web of material 100 is first provided. The width of the continuous material may be the width of a single window covering, or may be large enough to cut several window coverings side-by-side from a single web. In a preferred embodiment, a nominal web width of eight feet or ten feet is used. Non-woven polyester fabric is the preferred material; however, any fabric, film or other web material that can be permanently creased may be used. The web may, for example, be formed of suitable plastic film such as polyester film, or from woven or non-woven material formed from various fibers, including natural and synthetic, such as polyester that retains a crease when folded in the presence of heat.
[0032] Where desired, web 100 may be printed or dyed in order to impart a color, a design or both to the finished window covering. In such an embodiment, stripes 101 running the width of the web, may be printed on one side of the web using a rotogravure printing process applying solvent or water-based pigments. Other printing processes, such as screen printing, may also be used. Alternatively, fabric webs may be dyed through their entire thickness using a solvent or water-based dye.
[0033] Stripes 101 , shown schematically in cross-section in FIG. 5 , are located and sized so that the side 22 of the completed window covering appears uniformly shaded in the color of the stripes. As will be appreciated from the discussion of the forming method hereinbelow, the unprinted regions between the stripes will appear in the interior of the cells 11 and on the other side 29 of the window covering. In an embodiment comprising 1½ inch nominal pleats as shown diagrammatically in FIG. 5 , the width of the stripes is 1 7/16 inches and the stripes are spaced apart 1 9/16 inches.
[0034] The continuous web of material 100 is next pleated widthwise as shown in FIG. 1A , in a direction parallel to stripes 101 . Where material 100 is a non-woven polyester fabric, the fabric may be creased at about 175 to 200 degrees F., as is known in the art. The pleats may be compressed together and allowed to cool for about one-half hour to ambient temperature. Individual panels 73 are formed in this step, and are bounded by a first crease 70 projecting toward the side 29 of the pleated fabric, and a second crease 21 projecting toward the side 22 of the pleated fabric. Each panel has a first face 71 generally facing toward the side 29 of the material and a second face 72 generally facing toward the side 22 of the material.
[0035] Preferably, the creases are located such that the second creases 21 fall at the midpoints of the stripes 101 and the first creases 70 fall at the midpoints of the unprinted regions between the stripes, all as illustrated in FIG. 5 .
[0036] Adhesive beads forming bonding lines 27 , 30 are next applied transversely to the continuous web of material 100 as shown in FIG. 1B . The adhesive is preferably applied in a thin bead along the length of the web using shuttle-mounted adhesive applicators as is known in the art and as disclosed in U.S. Pat. No. 5,160,563 to Kutchmarek et al. The preferred adhesive is a moisture cured polyurethane, although other adhesives such as thermoplastics, including polyamides and polyesters, thermoset plastics or cold bonding adhesives may be used. Alternatively, other bonding methods such as ultrasonic welding or laser welding may be used. Alternatively, a contact-type adhesive may be applied to both adjacent faces 72 at opposing locations within the pleats.
[0037] In a preferred embodiment, moisture cured polyurethane is applied at 275 degrees F. to form a bead 1/32 inches or less in cross-sectional diameter running parallel with the creases 21 , 70 . To apply the adhesive, two adjacent panels 73 are partially spread or unfolded from the side 22 , exposing the faces 72 . The adhesive may be applied to every other face 72 along a line C at a spaced distance from crease, 70 to form bonding line 30 . Bonding line 30 may consist of a single bead of adhesive. Preferably, however, bonding line 30 comprises two separate beads of adhesive 31 a and 31 b spaced apart a distance W 2 symmetrically about line C. The distance W 2 between adhesive beads 31 a and 31 b is preferably between about 1/32 inches and about ¼ inches, and most preferably about 3/16 of an inch.
[0038] The panels 73 are next spread or unfolded from the side 29 , exposing the faces 71 , shown in FIG. 1B . The adhesive may be applied to every other face 71 to form a bonding line 27 between crease 70 and bonding line 30 . Alternatively, a contact adhesive may be applied to both adjacent faces 71 at opposing locations.
[0039] In the preferred embodiment shown schematically in FIG. 5 , having a nominal panel width W of 1½ inches, line C may be located a nominal distance D 1 of 25/32 inches from crease 70 . Bonding line 27 may be located a nominal distance D 2 of 1/16 inches from crease 70 . Printed stripe 101 would extend from line C on one panel 73 across crease 21 to an equivalent point on the next adjacent panel 73 .
[0040] Before the adhesive sets, each panel 73 to which adhesive has been applied is compressed against the previous adjacent panel. The panels are compressed alternately from side 22 and side 29 as the adhesive is applied from the opposite side. For example, referring to FIG. 1B , after bonding line 27 has been applied to a face 71 , a compression blade (not shown) entering the stack from side 22 compresses that panel against the previously compressed panels. That motion exposes faces 72 on side 22 for the application of adhesive forming bonding line 30 . The process is continued until a length of window covering suitable for cutting to size is formed. Typically, a fourteen inch high stack of compressed pleats forms approximately thirty to forty-five feet of window covering.
[0041] As a result of compressing the panels 73 together, the bonding lines 30 , 27 , which had been beads of adhesive, are flattened and widened as they contact adjoining panels 73 . Thus, for example, a 1/32 inch bead of adhesive may form a bonding line ⅛ inches or more in width after the panels are compressed.
[0042] The pleated material after bonding is shown expanded in a schematic end view in FIG. 1C . At this point, the process has produced two rows of partially overlapping cells, but that structure differs from the structure of U.S. Pat. No. 5,160,563 to Kutchmarek et al in that the two rows of cells in this case have different sizes and shapes. Cells 11 in a first row are each enclosed by two panels 73 of the material and bounded at one end by a crease 21 and at the other end by a bonding line 27 . Each cell 9 in the other row is also enclosed by two panels 73 and is bounded by the a bonding line 30 and a crease 70 .
[0043] The material forming creases 70 is next removed to form the single cell configuration of the final expandable and collapsible product, as shown partially expanded in FIG. 1D . In a preferred removal step, crease 70 is sanded from the pleated material while the material is compressed as described above. A fixture 200 , shown in FIG. 2 , may be used to tightly compress the stack of pleated material 201 as the material is fed through a sanding machine. The fixture 200 has a compression means 204 , such as a spring-loaded plunger or hand screw, to maintain a compressive force on the pleated stack 201 during sanding. The bottom 202 of the fixture has perforations 203 to permit a vacuum to be applied through the bottom 202 in order to hold the pleated stack 201 in place. The sides 206 of the fixture are shorter in height than the width of the stack 201 in order to permit the removal of material by the sander.
[0044] In the currently preferred embodiment, a Model 137-2 HPK/A Knife Planner/Sander sold by Timesavers, Inc. of Minneapolis, Minn., U.S.A. removes creases 70 from the pleated material. The, fixture 200 preferably is fed into the sanding machine on a perforated feed belt having vacuum drawn through the perforations to retain the material in the fixture. The fixture 200 preferably is fed into the machine in a direction parallel to the pleats, represented by arrow 205 in FIG. 2 , with the sanding belts extending perpendicular to the pleats across the entire stack in order to minimize disturbance of the stack by the sanding forces generated. The sanding operation preferably is performed in two stages within the sanding machine. First, an 80-grit belt removes between 0.040 and 0.045 inches from the side 29 of the completed stack. Creases 70 is removed during this first sanding step. A second sanding step using a 100-grit belt removes an additional 0.005 inches. The second sanding step also removes frayed ends of fibers left by the initial sanding step.
[0045] Other material removal processes may also be used to remove creases 70 . For example, the compressed, pleated stack may be planed, knife-sliced, milled or laser cut. Alternatively, the individual cells 9 may be opened by slitting each crease 70 using a knife, a laser or other means.
[0046] A line S defining the sanding depth is shown schematically in FIG. 1C . The line is located between creases 70 , which are removed in the sanding operation, and bonding lines 27 , which remain intact. The sanding operation exposes co-extensive longitudinal edges 25 , 26 , shown in FIG. 1D . The longitudinal edges, in turn, form a free edge 36 . The material between edge 36 and bonding line 27 forms a tab 28 protruding from the side 29 of each cell 11 .
[0047] As an alternative to sanding the free edges 36 flat, a profile may be formed by varying the depth to which the tabs 28 are machined. For example, a repeating, uniform profile, such as a sinusoidal pattern shown in FIG. 4 , may be formed on the tabs during the material removal step described above. Alternatively, such profile may be formed subsequent to the above-described material removal step by using a sanding disk, a grinding wheel, a laser or other material removal means. In addition to repeating uniform profiles, other patterns or indicia may be formed in the tabs, including patterns that will display a mural or other art work when the window covering is in the expanded condition. So that they remain self-supporting in their free state, the tabs preferably have a width between bonding lines 27 and the free edges 36 of between about 1/32 inches and ¼ inches.
[0048] Where heavier materials are used or where the pleats are wide, individual pleats of the window covering may tend to sag toward the bottom. Restraints fabricated from cord may be used in the art to maintain the pleats at an even pitch over the length of the window covering. Holes (not shown) may be drilled in the tabs 28 in order to accommodate knotted cord or a laddered cord to perform this function.
[0049] After the creases 70 have been removed, the exposed free edges 36 may be colored by spraying, rolling or otherwise applying a dye, paint, pigment or other coloring. This may be done, for example, where panel faces 71 have been colored, in order to provide a color on the free edges 36 that matches, accents or coordinates with the panel color.
[0050] After completion of the crease removal step, an expandable and collapsible product according to the invention has been formed. That product may be used in the manufacture of a window covering according to the invention as described hereinbelow. The steps comprising the method of producing the expandable and collapsible product may be altered in order. For example, the step of applying the adhesive may precede the step of creasing the web of material, as disclosed in U.S. Pat. No. 5,106,444 to Corey et al. which is hereby incorporated by reference in its entirety herein.
[0051] Holes 35 , shown in FIG. 1E , may be formed in the expandable and collapsible product in order to use it in a pleated window covering. The holes are preferably centered on the width of the pleat, and are used for routing one or more of the braided cords 12 ( FIG. 3 ) through the window covering. The holes preferably are drilled, but alternatively may be punched, laser cut or otherwise formed. The holes are formed while the pleated window covering is in the compressed state. The holes 35 are preferably ⅛ inches in diameter to provide sufficient clearance for braided cords 12 to move smoothly therethrough without binding or catching.
[0052] In the embodiment in which two connecting lines 31 a and 31 b comprise the bonding line 30 , the hole 35 is drilled between the connecting lines as shown in FIG. 1E . Alternatively, where the first bonding line 30 is a single line of adhesive, the hole 35 may be drilled through the bonding line. It is preferred to drill between the connecting lines 31 a , 31 b , as opposed to drilling through a single bonding line, because the relative hardness of the adhesive slows the drilling operation and requires a greater drilling force. Further, adhesive that has been drilled tends to adhere to the drilling tool, interfering with the drilling operation.
[0053] The window covering is next cut to size. The cutting operation may be performed before or after drilling. In the embodiment in which the width of the window covering as manufactured exceeds the width of the finished products, the individual window coverings are cut to width using a saw, guillotine, hot wire, laser or other cutting means. In addition, the window coverings are cut to length in order to accommodate the individual window length. This may be done by using a saw, laser or hot wire, by shearing along a bond line 30 or by other means. Alternatively, the adhesive applicator for the bond line 30 may be programmed to skip one panel at a predetermined count of panels equaling the number of panels in a single window covering.
[0054] A braided cord 12 is routed through the holes 35 in each of the cells 11 . Near the top of the window covering 5 , the braided cord is routed through a pulley and retainer system (not shown) as is conventional in the art to enable an operator to expand and collapse the window covering. Grommets such as grommet 53 may be installed to provide a wear surface for the cord 12 . A headrail 58 and bottom rail 65 are attached to the top and bottom cells, respectively, as is known in the art. End caps 52 , 50 may be force fit into the headrail 58 and bottom rail 65 , respectively.
[0055] A completed expandable and collapsible window covering 5 according to the invention is shown in FIG. 3 . The product comprises a series of cells 11 arranged vertically on one or more braided cords 12 . Each of the cells 11 is aligned with the adjacent cells above and below.
[0056] As shown schematically in FIG. 1E , each cell 11 comprises a single strip of material 20 having a single creased fold 21 on a side 22 of the window covering. The creased fold 21 separates the strip of material into an upper panel 23 and a lower panel 24 . Each strip of material 20 has first and second longitudinal edges 25 , 26 . A bonding line 27 is formed by an adhesive that bonds the upper and lower panels 23 , 24 near the longitudinal edges 25 , 26 . The portions of the panels 23 , 24 between the bonding line 27 and the longitudinal edges 25 , 26 form a tab 28 having a width W 1 which preferably is between about 1/32 inches and ¼ inches, and most preferably less than about 1/16 inches wide.
[0057] Each cell 11 is joined to an adjacent cell at a bond line 30 . The width W 2 of the bond line 30 preferably is between about 1/32 inches and ¼ inches. In a currently preferred embodiment, the bond line 30 comprises two parallel connecting lines 31 a , 31 b formed of adhesive and spaced apart a predetermined distance. A cord hole 35 passes through each cell at or near the bonding lines 30 . Where two connecting lines 31 a , 31 b comprise the bonding line 30 , it is preferred that the cord hole 35 passes midway between the connecting lines, as shown in FIG. 1E .
[0058] The first and second longitudinal edges 25 , 26 form a free edge 36 at the end of each tab 28 . The expandable and collapsible window covering shown in FIG. 1E has uniform free edges 36 aligned with free edges of adjacent cells 11 . The tab width W 1 is uniform throughout the length L 1 , as shown in FIG. 3 . Alternatively, the free edge 36 may depict a design or indicia by varying the width W 1 . For example, as shown in FIG. 4 , the free edge 36 may be scalloped. The scallops may be aligned from cell to cell in order to depict vertical bands on the side 29 of the expandable and collapsible window covering. Alternatively, horizontal stripes, diagonal stripes, patterns or even pictures or murals may be depicted in a similar manner.
[0059] A pigment or dye 40 , shown schematically in FIG. 1E , may be applied to all or part of the side 22 of the expandable and collapsible window covering. The pigment or dye may be used to impart a solid color, a pattern or indicia on the window covering as described above.
[0060] The braided cord 12 , shown in FIG. 3 , passes through the holes 35 in cells 11 . The headrail 58 is connected to the uppermost of the cells 11 . The headrail improves the appearance of the window covering 5 , and provides a mounting surface to mount the window covering to the window. The bottom rail 65 is connected to the lowermost of the cells 11 . The grommets, such as grommet 53 , provide a wear surface for the braided cord 12 .
[0061] The braided cord 12 passes through each of the holes 35 ( FIG. 1E ) in each of the cells, maintaining the cells in alignment. The braided cord 12 may be extended and retracted in order to extend and collapse the window covering as is known in the art.
[0062] Although the invention herein has been described with reference to particular embodiments, it is to be understood that these embodiments are merely illustrative of the principles and applications of the present invention. It is therefore to be understood that numerous modifications may be made to the illustrative embodiments and that other arrangements may be devised without departing from the spirit and scope of the present invention as set forth in the appended claims.
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A method for producing a cellular window covering product includes the steps of pleating a continuous length of material, bonding together opposing faces on one side of the product to form a series of enclosed cells, bonding together opposed faces on the other side of the product to form another series of enclosed cells, and removing creases from one side of the product to open one of the series of enclosed cells while the other series of enclosed cells remains intact and connected. The creases may be removed by abrading the material along the creases. The opposed faces may be bonded by applying a bead of adhesive to one of the faces and compressing the faces together. Also provided is a window covering having an expandable and collapsible body. The body has a number of strips of material that are creased in the center parallel to the long edges, which are joined together to form a tab. Each of the strips of material define an elongated cell bounded by the creased fold on one side and the tab on the other. Successive cells are joined together by bond lines intermediate the folds and the tabs. A headrail is connected to the top of the body, and a bottom rail is connected to the bottom of the body. The body is provided with a means for raising and lowering the bottom rail with respect to the headrail.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present application claims priority from earlier filed provisional application Ser. No. 60/973,611, filed Sep. 19, 2007, entitled “Mobile Land Drilling Rig and Method of Installation by the same inventor.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to oil, gas and geothermal well drilling rigs and, more specifically, to a mobile well drilling rig and to the transport, assembly, and disassembly of such a rig.
[0004] 2. Description of the Prior Art
[0005] With the ever increasing pressure in recent years on domestic oil and gas production, it has become increasingly important to provide mobile drilling rigs which can be easily transported over the highway and which can be rapidly assembled and disassembled at the well site. For example, present well exploration and completion in the Barnett Shale region in Texas has expanded even into urban areas. In these and other settings, to be economically competitive, oil and gas drilling and exploration activities require the rapid deployment, assembly and disassembly of drilling structures. One way to accomplish these goals is to provide a mobile, highly capable rig which maximizes productive on-site drilling time in urban or rural settings, while minimizing essentially non-productive erection, disassembly and road transportation time. As a result, the transportability of components and the speed at which components can be assembled with the minimum amount of auxiliary equipment becomes a paramount concern.
[0006] A transportable drilling rig typically includes, for example, a support base, a derrick, pipe sections, and a drill floor Often times however, auxiliary support equipment such as cranes are required to facilitate the setup and takedown of large components such as the base, the drill floor, the pipe racking board, and the like, having the effect of increasing operational costs. Further, drilling sites are often located in remote areas requiring truck transportation of the components of the rig accompanied by equipment used to assemble the rig. In some cases, the process is further complicated by the need to change locations once a hole is drilled and it is determined whether the site will be sufficiently productive to merit a pumping installation, whether the site will be unproductive all together, or whether a more ideal location exists to drill a hole. Typically, site changes can occur once every several months, and, in response, prior art systems have attempted to increase the degree of mobility of rig components. Auxiliary equipment however is still necessary for performing many of the steps involved in assembly and disassembly of the rig.
[0007] Since the variable costs associated with leased support equipment, such as cranes and the like, are calculated on a per hour or per day basis, expediting the takedown, transport, and setup operations is crucial for minimizing equipment leasing costs. Typical takedown and setup time is on the order of days. With equipment leasing costs ranging from several hundred dollars per day or more, many thousands of dollars in costs may be incurred for each end of a setup and takedown operation. For larger or more complex rigs, the cost may be even higher. Even where the prior art drilling rigs are geared towards facilitating rapid setup, takedown and transport, they have still generally required external cranes, external winches, and the like which increase the overall expense.
[0008] A number of factors contributed to the takedown and setup time required by the prior art systems. For example, in the past, disassembly of the drilling rig mast assemblies normally required unstringing and removal of the traveling block cables and traveling block prior to lowering the mast from the drill rig or at least prior to disassembly or telescoping of the mast preparatory to moving on to a new well site. Also, erection of the mast assemblies of the prior art mobile drilling rigs tended to delay start-up of drilling operations since the drill-pipe cannot be moved into a suitable ground position for racking until such time as the mast is raised to the vertical and the pipe racking ground area is cleared. Further, the access road to a drilling rig normally courses directly up to the drawworks side of the rig. Where the intended well site is located on marshy ground, it is normally necessary to expend substantial time and effort in grading and stabilizing a substantial ground area completely around the rig in order to provide access and working area for the necessarily heavy equipment required to move and erect the mast. These are merely intended to be exemplary problems of the type encountered by the prior art, as there were numerous other problems associated with assembly and disassembly of drilling rigs of the type under consideration.
[0009] Although a number of prior art references exist which show purported “portable” or mobile drilling rigs, such devices tended to suffer from one or more deficiencies. One such prior art system for erecting an oil well derrick is shown in U.S. Pat. No. 3,922,825, to Eddy's et al, issued on Dec. 2, 1975. Eddy's system employs a stationary substructure base with a companion movable substructure base mounted thereon. Eddy's movable substructure base is coupled to the stationary base but swings upright into an elevated position on a series of struts that are connected to the stationary base. Eddy's movable base is otherwise stationary, since neither the stationary base nor the “movable” base are mobile or repositionable without the use of an auxiliary crane. Also, simply raising the movable substructure base and the drill mast requires the use of a winch mounted on an auxiliary winch truck.
[0010] Another prior art system for assembly of a drill rig is shown in U.S. Pat. No. 3,942,593, to Reeve, Jr., et al, issued on Mar. 9, 1976. The Reeve apparatus includes a trailerable telescoping mast and a separate sectionable substructure assembly further comprising a rig base, a working floor, and a rail means. The mast is conveyed to the top of the substructure by rollers and may be raised by hydraulic raising means to the upright position. A disadvantage of the Reeve system is the need for drawlines and a winch to raise the mast onto the working floor.
[0011] U.S. Pat. No. 4,269,395, to Newman et al., issued May 26, 1981, shows a portable rig which includes a telescoping mast for telescoping to a reduced length for transport. The mast is also cantilevered in use so that the traveling block moves vertically at one side of the mast.
[0012] U.S. Pat. No. 4,290,495, to Elliston, issued Sep. 22, 1981, shows a portable workover rig with a base platform and a collapsible mast which is movable from a reclining position during transport to an erect position in operation.
[0013] U.S. Pat. No. 4,821,816, to Willis, issued Apr. 18, 1989, shows an “Apache” modular drilling machine. The machine has a substructure skid and a platform which supports a draw works. A pipe boom is mounted on another skid and is designed to fit between skid runners on the drilling substructure skid. The drilling substructure skid supports four legs which are pivotally mounted at the platform and at the substructure. A pair of platform cylinders are provided to raise and lower the drilling platform.
[0014] U.S. Pat. No. 4,899,832, to Biersheid, issued Feb. 13, 1990, shows a modular drilling apparatus that is transported in modular units to the well site. The apparatus includes a drilling unit and two raising units that are locked to the respective opposite sides of the drilling unit. After base structures on the raising units are lowered to the ground to provide a support, the towers of the raising units and the mast of the drilling unit are simultaneously elevated to the vertical.
[0015] U.S. Pat. No. 6,634,436, to Desai, issued Oct. 21, 2003, shows a mobile land drilling rig with a mobile telescoping substructure box which assists in the rapid placement, assembly, disassembly and repositioning of the drilling rig and associated drilling equipment.
[0016] U.S. Pat. No. 6,860,337, to Orr et al., issued Mar. 1, 2005, describes a process for lowering or raising a drilling rig for transportation. The top drive is moved within the mast with a vertical guide and torque reaction mechanism to a locked position prior to transport.
[0017] As has been mentioned, a number of the devices shown in the above described prior art require the need for auxiliary equipment such as cranes, winch trucks and the like to erect the derrick. Several of the systems described above require a large substructure that must be set down with a crane prior to the imposition of any additional structure thereupon. Further movement or repositioning of the base structure requires cranes or other heavy equipment to effect movement of the component parts.
[0018] It is therefore an object of the present invention to provide a mobile land rig that is self sufficient and thus capable of being transported, erected, and disassembled without the need for extensive auxiliary equipment such as cranes and winch trucks. Such a system would save costs associated with leasing cranes and the like for periods of days during erection and disassembly of rigs.
[0019] Another object of the invention is to provide a drilling rig system with a self contained substructure base capable of being easily moved. Such a system would allow rapid placement and repositioning of the substructure base without the need for a crane or the like.
[0020] Another object of the invention is to provide such a drilling system wherein all system components are easily trailerable and transportable by truck. Such a system could be easily moved from one site to another with a minimum of setup and takedown time.
[0021] The above needs and objectives are met in the invention as described in the discussion which follows.
SUMMARY OF THE INVENTION
[0022] It is accordingly a principal object of the present invention to provide an improved mobile drill rig assembly having advantages over the prior art systems described above.
[0023] It is another object of the invention to provide a mobile drill rig assembly which is rapidly erected and dismantled at the well site.
[0024] It is yet another object of the invention to provide a drill rig assembly having good wind stability.
[0025] It is another object of the invention to provide a drill rig assembly including a support base and working floor which is trailerable and which can be rapidly erected to a working height at the well site.
[0026] It is another object of the invention to provide a one piece derrick mast assembly which is itself a trailerable component of the system.
[0027] The drilling rig of the invention is adapted for use in oil, gas and geothermal exploration and drilling operations. In particular, the present invention is a mobile land rig and method for the rapid placement, assembly, disassembly, and repositioning of such an oil and gas drilling rig and associated drilling equipment. The rig includes a variety of drilling rig components including at least a base support structure, a drawworks trailer, a one-piece derrick initially carried on the drawworks trailer, a pipe handler, a mud delivery system and a power package.
[0028] Preferably, the drawworks trailer has at least a rear axle coupled thereto, the axle having at least one set of wheels for supporting both drawworks and the derrick in rolling relation to a ground surface when the derrick is in a horizontal, transport position on the drawworks trailer. A pair of oppositely arranged hydraulic piston-cylinders are located on either of two sides of the drawworks trailer, the cylinders being pivotally connected at one end to the trailer and at an opposite end to the rig derrick, whereby activating the piston-cylinders between a retracted position and an extended position causes the derrick to move between the horizontal, transport position and a vertical, working position. Movement of the derrick from the horizontal, transport position to the vertical, working position serves to off-loading the derrick from the drawworks trailer to the base support structure.
[0029] The pipe handler which is used with the mobile land rig of the invention includes a Y-shaped yoke element with gripping jaws located at either of two opposite extents thereof, the yoke element being positionable between a horizontal pipe receiving position and a vertical pipe delivery position. The pipe handler jaws are sized to handle pipe up to 13⅝ inches in diameter.
[0030] The mobile rig of the invention also preferably includes a stationary ramp having an inclined, upper ramp surface, the ramp being delivered to the drilling site on ground engaging wheels. Driving the drawworks trailer up the inclined surface of the stationary ramp serves to raise one end thereof with respect to an opposite end of the trailer. The opposite end of the trailer is equipped with a hydraulic piston-cylinder for thereafter raising the rear end of the trailer hydraulically so that the derrick forms a horizontal plane with respect to the ground prior to the erection of the derrick.
[0031] The derrick is adapted to receive a top drive drilling apparatus.
[0032] The mud delivery system of the mobile rig of the invention includes at least one mud process tank having a curved tank bottom.
[0033] The rig components also preferably include both a bottom dog house and a top dog house. The top dog house is preferably equipped with at least one hydraulic piston-cylinder for hydraulically raising the dog house and at least one hydraulic piston cylinder to pin and secure the top dog house once raised.
[0034] The improved method for erecting, transporting, and disassembling a drilling rig on the ground from variety of rig components includes, as a first step, rolling the drilling rig components into proximity with a drilling site on ground engaging wheels, where the drilling rig components include at least a base support structure, a drawworks trailer, a one-piece derrick initially carried on the drawworks trailer, a pipe handler, a mud delivery system and a power package. The one-piece derrick is raised from a horizontal, transport position to a vertical, working position while off-loading the derrick from the drawworks trailer to the base support structure. In the preferred method of assembly and disassembly of the invention, the drilling rig components are delivered and assembled without the use of cranes.
[0035] Additional objects, features and advantages will be apparent in the written description which follows.
BRIEF DESCRIPTION OF THE DRAWINGS
[0036] FIG. 1 is a plan view of the assembled drilling rig of the invention showing the various components thereof,
[0037] FIG. 2 is an isolated, perspective view of the pipe handler component of the drilling rig of the invention;
[0038] FIG. 3 is a simplified view of a portion of the draw works trailer of the drilling rig of FIG. 1 showing the drill line spool on the opposite end of the trailer from the draw works;
[0039] FIG. 4 is a view of a portion of the mast of the drilling rig of FIG. 1 showing the integrated top drive, traveling block and components thereof;
[0040] FIG. 5 is an isolated view of the utility boom component of the drilling rig of the invention;
[0041] FIGS. 6-10 illustrate, in simplified fashion, the steps involved in assembling the base support structure and associated components of the drilling rig of FIG. 1 ;
[0042] FIGS. 11-15 are a simplified, schematic representation of the steps involved in erecting the derrick mast structure, showing the loading of the derrick being transferred from the drawworks trailer to the base support substructure of the rig;
[0043] FIG. 16 is top view of the assembled drilling rig of the invention showing the various component parts thereof.
DETAILED DESCRIPTION OF THE INVENTION
[0044] The embodiments herein and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments that are illustrated in the accompanying drawings and detailed in the following description. Descriptions of well-known components and processes and manufacturing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the invention herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the claimed invention.
[0045] Turning to FIG. 1 of the drawings, there is shown a highly mobile and capable drilling rig that can be assembled and disassembled in record time as compared to the devices of the prior art. In one exemplary form, the total rig transports in just 16 trailer loads, saving time and money. The loads are compact and self-contained. Rig-up is faster than in the prior art and is hydraulically powered. The entire rig is designed to be moved without the use of cranes.
[0046] The mobile drilling rig of the invention is designed to streamline drilling operations with fast moves and more efficient drilling operations. The rig can be used over a broad depth range, i.e., on the order of 6,000 to 12,000 feet. The rig footprint is smaller, which means lower construction costs and less environmental impact or the necessity of extensive site preparation. The pipe handling system is mechanized and safer for rig crews to use, allowing a single operator to make a connection, if necessary.
[0047] The assembled rig, as shown in FIG. 1 , includes a horizontal pipe handler (shown in simplified fashion as 11 in FIGS. 1 , 11 , 15 and 16 ) located adjacent an upper dog house 13 and a lower dog house 15 . Once delivered on site, the upper dog house 13 is raised to a desired height by means of hydraulic cylinder legs 14 , 16 . The pipe handler 11 sits in front of the derrick 17 and the draw works trailer 19 . The pipe handling system includes a hydraulically powered, remotely operated pipe boom (best seen as 47 in FIG. 2 ). A pair of spaced jaws 49 , 51 receive a stand of horizontally stored pipe ( 53 in FIG. 16 ). The boom then pivots at the yoke end ( 55 in FIG. 16 ) between the rest position shown in FIGS. 2 and 16 and a vertical position (not shown) aligned with the derrick for making a pipe connection and inserting the joint of pipe into the string of drill pipe extending into the well bore. The pipe boom can handle tubulars from 2⅞ inches to 13⅝ inches in diameter.
[0048] As will be appreciated from FIG. 2 , the pipe boom 47 of the pipe handler has a series of upright pillars 12 , 14 and 16 , each of which forms a primary structural support for the pivoting tubular section 18 . The tubular, section 18 is pivoted in a horizontal plane as viewed in FIG. 2 by means of the hydraulic cylinders 8 , 10 . The pivoting action orients the gripping jaws 49 , 51 for gripping a stand of pipe located in the horizontal pipe racks ( 53 in FIG. 16 ). Each of the upright pillars 12 , 14 and 16 has an engagement collar ( 20 , 22 , 24 in FIG. 2 ) which can be bolted and unbolted from the top surface of the respective pillar. In this way, the entire pivoting tubular section 18 with its gripping jaws 49 , 51 can be removed and switched out with, for example, a boom having gripping jaws of a different size range for handling a different size of pipe.
[0049] Returning to FIG. 1 , immediately behind the dog houses are located a water tank 21 , a lubrication skid 23 , a hydraulics package 25 , a power unit generator package 27 , and a fuel tank 29 . The tankage provided on site in the form of the water tank 21 and fuel tank 29 comprises, for example, a 285 barrel cylindrical water tank capacity and a 500 barrel cylindrical diesel fuel tank, respectively. The power system can be, for example, a CAT C-15; CAT 455 KW (two each) generators capable of providing continuous output. This diesel engine/generator can individually produce 540 hp of maximum continuous power at a rotation speed of 1200 rpm. The output voltage of the AC generator is 60 Hz, 480 volts.
[0050] In the particular version of the invention illustrated in simplified version in FIG. 1 , the derrick 17 is a one piece mast with integrated top drive (shown in greater detail as 26 in FIG. 4 ). The mast is a single piece 72 foot structure using a split block hoisting on a 1⅛″ drill line. The wire line unit can be, for example, an Oil Works OWI-1000™ holding 12,000′ of 0.092 to 0.108 inch wire. The crown block is an IDS model having a rated capacity of 500,000 SHL. There are 7 vertical sheaves and 1 horizontal sheave. The sheaves in the crown/traveling block have been upgraded from 24 inches to 30 inches. The traveling block is a Cowan Integrated 4-Sheave Split Block™ having a rated capacity of 250 tons. There are 4 sheaves of 30″ diameter, labeled as 28 , 30 , 32 , 24 in FIG. 4 . The derrick has a set of C-shaped front rails ( 18 in FIG. 1 ) to accommodate the travel of the top drive. The top drive can be, for example, a Venture Tech XK-250™ 250 ton drive providing a maximum torque of 24,000 ft/lbs at a maximum speed of 160 RPM. The top drive has a 5,000 psi pressure rating. The dimensions of the exemplary derrick base and crown illustrated are 8′1″ wide×6′ deep.
[0051] As can be best seen in FIG. 4 , the 4 sheave traveling block and top drive 26 have oppositely arranged “bat wings” 36 , 38 which engage the C-shaped rails of the derrick structure and allow the top drive unit to move vertically along the mast. In earlier versions of the drilling rig, the utility lines 40 which extend downwardly from the top drive were found to create an undue load off one side of the mast which affected the travel of the top drive along the mast. As a result, the top portion of the bat wings have now been extended in length from the original three and one half feet to five and one half feet, the extended portion being designated as “1” in FIG. 4 . The extended length of the bat wing improves the load distribution and provides added stability for the top drive as it moves along the derrick mast legs.
[0052] The rig drawworks ( 99 in FIG. 1 ) is comprised of a Rig Tech RT-400B™ powered by a CAT C-15 engine with a rated input power of 540 hp. The drawworks is shown in greater detail in FIG. 3 . The drawworks drum 42 is a 18″×25⅛″ diameter grooved drum supported between bearing assemblies 44 , 46 , and is provided with a disk drum style brake system which provides an auto spool safety feature. The spool arrangement also allows the operator to move the wear points in the drill line 48 by slipping and cutting, e.g., 70-100 feet of line between drilling sessions. The maximum hook load of the assembly with 8 lines is 435,000 lbs. An independent fresh water cooling system is provided for the drawworks and clutch brake, such as the Eaton-Airflex Model RT-BWCS-101™.
[0053] At the derrick base there will be located a conventional make-up/break-out tool (not shown) such as the Gray EOT Floor Hand™, providing up to 80,000 ft/lbs of torque for making and breaking drill pipe connections as well as rig floor pneumatic air slips. The rotary opening of the derrick substructure is approximately 14′8″ above ground level in the exemplary illustrations. The slip bowl capacity is 250 tons with a clearance height below the slip bowl to ground level of 10′6″.
[0054] The additional rig components located in the foreground include a trip tank/choke skid 31 , a mud process skid 33 and a mud mixing skid 35 . The trip tank/choke skid 31 houses a trip tank, choke manifold and mud-gas separator. Mud pump skids 37 and 39 are located adjacent the mud mixing skid 35 A utility swing arm 41 pivots from a support point on the mud process and mixing skid.
[0055] FIG. 5 shows the utility swing arm 41 in greater detail. The swing arm 41 has opposing ends 50 , 52 and an intermediate length. The end 50 pivots about a pivot point 54 located on the mud process skid 35 . The length of the swing arm accommodates a number of different water and electrical lines, generally designated as 56 in FIG. 5 . The swing arm 41 replaces the previous arrangement of utility lines running on the surrounding ground encased in rectangular boxes, moving the lines to an unobtrusive overhead location which improves the safety aspects of the arrangement and eliminates a danger of tripping over the lines. The pivot point 54 allows the swing arm to be pivoted, between the deployed position shown in FIG. 5 , and a retracted or stowed position (not shown) aligned with the side of the mud skid for transport purposes. The opposing end of pivot point 54 also provides a “quick disconnect” point for the swing arm during rig mobilization activities. It can then be stored in the mud tank, if desired.
[0056] The mud pump skids 37 , 39 accommodate either 1,000 hp or optional 1,300 hp triplex pumps and available Caterpillar™ engines, in this case the 3508 and 3512 engines. For example, the mud pumps can be Weatherford MP10™ or MP13™ pumps driven by variable speed diesel engines. The maximum rated working pressure for the mud pumps is 5,000 psi in the example illustrated. The transfer/mixing pumps used on the unit can be, for example, two 5″×6″ W/50 H.P. Electric Motors™ mixing pumps having 11″ impellers that are rated for 80 to 110 gallons per minute flow.
[0057] These pumps are used together with two charging pumps which can be 5″×6″ MCM Pinion Shaft™ designs having an output capacity of 80 to 110 gallons per minute using 11″ impellers. The mud process skid 33 and mud mixing skid 35 feature curved bottom tanks 36 , 38 and together comprise a 700 barrel active, two tank system equipped with conventional shale shakers, a desander and a desilter (not shown).
[0058] The well blow-out preventer (best seen as 45 in FIG. 2 ) can be of conventional design such as, for example, the Townsend Type 90™ 11×5M annular type; or the Townsend Type 82™ 11×5M double ram which is used in conjunction with a M.D. Cowan 2-Rail BOP™ skid trolley.
[0059] Turning now to FIG. 6 of the drawings, there is shown, in simplified fashion, the beginning step in the assembly of the mobile drilling rig of the invention. In FIG. 6 , a semi-trailer rig has delivered and deposited the mixing skid for the process mud system. FIG. 7 shows the similar delivery of the process mud skid 33 which is aligned longitudinally with the mixing skid 35 and joined by an intermediate platform 53 and steps 55 , 57 . FIG. 8 shows the delivered mud pumps 37 , 39 , each being delivered on a skid 59 , 61
[0060] FIG. 9 shows the support base (designated generally as 63 ), drill floor 65 and oppositely arranged side extensions 67 , 69 . The pipe handler (shown in simplified fashion in FIG. 9 ) is also aligned with the well head and the support base and is positioned in a plane generally parallel to but spaced apart from the mixing skid 35 and process skid 33 of the mud system. FIG. 10 shows the side extensions 67 , 69 raised to form a horizontal support surface on either side of the drill floor 65 .
[0061] FIG. 11 shows the rig derrick 17 being delivered atop a drawworks trailer 19 The drawworks trailer is backed up a ramp substrate 71 to a point adjacent the support base 63 . Once the drawworks trailer 19 is backed up the ramp substrate 71 , the trailer cab is removed and the hydraulic legs 73 at the front end of the trailer 19 are actuated to level the front end of the trailer. With the drawworks trailer 19 in position, the rig derrick 17 can then be moved from the horizontal transport position shown in FIG. 11 to the vertical, working position shown in FIG. 12 .
[0062] FIGS. 13-15 illustrate the off-loading of the rig derrick 17 from the drawworks trailer 19 in simplified, schematic fashion. As shown in FIG. 13 , the derrick 17 is pivotally mounted on the drawworks trailer 19 by means of a pair of oppositely arranged hydraulic piston cylinders ( 75 , 77 in FIG. 12 ). Each piston cylinder, e.g., cylinder 75 in FIG. 13 is attached at opposing pivot points 79 , 81 . Movement of each piston cylinder 75 , 77 from the retracted position shown in FIG. 13 to the fully extended position (the intermediate position being shown in FIG. 15 ) causes the rig derrick 17 to be raised from the horizontal transport position to the vertical position shown in FIGS. 1 and 15 . This movement of the hydraulic piston cylinders 75 , 77 also causes the load of the derrick to be shifted off the drawworks trailer 19 and onto the support base substructure 63 of the drilling rig. While the hydraulic piston cylinders 75 , 77 might not actually be physically detached, as shown in FIG. 15 , this figure is intended to illustrate the point that the rig weight now resides on the support base 63 , rather than upon the drawworks trailer 19 , including its axles and tires 83 . Note the force vector “F” in FIG. 15 showing the direction of the weight of the drilling rig once the derrick 17 is in the fully erect position.
[0063] FIG. 16 is a top view of the fully assembly drilling rig showing the relative position of the various component parts of the rig.
[0064] Thus, the improved method for erecting, transporting and disassembling a drilling rig on the ground from variety of rig components includes, as a first step, rolling the drilling rig components into proximity with a drilling site on ground engaging wheels, where the drilling rig components include at least a base support structure, a drawworks trailer, a one-piece derrick initially carried on the drawworks trailer, a pipe handler, a mud delivery system and a power package. The one-piece derrick is raised from a horizontal, transport position to a vertical, working position while off-loading the derrick from the drawworks trailer to the base support structure. In the preferred method of assembly and disassembly of the invention, the drilling rig components are delivered and assembled without the use of cranes.
[0065] An invention has been provided with several advantages. As will be appreciated from the foregoing, the mobile rig of the invention is self sufficient in the sense that it is capable of being transported, erected, and disassembled without the need for large and extensive auxiliary equipment such as cranes. This results in a cost savings in eliminating the need for leasing cranes or other expensive erection equipment for periods of days during erection and disassembly of the rig. The rig is made up of components which are easily trailerable and transportable by tractor-trailer. As a result, the entire system can be easily moved from one site to another with a minimum of setup and takedown time. The drawworks trailer which initially transports the rig derrick is driven up a stationary ramp and leveled by means of hydraulic cylinders on the front end of the trailer. Another set of hydraulic piston-cylinders then moves the one-piece derrick from the horizontal, transport position to the vertical, working position where it is off-loaded onto the support base for the rig. This completely removes the vertical load from the drawworks trailer and places it on the more permanent and stationary support base of the rig.
[0066] While the invention has been shown in only one of its forms, it is not thus limited but is susceptible to various changes and modifications without departing from the spirit thereof.
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A highly mobile and capable oil, gas and geothermal well drilling rig is shown which provides for the rapid placement, assembly, disassembly, and repositioning of various rig components of the drilling rig The drilling rig includes a support base and working floor which is trailerable and which can be rapidly erected to a working height at the well site. A special drawworks trailer both transports the drawworks and the rig derrick. Hydraulic cylinders on the drawworks trailer are used to move the derrick from a horizontal, transport position to a vertical, working position. At the same time, the weight of the derrick is off-loaded from the drawworks trailer to the base support structure. The selection and arrangement of the various rig components provides a faster set up and take down operation than was previously obtained.
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BACKGROUND OF INVENTION
[0001] 1. Field of Invention
[0002] The present invention relates to a post driver. More specifically, the present invention relates to a vibration dampening post driver for driving posts into the ground more comfortably and with less risk of injury.
[0003] 2. Background Art
[0004] Fences have been used to mark territorial boundaries, prevent trespassers from entering a property, and contain livestock. These fences require that hundreds or thousands of posts be driven into the ground at regular or evenly spaced intervals. Historically, fence builders used large hammers to drive posts, though this was backbreaking—and often dangerous—work.
[0005] There have been some advances in the post driving art area. Cylindrical post driving devices, such as that shown in Hunt, U.S. Pat. No. 2,098,146—including a post tube, which is open only at the bottom of the tube, and handles on both sides of the tube—were invented long ago. In use, these post driving devices were positioned with the open end of the tube over the post, grasped at the handles, and repeatedly driven down so that the closed top end of the tube impacted the top of the post, driving the post into the ground.
[0006] However, these traditional post driving devices caused a great deal of vibration and tended to be very jarring to the hands and wrist of the user. Users of these post driving devices often experienced pain in their arms and back and typically experienced discomfort in their hands after repeated use.
[0007] More recent advances in the area included the use of springs located inside and at the top of the post tube, also known as a driver housing, to somewhat dampen the force of the blow received when the posts are driven into the ground, such as that shown in Iddings, U.S. Pat. No. 2,998,087, and Bowers, U.S. Pat. No. 5,097,912. However, these newer post driving devices with springs internal to the post tube are limited in that the size and number of springs utilized is limited, and thus the dampening ability is minimal. While better than traditional post driving devices that have little or no impact dampening abilities, even these newer post driving devices do not contain sufficient impact dampening capabilities for many people who need to drive a large number of posts. Also, the location of the dampening spring is not effective for dampening the forces transferred from the handles to the hands or wrist of the user.
[0008] Consequently, a need has long been felt for a post driving device with better dampening abilities to better cushion the jarring impact of driving posts into the ground.
BRIEF SUMMARY OF THE INVENTION
[0009] One or more of the embodiments of the present invention provide for an impact dampening post driving device which includes a shaft having an interior cavity extending to a downward facing opining or openings at a distal end of said shaft. Brackets are physically mounted onto the outside of the shaft for attaching the handles to the shaft. The handles are attached to the bracket by a floating mount. The floating mount allows for a dampening device or spring to be positioned between the handle attach points, or mounting flanges, and the brackets. For example, in one embodiment the mounting flange of a handle has an oversized aperture, and the bracket has a similarly sized aperture where the mounting flange is floatingly mounted to the bracket by threading an undersized bolt through the apertures and capturing the bolt with a nut larger than said apertures. A dampening device is then positioned within the floating region between the bracket and mounting flange. In this way, a dampening spring sits between each handle and the shaft, as opposed to the handles being mounted directly to the shaft.
[0010] The dampening device or dampening spring by definition can be any elastic device or shock absorbing device, such as for example, but not limited to a bushing made of elastomeric material or a coiled spring or any other elastic device that substantially regains its original shape after compression or extension.
[0011] A user can grasp the handles and lift the device over a post such that the post is aligned with the opening at the bottom of the shaft. The user can then force the shaft down over the post such that the post enters the interior cavity through the downward facing opening and strike the closed top end of the shaft. This creates vibration and shock in the shaft, but the dampening springs between the shaft and the handles greatly reduce the vibration and shock reaching the handles held by the user, thus reducing the force transferred to the hands, arms and wrist of the user.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] For a better understanding of the present invention, reference may be made to the accompanying drawings in which:
[0013] FIG. 1 is an elevation view of the post driving device.
[0014] FIG. 2 is a bottom view of the post driving device shown in FIG. 1 .
[0015] FIG. 3 is a magnified view of the top dampening assembly shown in FIG. 1 .
[0016] FIG. 4 is a magnified view of the bottom dampening assembly shown in FIG. 1 .
[0017] FIG. 5 is an elevation view of an alternative embodiment.
[0018] FIG. 6 is a bottom view thereof.
DETAILED DESCRIPTION OF THE INVENTION
[0019] A shock-dampening post driving device, according to an embodiment of the present invention, includes a shaft having an axially extending interior cavity that extends to a closed top end of the shaft and to a distal open bottom end of the shaft. The closed top end of the shaft forms a striking surface that is used to strike posts. The shaft also has a first mounting bracket extending from an exterior wall of the shaft. Additionally, an upper mounting flange of a handle is mounted to the first mounting bracket of the shaft by a first floating mount with a first floating region. Further, a first dampening spring is positioned between the upper mounting joint of the handle and the first mounting bracket. This first dampening spring extends into the first floating region, where it dampens vibration between the shaft and the handle.
[0020] Another embodiment of a shock-dampening post driving device includes a handle mounted to a shaft by a first floating mount having a first floating region, where the first floating mount allows the handle to float or oscillate within said first floating region. Additionally, a first dampening spring is positioned between the handle and the shaft, where the first dampening spring extends into the first floating region, and where the first dampening spring dampens vibration between the shaft and the handle.
[0021] An embodiment of a shock-dampening post driving method includes striking an object with [a closed top end of] a shaft [while said object is in an axially extending interior cavity of said shaft] and dampening vibration between the shaft and a handle. The handle is floatingly attached to the shaft by a floating mount, and the dampening occurs in a dampening spring positioned in a floating region of the floating mount between said handle and said shaft.
[0022] FIGS. 1 and 2 illustrate multiple views of a post driving device 100 according to a preferred embodiment of the present invention. As shown in FIG. 1 , the post driving device 100 includes a cylindrical shaft 110 having a closed top end 112 forming a striking surface 117 , and an axially extending interior cavity 114 extending to a distal open bottom end 116 . The post driving device 100 of FIG. 1 further includes two handles 120 , two upper dampening assemblies 130 , two lower dampening assemblies 140 , and a level 150 .
[0023] Each handle 120 is physically connected to an upper dampening assembly 130 and a lower dampening assembly 140 . Both upper dampening assemblies 130 are physically mounted to the cylindrical shaft 110 toward the top end 112 of the cylindrical shaft 110 . Both lower dampening assemblies 140 are physically mounted to the cylindrical shaft 110 toward the bottom end 116 of the cylindrical shaft 110 . The level 150 is physically mounted proximate the top end 112 of the cylindrical shaft 110 . The axially extending interior cavity 114 is inside the cylindrical shaft 110 and extends to the open bottom end 116 .
[0024] In operation, a post is held vertically on the spot where it is to be driven into the ground. The open bottom end 116 of the cylindrical shaft 110 is then placed over the top end of the post, and the post is allowed to slide up through the open bottom end 116 of the cylindrical shaft 110 into the axially extending interior cavity 114 of the cylindrical shaft 110 until the top of the post comes to rest against the closed top end 112 of the cylindrical shaft 110 . The level 150 in the cylindrical shaft 110 then alerts the user if the post is currently perpendicular to the ground
[0025] The user of the post driver device 100 grasps the handles 120 , one in each hand, and lifts the post driver device 100 . Once the post driver device 100 has been sufficiently lifted, the user quickly forces the post driver device 100 downward onto the post, such that the post again slides up through the open bottom end 116 of the cylindrical shaft 110 into the axially extending interior cavity 114 of the cylindrical shaft 110 until the closed top end 112 of the cylindrical shaft 110 , which acts as a striking surface, forcefully impacts the top of the post, driving the post into the ground. This impact creates a great deal of vibration and shock in the cylindrical shaft 110 that is transferred to the handles 120 . The upper damper assemblies 130 and the lower damper assemblies 140 dampen the vibration generated in the cylindrical shaft 110 before the shock and vibration reach the hands and body of the user. The previous post driver designs, which have the handles rigidly mounted to the cylindrical shaft, does not dampen the force transferred to the hands of the user, and the post drivers having the interior springs are not very effective because they only require the user to drive downward with a greater velocity and more force in order to drive a post.
[0026] The cylindrical shaft 110 may alternatively have a non-circular cross-section, such as a triangular, rectangular, or pentagonal cross-section, or any other shaped cross-section. The cylindrical shaft 110 may be made of a metal or metal alloy, or other material conducive to repeated impacts. The level 150 may alternatively be mounted anywhere on the post driving device 100 , and more levels may be added to give information on more than just one axis. The closed top end 112 of the cylindrical shaft 110 may have some sort of a weight or durable substance with which to exert even more force on a post being driven into the ground. The post driver device 100 may be used to drive things other than posts in directions other than down into surfaces other than the ground. There may alternatively be more or less than two handles 120 , and more or less than two upper damper assemblies 130 and two lower damper assemblies 140 . Further, handles 120 may alternatively be mounted to more or less than two dampener assemblies 130 , 140 , though never less than one.
[0027] FIG. 3 shows a magnified view of the upper damper assembly 130 according to an embodiment of the present invention. As shown in FIG. 3 , the upper damper assembly 130 includes a first mounting bracket 131 , a first damper 132 , a first bolt 133 , a first nut 134 , a third mounting bracket 135 , and a handle 120 having an upper mounting flange 125 at one end.
[0028] The first mounting bracket 131 and the third mounting bracket 135 are affixed to the cylindrical shaft 110 . Between the two mounting brackets 131 , 135 are, from bottom to top, the first damper 132 , the upper mounting flange 125 of a handle 120 , and the first nut 134 . The first bolt 133 is inserted through an aperture of the first mounting bracket 131 up through an aperture in the first damper 132 and an aperture in the upper mounting flange 125 of a handle 120 , and is secured in place by the first nut 134 . A portion of the first bolt 133 extends through the first nut 134 and up through an aperture in the third mounting bracket 135 . This creates a floating mount between the upper mounting flange 125 of the handle and the brackets 131 , 135 attached to the cylindrical shaft 110 .
[0029] In operation, the first bolt 133 and first nut 134 hold the components of the upper damper assembly 130 in place. The third mounting bracket 135 and first mounting bracket 131 connect the upper damper assembly 130 to the cylindrical shaft 110 . The first bolt 133 connects the first damper 132 and the upper mounting flange 125 (and thus the handle 120 ) to the third mounting bracket 135 and the first mounting bracket 131 , while the first nut 134 secures the first bolt 133 in place. The positioning of the components allows the upper mounting flange 125 (and thus the handle 120 ) to oscillate or float along the first bolt 133 and compress the first damper 132 when the closed top end 112 of the cylindrical shaft 110 is brought down and strikes an object. This dissipates much of the vibration and shock before it can travel from the cylindrical housing 110 to the handles 120 . The first damper 132 then rebounds, pushing the upper mounting flange 125 (and thus the handle 120 ) back to its original position, completing one oscillation. In other words, the floating mount created by this assembly allows the upper mounting flange 125 of the handle 120 to oscillate or float up and down along a floating region 137 in which the damper 132 is installed.
[0030] In the alternative, things other than the first bolt 133 and first nut 134 may be used to hold the components of the upper assembly 130 in place in a floating relationship, such as adhesive, rivets, welding or other bonding techniques. The first damper 132 may take the form of dense foam or other elastomeric material or shock absorbing material, or may alternatively be a dampening spring or other mechanical shock absorbing device such as a pneumatic or hydraulic shock absorber. The order of the components in the upper damper assembly 130 may change, such as the position of the first nut 134 moving from under to over the third mounting bracket 135 or any similar change. The first damper 132 size and dampening ability may vary according to the needs of the user.
[0031] FIG. 4 shows a magnified view of the lower damper assembly 140 according to an embodiment of the present invention. As shown in FIG. 4 , the lower damper assembly 140 includes a second mounting bracket 141 , a second damper 142 , a second bolt 143 , a second nut 144 , and a handle 120 having a lower mounting flange 127 at one end.
[0032] The second mounting bracket 141 is connected to the cylindrical shaft 110 . Above the second mounting bracket 141 is, from bottom to top, the second damper 142 , and the lower mounting flange 127 of the handle 120 . The second bolt 143 is inserted down through an aperture in the lower mounting flange 127 , through an aperture in the second damper 142 and an aperture in the second mounting bracket 141 , and is secured in place by the second nut 144 below the second mounting bracket 141 to a portion of the second bolt 143 extending through an aperture in the second mounting bracket 141 . This creates a floating mount between the lower mounting flange 127 of the handle 120 and the second mounting bracket 141 attached to the cylindrical shaft 110 .
[0033] In operation, the second bolt 143 and second nut 144 hold the components of the lower damper assembly 140 in place. The second mounting bracket 141 connects the lower damper assembly 140 to the cylindrical shaft 110 . The second bolt 143 connects the second damper 142 and the lower mounting flange 127 of the handle 120 to the second bracket 141 , while the second nut 144 secures the second bolt 143 in place. The positioning of the components allows the lower mounting flange 127 (and thus the handle 120 ) to oscillate or float along the second bolt 143 and compress the second damper 142 when the closed top end 112 of the cylindrical shaft 110 is brought down and strikes an object. This dampens much of the vibration and shock before it can travel from the cylindrical housing 110 to the handles 120 . The second damper 142 then rebounds, pushing the lower mounting flange 127 (and thus the handle 120 ) back to its original position, completing one oscillation. In other words, the floating mount created by this assembly allows the lower mounting flange 127 of the handle 120 to oscillate or float up and down along a floating region 147 in which the damper 132 is installed.
[0034] In the alternative, things other than the second bolt 143 and second nut 144 may be used to hold the components of the lower assembly 140 in place, such as adhesive, rivets, welding or other bonding techniques. The second damper 142 may take the form of dense foam or elastomeric material or shock absorbing material, or may alternatively be a dampening spring or other mechanical shock absorbing device such as a hydraulic or pneumatic shock absorber. The order of the components in the lower damper 140 assembly may change, such as the orientation of the second bolt 144 being flipped 180 degrees such that it is inserted from the top down as opposed to from the bottom up, or any similar change.
[0035] FIGS. 5 and 6 illustrate multiple views of a post driving device 500 according to a preferred embodiment of the present invention. As shown in FIG. 5 , the post driving device 500 includes a cylindrical shaft 510 having a closed top end 512 forming a striking surface 517 , and an axially extending interior cavity 514 extending to a distal open bottom end 516 . The post driving device 500 of FIG. 5 further includes two handles 520 , two upper dampening assemblies 530 , two lower dampening assemblies 540 , and a level 550 .
[0036] Each handle 520 is physically connected to an upper dampening assembly 530 and a lower dampening assembly 540 . Both upper dampening assemblies 530 are physically mounted to the cylindrical shaft 510 toward the top end 512 of the cylindrical shaft 510 . Both lower dampening assemblies 540 are physically mounted to the cylindrical shaft 510 toward the bottom end 516 of the cylindrical shaft 510 . The level 550 is physically mounted proximate the top end 512 of the cylindrical shaft 510 . The axially extending interior cavity 514 is inside the cylindrical shaft 510 and extends to the open bottom end 516 .
[0037] In operation, a post is held vertically on the spot where it is to be driven into the ground. The open bottom end 516 of the cylindrical shaft 510 is then placed over the top end of the post, and the post is allowed to slide up through the open bottom end 516 of the cylindrical shaft 510 into the axially extending interior cavity 514 of the cylindrical shaft 510 until the top of the post comes to rest against the closed top end 512 of the cylindrical shaft 510 . The level 550 in the cylindrical shaft 510 then alerts the user if the post is currently perpendicular to the ground
[0038] The user of the post driver device 500 grasps the handles 520 , one in each hand, and lifts the post driver device 500 . Once the post driver device 500 has been sufficiently lifted, the user quickly forces the post driver device 500 downward onto the post, such that the post again slides up through the open bottom end 516 of the cylindrical shaft 510 into the axially extending interior cavity 514 of the cylindrical shaft 510 until the closed top end 512 of the cylindrical shaft 510 , which acts as a striking surface, forcefully impacts the top of the post, driving the post into the ground. This impact creates a great deal of vibration and shock in the cylindrical shaft 510 that is transferred to the handles 520 . The upper damper assemblies 530 and the lower damper assemblies 540 dampen the vibration generated in the cylindrical shaft 510 before the shock and vibration reach the hands and body of the user. The previous post driver designs, which have the handles rigidly mounted to the cylindrical shaft, does not dampen the force transferred to the hands of the user, and the post drivers having the interior springs are not very effective because they only require the user to drive downward with a greater velocity and more force in order to drive a post.
[0039] The cylindrical shaft 510 may alternatively have a non-circular cross-section, such as a triangular, rectangular, or pentagonal cross-section, or any other shaped cross-section. The cylindrical shaft 510 may be made of a metal or metal alloy, or other material conducive to repeated impacts. The level 550 may alternatively be mounted anywhere on the post driving device 500 , and more levels may be added to give information on more than just one axis. The closed top end 512 of the cylindrical shaft 510 may have some sort of a weight or durable substance with which to exert even more force on a post being driven into the ground. The post driver device 500 may be used to drive things other than posts in directions other than down into surfaces other than the ground. There may alternatively be more or less than two handles 520 , and more or less than two upper damper assemblies 530 and two lower damper assemblies 540 . Further, handles 520 may alternatively be mounted to more or less than two dampener assemblies 530 , 540 , though never less than one. The handle can include a dampening device system 550 and 551 and gripper handle 552 in addition to the damper assembly 130 described above or in lieu of damper assembly 130 .
[0040] One or more embodiments of the present invention dissipate the vibration and shock that are created by driving posts into the ground more readily than current post drivers through the use of more and bigger and better dampers mounted directly between the handles and cylindrical shaft of the device. This increased shock absorption decreases the strain on the user of the device, which lessens the likelihood of injury and allows users to use the device for longer periods of time.\
[0041] While particular elements, embodiments, and applications of the present invention have been shown and described, it is understood that the invention is not limited thereto because modifications may be made by those skilled in the art, particularly in light of the foregoing teachings. It is therefore contemplated by the appended claims to cover such modifications and incorporate those features which come within the spirit and scope of the invention.
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A post driver having a dampening device adapted to isolate the hands and arms of the user from shock.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE DISCLOSURE
This disclosure is directed to an apparatus for drilling slant holes. A slant hole is used to tunnel beneath rivers or similar areas. As one example, slant holes can be used to drill under highways and other areas where trenching activities are not acceptable. The slant hole is useful for going under areas where construction work is prevented or costly. In a typical situation, the hole that is drilled is formed at a very shallow angle with respect to the surface. As an example, the well may enter the surface at a slant angle while drilling. Drilling is accomplished by mounting a drive unit connected to a kelly which is rotated by the drive unit. This slant well drilling apparatus is not the same as a conventional well drilling apparatus which forms conventional oil or water wells. The kelly, in turn, is threaded to a first joint of drill pipe. As drilling progresses, additional joints of drill pipe are added between the drill string and the kelly. Moreover, the drilling process utilizes electrically powered and guided control mechanisms at the end of the drill string. The end of the drill string supports a drill bit and various steering devices which enable drilling in the desired direction. The equipment at the drill bit, including the steering device, requires an electrical connection. Ordinarily, this is accomplished by positioning an electrical cable through the drill string extending to the kelly which is a hollow member. Each time a joint is added, the electrical conductor must be cut, additional lengths spliced in it and it must be rethreaded through the added joint of pipe. The present disclosure is directed to an apparatus which reduces the number of cuts required for the conductor string and therefore expedites drilling speed. The present apparatus is incorporated within a drill string to enable quick connection and disconnection, and to further enable continued drilling.
The present disclosure is directed to an insert having the form of a cartridge with protruding lugs. It is axially hollow to provide a flow path through the device for drilling fluid. In the ordinary situation, drilling fluid is introduced through the kelly and is forced through the drill string and emerges from the drill bit. This flow forces electrical cables deployed in the drill string down the drill string to the drill bit. The present apparatus is a device which stores an excessive amount of electrical cable or wire, but it is spooled out slowly to avoid cable accumulation which would otherwise occur. It requires a specified pull on the cable which is held within a housing. The cable is pulled turn by turn from the housing and deployed in the drill string. This avoids bunching of the cable in the drill string.
Through the use of the present equipment, a connector is located in the drill string which enables quick and easy connection and disconnection as a joint of pipe is added. Moreover, the device is readily moved from a first joint of pipe into the new joint of pipe after the first joint has been drilled into the well. This procedurally speeds up the addition of another joint of pipe in the drill string.
The present apparatus is summarized as a cartridge which has protruding tabs or ears which extend outwardly at the top end. This enables it to be locked at a pin and box coupling in the drill string. It has a transverse bar which serves as a hook or eyelet for retrieval so that it can be pulled upwardly. The cartridge has a transverse top end which is drilled in the center with a passage of sufficient diameter to serve as a mud flow path for drilling fluid which is pumped through the drill string. It is relatively short, shorter than a typical joint of drill pipe. Moreover, the top end supports a fixed connector functioning as an electrical feedthrough. The top of the connector connects with an externally directed conductor. The bottom of the connector connects with a coil of wire which is stored in an internal cavity. The wire is sufficiently long to span several joints of drill pipe. It is stored and held out of the way between a pair of cylindrical tubular sleeves. The inner sleeve defines the axial mud flow path while the outer sleeve is concentric around the inner sleeve defining a narrow space. The coiled wire is pulled free through a resilient lip which retards feeding of the wire.
BRIEF DESCRIPTION OF THE DRAWINGS
So that the manner in which the above recited features, advantages and objects of the present invention are attained and can be understood in detail, more particular description of the invention, briefly summarized above, may be had by reference to the embodiments thereof which are illustrated in the appended drawings.
It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
FIG. 1 shows a river crossing drilling procedure utilizing a kelly connected at the top end of a drill string formed of multiple joints of drill pipe and terminating at a drill bit with steering equipment wherein electrical power is required through a conductor in the drill string;
FIG. 2 is a sectional view through a portion of the drill string showing the present apparatus located at the top most joint of drill pipe just below the kelly and further showing a conductor extending from the cartridge of this disclosure to the lower end of the drill string;
FIG. 3 is a view similar to FIG. 2 showing a first joint of drill pipe which has been drilled down, a second joint added in the drill string and further showing the cartridge of the present disclosure prior to pulling the cartridge through the second joint of pipe;
FIG. 4 is a view similar to FIG. 3 showing the cartridge after it has been pulled up in the drill string so that it is now at the top end of the second joint of pipe, and further including the kelly which is then connected to continue drilling;
FIG. 5 is a sectional view longitudinally of the cartridge of the present disclosure showing its construction; and
FIG. 6 is a sectional view along the line 6--6 of FIG. 5 showing details of construction of certain latches which are included to hold the cartridge at a specified depth in the well.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Attention is now directed to FIG. 1 of the drawings where a river crossing is being drilled. This will be explained to provide the context of the present apparatus and its method of use. In FIG. 1 of the drawings, a drilling system is generally identified at 10. It is typically mounted on a flat bed trailer which is sloped or tilted at a requisite angle to cause a kelly 12 to align at a particular angle with respect to the surrounding ground. The drill string penetrates the earth typically at a slant angle of perhaps of a few degrees. The kelly 12 is powered by the power plant in a fashion believed to be well known. It extends through a guide bushing 14, and is reciprocated on adding joints of pipe in the drill string. The drill string is identified generally by the numeral 16, and is made up of individual joints of pipe. There is a drill bit 18 at the remote end of the drill string. The drill bit typically is installed in conjunction with various steering tools. In general terms, the equipment at the drill bit 18 requires electrical power for operation. Accordingly, an electrical conductor is strung through the drill string. The present disclosure describes how this conductor can be placed in the drill string more readily.
The drill string 16 is made up of individual joints of drill pipe 20. They are constructed in accordance with industry standards to have pin and box connections at the two ends. They typically are about thirty feet in length. The steering tool, cooperative with the drill bit 18, deviates the slant hole 22. It is typically drilled subject to control of the steering tool so that it passes underneath a surface obstacle such as the river 24. Other surface obstacles can be avoided in similar fashion. It is not uncommon to direct the slant hole 22 for several hundred or several thousand feet. Slant holes can be drilled for a few thousand feet or more. Ordinarily, in drilling the slant hole, the drill string 16 provides an axial passage for drilling fluid which is pumped through the kelly 12 and into the drill string. It emerges from the drill bit and normally saturates the surrounding soil, forming a mud cake which defines the hole 22. It helps secure the side walls to prevent collapse after the drill bit has passed. Typically, the slant hole 22 is drilled in the fashion shown in FIG. 1 so that it traverses at a controlled depth below the surface of the ground and the two ends of the slant hole 22 may be exposed at controlled locations several thousand feet apart.
One routine involves the drilling of the slant hole to complete a river crossing of a pipeline. It is desirable that the pipeline be buried well below the water level in the river. As an example of one such installation, the drill pipe might have a nominal measure of five and one half inches while the drill bit forms a hole of about nine and one half inches. The pipeline to be installed might be larger such as a twelve inch pipeline. When the drill bit 18 emerges at the remote end of the slant hole 22, it is removed, and a reamer is then attached. The reamer is also connected with the twelve inch pipe making up the pipeline. The drilling equipment is then used to pull the drill string 16 back out of the hole. In backing out, the reamer cuts the hole larger to the diameter necessary to receive and hold the pipeline which is then installed. The pipeline is installed as the reamer is pulled from the slant hole. This procedure involves removal of the drill string joint by joint. This proceeding can be carried out without electrical power required for the drill bit.
Attention is now directed to FIG. 2 of the drawings. There, the top most joint of pipe is identified by the numeral 30. It is threaded to the kelly 12. The present disclosure is generally identified by the numeral 32. It is inserted at the end of the pipe 30 and catches so that it is held. The pipe and kelly are joined with the conventional pin and box connection. The cartridge 32 extends an electrical conductor 34 in a fashion to be described in detail hereinafter. Compare FIGS. 2 and 3; in FIG. 2, the kelly is connected to the pipe 30. In FIG. 3, an additional joint 36 has been added to the drill string. The joint 36 is added by first breaking the threaded connection between the kelly 12 and the pipe 30. After breaking the threaded connection, the kelly is retracted for clearance whereby the pipe joint 36 can be inserted in the drill string. It is threaded to the pipe 30 with a conventional pin and box connection. The upper end of the pipe 36 is left clear of connection for the moment for additional procedures to be carried out. At this point, the cartridge 32 of the present disclosure is still located in the pipe joint 30. The procedure of the present disclosure envisions placing a rope or line with a hook in the pipe 36. The line 38 supports a hook which hooks the cartridge 32 and pulls it upwardly through the pipe joint 36. It is constructed so that it can be pulled with the soft line 38.
As shown in the contrast of FIGS. 3 and 4, when the cartridge is pulled up, the conductor 34 is strung through the new joint of pipe.
The cartridge 32 is shown in greater detail in FIG. 5 of the drawings. There, the cartridge is shown to be formed of a top circular flange 40 which has a handle 42 thereabove. The handle or eyelet is for gripping a hook on the end of the rope or line 38. The flange 40 has holes at 44 and 46 which surround an electrical feedthrough connector 48. At the top end, it connects with a surface located conductor extended through the kelly. At the lower end, the connector 48 joins to the wire 34. In other words, the feedthrough connector 48 can be broken at the top end and bottom end. The feedthrough is used so long as the cartridge 32 is in the system. As first one cartridge and then the next is exhausted of cable, cable segments are interconnected by connectors not involving the feedthrough 48.
The flange 40 supports at least two, preferably three or four protruding latches 50. The latch 50 extends outwardly and is forced outwardly by a bias spring 52. It is rotated on a shaft 54, the shaft spanning a notch or recess 56. The latch is able to rotate approximately ninety degrees. The bias spring forces it outwardly as shown in FIG. 5. It can be forced to rotate where it points downwardly in FIG. 5. This enables the cartridge 32 to be pulled relatively upwardly through a joint of pipe. Because the latch extends, the device cannot fall down the pipe. The latches are sized in conjunction with other dimensions of the cartridge so that the latches extend and hold in the pipe when the cartridge 32 catches at the pin and box coupling.
The cartridge is constructed with two concentric cylindrical sleeves. The inner sleeve is affixed to the flange plate 40. It is identified by the numeral 60. The sleeve 60 is on the interior and defines a mud flow passage 62. The passage 62 extends the length of the cartridge. There is a second sleeve 64. The sleeve 64 is concentric to the first sleeve 60. An annular gap between the two is defined. The gap is partially filled by means of a resilient liner sleeve 66 between the two sleeves. The liner sleeve frictionally engages the bights of the coiled wire 34. A port 70 permits the wire 34 to be extended from the feedthrough connector 48 into the space between the two cylindrical members 60 and 64. The gap is sized so that the wire fits in the gap snugly, and the bights are wound in the gap rather tightly. This frictionally grips the wire 34. The wire typically is a multi-conductor cable which is formed of one or more electrical conductors, each of which is electrically insulated, and the wire has an outer sleeve which defines it as a generally round member. The wire extends downwardly as it emerges from the gap between the two sleeves 60 and 64. The resilient liner 66 is biased to define a closure lip 72. This lip fits snugly around the sleeve 60. The wire is pulled downwardly through this lip. As the bights of the wire are pulled downwardly, the wire emerges from the gap adjacent the resilient lip 72 and unspools something in the fashion of a spinning reel. The unspooled wire, however, does not come out freely; rather, there is a drag encountered because the liner 66 grips the wire and holds it against the sleeve 60. This assures that the wire cannot spool freely through the gap at the lower end of the cartridge 32.
The cartridge is relatively easy to assemble. In the initial assembly sequence, the wire 34 is connected to the feedthrough 48 and then is wrapped around the exposed exterior surface of the sleeve 60. It is wrapped around this from one end to the other. After the cylinder 62 has been wrapped to the lower end, the next step is to slide the resilient sleeve 66 over the wire and to position the outer metal sleeve 64 on the exterior. The latter two components can be bonded together as desired so they slide as a unit over the wire wrapped cylinder 60. The notch 70 is aligned so that it will be properly positioned relative to the feedthrough 48 and the upper end of the wire 34. When assembled, the wire 34 hangs from the lower end of the device, the multiple bights of the wire being looped around the sleeve 60 and the wire can thereafter be pulled free, but only on exerting a specified pull.
The cartridge 32 will typically store enough wire to span many joints of pipe. Actual cartridge storage capacity is a scale factor depending on the size of the wire, the gap for receiving the wire and the length of the cartridge. In the preferred embodiment, the cartridge should not exceed the length of a joint of the drill pipe. The latches 50 should extend outwardly and therefore have an extended diameter sufficient to lock against the top end of the drill pipe, namely, at the box end where entry into the stem of the pipe is prevented. The axial passage is preferably sized so that fluid flow is not restricted during use. In use, when the drill string is first assembled, it comprises only the kelly, one joint of pipe and the drill bit and associated apparatus, and the cartridge 32 is positioned in the only joint of pipe and the conductor 34 is extended downwardly to connect with the steering equipment and other electrical power consuming equipment at the lower end of the drill string. The cartridge is then pulled from the first joint of pipe into the next joint of pipe after drilling down the first joint. The sequence of adding pipe is suggested in FIGS. 2, 3 and 4. As the first joint 30 is drilled down, the threaded connection with the kelly 12 is broken and the next joint of pipe 36 is then prepared for positioning in the drill string. The joint 36 is ideally first threaded with a soft line 38 which has a hook on the bottom of the line, and that hook is engaged with the eyelet 42, shown in FIG. 5. This strings the joint 36 on the soft line, so to speak. The threaded connection is made as shown in FIG. 3 and the cartridge is then pulled upwardly through the drill string. It is pulled to the position shown in FIG. 4, namely, where the latches pop out and extend into the box end and connection can now be made. In other words, the cartridge 32 is pulled up as shown in FIG. 4, latches at that point in the drill string and is secure against falling down the drill string. The wire 34 has been pulled out sufficiently to span the length of the joint 36. The feedthrough connector 48 is used to connect and disconnect so that electrical power is provided through the wire and that connection is thus shown in FIG. 4 also. The soft line 38 is disconnected after the cartridge has been landed. The kelly is then threaded into the drill string as suggested at the right hand end of FIG. 4. Further drilling then occurs. This drills down the joint 36 until another joint of pipe has to be added.
Ultimately, the cartridge 32 is depleted of cable. At that time, it can be discarded, and a second cartridge installed which is loaded with cable. The cable in the single cartridge is typically enough to span many joints of pipe. These electrical connections are made and unmade more readily. So, the first cartridge is depleted, leaving the cable 34 hanging out of the drill string whereupon the next cartridge is brought into play. The next cartridge is connected by connecting the wire 34 from it to the wire already in place in the drill string. The number of wire to wire connections which are exposed on the interior of the drill string is markedly reduced. This enables the operator to install the second cartridge in the drill string for operation in the illustrated fashion.
When drilling fluid flows through the drill string, it creates a downward pull on the wire. The wire does not pull free of the cartridge because the wire is gripped by the lip 72 and held tightly. This tight grip places controlled drag on the cable as the cable is pulled out of the cartridge. In drilling 1,000 feet, approximately thirty-three joints of pipe are required. In the old approach, this required approximately sixty-six electrical connections in the electrical cable strung through the drill string. The present invention reduces the electrical splices to only three or four. In this example, greater speed is accomplished by using this apparatus to speed up drilling down joint after joint. Operator speed is markedly enhanced by the present procedure. One estimate is that the present apparatus will decrease rig down time and add about two hours of drilling time per day in a typical situation.
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A method for positioning an added length of wire in a drill string is set forth, and it is especially intended for use in drilling a slant hole, as typically occurs to drill under a river, or under other surface obstacles. A cartridge is disclosed; it has an upper flange at one end, a hook or eyelet across the flange to engage a hook and line for pulling the cartridge along the drill string, and further includes latching means for latching the cartridge at a specified location in a drill string. It further includes a spool for storage of wire, and the wire extends from an annular space for storage and the annular space is defined by a pair on concentric cylindrical sleeves. A method of use is also set forth wherein the cartridge is moved from drill pipe joint to joint and supports an elongate wire which is spooled therearound and which is pulled from the spool position. The wire, on emerging, encounters frictional drag to assure that only the wire length necessary is spooled out of the device.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
This application claims the benefit under 35 U.S.C. 119(e) of U.S. Provisional Patent Application No. 61/453,123 filed Mar. 15, 2011. Such provisional application is hereby incorporated by reference in its entirety into this application.
FIELD OF THE INVENTION
The present invention relates generally to a barrier for an inside of a home, particularly to a barrier having two panels that slide parallel to each other, and specifically to such a barrier having wooden rectangular frames for aesthetic purposes and to minimize weight.
BACKGROUND OF THE INVENTION
One type of gate intended for the inside of a home may be a pressure gate that, by its structure and design, is supported by internal pressure between, for example, two door jambs. These gates are often formed of metal or include a relatively great amount of metal.
Another type of gate intended for the inside of a home may be a gate that is fixed via pin connectors to and between two opposing structures such as two opposing door jambs. These gates too are often formed of metal or include a relatively great amount of metal.
SUMMARY OF THE INVENTION
A feature of the present invention is the provision in an in-house residential barrier, of four panels cooperating with each other so as to be self-supporting or so as to stand alone, of the four panels including two main panels and two side panels, of each of the panels including a rectangular wood frame and metal grid, of each of the two side panels having a bottom horizontally extending frame member cutting through each of the planes in which the two main panels reside to extend to the front and back of each of the two main panels, and of the bottom horizontally extending frame member being one-piece and integral to minimize parts for assembly.
Another feature of the present invention is the provision in an in-house residential barrier, of a first panel including a first rectangular wood frame and a first metal grid within the first rectangular wood frame, of a second panel including a second rectangular wood frame and a second metal grid within the second rectangular wood frame, of the first and second panels being engaged to each other and being slideable relative to each other in parallel fashion, and of each of the grids being received in channels formed in inner peripheries or inner edges of the rectangular wood frames.
Another feature of the present invention is the provision in an in-house residential barrier, of a first panel comprising a first rectangular frame and a first grid within the first rectangular frame, of a second panel comprising a second rectangular frame and a second grid within the second rectangular frame, with the first and second panels being engaged to each other and being slideable relative to each other in parallel fashion, of a connector between the first and second panels, of the connector including a base, of the base traversing each of the first and second panels, of the base being fixedly connected to one of the first and second panels and including a lip for confronting the other of the first and second panels that slides within the lip, and of the connector further including a swinging clamp pivotally connected to the base and engagable to the panel that slides within the lip to fix the first and second panels relative to each other in a nonsliding fashion.
Another feature of the present invention is the provision in such an in-house residential barrier, of the swinging clamp including first and second ends, of the first end being pivotally connected to the base, and of the second end including a roller, where the roller engages the panel that slides within the lip to fix the first and second panels relative to each other in a nonsliding fashion.
Another feature of the present invention is the provision in an in-house residential barrier, of at least two main panels, and of the two main panels being slideably adjustable relative to each other and fixable relative to each other with a swinging clamp.
Another feature of the present invention is the provision in a locking mechanism for permitting first and second objects to slide by each other and for fixing the first and second objects together in a nonsliding fashion, of a base for being fixed to the first object, of a lip for confronting the second object, with the lip being engaged to the base, and of a swinging element having first and second ends, with the first end being pivotally connected to the base on a first axis, with the second end having a roller on a second axis, with the first and second axis being parallel, whereby the swinging element swings to an unlocked position in which the first and second objects can slide by each other, whereby the swinging element swings to a locked position in which the roller engages the second object and in which the first and second objects are fixed together in a nonsliding fashion.
An advantage of the present invention is that the present in-house residential barrier is lightweight. One of the features contributing to this advantage is that each of the frames of each of the panels is wood. Another feature contributing to this advantage is that each of the panels includes lightweight rods, lightweight tubes, lightweight bars or lightweight wires to run between top and bottom horizontal frame members and to run between vertical side frame members.
Another advantage of the present invention is that sharp edges are minimized. One of the features contributing to this advantage is that wood is employed to serve as rectangular frames around each of the four panels.
Another advantage of the present invention is aesthetics. The in-house residential barrier is more pleasing to the eye with wood frames around each of the four panels.
Another advantage of the present invention is that the length or width (i.e., the distance between two opposing door jambs for example) of the barrier is slideably adjustable.
Another advantage of the present invention is that the length or width (i.e., the distance between two opposing door jambs for example) of the barrier is incrementally adjustable. One feature contributing to this advantage is the swinging clamp that can lock in several positions, such as when a roller of the swinging clamp is seated in a channel that also receives the metal grids, and such as when the roller abuts a rod of the grid and rests on an edge or corner of a horizontal member without protruding into the grid.
Another advantage of the present invention is that the material used to make the two side panels has been minimized. For example, the bottom horizontally extending frame member of the side panels runs to each of the front and rear of the main panels. On the rear or rear face of the main panels, a rear section of the bottom horizontally extending frame member also serves as a portion of a fence or fence section of the barrier. However, on the front or front face of the main panels, a front section of the bottom horizontally extending frame member serves only the stabilizing purpose. This front section has been provided with a minimum height so as to minimize tripping. This front section is rectangular in shape.
Another advantage is ease of fixing the main panels relative to each other. The connector or swingable clamp or roller latch is easy to open and easy to close. The roller latch pops into or snaps into a locked position and pops out of or snaps out of the locked position. Features contributing to this ease of operation are, for example, the roller on the swinging end of the clamp, the offset in the vertical direction between the axis of the pin of the base end of the swinging clamp and the axis of the pin of the roller when the roller is seated in the channel that also receives the grid.
Another advantage is that the swinging clamp or roller latch does not mar, dent, scratch or otherwise damage the wood of the panels which the roller latch engages. Relative to many metals such as aluminum and steel, wood is a soft material.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective detail view of the present in-house stand alone residential barrier having main panels and side panels, with the main panels interconnected with swinging clamps.
FIG. 2 is a perspective detail view of the present in-house residential barrier of FIG. 1 , where the barrier includes the main panels of FIG. 1 interconnected with swinging clamps, where the barrier does not include the side panels of FIG. 1 , and where the barrier further includes in-line connectors between the main panels and a vertical surface.
FIG. 3A is a perspective detail view of the swinging clamp of FIG. 1 , showing the swinging clamp in an open position.
FIG. 3B is a perspective detail view of the swinging clamp of FIG. 3A , showing the swinging clamp in a closed position.
FIG. 3C is a section detail side view of the swinging clamp of FIG. 3A , showing the swinging clamp in an open position.
FIG. 3D is a section detail side view of the swinging clamp of FIG. 3A , showing the swinging clamp in a position between the open and closed positions.
FIG. 3E is a section detail side view of the swinging clamp of FIG. 3A , showing the swinging clamp in a closed position.
FIG. 4 is a perspective detail view of the present in-house residential barrier of FIG. 1 having main panels and side panels, with the main panels interconnected with swinging clamps, and with one of the main panels having a pet door.
DESCRIPTION
As shown in the FIG. 1 , the present self-supporting or stand alone in-house barrier with four panels is indicated by reference number 10 . Self-supporting barrier 10 includes main panels 12 , 14 and side panels 16 , 18 . Each of the panels 12 , 14 includes therein a grid or mesh 20 and each of the side panels 16 and 18 includes therein a grid or mesh 21 . The self-supporting barrier 10 further includes a set of four connectors 22 between the main panels 12 , 14 that permit the main panels 12 , 14 to slide relative to each other and that fix the main panels 12 , 14 relative to each other such that the main panels 12 , 14 cannot slide relative to each other. The self-supporting barrier 10 further includes a set of eight feet 24 to space the barrier 10 from a surface such as a floor.
Each of the main panels 12 , 14 is rectangular and includes a rectangular wooden frame having an upper or top wooden horizontally extending frame member 26 , a lower or bottom wooden horizontally extending frame member 28 , an outer wooden vertically extending frame member 30 , and an inner wooden vertically extending frame member 32 . The reference to outer means that which is fixed close to the side panel of the respective main panel. Side panels 16 , 18 are on an outside of the barrier 10 as a whole. The reference to inner means that which is fixed away from outer elements on the respective panel.
The upper and lower horizontal members 26 , 28 have the same length (a direction defined as running from outer member 30 to inner member 32 ). The outer and inner vertical members 30 , 32 have the same height (a direction defined as running from member 28 to 26 ). Members 26 , 28 , 30 , 32 have the same thickness (a direction defined as running from a front face of one of the main panels 12 , 14 to the rear face of the same panel).
Members 30 , 32 are more narrow than members 26 , 28 . In other words, the length of each of members 30 , 32 is less than the height of each of the members 26 , 28 .
The outer and inner vertical members 30 , 32 are sandwiched between the upper and lower horizontal members 26 , 28 . In other words, the bottom edge of each of members 30 , 32 engages the top edge of lower member 28 . The upper edge of each of members 30 , 32 engages the lower edge of upper member 26 . The outer edge of outer vertical member 30 lies flush with the outer edge of upper and lower horizontal members 26 , 28 . The outer edge of inner vertical member 32 lies flush with the inner edge of upper and lower horizontal members 26 , 28 .
A grid receiving channel 34 is formed in an inner periphery or inner edge of each of the main panels 12 , 14 . Member 26 includes a lower edge having a channel portion formed therein, with such channel portion terminating short of the inner and outer edges of member 26 . Member 28 includes an upper edge having a channel portion formed therein, with such channel portion terminating short of the inner and outer edges of member 26 . Each of members 30 , 32 includes an inner vertical edge having a channel portion formed therein, with such channel portion opening out of the upper and lower edges of the members 30 , 32 . As a whole, such channel portions of members 26 , 28 , 30 and 32 communicate with each other and make up channel 34 . Channel 34 receives upper, lower and side edges of the grid 20 and retains the grid 20 in its respective main panel 12 or 14 . Channel 34 is formed midway between opposing faces of the rectangular frame portion in which it is formed.
Side panels 16 , 18 are formed identically to main panels 12 , 14 except that side panels 16 , 18 are shorter in length and except that each of the side panels includes a relatively long lower horizontal member. In other words, each of side panels 16 , 18 includes a rectangular wooden frame having an upper or top wooden horizontally extending frame member 36 , a lower or bottom wooden horizontally extending frame member 38 , an outer wooden vertically extending frame member 40 , and an inner wooden vertically extending frame member 42 .
The upper and lower horizontal members 36 , 38 have a different length (a direction defined as running from member 40 to 42 ). Lower member 38 is generally about twice the length of upper member 36 . Lower member 38 forms an inverted T-shape with vertical member 42 .
The outer and inner vertical members 40 , 42 have the same height (a direction defined as running from member 38 to 36 ). Members 36 , 38 , 40 , 42 have the same thickness (a direction defined as running from an outside face of one of the side panels 16 , 18 to the inner face of the same side panel).
Members 40 , 42 are more narrow than members 36 , 38 . In other words, the length of each of members 40 , 42 is less than the height of each of the members 36 , 38 .
The outer and inner vertical members 40 , 42 are sandwiched between the upper and lower horizontal members 36 , 38 . In other words, the bottom edge of each of members 40 , 42 engages the top edge of lower member 38 . The upper edge of each of members 40 , 42 engages the lower edge of upper member 36 . The outer edge of outer vertical member 40 lies flush with the outer edge of upper and lower horizontal members 36 , 38 . The outer edge of inner vertical member 42 lies flush with the inner edge of upper and lower horizontal members 36 , 38 .
A grid receiving channel 44 is formed in an inner periphery of each of the side panels 16 , 18 . Member 36 includes a lower edge having a channel portion formed therein, with such channel portion terminating short of the inner and outer edges of member 36 . Member 38 includes an upper edge having a channel portion formed therein, with such channel portion terminating at one end just beyond the junction between the inner edge of outer vertical member 40 and the upper edge of member 38 and at the other end just beyond the junction between the inner edge of inner vertical member 42 and the upper edge of member 38 . Each of members 40 , 42 includes an inner vertical edge having a channel portion formed therein, with such channel portion opening out of the upper and lower edges of the members 40 , 42 . As a whole, such channel portions of members 36 , 38 , 40 and 42 communicate with each other and make up channel 44 . Channel 44 receives upper, lower and side edges of the grid 21 and retains the grid 21 in its respective side panel 16 or 18 . Like channel 34 , channel 44 is formed half-way between the faces of the rectangular frame portion in which it is formed.
Each of the grids 20 , 21 includes four horizontally extending rods 46 spaced apart equidistantly from each other. The upper and lower horizontal rods 46 of each of grids 20 , 21 is set in its respective channel portion of the upper horizontal member 26 , 36 or lower horizontal member 28 , 38 . The middle pair of horizontal rods 46 are exposed to view.
Each of the grids 20 , 21 includes a set of vertically extending rods 48 spaced apart equidistantly from each other. Grid 20 includes twenty-two vertically extending rods 48 . Grid 21 includes four vertically extending rods. The innermost and outermost vertically extending rods 48 are set in its respective channel portion of the outer and inner vertical members 30 , 32 , 40 , 42 . The remaining vertically extending rods 48 are exposed to view.
Panel 12 includes a pair of feet 24 , where one foot 24 is engaged to the lower edge of lower horizontal member 28 at an inner end portion of the lower horizontal member 28 and adjacent to the inner vertical member 32 of panel 12 , and where the other foot 24 is engaged to the lower edge of lower horizontal member 28 at an outer end portion of lower horizontal member 28 and adjacent to the outer vertical member 30 of panel 12 . Panel 14 also includes a pair of feet 24 , where one foot 24 is engaged to the lower edge of lower horizontal member 28 at an inner end portion of the lower horizontal member 28 and adjacent to the inner vertical member 32 of panel 14 , and where the other foot 24 is engaged to the lower edge of lower horizontal member 28 and adjacent to the outer vertical member 30 of panel 14 . A pair of feet 24 affixed to each of the panels 12 , 14 (rather than a single foot 24 on each of the panels 12 , 14 ) keeps the respective horizontal members 28 (and the upper members 26 ) more parallel with each other and leads to a smoother sliding between members 28 (and member 26 ) in their respective connectors 22 . Each of side panels 16 , 18 includes a pair of feet 24 engaged at opposite end portions of lower horizontal member 38 and engaged to the lower edge portion of lower horizontal member 38 . Feet 24 space the barrier 10 from a surface such as a floor. Feet 24 are frustoconical in shape and taper inwardly and downwardly. Feet 24 are fixed to their respective panels 12 , 14 , 16 , 18 with a pin connector. Feet 24 are formed from a resilient plastic or resilient elastomer that allows for sliding on a floor but minimizes excessive sliding and minimizes slipping on smooth surface such as wood or tile.
Barrier 10 is maintained in an upright self-supporting or stand alone position by fixing the side panels 16 , 18 to the main panels 12 , 14 such that side panel 16 forms a T-shape with main panel 12 and such that side panel 18 forms a T-shape with main panel 14 . A pair of pin connectors 50 run from inner vertical member 42 to outer vertical member 30 to fix the side panels 16 , 18 to the main panels 12 , 14 in the T-shape. Pin connectors 50 are readily removable. Pin connectors 50 pass through metal receptors set in vertical members 42 and engage threaded metal receptors set in vertical members 30 .
Connector 22 connects the main panels 12 , 14 to each other and permits the main panels 12 , 14 to slide parallel to each other. Connector 22 is in the nature of a swinging clamp or over-center clamp, where over-center is defined by the body of the connector 22 first being at rest, then by the body of the connector 22 flexing, and then by the body of the connector 22 returning at least partially from the flexed state to the locked state.
Connector 22 includes a base 52 . Base 52 includes a first side section or lip 54 , a tranversing section 56 , and a second side section or lip 57 . Sections 54 , 57 are set at a right angle to traversing section 56 such that base 52 is C-shaped. First side section 54 confronts one of the outside faces of one of the upper or lower horizontal members 26 , 28 . Transversing section 56 confronts each of the horizontal members 26 , 28 . Second side section 57 confronts one of the outside faces of the other of the upper or lower horizontal member 26 , 28 . Base 52 is fixed to one of the upper or lower horizontal members 26 , 28 by a pair of pin connectors 58 extending through the tranversing section 56 .
Connector 22 further includes a roller latch or swinging clamp or locking mechanism 60 that is swingably fixed to an end of the transversing section 56 that is distal of the side section 54 and proximal to side section 57 . Swinging clamp 60 includes a base end 62 affixed to tranversing section 56 by a pin connector 64 . Swinging clamp 60 includes a clamping or bifurcated end 66 that includes a roller 68 . Clamping end 66 is bifurcated or forked to receive the roller 68 between the bifurcated portions 70 . Roller 68 rolls on an axis defined by pin connector 72 running through the bifurcated portions 70 and roller 68 . Roller 68 has a cylindrical outer surface 74 that extends beyond outer surfaces of the bifurcated portions 70 so as to engage an edge 76 of upper or lower horizontal member 26 , 28 . Edge 76 can be an upper edge of lower horizontal member 28 or a lower edge of upper horizontal member 26 .
Swinging clamp 60 may be referred to as an over-center clamp. Clamp 60 includes a body 78 between the base end 62 and the bifurcated end 66 . Body 78 is plastic and is one-piece and integral with base end 62 and bifurcated end 66 . Body 78 is resilient. When swinging clamp 60 is swung toward edge 76 , roller 68 may first make contact with a face 80 of member 26 or 28 or a corner 82 formed by face 80 and edge 76 . As the swinging clamp 60 is swung further into a clamping position, one or more of body 78 , base end 62 , bifurcated end 66 , pin connector 72 and roller 68 may flex to permit travel of the roller 68 over corner 82 and onto edge 76 . Bifurcated end 66 is elongate and straight and includes an axis 84 . Prior to the roller 68 making contact with one or more of face 80 , corner 82 or edge 76 , axis 84 has a position A as shown in FIG. 3D . In position A, clamp 60 is unflexed. When clamp 60 flexes upon contact with one or more of corner 82 , face 80 or edge 76 , axis 84 may have a position B as shown in FIG. 3D . As roller 68 rolls over one or more of face 80 , corner 82 or edge 76 and into a position where body 78 more closely confronts face 80 , clamp 60 attains an over-center position C as shown in FIG. 3E . In position C, axis 84 may extend at an angle between the angles of axis 84 shown by position A and B in FIG. 3D . In the over-center position shown in FIG. 3E , roller 68 may engage the channel 34 such that channel 34 serves as a seat for roller 68 , which holds one of the horizontal members 26 , 28 stationary relative to the other of the horizontal members 26 , 28 .
When the clamp 60 is pushed or pulled out of the channel or seat 34 and rotated or swung to an out-of-the-way position where roller 68 is free of horizontal members 26 , 28 , the horizontal members 26 , 28 may slide relatively to each other. An edge 86 of one of the horizontal members 26 , 28 slides on the traversing section 56 and face 80 slides by second section 57 of the base 52 .
Base 52 includes the first side section 54 , the traversing section 56 , and the second side section 57 . Base 52 is integral and one-piece. First side section 54 , traversing section 56 , and second side section 57 are integral and one-piece with each other. Second side section 57 extends at a right angle to traversing section 56 . Second side section 57 extends parallel to first side section 54 . Second side section 57 is a lip that guides and retains one of the horizontal members 26 , 28 as the horizontal members 26 , 28 slide relatively to each other.
As shown in FIG. 3A , swinging clamp 60 includes bifurcated portions 88 at the swing base end 62 as well as bifurcated portions 70 at the clamping end 66 . Bifurcated portions 88 are fixed to traversing section 56 by pin connector 64 . Bifurcated portions 88 form a cutout for reception therein of second side section 57 that confronts the sliding face 80 of one of the horizontal members 26 , 28 .
As shown in FIG. 3E , pin 64 defines a horizontal axis for swinging of base end 62 and pin 72 defines a horizontal axis for rolling of roller 68 . The horizontal axes of pins 64 and 72 are offset from each other in the vertical direction. In other words, lower horizontal member 28 of panel 12 includes a vertical plane splitting the member 28 into two one-half sections. The horizontal axis of pin 72 lies in this vertical plane when the roller 68 is seated in the channel 34 . At all times, since pin 64 is fixed at one location, the horizontal axis of pin 64 lies between such vertical plane and the plane defined by face 80 of lower horizontal member 28 of panel 12 . The horizontal axes of pins 64 and 72 are parallel to each other. The horizontal axis of pin 64 is disposed between the vertical plane splitting member 28 into equal half-sections and the vertical plane of face 80 . With such a structure or relationship between pins 64 and 72 , roller 68 is more securely seated in channel 34 . With such a structure of relationship between pins 64 and 72 , clamp 60 can secure in a nonsliding fashion two adjacent panels 12 , 14 together prior to when roller 68 is seated in channel 34 ; for example, roller 68 can make head on contact with one of the vertical rods 48 , can securely pinch against edge 76 and/or corner 82 , and can in this position secure in nonsliding fashion two adjacent panels 12 , 14 together such that panels 12 , 14 can be incrementally adjusted in length relative to each other.
As shown in FIG. 1 , barrier 10 includes four connectors 22 . Each of these connectors 22 are identical. However, for discussion purposes, these connectors are hereby given different reference numbers, namely, 92 , 94 , 96 , and 98 .
Connector 92 is fixed with connector pin 56 to the lower horizontal member 28 of main panel 12 and permits sliding movement thereby of lower horizontal member 28 of main panel 14 . Connector 92 , via roller 68 , releasably fixes thereto lower horizontal member 28 of main panel 14 .
Connector 94 is fixed with connector pin 56 to the upper horizontal member 26 of main panel 12 and permits sliding movement thereby of upper horizontal member 28 of main panel 14 . Connector 94 , via roller 68 , releasably fixes thereto upper horizontal member 28 of main panel 14 .
Connector 96 is fixed with connector pin 56 to the lower horizontal member 28 of main panel 14 and permits sliding movement thereby of lower horizontal member 28 of main panel 12 . Connector 96 , via roller 68 , releasably fixes thereto lower horizontal member 28 of main panel 12 .
Connector 98 is fixed with connector pin 56 to the upper horizontal member 26 of main panel 14 and permits sliding movement thereby of upper horizontal member 28 of main panel 12 . Connector 98 , via roller 68 , releasably fixes thereto upper horizontal member 28 of main panel 12 .
Connectors 92 , 94 are fixed with connector pin 56 to an outer end portion of main panel 12 . Connectors 96 , 96 are fixed with connector pin 56 to an outer end portion of main panel 14 .
In operation, to fashion a relatively wide gate, the swinging clamps 60 of each of the connectors 92 , 94 , 96 , 98 are disengaged from their respective upper or lower horizontal member 26 , 28 . Upon such a disengagement, the main panels 12 , 14 can slide by each other and outwardly where the outer vertical members 30 slide away from each other. This outward sliding stops when the inside edges of connectors 92 , 94 make contact with the inside edges of connectors 96 , 98 .
To fashion a relative narrow gate, the swinging clamps 60 of each of the connectors 92 , 94 , 96 , 98 are disengaged from their respective upper or lower horizontal member 26 , 28 . Upon such a disengagement, the main panels 12 , 14 can slide by each other and inwardly where the outer vertical members 30 slide toward each other. This inward sliding stops when the outer vertical edge of inner vertical member 32 of main panel 12 makes contact with the upper and lower horizontal members 36 , 38 of side panel 18 and when the outer vertical edge of inner member 32 of main panel 14 makes contact with the lower horizontal member 38 of side panel 16 .
To manufacture the barrier 10 , lower horizontal member 28 can be fixed, such as with glue, to outer and inner vertical members 30 , 32 so as to form a C-shaped frame. Then grid 20 can be slid into the channel portions of the channel 34 of the outer and inner vertical members 30 , 32 and further slid into the channel portion of the channel 34 of the lower horizontal member 28 . Then the upper horizontal member 26 can be set on the upper ends of the outer and inner vertical members 30 , 32 so as to receive the upper horizontal rod 46 in the channel portion of the channel 34 of the upper horizontal member 26 . Then the upper ends of the outer and inner vertical members 30 , 32 can be fixed, such as with glue, to the outer and inner ends of the upper horizontal member 26 to encapsulate the grid 20 in one of the main panels 12 , 14 . It should be noted that four pieces capture grid 20 and that these four pieces can be set about the grid 20 in any sequence. For example, upper and lower horizontal members 26 , 28 can first be set on the grid 20 . Then the outer and inner vertical members 30 , 32 can be brought onto the grid 20 and then glued to the upper and lower horizontal members 26 , 28 . Except for being captured or entrapped in the channel 34 , grid 20 is not otherwise affixed to the main panel 12 , 14 such that there is play (small vertical and horizontal movement of the grid 20 ) between the grid 20 and the main panel 12 or 14 . Grid 21 can be encapsulated in each of the side panels 16 , 18 in the same way as grid 20 is encapsulated.
Barrier 10 shown in FIG. 1 is a self-supporting or stand alone barrier. It requires no connection to a vertically running surface, such as the vertically running surface of a door jamb or wall, to keep the main panels 12 , 14 upright. The T-connection between side panel 16 and main panel 12 and the T-connection between side panel 18 and main panel 14 maintains the interconnected panels 12 , 14 in an upright position.
Barrier 10 shown in FIG. 1 can be self-supporting or stand alone with just one of the side panels 16 , 18 . In other words, with side panel 18 removed, side panel 16 and the T-connection the side panel 16 makes with main panels 12 and 14 is sufficient to hold main panels 12 , 14 in the upright position. Panels 12 , 14 can be slid relative to each other in the three paneled embodiment. A three paneled embodiment can also be formed with side panel 18 , main panel 12 and main panel 14 .
As shown in FIG. 2 , pressure barrier 100 includes neither side panel 16 nor side panel 18 but does includes each of the main panels 12 , 14 and their features. In lieu of the side panels 16 , 18 , barrier 100 includes a set of four in line connectors 102 . Each of the connectors 102 includes fixed knob 104 set on the proximal end of a threaded shaft 106 . Fixed knob 104 and shaft 106 turn as one unit. Fixed knob 104 and shaft 106 do not rotate relative to each other. Connector 102 further includes a rotating threaded spacer or knob 108 that mates with and turns on threaded shaft 106 from a proximal end to a distal end of the shaft 106 . The distal end of the shaft 106 is inserted into an opening formed on the outer edge of outer vertical member 30 of main panels 12 , 14 . The opening into which the distal end of shaft 106 is inserted extends horizontally into the upper or lower horizontal member 26 , 28 and can consist of a metal or plastic receiver that is threaded or nonthreaded so as to be cylindrical. The opening into which the distal end of shaft 106 is inserted may not include a metal or plastic receiver, may not be lined in any fashion, and may be cylindrical. Both the fixed knob 104 and rotating knob 108 have diameters that are greater than the shaft 106 . Fixed knob 104 is shaped in the form of a disk and has an outside roughened face with a relatively great amount of surface area to make contact with a vertically running surface such as the vertically running surface 110 of a door jamb 112 . Rotating knob 108 includes an inner smooth surface with a relatively great amount of surface area to make contact with the outer edge of the outer vertical member 30 of main panel 12 or 14 . By turning knob 108 and running knob 108 back and forth along the shaft 106 from the distal end to the proximal end, connectors 108 can incrementally be adjusted to a certain width between two vertically running surfaces such as the vertically running surfaces 110 of two door jambs 112 . Connectors 108 may hold barrier 100 , including feet 24 , above the floor and upright at the same time. Connectors 108 may hold barrier 100 upright and, at the same time, feet 24 may engage the floor. As well as adjusting connectors 102 in the horizontal direction, connectors 22 can be operated to adjust the main panels 12 , 14 relative to each other horizontally. In other words, to adjust the effective or total length of barrier 100 , an operator has the options of adjusting only the connectors 22 , or adjusting one or more of the connectors 102 , or adjusting the connectors 22 and one or more of the connectors 102 .
Each of the main panels 12 , 14 has an upper visible horizontally extending rod 46 and a lower visible horizontally extending rod 46 . The upper visible horizontally extending rod 46 is set at about one-third of the distance from the lower edge of top horizontal member 26 to the upper edge of lower horizontal member 28 . Lower horizontally extending rod 46 is set at about two-thirds of the distance from the lower edge of top horizontal member 26 to the upper edge of lower horizontal member 28 . A first space 114 between the upper visible horizontally extending rod 46 and the lower edge of top horizontal member 28 has only interrupting vertical members. A second space 116 between the upper visible horizontally extending rod 46 and lower visible horizontally extending rod 46 has only interrupting vertical members. A third space 117 between the lower visible horizontally extending rod 46 and the upper edge of the lower horizontal member 28 has only interrupting vertical members. Vertically extending rods 48 are the interrupting vertical members.
None of the first, second or third spaces 112 , 114 , 116 of grid 20 takes up at least a three-fifths portion (60%) of the open space running from the lower edge of top horizontal member 26 to the upper edge of the lower horizontal member 28 . Each of the first, second, and third spaces takes up about 33% of the open space running from the lower edge of the top horizontal member 26 to the upper edge of the lower horizontal member 28 . Grid 21 has the same first, second, and third spaces taking up, respectively, about 33% of such open space. The structure, or pattern, of the rods or wires of grid 20 is the same as the structure, or pattern, of the rods or wires of grid 21 .
Each of the side panels 16 , 18 includes a lower horizontal member 38 . Each of the lower horizontal members 38 includes a front or forwardly or laterally extending leg 118 that extends forwardly of or beyond a plane defined by the main panel 12 , 14 to which the leg 118 is directly connected. Leg 118 is one-piece and integral with the lower or bottom wooden horizontally extending frame member 38 of side panel 16 , 18 . Frame member 38 of side panel 16 , 18 is in turn connected to vertically extending member 42 of side panel 16 , 18 . Member 42 of side panel 16 , 18 is in turn connected to its respective main panel 12 , 14 .
It should be noted that legs 118 are not directly connected to their respective main panels 12 , 14 . Instead, such legs 118 lead integrally into their respective lower or bottom horizontally extending frame members 38 , which in turn are connected to their respective vertically extending members 42 , which in turn are connected to their respective main panels 12 , 14 . The vertically extending members 42 are connected via pin connectors 50 that extend from vertically extending members 42 to their respective vertically extending members 30 of the main panels 12 , 14 .
The barrier 10 includes a set of four transversely extending slide connectors 92 , 94 , 96 , 98 that slidingly connect the main panels 12 and 14 to each other. Connectors 92 , 94 are rigidly affixed to main panel 12 and are offset from (or spaced apart from) the inner vertically extending frame member 32 of main panel 12 . Connectors 96 , 98 are rigidly affixed to main panel 14 and are offset from (or spaced apart from) the inner vertically extending frame member 32 of main panel 14 .
The slide connectors 92 , 94 , 96 , 98 are structured such that main panels 12 , 14 are continuously slideable incrementally past each other to positions that have been previously undefined. In other words, a position where main panel 12 stops and a position where main panel 14 stops are determined not by predefined structures present on main panels 12 , 14 , but by the width of a unique opening found in a residential home. Slide connectors 92 , 94 , 96 , 98 grip the top and lower frame members 26 , 28 with a friction fit between vertical rods 48 or on edge 76 between rods 48 and face 80 .
The in-house residential barrier 10 is employed to keep children or pets in or out of certain areas in the house. The barrier 10 includes a pair of main panels 12 , 14 , each of which includes a rectangular frame and a set of vertically extending rods 48 and horizontally extending rods 46 within the rectangular frame.
The rectangular frame of each of the panels 12 , 14 includes a top horizontally extending frame member 26 , a bottom horizontally extending frame member 28 , an outer vertically extending frame member 30 , and an inner vertically extending frame member 32 .
The top horizontally extending frame member 26 includes an outer end 120 and an inner end 122 . The bottom horizontally extending frame member 28 includes an outer end 124 and an inner end 126 . The outer vertically extending frame member 30 confronts the outer ends 120 , 124 of the top and bottom horizontally extending frame members 26 , 28 . The inner vertically extending frame member 32 confronts the inner ends 122 , 126 of the top and bottom horizontally extending frame members 26 , 28 .
The grid 20 or set of vertically and horizontally extending rods includes horizontal rods 46 extending to and between the outer and inner vertically extending frame members 30 , 32 . The vertical rods 48 extend to and between the top and bottom horizontally extending frame members 26 , 28 .
Each of the side panels 16 , 18 includes a rectangular frame and a grid or set 21 of vertically extending rods 48 and horizontally extending rods 46 within the rectangular frame.
The rectangular frame of each of the side panels 16 , 18 includes an upper horizontally extending frame member 36 , a bottom horizontally extending frame member 38 , an outer or rear vertically extending frame member 40 , and an inner or front vertically extending frame member 42 .
The top horizontally extending frame member 36 includes an outer end 128 and an inner end 130 . The bottom horizontally extending frame member 38 includes a pair of ends 132 , 134 . The outer vertically extending frame member 40 confronts the outer end 128 of the top horizontally extending frame member 36 and an end 132 of the bottom horizontally extending frame member 38 . The inner vertically extending frame member 42 confronts the inner end 130 of the top horizontally extending frame member 36 and a midsection 136 of the bottom horizontally extending frame member 38 .
The grid or set 21 of vertically and horizontally extending rods of each of the side panels 16 , 18 includes horizontal rods 46 extending to and between the outer and inner vertically extending frame members 40 , 42 and vertical rods 48 extending to and between the top and bottom horizontally extending frame members 36 , 38 .
The first panel 12 is engaged to the second panel 14 . The first panel 12 lies generally in a first plane. The second panel 14 lies generally in a second plane. The first and second planes of the panels 12 , 14 are parallel to each other.
The third panel 16 is engaged to the first panel 12 . The third panel 16 lies generally in a third plane. The first and third planes of the first and third panels 12 , 16 are generally at a right angle to each other.
The fourth panel 18 is engaged to the second panel 14 . The fourth panel 18 lies generally in a fourth plane. The second and fourth planes of the second and fourth panels 14 , 18 are generally at a right angle to each other. The fourth plane of the fourth panel 18 is parallel to the third plane of the third panel 16 .
The first plane or the first panel 12 includes a first front face 138 and a first rear face 140 . The bottom horizontally extending member 38 extends beyond each of the first front and rear faces 138 , 140 . The top horizontally extending member 36 extends only beyond the first rear face 140 . The inner vertically extending frame member 42 of side panel 16 confronts the outer vertically extending frame member 30 of main panel 12 .
The second plane or the second main panel 14 includes a front face 142 and a rear face 144 . The bottom horizontally extending member 38 of side panel 18 extends beyond each of the front and rear faces 142 , 144 , and further extends beyond each of the front and rear faces 138 , 140 . Also, bottom horizontally extending member 38 of side panel 16 extends beyond each of the front and rear faces 142 , 144 of main panel 14 . The top horizontally extending member 36 of side panel 18 extends beyond the rear face 144 and beyond the rear face 140 . The top horizontally extending member 36 of side panel 16 also extends beyond the rear face 144 of main panel 14 . The inner vertically extending frame member 42 of side panel 18 confronts the outer vertically extending frame member 30 of main panel 14 .
The first panel 12 overlaps the second panel 14 . The outer vertically extending frame member 30 of first panel 12 is incrementally and slideably adjustable to and away from the inner vertically extending frame member 32 of the second panel 14 . The outer vertically extending frame member 30 of the second panel 14 is incrementally and slideably adjustable to and away from the inner vertically extending frame member 32 of the first panel 12 . Also, the outer vertically extending frame members 30 of the main panels 12 , 14 are incrementally and slideably adjustable to and away from each other. Also, the inner vertically extending frame members 32 of the main panels 12 , 14 are incrementally and slideably adjustable to and away from each other.
The barrier 10 includes a pair of feet 24 depending from the bottom horizontally extending frame member 38 of each of the side panels 16 , 18 . Each foot 24 of such pair of feet depend from an end portion of the bottom horizontally extending frame member 38 to space an underside of the bottom horizontally extending frame members 38 from a floor.
The barrier 10 further includes a set of feet 24 , where a first pair of feet 24 depends from bottom horizontally extending frame member 28 of first panel 12 , and where a second pair of feet 24 depends from bottom horizontally extending frame member 28 of second panel 14 to space the undersides of the bottom horizontally extending frame members 28 from a floor.
The horizontal rods 46 of each of the grids 20 , 21 are spaced equidistantly from each other. The vertical rods 48 of each of the grids 20 , 21 are spaced equidistantly from each other.
Each of the first and second rectangular frames of the first and second panels 12 , 14 is formed from and consists essentially of wood. Each of the third and fourth rectangular frames of the third and fourth panels 16 , 18 is formed from and consists essentially of wood.
Frames of panels 12 , 14 , may be formed of distinct horizontally and vertically running frame members, where members 26 , 28 , 30 and 32 are formed of a natural wood product or a molded or synthetic wood product. Frames of panels 12 , 14 , 16 , 18 may be integral and one-piece where the frames of such panels 12 , 14 , 16 , 18 are formed of a molded or synthetic wood product and where, in such a case, grids 20 , 21 are set therein prior to or during the molding or fabrication process.
FIG. 4 shows an embodiment or barrier 146 . Barrier 146 is identical to barrier 10 shown in FIG. 1 , except that barrier 146 includes a pet door 148 . Pet door 148 can have a wooden, metal, or plastic outer frame 150 that is anchored in main panel 14 by vertical and horizontal rods 46 , 48 engaging upper and side portions of the frame 150 . Frame 150 is generally three sided, with the fourth side being defined by the bottom horizontally extending frame member 28 . Pet door 148 further includes an inner frame 152 that is hingedly connected to the outer frame 150 and swings toward the rear face 144 of main panel 14 . Inner frame 152 sits inside of outer frame 150 when the pet door 148 is closed, i.e., when inner frame 152 is closed. Inner frame 152 includes a latch 154 to engage and disengage the frames 150 , 152 to and from each other. Inner frame 152 includes vertical rods 156 and, if desired, may include horizontally extending rods. Pet door 148 is sufficiently large to permit cats and small dogs to pass therethrough. Pet door 148 is sufficiently small to prevent toddlers or crawling babies from passing through or may be sized sufficiently small to prevent a large dog from passing through.
Rods 46 , 48 of grids 20 , 21 and rod 156 of the grid in pet door 148 may be bars or tubes or wires or other elongate, relatively narrow members. Vertical rods 48 and horizontal rods 46 cross each other at junctions. The rods 46 , 48 may be welded or otherwise engaged at such junctions. The rods 46 , 48 may be woven relative to each other so as to alternatively pass frontwardly and rearwardly of the other.
Rods 46 , 48 , 156 extend from a central section of the respective frame member to which such rod is anchored, i.e., midway between, for example, the front face 142 and the rear face 144 where such rod is on one of the main panels 12 , 14 . Rods 46 , 48 in the side panels 16 , 18 also extend from a central section of the respective frame member to which such rod is anchored. Rods 156 extend from a central section in inner frame 152 of the pet door 148 .
Slide connectors 22 (i.e., individual connectors 92 , 94 , 96 , 98 ) can extend for 360 degrees or can stop short of 360 degrees. Connectors 22 can be tightened to prevent sliding of the panels 12 , 14 relative to each other. Connectors 22 can be loosened to permit sliding of the panels 12 , 14 relative to each other. Two top connectors 94 , 98 fix the top horizontally extending members 26 of panels 12 , 14 to each other. Two bottom connectors 92 , 96 fix the bottom horizontally extending members 28 of panels 12 , 14 to each other. Each of the connectors 92 , 94 , 96 , 98 is affixed to either an inner end portion of upper horizontal member 26 or an inner end portion of lower horizontal member 28 .
Bottom horizontally extending member 38 is integral and one-piece from end 132 to end 134 and from its lower edge to its upper edge.
Main panel 12 and main panel 14 can be slid relatively closely together such that side panels 16 , 18 can fit inside of a relatively narrow opening such as a doorway opening. Main panel 12 and main panel 14 can be slid relatively far apart to partition a room in half. Each of barriers 10 , 146 can wall off a corner of a room so as to form a triangular playpen for a pet or child. Each of barriers 10 , 100 and 146 can be picked up as one piece and moved to another location in the house. Each of barriers 10 and 146 can be can be stored in a generally flat form by removing pin connectors 50 so as to disengaged side panels 16 , 18 from their respective main panels 12 , 14 . Barrier 100 , having only panels 12 , 14 , is operative in a flat form and can be stored in its operating flat form.
Grids 20 , 21 and the grid in inner frame 152 of pet door 148 can be a mesh or network, or an arrangement of metal or plastic links or wires or rods or elongate elements that engage each other and have small openings, such as evenly spaced, uniform small openings.
Thus since the invention disclosed herein may be embodied in other specific forms without departing from the spirit or general characteristics thereof, some of which forms have been indicated, the embodiments described herein are to be considered in all respects illustrative and not restrictive. The scope of the invention is to be indicated by the appended claims, rather than by the foregoing description, and all changes which come within the meaning and range of equivalents of the claims are intended to be embraced therein.
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A barrier employed to keep children and/or pets in or out of certain areas in the house. The barrier includes four panels. Two main panels slide parallel to each other to lengthen or shorten the barrier as a whole. Two side panels stabilize the main panels and extend to the front and rear faces of the main panels to provide a self-supporting in-house barrier. Each of the panels includes a wooden frame. The wood lends less weight, less sharp edges, and more pleasing aesthetics than, for example, a metal gate.
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This application is a 371 of PCT/CA61/00733 filed May 25, 2001 which claims benefit of U.S. Application No. 60/207,052 filed May 25, 2000.
BACKGROUND ART
1. Field of the Invention
The invention relates to a system for moving a component part of a motor vehicle. In particular, the invention relates to an actuator used to selectively provide access to an enclosure of a motor vehicle.
2. Description of the Related Art
As motor vehicles characterized by their utility become a mainstream choice, consumers demand certain luxuries primarily associated with passenger cars, either due to their inherent design and/or size. One of the features desired by consumers is the automated movement of such items as sliding doors and lift gates. While features providing automated motion are available, the designs for mechanisms used to accommodate manual overrides are lacking in capability and functionality.
U.S. Pat. No. 5,144,769 discloses an automatic door operating system. This system requires a great deal of control, both by an electronic controller and an operator of the motor vehicle. To overcome forces due to manual operation, the manually operated seesaw switch used by the operator to electromechanically operate the door is in an open state, preventing current from passing through the motor.
SUMMARY OF THE INVENTION
An automated closure assembly is disclosed for a motor vehicle. The motor vehicle includes a body defining an opening and a door that is slideable between a closed position covering the opening and an open position providing access through the opening. The automated closure assembly includes a guide fixedly secured to the motor vehicle at a position in spaced relation to the opening. A drive mechanism is fixedly secured to the guide. The drive mechanism converts electrical energy into a rotational force. A lateral linkage is connected to the drive mechanism receiving the rotational force. The lateral linkage translates the rotational force into a linear force to move the door between the open position and an intermediate position between the open position and the closed position. The automated closure assembly also includes a secondary linkage that is connected to both the lateral linkage and the drive mechanism. The secondary linkage translates the rotational force into a linear force to move the door between the intermediate position and the open position such that the door is able to move to its open position past the opening within which the lateral linkage extends.
BRIEF DESCRIPTION OF THE DRAWINGS
Advantages of the invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:
FIG. 1 is a side view of a motor vehicle incorporating one embodiment of the invention, with a sliding door of the motor vehicle in the open position;
FIG. 2 is a cross-sectional side view, partially cut away, of one embodiment of the invention;
FIG. 3 is a perspective top view, partially cut away, of a portion of a second embodiment of the invention;
FIG. 4 is a perspective bottom view of the portion of the second embodiment of the invention shown in FIG. 3;
FIG. 5 is a perspective top view of the second embodiment of the invention from another angle;
FIG. 6 is a side view, partially cut away, of another portion of the second embodiment of the invention; and
FIG. 7 is a perspective view of a motor incorporated into the second embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the FIG. 1, a motor vehicle is shown at 10 . The motor vehicle 10 includes a sliding door 12 providing access to an inner compartment 14 of the motor vehicle 10 . The inner compartment 14 is generally a passenger compartment having a plurality of seat assemblies 16 (one partial seat assembly shown). It should be appreciated that other doors 18 provide access to the inner compartment 14 . Further, a plurality of sliding doors 12 may be utilized in one motor vehicle design. Only one is shown in FIG. 1 for simplicity. Throughout this discussion, the orientation from which reference of the invention 20 will be made will be the driver side sliding door 12 with a front being directed toward a front 22 of the motor vehicle 10 .
Referring to FIG. 2, the invention 20 is an automated closure assembly. The automated closure assembly 20 provides power to move the sliding door 12 between a closed position and an open position. The closed position is a latched position preventing access to the inner compartment 14 . The open position is defined as when the access to the inner compartment 14 is the greatest. In other words, the sliding door 12 is at its furthest most position from the front 22 of the motor vehicle. Referring back to FIG. 1, the sliding door is in an intermediate position defined as a position between the open and closed positions. The intermediate position will be discussed in greater detail subsequently.
The embodiment of the automatic closure assembly 20 shown in FIG. 2 allows for two types of motion for the sliding door 12 . The first type of motion is the bidirectional axial motion of the sliding door 12 between its closed position and the intermediate position. The second type of motion is bidirectional axial motion of the sliding door 12 between the intermediate position and its open position. Because an automated closure assembly 20 can only extend as far as the opening of the sliding door 12 , it requires a second subassembly, discussed subsequently, to move the sliding door 12 past the opening 24 defined by the motor vehicle 10 . The point at which the automated closure assembly 20 cannot move the sliding door 12 past without the aid of the additional subsystem is defined as the intermediate position. The intermediate position is not a median position and is further from the front 22 of the motor vehicle 10 than the median of the opening 24 .
The automated closure assembly 20 includes a drive mechanism, generally shown at 25 . The drive mechanism 25 is driven by a motor 26 , shown in FIG. 7 . In the preferred embodiment, the motor 26 is a coreless motor 26 for reasons set forth in copending patent application Ser. No. 10/258 644, which is of common assignment, and is hereby incorporated by reference. The coreless motor 26 includes an output gear 28 fixedly secured to an output shaft (not shown) thereof. The output gear 28 drives a transmission gear 30 , which, in turn, rotates a motor pulley 32 . The motor pulley 32 drives the toothed belt (not shown). The motor 26 provides a support for a belt tensioner 34 . The belt tensioner 34 includes a spring 36 and a slideable plate 38 that maintains the belt in the proper tension.
Returning to FIG. 2, the coreless motor 26 drives the drive belt 40 . The drive belt 40 is a continuous loop, toothed belt. It travels along a path defined by rollers positioned on a platen (neither shown). A lower hinge, generally shown at 42 , is driven by the movement of the drive belt 40 . The lower hinge 42 includes a base 44 that includes a channel 46 allowing the drive belt 30 to pass therethrough. A hinge pulley 48 rotates about a shaft 50 that is secured to the base 44 within the channel 46 .
During much of the movement of the drive belt 40 , the hinge pulley 48 is locked in place against the drive belt 40 by a pulley lock lever 52 . The pulley lock lever 52 includes a plurality of teeth 54 that engage the teeth of the drive belt 40 .
The pulley lock lever 52 is pivotal about a pin 56 . When the pulley lock lever 52 rotates counter clockwise, as taken from the perspective of FIG. 2, the hinge pulley 48 will be unlocked allowing the drive belt 40 to rotate it. The rotation of the hinge pulley 48 rotates a cable 58 that rotates an articulation pulley 60 . The articulation pulley 60 moves a rack 62 which is fixedly secured to the sliding door 12 , resulting in the articulation of the sliding door 12 away from the intermediate position toward either the open or closed positions.
The hinge lock lever 52 is locked by a fork bolt 64 . The rotation of the fork bolt 64 to release the hinge lock lever 52 is initiated by the fork bolt 64 engaging a striker 66 . A push pull cable 68 , secured to the end of the pulley lock lever 52 , locks and unlocks the articulation pulley 60 .
Referring to FIGS. 3 through 6, a second embodiment of the automated closure assembly is generally indicated at 70 . FIGS. 3 through 5 represent a portion of the invention 70 referred to as the secondary linkage and FIG. 6 represents a portion of the invention referred to as a lateral linkage.
Beginning with the lateral linkage 71 shown in FIG. 6, wherein like named elements represent elements in the first embodiment, FIG. 2, of similar function, a continuous loop, toothed drive belt 72 extends around a path defined by roller 74 (one shown). A hinge pulley 76 travels along a path defined by a bracket 78 . The entire lateral linkage 72 travels along the bracket 78 when the drive belt 72 is moving and the hinge pulley 76 is locked in relative position by a pulley lock lever 80 . The sliding door 12 , represented by extension 82 , moves along therewith. As the sliding door 12 moves from the closed position to the intermediate position, the pulley lock lever 80 is moved out of engagement with the hinge pulley 76 allowing the hinge pulley 76 to rotate in response to the travel of the drive belt 72 .
A transition linkage, generally shown at 83 , extends between the hinge pulley 76 and the sliding door 12 . The transition linkage 83 changes the linkage between the coreless motor 26 and the sliding door 12 between the lateral linkage 71 and the secondary linkage 94 , discussed subsequently.
The rotation of the hinge pulley 76 rotates a power cable 84 . The power cable 84 rotates a power gear 86 . The power gear 86 rotates an transition pulley 88 , discussed subsequently.
The pulley lock lever 80 is rotated when a lock ratchet 90 is pivoted. The lock ratchet 90 is controlled by a push pull cable 92 . The movement of the push pull cable 92 will also be discussed in greater detail subsequently.
Returning to the secondary linkage, generally shown at 94 , the push pull cable 92 (not shown in FIGS. 3 through 5) is secured to a secondary ratchet 96 . The secondary ratchet 96 is held in a specific orientation by a pawl 98 . The secondary ratchet 96 is spring loaded by spring 100 to maintain the push pull cable 92 in an extended position allowing the pulley lock lever 80 to remain in a locked position keeping the hinge pulley 76 from rotating.
The pawl 98 is linked to a bell crank 102 via a rod 104 . In the embodiment shown in FIGS. 3 through 5, the rod 104 is shown as a two-piece adjustable rod 104 . It should be appreciated by those skilled in the art that a simple rod 104 may be used.
The bell crank 102 includes a receiving extension 106 . The receiving extension 106 selectively receives a slide 108 that moves axially with the sliding door 12 through a guide 110 . Therefore, movement of the sliding door 12 from its open position to the intermediate position pivots the bell crank 102 to pull the pawl 98 away from the secondary ratchet 96 allowing it to return to its disengaged position which, in turn, allows the pulley lock lever 80 to lock the hinge pulley 76 to move lateral linkage 71 . Lateral movement of the lateral linkage 71 allows the sliding door 12 to move past the intermediate position toward the closed position.
The slide 108 is moved, i.e., movement of the sliding door 12 between the intermediate and open positions, by a secondary belt 112 . The transition pulley 88 drives the secondary belt 112 . The transition pulley 88 is coaxially mounted to the secondary linkage 94 with a secondary gear 114 . The secondary gear 114 receives its rotational power from the power gear 86 of the lateral linkage 71 .
Referring specifically to FIG. 4, a dog 116 is connected to a back side of the secondary ratchet 96 . The dog 116 holds the secondary gear 114 in a position to receive power from the power gear 86 . When the pawl 98 releases the secondary ratchet 96 , the dog 116 moves the secondary gear 114 out of engagement with the power gear 86 preventing any forces from being applied to the sliding door 12 via the slide 108 . This allows for the sliding door 12 to latch in the closed position with a minimal effort.
In the operation of unlatching the sliding door 12 from its closed position and moving it to its open position, the coreless motor 26 is activated and rotates the drive belt 72 . Because the hinge pulley 76 is locked by the pulley lock lever 80 , the hinge pulley 76 travels with the drive belt 72 . This moves the sliding door 12 from the closed position toward the intermediate position.
The lock ratchet 90 engages a striker (not shown) that pivots the pulley lock lever 80 out of engagement with the hinge pulley 76 . This allows the hinge pulley 76 to rotate with the passing of the drive belt 72 thereby. Movement of the lock ratchet 90 also moves the secondary ratchet 96 through the push pull cable 92 .
This forces the secondary gear 114 into engagement with the rotating power gear 86 . The rotation of the secondary gear 114 moves the secondary belt 112 to move the slide 108 and the sliding door 12 out from the intermediate position to the open position.
The return of the sliding door 12 reverses this operation with the addition of using the bell crank 102 to move the secondary ratchet 96 , through pawl 98 , back to its inactive position allowing the pulley lock lever 80 back into engagement with the hinge pulley 76 to lock the hinge pulley 76 in a specific orientation. The return of the lateral linkage 71 to its original position returns the sliding door 12 to its closed position.
The invention has been described in an illustrative manner. It is to be understood that the terminology which has been used is intended to be in the nature of words of description rather than of limitation.
Many modifications and variations of the invention are possible in light of the above teachings. Therefore, within the scope of the appended claims, the invention may be practiced other than as specifically described.
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An automated closure assembly ( 20 ) is disclosed for a motor vehicle ( 10 ). A lateral linkage is connected to the drive mechanism ( 25 ) receiving the rotational force and translates the rotational force of the drive mechanism into a linear force to move the door between the open position and an intermediate position between the open position and the closed position. The automated closure assembly also includes a secondary linkage that is connected to both the lateral linkage and the drive mechanism. The secondary linkage translates the rotational force into a linear force to move the door between the intermediate position and the open position such that the door is able to move to its open position past the opening within which the lateral linkage extends.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Patent Application No. 60/467,988, filed May 2, 2003, which is hereby incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to rail joints and, more particularly, to a rail joint having a rolled profiled bar.
[0004] 2. Description of Related Art
[0005] Railroad rails used in the railroad industry are typically formed of a plurality of railroad rail sections joined together by rail joints. As shown in FIG. 1 , a prior art rail joint 10 positioned between a first railroad rail 12 and a second railroad rail 14 is used to hold two ends 13 , 15 of the railroad rails 12 and 14 , respectively, in place. A plurality of holes 16 are defined in the rail joint 10 , wherein the holes 16 are adapted to receive fasteners, such as a bolt and nut arrangement, for securing the rail joint 10 to the railroad rails 12 , 14 . The rail joint 10 prevents lateral and/or vertical movement of the rail ends 13 , 15 of the railroad rails 12 , 14 and permits the longitudinal movement of the railroad rails 12 , 14 for expanding or contracting. Prior art rail joints have various strength requirements, as well as weight requirements set by the railroad industry. It is desirable to have a rail joint that is inexpensive to manufacture while having a maximum amount of strength for a minimum amount of weight per joint.
[0006] Further, due to technological advances in rail grinding and lubrication, present rail structures are lasting longer, thereby allowing more usable wear out of the rail heads than in the earlier constructed rail structures. This results in a decrease in distance between the rail head and a top portion of the rail joint, thus resulting in the possibility of the vehicle wheels contacting the rail joint, thereby causing premature failure of the rail joint. Therefore, it is an object of the present invention to overcome the above problems and to provide a strong rail joint that is inexpensive to manufacture.
SUMMARY OF THE INVENTION
[0007] The present invention provides for a rail joint made from a metallic bar that is rolled or forged. The rail joint includes a body having a length defined between a first end and a second end and defining a base section having a base front side and base back side, a web section having a web front side and a web back side, and a head section having a head front side and a head back side and defining an upper surface. The base section depends from the web section, and the web section depends from the head section. The web section of the body of the rail joint defines a plurality of holes for receiving fasteners. The head portion defines an abutting portion, an intermediate portion and a lug portion. A distance between the head front side and the head back side of the head section is greater than or equal to a distance between the base front side and the base back side of the base section. The strength of the rail joint as defined by the Moment of Inertia (I) is in a range of 14 to 15 in 4 and the weight of the rail joint is in a range of 1.5 to 1.65 pounds per inch of length of the rail joint.
[0008] The present invention also provides for a railroad rail assembly that includes a pair of abutting railroad rails and a pair of rail joints, as previously discussed, fastened to each side of the pair of railroad rails. A purpose of the present invention is to provide increased wheel flange clearance while maintaining the integrity of joining two rails together.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a right side elevational view of a prior art rail joint connecting two adjacent railroad rails together;
[0010] FIG. 2 is a side elevational view of a rail joint made in accordance with the present invention;
[0011] FIG. 2 a is a side elevational view of the rail joint shown in FIG. 2 having dimension lines;
[0012] FIG. 3 is a top plan view, partially in section, of the rail joint shown in FIG. 2 ;
[0013] FIG. 4 is a right side elevational view, partially in section, of the rail joint shown in FIG. 2 ;
[0014] FIG. 5 is a left side elevational view, partially in section, of the rail joint shown in FIG. 2 ;
[0015] FIG. 6 is a bottom plan view, partially in section, of the rail joint shown in FIG. 2 ;
[0016] FIG. 7 is a front elevational view of a typical prior art railroad rail;
[0017] FIG. 8 is a side elevational view of the rail joint shown in FIG. 2 co-acting with a railroad rail;
[0018] FIG. 9 is a side elevational view of a rail joint assembly made in accordance with the present invention;
[0019] FIG. 10 is a side elevational view of a prior art rail joint profile; and
[0020] FIG. 11 is a side elevational view of the rail joint shown in FIG. 2 and prior art rail joint profiles co-acting with a railroad rail.
DETAILED DESCRIPTION OF THE INVENTION
[0021] The present invention provides for a rail joint 20 made from a metallic bar that is rolled or forged. The rail joint 20 can be made of steel or other metal. Referring to FIGS. 2-6 , the rail joint 20 includes a body 22 having a first end 24 and a second end 26 and defining a base section 28 , a web section 30 and a head section 32 . The base section 28 depends from the web section 30 , and the web section 30 depends from the head section 32 . The web section includes a web front side 34 and a web back side 36 and defines a plurality of holes 38 for receiving fasteners (shown in FIGS. 4 and 5 ). Referring to FIG. 2 , the base section 28 has a bottom surface 29 , a base front side 40 and a base back side 42 . The base section 28 also defines a heel portion 44 , a blended portion 46 , and a toe portion 48 . The heel portion 44 depends from the blended portion 46 , and the blended portion 46 depends from the toe portion 48 . The toe portion 48 extends away from the web front side 34 of the web section 30 and the heel portion 44 extends in an opposite direction from the toe portion 48 away from the web back side 36 of the web section 30 . The head section 32 has an upper surface 33 and includes a head front side 50 and a head back side 52 . The head section 32 defines an abutting portion 54 , an intermediate portion 60 and a lug portion 62 . The abutting portion 54 depends from the intermediate portion 60 , and the intermediate portion 60 depends from the lug portion 62 . The abutting portion 54 further defines a curved portion 56 and a straight portion 58 , wherein the curved portion 56 defines a contacting surface 59 . The lug portion 62 extends away from the web front side 34 of the web section 30 and the abutting portion 54 extends in an opposite direction from the lug portion 62 away from the web back side 36 of the web section 30 . A front recess area 64 is defined between the lug portion 62 of the head section 32 and the toe portion 48 of the base section 28 , and a back recess area 66 is defined between the abutting portion 54 of the head section 32 and the heel portion 44 of the base section 28 .
[0022] With continued reference to FIG. 2 , the specific design of the rail joint 20 provides the rail joint 20 with a maximum amount of strength for a minimum amount of weight. A distance L 1 between the head front side 50 and the head back side 52 of the head section 32 is greater than or equal to a distance L 2 between the base front side 40 and the base back side 42 of the base section 28 of the body 22 of the rail joint 20 . The lug portion 62 extends from the web front side 34 of the web section 30 a distance D 1 approximately equal to a distance D 2 the toe portion 48 extends from the web front side 34 of the web section 30 . Preferably, the distance D 1 is approximately within 0.125 inches or less of the distance D 2 . A recess 68 is defined between the abutting portion 54 and the lug portion 62 on the upper surface 33 of the head section 32 of the body 22 of the rail joint 20 . When the rail joint 20 is attached to a railroad rail, the recess 68 in the head section 32 is capable of receiving a wheel of a rail car riding on the railroad rail. The recess 68 preferably has a depth (D t ) that is sufficient to provide enough clearance for a wheel of a railcar riding on a railroad rail so as to prevent contact of the wheel on the lug portion of the head section of the body of the rail joint 20 . The depth (D t ) for a rail joint for uses in larger rails (i.e. 132-RE, 136-RE and 141-RE) of the recess 68 can be in a range of 0.6 to 0.8 inches and preferably is 0.631 inches, and the thickness of the lug portion D L is in a range of 0.35-0.50 inches, and preferably 0.40-0.47 inches.
[0023] Rail joint 20 can be used on any size or type of standard tee railroad rail 12 as shown in FIG. 7 . However, rail joint 20 is preferably used with 132-RE, 136-RE and 141-RE rails according to the American Railway Engineering and Maintenance Way Association (AREMA) specifications. Referring to FIG. 7 , railroad rail 12 that includes a body 72 having a head 74 , a web 78 , and a base 80 having an upper surface 82 . The head 74 having a top surface 76 is connected to the web 78 , which is connected to the base 80 . The web 78 defines a plurality of slots 84 (shown in phantom in FIG. 8 ) for receiving fasteners. A web recess 86 is defined between the head 74 and the base 80 on each side of the railroad rail 12 and a rail head recess 88 is defined between the head 74 and the web 78 on each side of the railroad rail 12 . The dimensions of the railroad rail 12 , designated by the letters A-H, can vary depending on the size and type of rail required for a particular need. For example, a railroad rail having the 136-RE designation weighs 136 pounds per yard and includes the following dimensions in inches as shown in FIG. 7 : Height (A) of railroad rail is 7{fraction (5/16)}; Width (B) of base 80 is 6; Width (C) of head 74 is 2{fraction (15/16)}; Thickness (D) of web 78 at center is {fraction (11/16)}; Depth (E) of head 74 is 1{fraction (15/16)}; Height (F) of web 78 is 4{fraction (3/16)}; Head angle (a) is 1 to 4 degrees; Base angle (a′) is 1 to 4 degrees; Slope (s) of head 74 is 1 to 40 degrees; and Height (H) of slot 84 is 3{fraction (3/32)}.
[0024] Referring to FIGS. 2-6 , it has been found that the specific shape and dimensions of the rail joint 20 results in improved strength characteristics when used with the preferred railroad rails. The strength of the rail joint 20 can be defined by the Moment of Inertia (I) and the Section Modulus (Z). “Moment of Inertia (I)” is defined as the capacity of a cross-section to resist bending, and can be expressed in inches to the fourth power (in 4 ). Section Modulus (Z) relates bending moment and maximum bending stress within the elastic range and can be expressed in inches to the third power (in 3 ). The “elastic range” is where the working stress does not exceed the elastic limit and the “elastic limit” is the maximum stress to which a structural member may be subjected and still return to its original length upon release of the load. Section Modulus (Z) can be expressed mathematically as: Z=I/c; wherein (I) is the Moment of Inertia of the cross-section about a neutral axis (N), and (c) is the distance from the neutral axis (N) to the outermost fibers.
[0025] The rail joint 20 when used with the preferred railroad rails (i.e., 132-RE, 136-RE and 141-RE) preferably has a length of 36 inches from the first end 24 to the second end 26 of the rail joint 20 and includes six holes 38 (partially shown in FIGS. 4 and 5 ) for receiving fasteners. Referring to FIG. 2 , the rail joint 20 preferably includes the following dimensions: Moment of Inertia (I) in a range of 14-15 in 4 (preferably 14.02-14.07 in 4 ); a top Section Modulus (Z) as defined from the neutral axis N to an upper end UE of the head section 32 in a range of 5.3-5.7 in 3 (preferably 5.54-5.57 in 3 ); and a bottom Section Modulus (Z) as defined from the neutral axis N to a bottom end BE of the base section 28 in a range of 5.3-5.7 in 3 (preferably 5.59-5.61 in 3 ). Preferably, the cross-sectional area is in a range of 5.6-5.7 in 2 (preferably 5.63-5.66 in 2) and the rail joint 10 has a weight in a range of 1.5-1.65 pounds per inch of length (preferably 1.59-1.60 pounds per inch). Preferably, the neutral axis N is about 2.53 inches from the upper end UE of the head section 32 and 2.51 inches from a bottom end BE of the base section 28 of the rail joint 20 .
[0026] The rail joint 20 when used with preferred smaller rails (i.e. 115-RE and 119-RE) preferably has a length of 36 inches from the first end 24 to the second end 26 of the rail joint 20 and includes six holes 38 (partially shown in FIGS. 4 and 5 ) for receiving fasteners. Referring to FIG. 2 , the rail joint 20 preferably includes the following dimensions: Moment of Inertia (I) in the range of 10-11 in 4 (preferably 10.24 in 4 ); a top Section Modulus (Z) in the range of 4.3-4.5 in 3 (preferably 4.44 in 3 ); the bottom Section Modulus (Z) 4.3-4.5 in 3 (preferably 4.45 in 3 ). Preferably, the cross-sectional area is in the range of 5.0-5.2 in 2 (preferably 5.12 in 2 ) and the rail joint 10 has a weight in a range of 1.4-1.5 pounds per inch of length (preferably 1.45 pounds per inch). Preferably, the neutral axis N is about 2.31 inches from the upper end UE of the head section 32 and 2.30 inches from the bottom end BE of the base section 28 of the rail joint 20 . The depth (D t ) of the recess 68 is within the range 0.550-0.700 inches and preferably 0.575 inches and the lug thickness D L is within a range of 0.35-0.45 inches, preferably 0.38-0.43 inches.
[0027] FIG. 2 a shows the rail joint 20 having dimensions designated as J1-J7. Table 1 shows the dimensions (J1-J7) of various size rail joints 20 along with the strength properties for the specific rail joint dimensions. The first two examples are for rail joints for railroad rails 132-RE, 136-RE and 141-RE. The last example is for a rail joint for railroad rails 115-RE and 119-RE. The dimensions are defined as follows: J1 is the length of the head section 32 from a central axis A; J2 is the length of the base section 28 from a central axis A; J3 is the height of the base section 28 ; J4 is the height of the head section 32 ; J5 is the distance from a neutral axis N to a top of the rail joint 20 ; J6 is the distance from a neutral axis N to a bottom of the rail joint 20 ; and J7 is the horizontal distance between central axis A and a longitudinal axis that first contacts the head section 32 . The strength properties include Moment of Inertia (I), top Section Modulus (Z) top , bottom Section Modulus (Z) bot , and weight in pounds per inch of length of the rail joint.
TABLE 1 J1 J2 J3 J4 J5 J6 J7 I Z top Z bot Weight (in) (in) (in) (in) (in) (in) (in) (in 4 ) (in 3 ) (in 3 ) (lbs/in) 2.747 2.879 1.260 1.327 2.53 2.51 0.405 14.04 5.55 5.60 1.60 2.747 2.879 1.260 1.217 2.53 2.51 0.405 14.02 5.54 5.59 1.59 2.624 2.624 1.150 1.241 2.31 2.30 0.378 10.24 4.44 4.45 1.45
[0028] FIG. 8 shows a rail joint arrangement 90 wherein rail joint 20 is attached to a railroad rail 12 . Referring to FIG. 8 , the base back side 42 of the base section 28 , the web back side 36 of the web section 30 , and the head back side 52 of the head section 32 of the body 22 of the rail joint 20 is received within the web recess 86 of the body 22 of the railroad rail 12 . The contacting surface 59 of curved portion 56 of the abutting portion 54 of the rail joint 20 abuts against a surface of the railroad rail 12 within the rail head recess 88 , thus defining a first fishing surface F 1 The bottom surface 29 of the base section 28 abuts against the upper surface 82 of the base 80 of the railroad rail 12 , thus defining a second fishing surface F 2 . By “fishing surface” is meant a surface where the rail joint 20 contacts a surface of a railroad rail. It has also been found that the rail joint 20 should be positioned a distance X between the top surface 76 of the railroad rail 12 and the upper surface 33 of the lug portion 62 in order to minimize the possibility of contact between rail wheels and the rail joint 10 . For example, the distance X is preferably, for larger rails, at least 2.0 inches, and, more preferably, 2.17 inches for a 132-RE rail, 2.37 inches for a 136-RE rail, and 2.52 inches for a 141-RE rail. The distance X is preferably, for smaller rails, at least 2.0 inches and, more preferably, 2.05 inches for a 115-RE rail and 2.24 inches for a 119-RE rail. It has been found that the present design maximizes Moment of Inertia (I) and minimizes weight of the rail joint 20 while providing additional wheel flange clearance over prior art rail joints resulting in a superior rail joint.
[0029] FIG. 9 shows a rail joint assembly 91 made in accordance with the present invention. Referring to FIGS. 8 and 9 , the assembly includes a pair of rail joints 20 , 20 ′, as previously discussed, attached to each side of a pair of abutting railroad rails 12 , 14 (shown in FIG. 1 ). A fastener 92 , such as a nut and bolt arrangement, passes through the hole 38 in rail joint 20 , slot 84 in railroad rail 12 , and a corresponding hole 38 ′ in rail joint 20 ′ and a nut 94 is received by the fastener 92 so as to attach the rail joints 20 , 20 ′ against each side of the adjacent railroad rail 12 .
[0030] FIG. 10 shows a prior art rolled rail joint 100 , resulting in a weaker rail joint 100 compared to rail joint 20 . The prior art rail joint 100 is similar to rail joint 20 , except for the differences noted below. Like reference numerals are used for like parts. The prior art rail joint 100 includes a body 22 having a base section 28 , a web section 30 , and a head section 32 . The shape of the web section 30 and the base section 28 of the prior art rail joint 100 are substantially similar to the web section 30 and base section 28 of rail joint 20 . The head section 32 of rail joint 100 also includes an abutting portion 54 , an intermediate portion 60 , and a lug portion 62 . However, the abutting portion 54 of rail joint 100 includes only a curved portion 56 and not a straight portion 58 as in rail joint 20 , thereby resulting in a weaker rail joint. Further, the distance D 1 the lug portion 62 of rail joint 100 extends outwardly relative to the toe portion 48 of the base section 28 is substantially less than the distance D 1 the lug portion 62 of rail joint 20 extends outwardly relative to the toe portion 48 .
[0031] FIG. 11 also shows other prior art rail joint profiles W, Y and Z (shown in phantom) attached to a railroad rail 12 . All of these joints are at least partially machined. Further, the shape of the head sections of the prior art rail joint profiles W, Y and Z, particularly the lug portions, does not extend as far as the lug portion 62 of rail joint 20 . The shape and dimensions of the present rail joint 20 are such that it can be rolled or forged, without any machinery, except for the bolt holes. This results in a stronger and less expensive rail joint having the same diameters of rail joints that are machined. The rail joint 20 begins with a forged billet that is rolled through various rolling stands resulting in the final profile, for example, steel having a minimum 125,000 psi tensile strength and a minimum 88,000 yield strength is preferred. Stronger steel having a higher tensile strength and higher yield strength can be used to compensate for resulting losses in mechanical properties of inertia and section modulus over prior art joints.
[0032] It will be readily appreciated by those skilled in the art that modifications may be made to the invention without departing from the concepts disclosed in the foregoing description. Accordingly, the particular embodiments described in detail herein are illustrative only and are 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 rail joint made from a metallic profiled bar that is rolled or forged and is used for connecting adjacent railroad rails to each other. A purpose of the present invention is to provide increased wheel flange clearance while maintaining the integrity of joining two rails together.
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This application claims priority to U.S. Provisional Patent Application Ser. No. 61/639,949 filed Apr. 29, 2012.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates generally to cementing equipment used with oilfield wellhead equipment and, in particular aspects, to couplings that are useful for such equipment.
2. Description of the Related Art
After a hydrocarbon wellbore has been drilled, a casing is typically cemented in along the length of the drilled bore. Cementing equipment is used to do this and typically includes a top drive cement head that permits balls or rubber darts to be dropped into the wellbore during the cementing operation. The cement head also must be capable of flowing cement from a cement supply downwardly into the wellbore. Suitable cementing equipment for these purposes includes a top drive cement head which is available commercially from Baker Hughes Incorporated of Houston, Tex.
SUMMARY OF THE INVENTION
The invention provides methods and devices for quickly connecting and disconnecting a conduit to a port. In a described embodiment, a quick connect coupling is described for quickly connecting and disconnecting a cement supply conduit to the port of a top drive cement swivel. An exemplary quick connect coupling includes a stinger assembly that is reversibly coupled to a breech lock box connector on the cement swivel. Raised keys on the breech lock barrel will interfit with complimentary ridges with a bore of the breech lock connector.
In certain embodiments, a locking arrangement that secures the stinger assembly against rotation within the breech lock connector. In one embodiment, a locking pin is used to lock the stinger assembly into place and against rotation with respect to the cement swivel. An exemplary locking pin is described that is retained by the cement swivel and is axially moveable between unlocked and locked positions. In the locked position, the locking pin will reside within a complimentary indentation within the stinger assembly thereby preventing rotation.
In operation, a user can quickly and easily couple the stinger assembly with the cement swivel easily and without the need for hammers and other tools to be used. A crane may be used to lift and move the stinger assembly and affixed cement conduit to a position that is proximate the breech lock box connector of the cement swivel. An operator can then orient the stinger assembly so that the keys of the stinger assembly are angularly offset from the ridges within the bore. The stinger and breech lock barrel are then inserted into the bore. Thereafter, the user rotates the stinger assembly to align the keys of the stinger assembly with the ridges of the bore. When aligned, each of the keys are preferably located in line with and behind a ridge, preventing the stinger assembly from being withdrawn from the breech lock connector. The locking arrangement is then engaged to lock the stinger assembly in place so that it cannot be rotated with the breech lock connector.
BRIEF DESCRIPTION OF THE DRAWINGS
The advantages and further aspects of the invention will be readily appreciated by those of ordinary skill in the art as the same becomes better understood by reference to the following detailed description when considered in conjunction with the accompanying drawings in which like reference characters designate like or similar elements throughout the several figures of the drawing and wherein:
FIG. 1 is a side view of portions of an exemplary wellbore cementing operation.
FIG. 2 is an isometric view of an exemplary stinger assembly in accordance with the present invention.
FIG. 3 is a side view of the stinger assembly shown in FIG. 2 .
FIG. 4 is a cross-sectional view taken along lines 4 - 4 in FIG. 3 .
FIG. 5 is a front view of an exemplary cement swivel with stinger assembly attached in accordance with the present invention.
FIG. 6 is a cross-sectional view taken along lines 6 - 6 in FIG. 5 .
FIG. 7 is a front view of the cement swivel and stinger assembly depicting the stinger assembly being coupled to the swivel.
FIG. 8 is an enlarged cross-sectional view of portions of an exemplary coupling in accordance with the present invention.
FIG. 9 is a side view of the exemplary cement swivel and stinger assembly shown in an unlocked condition.
FIG. 10 is a side view of the cement swivel and stinger assembly of FIG. 9 , now in a locked condition.
FIG. 11 is a cross-sectional view, partially in phantom, showing portions of the stinger assembly and cement swivel in an unsecured condition.
FIG. 12 is a cross-sectional view, partially in phantom, showing portions of the stinger assembly and cement swivel now in a secured condition.
FIG. 13 is an isometric view of an exemplary breech lock barrel shown apart from other components of the coupling.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates portions an exemplary cementing operation for a wellbore. A tubular working string 10 extends downwardly into a wellhead 12 . A cementing tool 14 is incorporated into the working string 10 which typically contains balls and/or plugs which are launched into the working string 10 during a cementing operation. A top drive cement swivel 16 is affixed to the upper end of the cementing tool 14 . The cement swivel 16 operates to receive cement and transmit it through a flowpath in the cementing tool 14 so that the cement can be flowed downwardly into the working string 10 . FIG. 1 also depicts a cement hose 18 with an affixed stinger assembly 20 . Cement can be flowed to the cement swivel 16 when the stinger assembly 20 is coupled to the cement swivel 16 . The cement hose 18 and stinger assembly 20 are depicted being lifted by block and tackle 22 .
The structure and operation of an exemplary stinger assembly 20 are better appreciated with further reference to FIGS. 2-4 . The stinger assembly 20 includes a curved rigid pipe portion 24 that is affixed to the hose 18 . A flange 26 with lifting eye 28 extends upwardly from the pipe portion 24 . A stinger 30 extends outwardly from the pipe portion 24 . A cement flow path 32 is defined within the pipe portion 24 and stinger 30 . A breech lock barrel 34 radially surrounds the stinger 30 and, as can be seen best in FIGS. 4 and 8 , secured to the stinger 30 by a sleeve 36 that preferably permits the breech lock barrel 34 to rotate about the stinger 30 . FIG. 13 shows the breech lock barrel 34 apart from the other components of the stinger assembly 20 . A flange 38 projects radially outwardly from the breech lock barrel 34 and presents at least one indentation 40 . In the depicted embodiment, there are six indentations 40 . In preferred embodiments, an enlarged grippable handle 42 also radially surrounds the stinger 30 and is secured by bolts 44 ( FIG. 2 ) to the breech lock barrel 34 so that the stinger 30 will be rotated when the handle 42 is rotated.
The outer radial surface of the breech lock barrel 34 preferably presents a plurality of raised keys 46 . As will be appreciated with regard to FIGS. 2 , 3 , 4 and 8 , the keys 46 are organized into rows (A, B and C) and perpendicular columns. The keys 46 are spaced apart from each other along each of the rows A, B and C and each of the columns. In some embodiments, there are six keys 46 per row A, B and C spaced angularly from each other at about 30 degrees apart. In certain embodiments, the breech lock barrel 34 also includes a row of raised anti-rotation locking dogs 47 . In the depicted embodiment, there are six locking dogs 47 that are positioned in a spaced relation from one another of about 30 degrees apart.
The structure of the exemplary top drive cement swivel 16 is better understood with reference to FIGS. 5-10 . It can be seen that the cement swivel 16 has a generally box-shaped main housing 50 . A central axial flowbore 52 passes vertically through the main housing 50 . Lateral fluid flow openings 54 , 56 extend through the main housing 50 and permit fluid communication between the central flowbore 52 and the exterior of the cement swivel 16 . A tubular breech lock box connector 58 extends outwardly from the main housing 50 . As illustrated in FIGS. 11 and 12 , the breech lock box connector 58 defines an interior bore 60 having a plurality of inwardly projecting ridges 62 . The ridges 62 are spaced apart from each other both radially and axially within the bore 60 . Preferably, the interior bore 60 also includes an annular fluid seal 63 ( FIG. 8 ) that creates a fluid seal against the stinger 30 when it is inserted into the bore 60 . In addition, the interior bore 60 also presents a row of inwardly projecting anti-rotation locking dogs 48 . The dogs 48 are meant to be complimentary to the anti-rotation dogs 47 of the breech lock barrel 34 .
FIGS. 9 and 10 illustrate a locking pin 64 which is preferably used with the cement swivel 16 and is used to lock the stinger assembly 20 into a coupled position with respect to the cement swivel 16 . The locking pin 64 is preferably retained by a sleeve 66 and is axially shiftable between two positions. In the unlocked position shown in FIG. 9 , the locking pin 64 does not prevent rotation of the stinger assembly 20 with respect to the cement swivel 16 . In the locked position shown in FIG. 10 , the locking pin 64 is disposed within an indentation 40 of the flange 38 and will prevent rotation of the stinger assembly 20 with respect to the cement swivel 16 . In particular embodiments, the locking pin 64 has a handle portion 68 that can be used to rotate and shift the locking pin 64 between the unlocked and locked positions.
In operation, a user can rapidly couple or uncouple the cement conduit 18 to the cement swivel 16 . In order to couple the stinger assembly 20 to the cement swivel 16 , the block and tackle 22 is used to lift and move the stinger assembly 20 by lifting eye 28 until the stinger assembly 20 is proximate the breech lock connector 58 of the cement swivel 16 . A user can then grasp the handle 42 of the stinger assembly 20 and rotate the stinger assembly 20 to the approximate position shown in FIG. 7 . In FIG. 7 , the stinger assembly 20 is rotated approximately 30 degrees from the vertical, as illustrated in FIG. 7 . This rotation will align the keys 46 of the stinger assembly 20 angularly between the ridges 62 of the breech lock barrel bore 60 so that the breech lock barrel 34 can be fully inserted into the bore 60 , as illustrated in FIG. 11 . Once fully inserted, the user will rotate the stinger assembly 20 approximately 30 degrees back to the position depicted in FIG. 5 . This rotation will move the raised keys 46 of the breech lock barrel 34 to the position illustrated in FIG. 12 , wherein each key 46 is located behind a ridge 62 within the bore 60 . Also, each row A, B and C of keys 46 is located behind a row of ridges 62 . The locking dogs 47 will radially abut the dogs 48 of the bore 60 (as depicted in FIG. 12 ), preventing further rotation beyond 30 degrees. In this position, the stinger assembly 20 cannot be axially withdrawn from the bore 60 . The stinger assembly 20 is now coupled to the cement swivel 16 . The user can now move the locking pin 64 from the unlocked position ( FIG. 9 ) to the locked position ( FIG. 10 ) as described previously. Seating of the locking pin 64 within the indentation 40 will prevent the stinger assembly 20 from being inadvertently rotated and uncoupled from the cement swivel 16 . Cement can now be flowed along the cement flow path 32 from the cement conduit 18 into the lateral flow opening 54 of the cement swivel and into the central flowbore 52 of the cement swivel 16 .
In order to uncouple the stinger assembly 20 from the cement swivel 16 , a user will reverse the operations. The locking pin 64 is moved from the locked position ( FIG. 10 ) to the unlocked position ( FIG. 9 ). A user can then rotate the stinger assembly 20 approximately 30 degrees to the position illustrated in FIG. 7 . The stinger assembly 20 can then be axially withdrawn from the bore 60 of the breech lock connector 58 .
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 those 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.
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Devices and methods are described for quickly connecting and disconnecting a conduit to a port. A quick connect coupling is described for quickly connecting and disconnecting a cement supply conduit to the port of a top drive cement swivel.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
RELATED APPLICATIONS
The present invention was first described in and claims the benefit of U.S. Provisional Application No. 61/286,906 filed on Dec. 16, 2009, the entire disclosures of which are incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates generally to spike strip devices for deflating vehicle tires, and in particular, to a spike strip device readily deployable from a moving vehicle.
BACKGROUND OF THE INVENTION
Motor vehicle chases are a relatively rare but particularly trying part of law enforcement processes. High-speed chases involving law enforcement officers in pursuit of criminals provide a serious threat to the lives of the officers, the pursued, and bystanders unintentionally in the path of the chase. Thus the primary concern of law enforcement officers during such chases is to stop or disable the pursued vehicle as quickly as possible.
One (1) common method utilized in such situations is spike strips, which are installed on roads or streets at a location further ahead on the current path of the pursued vehicle. Such spike strips are effective at stopping a vehicle when the vehicle's tires come in contact with the spike strip. However, in many cases, such contact is typically unlikely as the fleeing vehicle may be aware of such practices and will have ample visual warning to avoid these strips.
Additionally, such spike strips are dangerous for the officers who are deploying them and may unintentionally endanger other law enforcement vehicles and the vehicles of innocent citizens.
Various attempts have been made to provide selectively deployable tire deflating systems. Examples of these attempts can be seen by reference to several U.S. patents. U.S. Pat. No. 5,839,849 issued in the name of Pacholok et al., describes a mechanical tire deflating device including a compressed gas deployment mechanism which release a projectile on a tether. Once fully deployed, the projectile automatically deploys a plurality of spike arms in order to disable a target vehicle.
U.S. Pat. No. 6,474,903, issued in the name of Marts et al., describes a barrier strip with a plurality of retractable tire-puncture spikes with a selectable control mechanism which allows a user to quick expose and lock the spikes and subsequent retract the spikes as desired.
U.S. Pat. No. 6,527,475, issued in the name of Lowrie, describes a quick stop deployment system and method which includes a pair of tire deflation systems deployable on either side of a vehicle in order to inhibit progress of a vehicle in an adjacent lane.
While these devices fulfill their respective, particular objectives, each of these references suffer from one (1) or more of the aforementioned disadvantages. Many such devices require the device to be pre-disposed at a fixed location prior to use. Also, many such devices do not cover a sufficiently broad area when deployed which may inhibit the effectiveness of the device. Furthermore, many such devices are difficult to deploy and to reset due to complex, non-reversible release mechanisms. In addition, many such devices are unstable when connected to a pursuit vehicle and pose danger to those operating the device. Accordingly, there exists a need for a deployable spike strip system without the disadvantages as described above. The development of the present invention substantially departs from the conventional solutions and in doing so fulfills this need.
SUMMARY OF THE INVENTION
In view of the foregoing references, the inventor recognized the aforementioned inherent problems and observed that there is a need for a selectively deployable spike strip system for use with a moving vehicle which includes a simple and quick release and reset mechanism and a stable deployment process. Thus, the object of the present invention is to solve the aforementioned disadvantages and provide for this need.
To achieve the above objectives, it is an object of the present invention to comprise a spike strip system for deployment from a vehicle which allows selective disablement of a trailing vehicle, such as a law enforcement vehicle pursuing a fugitive vehicle. The system comprises a main body portion, first and second extension portions, and a pair of mounting brackets.
Another object of the present invention is to include a plurality of spikes which disable a trailing vehicle by damaging tire portions of the trailing vehicle including a plurality of upwardly extending spikes located on a top surface of the main body portion.
Yet still another object of the present invention is to securely fasten the system to an undercarriage frame of a vehicle using the pair of mounting brackets.
Yet still another object of the present invention is to allow a user to quickly release the main body portion and the first and second extension portions from the mounting bracket as desired. Each mounting bracket comprises a magnet further comprising an internal permanent magnet rotatably housed within a ferrous metal enclosure such that rotation of the internal permanent magnet provides deactivation of the magnetic attraction by the magnet upon an armature portion of a corresponding extension portion of the system, thereby causing the main body portion and the first and second extension portions to drop from the vehicle.
Yet still another object of the present invention is to allow the user to selectively deploy the main body portion and the first and second extension portions from within the vehicle. The system comprises a control module including a switch which is in electrical communication with a pair of rotary actuators attached to each mounting bracket. When the switch is manually actuated by the user, the magnets are rotated and the system is deployed as previously described.
Yet still another object of the present invention is to automatically extend the first and second extension portions upon deployment of the system using an internal spring-loaded deployment mechanism. Further upon extension of the first and second extension, a plurality of internal spring-loaded spikes are rotated upwardly through a plurality of correspondingly position rectangular spike slots in order to provide a spiked surface across the length of the system.
Yet still another object of the present invention is to provide stable, high-friction sliding against a pavement surface. The system further comprises a plurality of horizontally extending stabilizers and a plurality of downwardly disposed skid pads affixed to the main body portion and the first and second extension portions which provide the system with secure planar stability during deployment and when run over by the wheels of a trailing vehicle.
Yet still another object of the present invention is to provide a method of utilizing the device that provides a unique means of driving the leading vehicle to a location ahead of a trailing vehicle; selecting the “ON” position on the control module to deploy and jettison the main body and extension portions of the system onto the pavement into a path of the trailing vehicle; disabling the trailing vehicle wherein the tire portions of the trailing vehicle are punctured when traveling over the spike strip system; recovering the system; cleaning and repairing the system, if required; restoring the system to a ready state; and, benefiting from a mobile and compact means of deploying a spike strip to disable a trailing vehicle afforded a user of the system.
Further objects and advantages of the present invention will become apparent from a consideration of the drawings and ensuing description.
BRIEF DESCRIPTION OF THE DRAWINGS
The advantages and features of the present invention will become better understood with reference to the following more detailed description and claims taken in conjunction with the accompanying drawings, in which like elements are identified with like symbols, and in which:
FIG. 1 is a perspective environmental view of a spike strip system 10 depicting a deployed state, according to a preferred embodiment of the present invention;
FIG. 2 is a bottom view of the spike strip system 10 in a ready state mounted upon a an undercarriage portion of a vehicle 60 , according to the preferred embodiment of the present invention;
FIG. 3 a is a perspective view of the spike strip system 10 in a ready state, according to the preferred embodiment of the present invention;
FIG. 3 b is a perspective view of an end portion of the spike strip system 10 depicting a deployed state, according to the preferred embodiment of the present invention;
FIG. 4 is a close-up perspective view of spring-loaded spike portions 16 of the spike strip system 10 , according to the preferred embodiment of the present invention;
FIG. 5 a is a perspective bottom view of the spike strip system 10 in a deployed state depicting skid pad portions 34 , 35 , 36 , according to the preferred embodiment of the present invention;
FIG. 5 b is a partial cut-away view of main body 11 and second extension 12 b portions of the spike strip system 10 , according to the preferred embodiment of the present invention;
FIG. 5 c is a section view of main body 11 and extension portions 12 a , 12 b of the spike strip system 10 taken along section line A-A (see FIG. 3 a ), according to the preferred embodiment of the present invention; and,
FIG. 6 is an electrical block diagram of the spike strip system 10 , according to the preferred embodiment of the present invention.
DESCRIPTIVE KEY
10
spike strip system
11
main body
12a
first extension
12b
second extension
13a
first stabilizer
13b
second stabilizer
13c
third stabilizer
14a
first armature plate
14b
second armature plate
15
fixed spike
16
spring-loaded spike
17
first connector
18
second connector
19
main conductor
20
switch
21
male connector
22
female connector
23
control module
24a
first magnet
24b
second magnet
25a
first rotary actuator
25b
second rotary actuator
26
axle
27
spike slot
28
compression spring
30
backer plate
31
first extension stop
32
second extension stop
34
first skid pad
35
second skid pad
36
third skid pad
37
mounting bracket
38
aperture
40
existing vehicle electrical system
60
leading vehicle
61
pavement
70
trailing vehicle
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The best mode for carrying out the invention is presented in terms of its preferred embodiment, herein depicted within FIGS. 1 through 6 . However, the invention is not limited to the described embodiment and a person skilled in the art will appreciate that many other embodiments of the invention are possible without deviating from the basic concept of the invention, and that any such work around will also fall under scope of this invention. It is envisioned that other styles and configurations of the present invention can be easily incorporated into the teachings of the present invention, and only one particular configuration shall be shown and described for purposes of clarity and disclosure and not by way of limitation of scope.
The terms “a” and “an” herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced items.
The present invention describes a spike strip system (herein described as the “system”) 10 , and a method for deploying said system 10 from a vehicle which in turn provides a means for disabling a trailing vehicle 70 from a leading deploying vehicle 60 . The present invention is particularly suited for use when the leading deploying vehicle 60 is a law enforcement vehicle and the trailing vehicle 70 is a fugitive vehicle.
Referring now to FIG. 1 , a perspective environmental view of the system 10 , according to the preferred embodiment of the present invention, is disclosed. The system 10 is depicted in a state of having been jettisoned from an undercarriage portion of a moving leading vehicle 60 and deployed onto a subjacent pavement surface 61 . The system 10 provides an effective means of disabling a trailing vehicle 70 by damaging tire portions of said trailing vehicle 70 via fixed spike portions 15 and raised spring-loaded spike portions 16 of the system 10 . Said spring-loaded spikes 16 allow the system 10 to laterally collapse, thereby enabling compact storage under the leading vehicle 60 (see FIGS. 2 and 3 a ).
Referring now to FIG. 2 , a bottom view of the system 10 mounted upon an undercarriage portion of a leading vehicle 60 , according to the preferred embodiment of the present invention, is disclosed. The system 10 is depicted in a “ready” state wherein first extension 12 a and second extension 12 b portions are compactly retracted into a main body portion 11 of the system 10 and being transversely affixed to a rear undercarriage frame portion of the leading vehicle 60 via a pair of mounting brackets 37 (see FIGS. 3 a and 3 b ).
Referring now to FIG. 3 a , a perspective view of the system 10 according to the preferred embodiment of the present invention, is disclosed. The system 10 is depicted here with both extension portions 12 a , 12 b secured in a retracted state and being retained by respective first magnet 24 a and second magnet 24 b portions, which in turn magnetically act upon subjacent first armature plate 14 a and a second armature plate 14 b portions, respectively. Said first 24 a and second 24 b magnets preferably provide a similar magnetic clamping function as a magnetic dial indicator base commonly used in machining and tool making industries, wherein a manual half-turn rotation of an internal permanent magnet housed within a ferrous metal enclosure, directs magnetism to a subjacent flat ferrous metal surface. Rotation of the magnet portions 24 a , 24 b of the system 10 is achieved via direct connection of said magnets 24 a , 24 b to corresponding electric first rotary actuator 25 a and second rotary actuator 25 b members being powered by an existing vehicle electrical system 40 of the leading vehicle 60 . Rotation of said magnets 24 a , 24 b by said rotary actuators 25 a , 25 b provides activation or deactivation of the magnetic attraction exerted by said magnets 24 a , 24 b thereupon the corresponding armature plates 14 a , 14 b , thereby enabling the main body 11 and extension 12 a , 12 b portions of the system 10 to be selectively retained in the retracted state or to be released downwardly and deployed outwardly when needed. The armature plates 14 a , 14 b comprise flat rectangular magnetic mild steel plates approximately six (6) to eight (8) inches on a side and approximately one-half (½) to one (1) inch in thickness. Said armature plates 14 a , 14 b are preferably welded or otherwise fastened to top surfaces of each end portion of the extensions 12 a and 12 b , respectively.
Electrical power is conducted to the first 25 a and second 25 b rotary actuators by respective first wire 17 and second wire 18 portions in a synchronous manner via electrical connection to a selectable “ON” and “OFF” position upon a control module 23 being preferably mounted upon a dashboard portion of the leading vehicle 60 . The system 10 comprises a male connector 21 which provides a molded body portion which acts to join said first 17 and second 18 wires at a proximal end as well as providing a common electrical connection to a mating female connector 22 upon a distal end portion. Said female connector 22 in turn comprises an integral single main conductor 19 which is routed to the aforementioned control module 23 . In use, a user within the leading vehicle 60 may manually deploy the system 10 by utilizing a selector switch portion 20 of the control module 23 . The joined and interconnected first 17 and second 18 wires provide a resultant simultaneous release of the armatures 14 a , 14 b from the magnets 24 a , 24 b , thereby resulting in downward release of the system 10 and horizontal extension of both extension portions 12 a , 12 b , thereby ensuring that the system 10 contacts the pavement 61 in a flat, straight and uniform manner.
Each magnet 24 a and 24 b is housed within an upwardly extending mounting bracket 37 which provides a means to securely fasten of the system 10 to undercarriage frame portions of the leading vehicle 60 . The mounting brackets 37 are envisioned being made of a durable ferrous metal so as to effectively conduct the magnetism from the internal magnets 24 a , 24 b to the respective subjacent armature plates 14 a , 14 b . Said mounting brackets 37 are depicted here taking a form of “L”-shaped units comprising vertical plate portions further comprising a pair of fastening apertures 38 each; however, it is understood that various mounting brackets having different designs may be utilized to provide a fastening means to various makes and models of leading vehicles 60 onto which the system 10 may be applied and as such should not be interpreted as a limiting factor of the system 10 .
The system 10 further comprises a main body 11 , a first extension 12 a , a second extension 12 b , a first stabilizer 13 a , a second stabilizer 13 b , a third stabilizer 13 c , a plurality of fixed spikes 15 , and a plurality of spring-loaded spikes 16 . The structures of the main body 11 and the extensions 12 a and 12 b are envisioned to be rectangular in cross section and fabricated, cast, molded or extruded of rugged metal materials such as, but not limited to: steel or aluminum, in either an internally reinforced box-like structure, a flattened tubular shape, or in a honeycomb-like structure to reduce weight. Outer end portions of each extension 12 a , 12 b comprise forwardly extending first 13 a and second 13 b stabilizer portions, respectively. Said first 13 a and second 13 b stabilizers are preferably welded to outer end surfaces of the respective extensions 12 a , 12 b and extend perpendicularly in a forward direction approximately eighteen (18) inches and being angled slightly upward at an end portion, thereby providing smooth sliding along an uneven paved surface 61 . Furthermore, the system 10 comprises a third stabilizer 13 c being permanently welded to a rear vertical surface of the main body 11 at an intermediate position. Said third stabilizer 13 c is to extend in a rearward direction approximately six (6) to twelve (12) inches, thereby further enhancing a stable sliding motion. Said stabilizers 13 a , 13 b , 13 c are envisioned to be made using rectangular bar stock of metal materials similar to those of the main body 11 . The stabilizers 13 a , 13 b , 13 c provide the system 10 with secure planar stability while sliding across pavement 61 as well as when being run over by the wheels of the trailing vehicle 70 during deployment.
The system 10 further comprises a plurality of fixed spikes 15 located along a top surface of the main body 11 and a portion of each extension 12 a , 12 b along a top surface which protrudes beyond the main body 11 when said extensions 12 a , 12 b are in the retracted state. Said fixed spikes 15 comprise pointed triangle-shaped protrusions approximately two (2) to three (3) inches in height being capable of piercing vehicle tires and are to be securely welded to said top surface portions of said main body 11 and the extension 12 a , 12 b portions.
Referring now to FIG. 3 b , a perspective view of the second extension 12 b of the system 10 according to the preferred embodiment of the present invention, is disclosed. The second extension 12 b is depicted here having been released and downwardly deployed from the corresponding second magnet 24 b , and subsequently extended horizontally outward from the main body 11 by a force exerted by an internal compression spring 28 contained within said main body 11 (see FIG. 5 c ).
Referring now to FIG. 4 , a close-up perspective view of spring-loaded spike portions 16 of the system 10 , according to the preferred embodiment of the present invention, is disclosed. The system 10 comprises a plurality of spring-loaded spikes 16 within a portion of each extension 12 a , 12 b which is recessed within the main body 11 when said extensions 12 a , 12 b are in the retracted state. Each spring-loaded spike 16 comprises a spiral wound torsional spring portion having a first protruding end portion shaped into a sharp spike configuration and a second end being braced against an interior portion of the respective extensions 12 a and 12 b . Each spring-loaded spike 16 is supported and laterally positioned by an axle 26 being inserted through each spring-loaded spike 16 . Prior to activation and release of the system 10 , the spring-loaded spikes 16 are retained in a depressed position against an inner surface of the main body 11 . Upon release and horizontal extension of said extensions 12 a , 12 b , the spring-loaded spikes 16 are then free to rotate upwardly through correspondingly positioned rectangular-shaped spike slots 27 being machined or formed along top surfaces of the extensions 12 a , 12 b . Said spike slots 27 also provide a mechanical limitation to an upward rotation of said spring-loaded spikes 16 so as to retain said spring-loaded spikes 16 in a vertical orientation. Said spring-loaded spikes 16 protrude above a top surface of said extensions 12 a , 12 b approximately two (2) to three (3) inches being capable of piercing and shredding tire portions of the trailing vehicle 70 .
Referring now to FIG. 5 a , a perspective bottom view of the system 10 according to the preferred embodiment of the present invention, is disclosed. Underside portions of the main body 11 and both extensions 12 a , 12 b provide an increased friction and stabilizing means during contact with the pavement 61 upon deployment. Said main body 11 comprises a centrally located first skid pad 34 and four (4) second skid pads 35 being arranged along a bottom surface of said main body 11 so as to cover a majority of said surface area. Said extensions 12 a , 12 b further comprise respective third skid pads 36 being positioned adjacent to the aforementioned first 13 a and second 13 b stabilizers. Said pads 34 , 35 , 36 comprise various rectangular shapes being permanently bonded to the underside portions of the main body 11 and the extensions 12 a , 12 b . Said friction pads 34 , 35 , 36 are envisioned to be made of rubber, neoprene, or equivalent high-friction compounds having an appropriate durometer hardness, thereby providing a stable high-friction sliding action against the surface of the pavement 61 .
Referring now to FIG. 5 b , a partial cut-away view of main body 11 and second extension 12 b portions of the spike strip system 10 , according to the preferred embodiment of the present invention is disclosed. The extensions 12 a , 12 b are insertingly and slidingly engaged into an inner cavity portion of the main body 11 . A horizontal force to motion said extensions 12 a , 12 b outwardly is exerted via respective compression springs 28 (only the second extension 12 b is shown here). Said compression springs 28 propel respective extensions 12 a , 12 b outwardly a distance of approximately sixteen (16) to twenty (20) inches upon release from the respective magnets 24 a , 24 b . Said outward motion of the extensions 12 a , 12 b is mechanically limited via internal contact of first extension stop portions 31 of said extensions 12 a , 12 b with second extension stop portions 32 of the main body 11 (see FIG. 5 c ).
The preferred method for securing and releasing the system 10 is disclosed herein utilizing magnetic devices; however, it is understood by those skilled in the art, that various means of retaining the system 10 onto the undercarriage of the leading vehicle 60 , and ejecting the system 10 onto the pavement 61 may be utilized without deviating from the concept such as, but not limited to: various mechanically activated devices, electro-magnets, vacuum pad devices an electric pump, or the like.
Referring now to FIG. 5 c , a section view of main body 11 and extension portions 12 a , 12 b of the system 10 taken along section line A-A (see FIG. 3 a ), according to the preferred embodiment of the present invention, is disclosed. The first extension 12 a is depicted here in a retracted state and the second extension 12 b is depicted in an extended state for illustration sake. The retracted state of the first extension 12 a provides mechanical retention of the spring-loaded spikes 16 within the spike slot portions 27 along the top surface of said first extension 12 a and against a top surface of the main body 11 until said first extension 12 a is deployed outwardly (see FIG. 5 b ). Said retracted state of said first extension 12 a also results in compression of the compression spring 28 against an internal backer plate 30 being integral to the main body 11 . Said backer plate 30 comprises an internal perpendicular wall structure, thereby separating an inner space of said main body 11 into two (2) equal chambers to contain the respective first 12 a and second 12 b extensions and corresponding compression springs 28 .
The second extension 12 b is depicted here being horizontally extended outward from the main body 11 having been released and thereby propelled via the force exerted by the compression spring 28 . Outward extension of the extensions 12 a , 12 b is limited by mechanical contact between first extension stop portions 31 of the extensions 12 a , 12 b , and respective second extension stop portions 32 of the main body 11 . Each first extension stop 31 comprises an integral portion of the extensions 12 a , 12 b and comprises a widened end portion of each extension 12 a , 12 b being contained within the main body 11 . The second extension stops 32 comprise retaining rectangular openings at each end of the main body 11 being particularly sized to allow smooth inserted motioning of the extensions 12 a , 12 b while providing interference with said first extension stop portions 31 , thereby retaining the system 10 in a fully deployed state during use.
Referring now to FIG. 6 , an electrical block diagram of the spike strip system 10 , according to the preferred embodiment of the present invention, is disclosed. The system 10 utilizes polarized DC electrical power from an existing 12-volt vehicle electrical system 40 . Said electrical power 40 is in turn controlled via a double pole-single throw type switch 20 within a control module 23 envisioned to be mounted within convenient reach by an operator driving the leading vehicle 60 . Said switch 20 provides constant power to the first 25 a and second 25 b rotary actuators while the system 10 is in both “ready” and deployed states. Power is in turn conducted to the system 10 via a main conductor 19 being routed to a rear portion of the leading vehicle 60 . Said main conductor 19 is in turn removably connected to the first 17 and second 18 wires via joining male 21 and female 22 connectors. Said female connector 22 provides a junction means to said first 17 and second 18 wires which are in turn connected to respective first 25 a and second 25 b rotary actuators, thereby providing power to said rotary actuators 25 a , 25 b in a synchronous manner to deploy the system 10 in a downward parallel manner upon the subjacent pavement 61 .
It is envisioned that other styles and configurations of the present invention can be easily incorporated into the teachings of the present invention, and only one particular configuration shall be shown and described for purposes of clarity and disclosure and not by way of limitation of scope.
The preferred embodiment of the present invention can be utilized by the common user in a simple and effortless manner with little or no training. After initial purchase or acquisition of the system 10 , it would be installed as indicated in FIG. 2 .
The method of installing the system 10 to the leading vehicle 60 may be achieved by performing the following steps: procuring a model of the system 10 being suitable to a particular make and model of leading vehicle 60 onto which the system 10 is to be applied; fastening or welding the mounting brackets 37 to rear undercarriage frame portions of the leading vehicle 60 based upon requirements of a particular installation; routing and securing the first 17 and second 18 wires from the rotary actuators 25 a , 25 b along undercarriage frame portions of the leading deploying vehicle 60 ; mounting the control module 23 in a position within the leading vehicle 60 such as upon a dashboard area such that said control module 23 may be easily reached by the operator; providing electrical power to the system 10 by connecting the existing vehicle electrical system 40 within the dashboard to the control module 23 ; routing the main conductor 19 from the control module 23 along the undercarriage of the leading vehicle 60 to a location of the male connector 21 ; connecting the female connector portion 22 of the main conductor 19 to the male connector 21 portion of the first 17 and second 18 wires; and, mounting the extensions 12 a and 12 b and main body 11 portions of the system 10 to the mounting brackets 37 as described below.
The method of configuring the system 10 to the “ready” state may be achieved by performing the following steps: ensuring that the magnets 24 a and 24 b are deactivated by verifying that the control module 23 is set to the “OFF” position; raising the leading vehicle 60 ; placing a ratcheting strapping device horizontally around the system 10 ; operating the ratcheting device to progressively compress the compression springs 28 and retract the extensions 12 a and 12 b within the main body 11 while coincidentally and sequentially manually motioning the spring-loaded spikes 16 downwardly into the spike slots 27 ; raising and blocking the strapped system 10 so as to position the magnets 24 a , 24 b against the armature plates 14 a , 14 b ; activating and securing said magnets 24 a and 24 b to said armature plates 14 a , 14 b by turning the control module 23 to the “ON” position; reversing the ratcheting device to release and remove a temporary retaining strap portion; and, lowering the deploying vehicle 60 .
The method of utilizing the system 10 may be achieved by performing the following steps: driving the leading vehicle 60 to a location ahead of a trailing vehicle 70 ; selecting the “ON” position on the control module 23 to deploy and jettison the main body 11 and extension 12 a , 12 b portions of the system 10 onto the pavement 61 into a path of the trailing vehicle 70 ; disabling the trailing vehicle 70 wherein the tire portions of the trailing vehicle 70 are punctured when traveling over the spike strip system 10 ; recovering the system 10 ; cleaning and repairing the system 10 , if required; restoring the system 10 to the “ready” state by following the steps described above; and, benefiting from a mobile and compact means of deploying a spike strip to disable a trailing vehicle 70 afforded a user of the present invention 10 .
The foregoing descriptions of specific embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention and method of use to the precise forms disclosed. Obviously many modifications and variations are possible in light of the above teaching. The embodiment was chosen and described in order to best explain the principles of the invention and its practical application, and to thereby enable others skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated. It is understood that various omissions or substitutions of equivalents are contemplated as circumstance may suggest or render expedient, but is intended to cover the application or implementation without departing from the spirit or scope of the claims of the present invention.
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A system whereby a disabling spike strip is deployed from the rear undercarriage of a vehicle is enabled by a dashboard-mounted switch powered by the vehicle electrical system. The spike strip comprises a main body and two (2) extensions which are deployed outwardly from each side of the main body by the action of internal compression springs. The undersides of the main body and each extension are provided with a plurality of skid pads. The spike strip further comprises front and rear stabilizer bars. The purpose of the pads and the stabilizers are to retain the location of the spike strip against the pavement and against the action of a trailing vehicle's wheels. The top portion of the spike strip comprises a plurality of fixed and spring-loaded spikes being designed to shred the tires of the trailing vehicle.
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REFERENCE TO RELATED APPLICATION
This application is a divisional application of prior U.S. application Ser. No. 08/649,450, filed May 17, 1996 now U.S. Pat. No. 5,895,536.
BACKGROUND OF THE INVENTION
The present invention relates generally to methods of roof construction, and more particularly relates to an improved method for adhering roof tiles to substrates using economical one-component adhesives, including one-component high-density polyurethane adhesive foams.
Roof construction, especially in residential construction, varies by location throughout the United States. In the northern climates, most roofs utilize a thin covering of tar paper-based shingles or thick wooden shingles as a final covering for the roof. In southern climates, tiles are used as the final covering of the roof. These roof tiles may be made from a variety of materials, including synthetic materials, such as plastics, and natural materials, such as stone, concrete, clay, ceramic and fired brick. In the application of these latter types of roof tiles, mortars or cementitious materials have been used in the past to apply the roof tiles to the roof substrate.
The use of mortars as roof tile adhesives is expensive because the mixing and application of the mortar is very labor intensive. Mortars are dense materials and their use as roof adhesives increases the load placed on the roof. The curing time for mortar may also be relatively long, thereby hampering quick completion of the roof. A need therefore exists for a lighter adhesive which is less labor intensive than mortar and which lends itself to efficient application of roof tiles.
Adhesives, and in particular adhesive foams, have been developed to replace mortars used in roof construction. U.S. Pat. No. 5,362,342, issued Nov. 8, 1994 describes the use of a two-component polyurethane foam to bond roof tiles to a substrate. This patent further describes the use of a bulky, complex pressurized dispensing system which is necessary to mix the two components together so that they may react to create a sufficient amount of foam with the desired adhesive characteristics. The aforesaid '342 patent further describes a particular method of using two-component foams to bond roof tiles to a roof substrate in which thick, linear beads of foam are applied to the entire length of the roof tiles.
One-component adhesives, such as those sold under the trade name INSTA-STIK by Insta-Foam of Joliet, Illinois have been utilized in the past, primarily for adhering roof insulation boards to roof substrates. These one-component adhesives are collapsible foams and are applied in long beads of foam for all or most of the entire length of the insulation boards to adhere the insulation boards to the roof. The use of long, linear beads of adhesives increases the cost of applications by using large amounts of adhesives and lengthening the application process.
The present invention is directed to a roof tile adhesion method which uses inexpensive one-component adhesives, and in a preferred embodiment one-component polyurethane adhesive foams, in a novel application pattern which significantly reduces the amount of adhesive used per roof tile without detracting from its adhesive strength.
It is therefore an object of the present invention to provide a method of adhering roof tiles to a roof substrate using economical one-component adhesives, including one-component adhesive foams.
Another object of the present invention is to provide a method for adhering roof tiles to a substrate using a modest amount of adhesive in a unique pattern which reduces the amount of adhesive used for application, yet provides sufficient adhesive strength between the roof tile and the substrate.
Yet another object of the present invention is to provide a method for adhering roof tiles to a substrate by applying a one-component, high-density polyurethane adhesive foam to opposing corners of the roof tile and placing the tiles into contact with the substrate, and letting the adhesive foam cure to adhere the roof tile to the substrate.
Still yet another object of the present invention is to provide an improved tiled roof construction having a substrate, a plurality of roof tiles adhered to the substrate, the roof tiles being adhered to the substrate by an adhesive deposited in alignment with opposing corners of the roof tiles, the adhesive deposits having a pad-like profile, the adhesive pads adhering opposite corners of the tile to the roof substrate and a preceding tile course, the adhesive pads further defining a discontinuous adhesive pattern which does not subdivide the space between the tile undersurfaces and the roof substrate into discrete spaces to restrict air circulation between the roof tile and the roof substrate.
SUMMARY OF THE INVENTION
In one principal aspect of the present invention, a roof construction method is provided in which successive courses of roof tile are adhered to a roof substrate by applying a one-component adhesive to the undersurface of the roof tiles; laying the tiles in successive courses on the roof; and, permitting the foam to cure.
In another principal aspect of the present invention and as exemplified in one preferred embodiment, a method for applying roof tiles to a roof substrate is provided which includes the steps of: providing a one-component adhesive, particularly a one-component adhesive foam; applying a first course of roof tile to a roof substrate by depositing the adhesive in a discontinuous pattern comprising two separate deposits in registration with opposite corners of the roof tiles; adhering the first course of roof tiles to the roof substrate by placing the first course of roof tiles onto the roof substrate to effect contact between the adhesive deposits, the roof tiles and the roof substrate; dispensing a series of second deposits of the adhesive in registration with opposite corners of the undersurfaces of a second course of roof tiles; placing the second course of roof tiles over the roof substrate and the first course of roof tiles such that the tail portions thereof and adhesive deposits aligned therewith contact the roof substrate and the head portions thereof and adhesive deposits aligned therewith overlie and contact the first course of roof tiles; and, permitting the adhesive to cure such that the first and second roof tile courses become adhered to roof substrate.
In another principal aspect of the present invention and as exemplified by another embodiment of the invention, a roof construction includes a roof substrate and a plurality of roof tiles attached to the substrate in successive courses, each of the tiles being attached to the roof substrate by discontinuous deposits of a one-component adhesive aligned with opposing corners of the undersurfaces of roof tiles, the adhesive foam deposits spacing the tiles partially away from the roof substrate so as to create an air channel therebetween.
These and other objects, features and advantages of the present invention will be apparent through a reading of the following detailed description, taken in conjunction with accompanying drawings, wherein like reference numerals refer to like parts.
BRIEF DESCRIPTION OF THE DRAWINGS
In the course of the description, reference will be made to the attached drawings in which:
FIG. 1 illustrates a typical pitched roof upon which roof tiles are attached;
FIG. 2 is a perspective view of a segment of a prior art roof construction utilizing a two-component adhesive foam to adhere a roof tile course to a roof substrate using, continuous, linear beads of adhesive foam along the entire length of the roof tiles;
FIG. 3 is a sectional view of FIG. 2 taken along lines 3 — 3 thereof illustrating the longitudinal extent of the adhesive foam;
FIG. 4 is a perspective view of a section of a roof illustrating the placement of two courses of flat roof tiles installed thereon using the present invention;
FIG. 5 is a perspective view of a section of a roof illustrating the placement of two courses of roof tiles installed using the present invention and used with low profile, non-planar roof tiles;
FIG. 6 is a perspective view of a section of a roof illustrating the placement of two courses of roof tiles installed thereon using the present invention as used with S-shaped, high profile roof tiles;
FIG. 7 is a view of a tennis-ball like adhesive deposit used in the present invention;
FIG. 8 is a view of a pad-like deposit of adhesive foam used in the present invention; and
FIG. 9 is a cross-sectional view of FIG. 1 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates a structure 20 having a roof 22 disposed thereon at a particular angle, or pitch P. The roof 22 includes a substrate 23 is supported on the structure 20 by a series of structural members, shown as roof joists 24 which are spaced apart from each other along the walls 26 of the structure. The roof joists 24 extend from the edge, or eave 25 of the roof upwardly at the pitch P and may be connected to a central ridge beam 28 at the apex 29 of the roof in a conventional manner.
The roof substrate 22 is commonly of a multiple layer construction and may include sheathing, or decking 30 , in the form of plywood, particle board, cement boards or the like which is preferably fixed to the joists 24 such as by nailing. This sheathing 30 serves as a support surface for the final covering, or cap sheet, of the roof 22 . This covering may be a water resistant material 32 , such as roofing felt or tar paper and is commonly referred to in the art as an “underlayment”. When circumstances dictate, such as when the pitch of the roof is steep, the substrate 20 may further include a series of spaced-apart batten strips 34 (shown in phantom) laterally applied to its surface to provide engagement points for anchor lugs formed in the roof tiles to engage in order to prevent movement of the roof tile during application to the substrate 22 .
FIGS. 2 & 3 illustrate a prior art roof construction 100 which is typical of the construction described in U.S. Pat. No. 5,362,342, in which roof tiles 102 are adhered to a roof substrate 22 . As described in the '342 patent, the construction 100 includes a plurality of low profile roofing tiles 102 having a Spanish-influenced design. Each roof tile 102 is rectangular in its exterior dimensions with a non-planar upper surface and has a hollow central semi-circular portion 103 flanked by two hollow quarter portions 104 , 105 which include respective engagement edges 106 , 107 . The central semi-circular portion 103 and its flanking quarter portions 104 , 105 meet together to define two support ribs 110 having a flat lower surface 112 which rest upon the exposed flat surface 33 of the roof 22 .
As taught in the aforesaid '342 patent, a two-component foam is deposited onto the exterior surface 33 of the roof 22 in the form of a thick, linear bead '15 of foam. This thick bead 115 of adhesive foam extends for the entire length of the tiles 102 . In the assembly of this type of roof construction, the foam bead 115 is used to apply a starter course 120 of roof tiles, and the length of the foam bead substantially matches the length L 1 of this first course 120 of tiles. Once the first course 120 has been applied, similar thick beads 125 having lengths L 2 which match the length of the second course 126 of tiles are applied to the roof substrate 23 and the first course 120 of tiles.
Although the use of the two-component foam 114 in this type of roof construction 100 is effective enough to adhere the roof tiles 102 in place upon the roof 22 , such two-component foams are generally expensive. Furthermore, the teachings of the '342 patent direct one skilled in the art to apply an adhesive foam bead for the entire length or substantially the entire length of the tiles 116 . This fashion of adhesive foam application promotes the use of more adhesive foam than necessary.
It has been discovered with the development of the present invention that a more economical one-component adhesive, including an adhesive foam, may be used to reliably adhere roof tiles to a roof substrate and in a particular pattern which uses significantly less adhesive than taught by the aforesaid '342 patent and other prior art roof-adhesive foam applications.
In an important aspect of the present invention, a one-component adhesive is utilized to adhere the roof tiles to the roof substrate. One advantage the use of one-component adhesives, especially one-component adhesive foams, have over two-components adhesive foams is cost. Another advantage is that one-component adhesives are dispensed from single pressurized containers, which avoids the use of maintaining separate adhesive foam components by the installer on site in inventory and the need for an elaborate and complex mixing, reacting and dispensing apparatus as are utilized with two-component adhesive foams an example of which is disclosed in the aforesaid '342 patent. Additionally, the methods of the present invention and, particularly the pattern used for the application of the adhesive, do not subdivide the undersurfaces of the roof tiles or the interstitial spaces between the undersurfaces and the roof substrate into discrete, areas which may inhibit the passage of air between the roof tile and the underlying roof substrate, and inhibit the opposing roof tile and substrate to grow and contract according to climatic conditions.
It has been found that the present invention significantly reduces the amount of adhesive needed to adhere a single roof tile to a roof substrate and further provides sufficient bonding strength to meet building code roof criteria. Table 1 which appears below in this detailed description, sets forth uplift test data for various profile roof tile using Tile Bond™ roof tile adhesive manufactured by Insta-Foam Products of Joliet, Illinois. This data indicates that the novel adhesive application pattern produces a sufficient uplift strength.
In another important aspect of the present invention, the one-component adhesive foam is dispensed onto the roof substrate and roof tiles in a discontinuous pattern so that the adhesive foam does not substantially subdivide the undersurfaces of each roof tile into discrete areas to thereby partially cut off air circulation as can the continuous, linear deposits of adhesive foam described in the aforesaid '342 patent. The adhesive foam is further concentrated in deposits at opposing corners of the underside of the roof tile.
The adhesive deposits of the present invention shall be aptly characterized in this detailed description as “pads” or “pad-like” deposits because they may comprise circular or irregular shapes, rather than comprise continuous or linear, longitudinal beads. It has been found through testing, the results of which are set forth below, that such pads provides optimum adhesive strength as measured by uplift resistance force with minimal usage of the foam. The pads 50 may be generally circular in configuration and approximately the size of a tennis ball about 2½-inches in diameter D, such as is shown in FIG. 7 . The adhesive pads may also have a generally rectangular pad-like configuration 52 of dimensions of about 1 inch high by 2 inches long by 3 inches wide as shown in FIG. 8 . It shall be understood that the adhesive configurations illustrated in FIGS. 7 and 8 are merely exemplary of suitable deposits which have been demonstrated to provide the necessary uplift strength for use in roof tile attachment. Other discontinuous deposits may be utilized to achieve the same results.
It has also been noted that the use of these adhesive deposits in the particular pattern mentioned above not only reduces the amount of foam used, but also beneficially does not subdivide the undersurface of the roof tile and the interstitial space which occurs between the roof tile undersurfaces and the roof surface to restrict the passage of air therethrough in both the longitudinal and lateral directions (“X”,“Y”). Rather the present invention does not impart any such restrictive subdivision and thereby facilitates air passage which permits the roof substrate and tile to expand and contact harmoniously in various climatic conditions.
Testing of one particular adhesive, Tile Bond™ roof tile adhesive manufactured by Insta-Foam Products of Joliet, Ill., was performed on various profile roof tiles to determine the static uplift strength and moment resistance of the adhesive pattern of the present invention. This testing was performed in accordance with the Dade County (Florida) Testing Protocol PA 101-95 (JAN) “Test Procedure for Static Uplift Resistance of Mortar or Adhesive Set Tile Systems”. This Tile Bond™ adhesive in a one-component, high-density polyurethane adhesive foam. This type of foam is a minimal expanding foam and has a density which ranges from about 1{fraction (1/2+L )} pounds per cubic foot to about 4 pounds per cubic foot. The density of this adhesive foam is increased when the roof tile is passed into contact with it. Greater density foams may be used up to about 10 pounds per cubic foot.
The testing was performed on roof panels constructed in accordance with that described in the PA 101-95 test protocol. The roof panels had dimensions of around 4 by 8 feet upon which 14 test tiles were applied using the Insta Foam Tile Bond™ roof tile adhesive foam described above. The test sections were constructed using nominal ½ inch plywood, American Plywood Association 32/16 sheathing having a thickness of {fraction (15/32)} inches. The sheathing was nailed to 2-inch by 6-inch supports spaced at the perimeters of the sheathing and spaced on 24-inch centers in between. The nailing pattern was conventional using 8 d (8-penny) common nails spaced on 6-inch centers along the perimeters of the panels and 12-inches within the panel.
An underlayment was applied to the sheathing after nailing which consisted of an ASTM D226, Type II anchor sheet with 12 gauge roofing nails and 1⅝-inch tin caps. The nailing pattern was a 12-inch grid pattern staggered in two rows of the roof panel field and 6-inch centers at any laps. An ASTM D249 mineral surface top ply sheet was attached to the anchor sheet by way of a coating of ASTM D312, Type IV asphalt and allowed to dry for 24 hours before the application of any tile systems. Thus underlayment is known in the art as a “standard 30/90” underlayment.
Two other underlayments were used in the tests. One underlayment consisted of a 40 mil thickness rubberized SBS modified asphalt sheet sold under the tradename Rainproof-40 by the Protectowrap Company. The other underlayment consisted of a standard two-ply 30 system using two layers of ASTM D226, Type II sheets and horizontal batten strips. These roofing sheets were lapped 19 inches over preceding sheets and mechanically attached to the roof sheathing using nails at 6-inch centers in rows of 18-inch centers.
A number of roof panels were constructed using the three types of underlayments described above and after the 24-hour period drying period, various profile roof tiles were attached in respective sets to each roof panel. A test hole was drilled in each of the test tiles of the panels and was located on the centerline of the roof tile at a distance of 0.76 times the length (i.e., 0.76×Length) of the tile from the head of the tile. A ¼-inch diameter concrete anchor screw was installed in this hole to provide a point on the roof tile to which a test load could be applied.
The tiles tested consisted of the second course of tiles, which were applied to a preceding roof tile course with a nominal 2-inch overlap. That is, the trailing edge of the roof tile was laid upon the leading edge of the preceding roof tile course. Fourteen test tiles were evaluated for each of Tests 1 through 4 on roof panels constructed using a standard 30/90 underlayment and twelve test tiles were evaluated for Tests 5 and 6 on roof panels using the rubberized SBS modified asphalt sheet and two-ply 30 system underlayments. Tile Bond™ adhesive was dispensed in a discontinuous pattern in registration with the opposite corners of the roof tiles.
Four different styles of roof tiles were tested from two different roof tile manufacturers. Those style tiles were the “Colonial”, “Capri” and “Espana” styles manufactured by Lifetile and the “Villa” style tile manufactured by Monier. The adhesive dispenser was weighed after adhesive was applied to every 3 to 4 tiles in order to obtain an average value of the mass of adhesive used for each tile. The adhesive was allowed to cure overnight and then the roof tiles were tested to determine their uplift resistance.
A floor model Instron No. 1115 testing machine equipped with a 1000 lb load cell and chart recorder was used for testing the tiles. A chain was attached between the load cell of the Instron machine and the test screw of a particular tile. The roof panels were inclined at about 9.5° to emulate a roof pitch of 2:12, that is 2-inch rise for every 12-inch of horizontal extent. The test results are reproduced in Table 1 below:
TABLE 1
AVERAGE
AVERAGE
MINIMUM
ADHESIVE
ULTI-
RESIST-
TEST NUMBER
NUMBER
ROOF
AMOUNT
MATE
ANCE
RESISTING
& TILE
OF TILES
TILE
UNDERLAY-
(per
LOAD
LOAD
MOVEMENT
STYLE
TESTED
PROFILE
MENT
tile)
(LBS)
(LBS)
FT-LBS
1- Colonial
14
Flat
30/90
13.8
143.1
66.3
71.1
2- Capri
14
Low
30/90
12.3
185.1
87.3
93.5
3- Espana
14
High
30/90
9.8
131.8
60.2
65.0
4- Villa
14
Low
30/90
14.2
223.3
107.0
111.2
5- Colonial
12
Flat
SBS
12.8
223.3
106.0
113.9
Modified
6- Colonial
12
Flat
2-ply
11.1
224.2
106.4
101.0
30 with
batten
strips
It can be seen from Table 1 that the average mass of adhesive used per tile varied between about 9 grams to about 15 grams (or about 4 grams to about 8 grams per adhesive deposit), yet the least minimum ultimate load obtained was about 130 lbs as reflected in Test 3. Other testing of one component adhesives using about 2 grams per desposit have yielded uplift failure values of about 100 pounds of force. Thus, it can be seen that the discontinuous pattern of the present invention provides sufficient uplift force resistance with a substantial reduction in foam amount.
Turning now to FIGS. 4-7, examples of various types of roof tiles and their adhesion to a roof using the present invention are illustrated. FIG. 4 illustrates a section 400 of a pitched roof using flat profile roof tiles similar in configuration to the “Colonial” tiles of Test 1 of Table 1. The roof substrate 22 is planar and includes support sheathing 30 covered by an underlayment 32 . The roof section 400 depicted includes a lower eave 25 and the roof section 400 is angled upwardly at a preset pitch P up to a ridge 28 (shown in phantom).
In accordance with the present invention, a first set of roof tiles 405 is selected from a supply of tiles. The tiles 405 have opposing leading and trailing edges 406 , 407 and side edges 408 which interconnect the leading and trailing edges 406 , 407 together to define an overall rectangular configuration, the side edges 408 may include engagement members 410 as illustrated which permit the interconnection of adjacent ones of the first tiles 405 . A discontinuous pattern of a one-component adhesive as previously described is used for attachment of these tiles 405 to the roof substrate 22 . This pattern includes two separate adhesive deposits 420 , 421 which are preferably aligned with each other near the opposite corners 424 , 425 of the portions of the roof tiles 402 which oppose the roof 22 and near the leading and trailing edges 406 , 407 thereof. The lower adhesive deposits 421 are positioned close to the eave 25 of the roof 400 on the first course tiles 405 .
After the adhesive deposits 420 , 421 are applied to either to the exterior surface 33 of the underlayment 32 or directly to the undersurfaces 412 of the first course tiles 405 , the tiles 405 are placed onto the roof 400 so that contact is made between the adhesive deposits 420 , 421 , the roof tiles 405 and the roof underlayment 32 . In this regard, the tiles 405 are preferably pushed down onto the adhesive deposits 420 , 421 to effect a reliable contact with the underlayment 32 . The adhesive deposits do not subdivide the interstitial spaces occurring between the roof tiles and the roof substrate into discrete areas such as is taught in the aforementioned U.S. Pat. No. 5,362,342 which division would restrict air and moisture flow therebetween. Rather, the adhesive deposits 420 , 421 beneficially do not create any such subdivision so that the passage of air (and moisture) through the interstitial spaces is facilitated rather than inhibited as illustrated in the phantom arrows of FIG. 4 . Flow of air and moisture through these interstitial areas 414 occurs as indicated by the arrows in FIGS. 4 & 8, and permits the roof substrate and tiles to expand and contract in accordance with climatic conditions.
A second set of roof tiles 430 is then selected and the discontinuous adhesive pattern is repeated. That is, two adhesive deposits 431 , 432 are registered with the leading and trailing edges 434 , 435 and opposite corners 438 , 439 of a second course of tiles 430 in locations corresponding to the corner-corner arrangement illustrated in the upper left of FIG. 4 . Once the adhesive is deposited (either on the tile themselves or the opposing roof or preceding tile surfaces), the second tiles 430 are positioned over the roof substrate 23 and the leading edges 406 of the first tiles 405 so that an overlap “O” occurs as illustrated as per the tile manufacturer's installation instructions. The second tiles 430 are then pressed down so that effective contact is made between their undersurfaces 433 , the adhesive deposits 431 , 432 , and the roof substrate and first tile course overlap O. The second set 430 of tiles are further staggered, or offset, laterally a distance of approximately 50% of the width W of the tiles so that the interengaging side edges 436 of the tiles 430 are not aligned together in a line from the eave 25 of the roof up toward the ridge 28 of the roof 400 .
In FIG. 4, it can also be seen that the first set of tiles 405 which are applied at the eave 25 of the roof 22 includes a portion 410 which overhangs the eave 25 . The length of this overhang is commonly dictated by local building codes and a common overhang is in the order of 2 inches. Uplift forces may be exerted against these overhang portions 410 by high winds, and in order to provide an additional factor of safety for this first set of tiles 405 to counteract any such uplift forces, an additional adhesive deposit 422 may be applied in alignment with the remaining lower corner 426 of each of the tiles 405 of the first tile course near the trailing edges 407 thereof.
FIG. 5 illustrates another roof section 500 using a different profile tile. The tiles shown are a low profile tile similar to the “Capri” style tested in Test 2 of Table 1. The first course of tiles 502 have opposed leading and trailing edges 504 , 505 and side edges 506 which interconnect the edges 504 , 505 . The side edges 506 include interlocking strips 508 which permit adjacent tiles to be interlocked together. The first tiles 502 further have a curved exterior configuration and in this regard, the undersurfaces 510 of the tiles 502 include ribs 512 which are intended to contact the roof substrate.
Utilizing the present invention, two adhesive deposits 520 , 521 are positioned in a discontinuous pattern in alignment with and near the opposing corners 524 , 525 and leading and trailing edges 504 , 505 of the first tiles 502 . The first tiles 502 are placed onto the substrate so that the adhesive deposits 520 , 521 make effective contact between the substrate 23 and the tile undersurfaces 510 . A second set of tiles 530 is selected and the adhesive is either applied to those tiles 530 or to the substrate 23 and to the overlap area 532 of the first tiles 502 in the discontinuous pattern of the invention, as exemplified by the two adhesive deposits 535 , 536 shown exposed in the upper left of FIG. 5 . The second tiles 530 are then applied onto the adhesive deposits 535 , 536 so that the leading edges 538 of the tiles 530 oppose the roof substrate and the trailing edges 539 thereof oppose the first tiles 502 .
FIG. 6 illustrates another roof section 600 with a plurality of high profile S-shaped roof tiles similar in style to the “Espana” tiles tested in Test 3 of Table 1. The roof section 600 includes a first set of tiles 602 which have a non-planar configuration and S-shaped profile when viewed from either the leading edge 604 or trailing edge 606 of the tiles 602 . Side edges 606 interconnect the leading and trailing edges 604 , 605 and preferably include engagement strips 608 disposed therealong. The first tiles 602 are applied to the roof substrate 23 near the eave 25 of the roof 600 by first applying a one-component adhesive in the corner-corner discontinuous pattern of the invention as described above. The tiles 602 illustrated typically may also include anchor lugs 607 formed on their undersurfaces to assist in retention of the tiles 602 on steeply pitched roofs. These anchor lugs 607 will typically engage a batten strip 34 . The adhesive deposits 610 , 611 in this type application are preferably made in alignment with the opposite corners 614 , 615 of the tiles 602 to the extent that they oppose the roof 22 and make contact on the upper end with the anchor lugs 607 and batten strips 34 .
A second set of tiles 620 is selected and two additional adhesive deposits 622 , 623 are applied in alignment with opposite corners 624 , 625 of the tiles 620 . As shown in FIG. 6, the adhesive deposits 624 , 625 may be applied to the head lap portion of a lower, adjoining first tile 602 and to the roof substrate 23 , and the tile is then positioned so that it contacts the adhesive pads 624 , 625 .
It will be appreciated that the method of applying roof tiles, as described hereinabove, increases the efficiency and reduces the cost for the installation of tile roofs. No complex two-component adhesive foam pressurized supply is needed, and significantly less amounts of foam are used in the application, leading to material cost savings. Additionally, the corner-corner pattern does an unimpeded air channel between the undersurfaces of the tiles and the roof substrate.
It will be appreciated that the embodiments of the present invention which have been discussed are merely illustrative of some of the applications of this invention and that numerous modifications may be made by those skilled in the art without departing from the true spirit and scope of this invention. For example, the adhesive deposits may, in some application, take the form of beads applied in alignment with the leading and trailing edges of the tiles provided they do not subdivide the interstitial areas into discrete subareas. The deposits may also resemble mounds or piles.
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A method of adhering roof tiles to a roof utilizes a one-component adhesive and in particular, a one-component polyurethane adhesive foam applied to the undersurfaces of the roof tiles in a discontinuous patterns. The adhesive is applied in the form of separate deposits at opposing corners of the undersurfaces of the roof tiles and the roof tiles are laid on the roof in serial fashion and overlapping courses.
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This application is a continuation application of application Ser. No. 08/770,125, filed Dec. 19, 1996, now issued as U.S. Pat. No. 5,827,568, which is a continuation of application Ser. No. 08/570,739, filed Dec. 12, 1995, now abandoned
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to roadway paving materials and more particularly to an emulsion for adding rubber to asphalt paving material.
The benefits of adding rubber to asphalt paving were first proposed in the middle of the last century; however, it was not until about the middle of the present century that the idea of adding vehicle tire rubber to asphalt was developed and crumb rubber from vehicle tires was added. Crumb rubber in an asphalt emulsion proved to be elastic and flexible and is used as a crack sealer with satisfactory results.
It has been found that the use of crumb rubber from scrap vehicle tires added to asphalt also improves road durability. It is now a requirement that pavement asphalt contain a predetermined percentage of recycled rubber as the percentage of the total tons of asphalt laid which is financed in whole or in part by a Federal Assistance Program.
Most asphalts are products of the distillation of crude petroleum and range from hard and brittle-like solids to almost water-thin liquids. Asphalt cement is the basis of these products and may be liquefied for construction purposes by heating, adding solvents, or an emulsifier. Adding diesel fuel to base asphalt results in a product called "cut-back". The use of emulsions rather than cut-backs results in substantial fuel savings.
Asphalt dispersed in water with an emulsifier forms an emulsion.
The purpose of the emulsifier is dispersion of asphalt cement in water for pumping, prolonged storage and mixing. The emulsion should "break" quickly when it comes in contact with aggregate in a mixer or sprayed on a roadbed. When cured, the residual asphalt retains all the adhesive, durability, and water-resistant properties of the asphalt cement from which it was produced.
In the general method for emulsifying asphalt, concurrent streams of molten asphalt cement and water containing an emulsifying agent are directed by a positive displacement pump into a colloid mill and divided into tiny droplets by intense shear stress.
To accomplish its ultimate function of cementing and waterproofing, the asphalt must separate from the water phase. In "breaking" asphalt droplets coalesce and produce a continuous film of asphalt on the aggregate or pavement.
This invention provides a rubber containing emulsion easily added to substantially any conventional asphalt emulsion.
2. Description of the Prior Art
The most pertinent patents are believed to be U.S. Pat. No. 4,018,730 issued Apr. 19, 1977 to McDonald for METHOD FOR EMULSIFYING ASPHALT-RUBBER PAVING MATERIAL AND A STABLE THIXOTROPIC EMULSION OF SAID MATERIAL; and, U.S. Pat. No. 4,137,204 issued Jan. 30, 1979 to McDonald for CATIONIC METHOD FOR EMULSIFYING ASPHALT-RUBBER PAVING MATERIAL AND A STABLE THIXOTROPIC EMULSION OF SAID MATERIAL. U.S. Pat. No. 4,018,730 discloses a method requiring heat and an alkali hydroxide-asphalt emulsifier mixture, where the asphalt emulsifier is a resin, tall oil fatty acid, oleic acid, stearic acid, animal protein, or casein, for emulsifying an asphalt and reclaimed rubber pavement repair material into a thixotropic emulsion capable of flowing as a liquid upon agitation. U.S. Pat. No. 4,137,204 substantially discloses the same emulsion as a base and adds an asphalt-rubber soap containing a cationic water soluble emulsifying agent.
This invention is distinctive over these patents by forming an asphalt modifying emulsion, mixed under ambient temperature and containing a relatively high percentage of reclaimed rubber that may be added to and mixed with, under ambient temperature, substantially any known asphalt paving material mix containing less than a predetermined required percentage of rubber for increasing the rubber content thereof.
SUMMARY OF THE INVENTION
This emulsion contains equal parts by weight of rubber and solvent forming a base total for calculating the quantities of the remaining ingredients, consisting of: water; a nonionic emulsifier; binders; an antistripping agent; and, color.
All ingredients are mixed at ambient temperature before adding and commingling the crumb rubber with the emulsion.
The principal object of this invention is to provide an emulsion containing a relatively high percentage of rubber which may be added to substantially any asphalt emulsion under ambient temperature or up to 150° F. (66° C.) to increase the rubber content thereof to a predetermined percentage.
DESCRIPTION OF THE PREFERRED EMBODIMENT
This crumb rubber asphalt modifying emulsion consists of equal parts by weight of a solvent and crumb rubber. The total parts by weight of these two ingredients equal a 100% base for calculating the quantities of the remainder of the formula which comprises; an emulsifying agent; an antistripping agent; binders; and, color.
The solvent is an aliphatic solvent, preferably SHELL SOL 340HT, a complex combination of predominately C9 and C12 hydrocarbons, available from Shell Oil Co. This solvent tends to dissolve natural and synthetic rubber small size particles reclaimed from discarded vehicle tires and swells and softens the larger size particles of crumb rubber. The preferred size of the crumb rubber particles is 25-50 mesh.
The quantity of water used is 30-40% of the base weight.
The emulsifying agent comprising 10-15% of the base weight is a nonionic ethoxylated nonphyenol. A first binder, comprising 5% of the base weight is a clay mineral containing silicon and aluminum, marketed under the trademark IMVITE IGB, by Industrials Minerals Ventures, 2030 East Flamingo, Las Vegas, Nev. 89119.
An antistripping agent binder comprising 1-2% of the base weight, is aliphatic amines (polyamines), commonly known by the trademark NRD BOTTOMS which enhances asphalt sticking to a roadbed and retards asphalt bleeding through a chip seal wearing surface; 1-2% of the base weight of atactic polyproplene powder, commonly known as PPA; and 1-2% of the base weight of a selected color such as carbon black.
A preferred example of the emulsion consists of 100 pounds (45 kg) of the solvent; 100 pounds (45 kg) of rubber; 60 pounds (27 kg) of water; 4 pounds (1.8 kg) of nonionic emulsifier; 5 pounds (2.25 kg) IMVITE IGB; 2 pounds (0.9 kg) each of NRD BOTTOMS; PPA; and black color for a total of 275 pounds.
The quantity of each of the principal ingredients, solvent and rubber, may be varied from 3 to 7 parts by weight to achieve the base weight. The quantity of the remaining ingredients of the formula may be 3 to 4 parts by weight of water; emulsifying agent 1.5 parts by weight; binder IMVITE IGB 1/2 part by weight; and the three remaining ingredients as follows: antistripping agent, PPA and color, each 1/10 to 1/5 part by weight.
The invention has been described in conjunction with preferred embodiments and variations thereof and it seems obvious that various changes such as substitution of equivalents and other alterations may be made in the formula while maintaining a preferred quantity of crumb rubber.
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A gel-like emulsion containing natural rubber and crumb rubber from used vehicle tires which may be added to an asphalt paving emulsion at ambient temperature for chip coating, slurry sealing, microsurfacing, soil stabilization or pavement recycling.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND
1. Field of the Invention
The present invention relates to foldable work platforms.
2. The Prior Art
Conventional work platforms are commonly referred to as saw horses. Saw horses are commonly rigidly constructed from wood and present a wooden surface upon which boards and the like are placed for cutting and/or fabrication. Often saw horses are constructed on a job site because of their awkward shape and the attendant difficulty with which they are transported.
One of the most persistent problems, however, is the common practice of inadvertently cutting through the saw horse as boards thereon are being cut. When cut through, the saw horse is worthless and another must be constructed thereby incurring significant cost of time and materials.
Foldable work platforms for use as extensible support stands and surfaces for workpieces are known in the art. One prior art work platform is manufactured in West Germany and is sold under the trademark of WAKU and distributed by Cross State Sales, Inc. of Salt Lake City, Utah. The upper surfaces of the prior art work platform are, however, fabricated from metal stock and covered with a thin, rubberized mat surface. Experience has revealed that using a work platform with a metal surface frequently damages saws and other tools and the like when a board is accidentally cut through striking the upper metal surface of the work platform.
In view of the foregoing, it would be an advancement in the art to provide a foldable, extensible work platform which is more easily manipulated, has improved stability, and provides a surface which will not damage saws and the like if the same are accidentally brought into contact with the upper surface thereof. Such an invention is disclosed herein.
BRIEF SUMMARY AND OBJECTS OF THE INVENTION
The present invention relates to an improved metal work platform which is foldable into a generally flat configuration and includes replaceable wooden inserts for the working surfaces thereof. The wooden inserts extend above the adjacent metal parts of the platform to intercept saws or other cutting tools to prevent or at least minimize damage from accidentally striking the upper surfaces of the platform. The wooden inserts and the corresponding receiving areas of the platform are specifically designed to accommodate replacement. Novel interlock structure permits the workpiece to be secured in any one of a variety of work surface configurations.
Accordingly, it is the principal object of this invention to provide improvements in foldable work platforms.
It is another object of this invention to provide a foldable work platform with a replaceable wooden insert for the working surface thereof.
Another object of this invention is to provide improvements in the smooth operation and stability of an extensible, foldable work platform.
These and other objects and features of the present invention will become more fully apparent from the following description and appended claims taken in conjunction with the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a perspective illustration of the work platform of this invention in a first, folded position, the wooden inserts having been removed to reveal underlying structure;
FIG. 2 is a perspective illustration of the work platform of this invention in one operative position, a workpiece illustrated in broken lines being clamped thereon;
FIG. 3 is a perspective illustration of the work platform of this invention in another operative position with a workpiece illustrated thereon in broken lines;
FIG. 4 is a fragmentary plan view of one portion of the work platform with wood inserts removed; and
FIG. 5 is a fragmentary schematic perspective illustration of one portion of the work platform of this invention in transition from one position to another.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The invention is best understood by reference to the figures wherein like parts are designated with like numerals throughout.
Referring now to the drawing, the work platform is shown generally at 10 and includes a base 12, a support stand 20 and a scaffold 50.
Base 12 is generally configurated in the form of the letter H and includes vertical legs 14 and 16 which are formed from hollow metal tubes securely welded to a horizontal diametrally piece 18. The hollow tubes give the required strength and also give the work platform 10 a lightweight character. Lateral stability for base 12 is provided by a support stand 20 likewise formed of hollow tubular material. Support stand 20 further includes downwardly extending legs 34 and 36. Legs 34 and 36 terminate in feet 38 and 40, respectively which are preferably caps of non-skid rubber. Support stand 20 is rotatably and extensibly coupled to cross piece 18 with a hollow sleeve 28 welded or otherwise suitably permanently mounted upon cross piece 18. Hollow sleeve 28 telescopically receives a diametrically reduced neck 26 of support stand 20. The neck 26 is permanently joined to the stand 20 intermediate the length hereof and projects vertically upward. A set screw 30 is used to releasably lock the neck 26 in collar 28 and thereby accommodate setting the desired rotational position of support stand 20 with respect to base 12. It is also observed that the neck 26 is elongated to permit extension thereof out of the collar 28. Thus, on uneven terrain the stand 20 may be extended into ground engagement so that the stand 20 and one of the legs 14 or 16 will maintain the work platform 10 upright even if the other of the legs 14 or 16 does not engage the ground because of the uneven terrain.
Legs 14 and 16 terminate in a foot 22 and 24, respectively, each of which is a cap of non-skid rubber. Additional support between the legs 14 and 16 and the cross piece 18 is obtained by diagonal braces 42 and 44, respectively. The upper end of legs 14 and 16 is open to receive telescoping tubes 46 and 48 forming part of scaffold 50. The vertical height of the scaffold 50 may be adjusted by telescoping or extending the tubes 46 and 48 from the corresponding legs 14 and 16. Thumb screws 52 and 54 provide securement for the relative positions of the legs and tubes. Because the work platform may be required to support considerable weight, a positive interlock is desirable. Therefore, each tube 46 and 48 is provided with a plurality of apertures 56-58 into which thumb screws 52 and 54 advance so as to provide positive interlock between the legs 14 and 16 and corresponding tubes 46 and 48.
Scaffold 50 is constructed of a pair of support brackets 96 and 98 which are channel members opening upwardly. The tubes 46 and 48 are welded or otherwise suitably attached to the brackets 96 and 98, respectively, intermediate the length thereof. Each bracket 96 and 98 has an intermediate portion 55 from which the upstanding sides 72 and 75 of the channel member have been cut away. A through-bore 57 in the base of each bracket 96 and 98 is aligned with the corresponding tube 46 or 48 for a purpose hereinafter more fully described.
Each bracket 96 and 98 has a corresponding laterally extending support element 68 and 70 which projects beyond the legs 14 and 16 and which is separated from the remainder of the bracket 96 or 98 by intermediate portion 55. Angle braces 88 and 90 are welded or bolted between the tubes 46 and 48 to give vertical integrity to the brackets 96 and 98, respectively.
Cross channel 53 traverses the space between brackets 96 and 98 and is welded or otherwise permanently secured thereto. Cross channel 53 is configurated as an upwardly open channel having side walls 80 and 82 and in accordance with the present invention, receives a wooden insert 51 in nesting relationship, said insert 51 having a vertical dimension sufficient to extend above side walls 80 and 82 (see FIG. 3). It is presently preferred that at least half of the depth of the insert 51 project above the side walls 80 and 82. The insert 51 is illustrated as a wooden strip which is square in cross section and has a typical dimension of 2 inches (5.08 cm) square. Clearly, any suitable alternative dimensions could be used. The portion of insert 51 which is exposed above the cross channel 53 absorbs the inadvertent cuts and blows of saws or other tools and thus reduces damage to the tools which might otherwise result if the saw should strike a metal surface.
The versatility of the scaffold 50 is dramatically increased with the addition of rotatable arms 60 and 62. The arm 60 is an upwardly opening channel member having a depending shaft 64 mounted at the bottom thereof near one end. Arm 62 is similarly configurated and has a corresponding shaft 66 mounted adjacent one end thereof. Each of the shafts 64 and 66 has a substantial axial length which projects into the hollow of corresponding tubes 46 and 48. In the illustrated embodiment, the shafts 62 and 64 are rotatable within the corresponding tubes and, in addition, are telescopically extensible and retractable into and out of the corresponding tubes 46 and 48. The movability of the arms 62 and 60 permits the arms to be placed in any one of a plurality of desirable positions as illustrated in FIGS. 2-5 and as will be hereinafter more fully described. Once the position of the arms has been determined, the position is fixed by advancing thumb screws 92 and 94 through tubes 46 and 48, respectively so as to form a friction-securement of the thumb screws against the shafts 64 and 66.
The lateral dimension of the arms 60 and 62 is substantially the same as the lateral dimension of cross channel 53. Accordingly, the arms 60 and 62 will not nest within the cross channel 53 even when the wood insert 51 (FIG. 5) has been removed. However, it is observed that the laterally extending support elements 68 and 70 are slightly larger in width than the lateral dimension of the arms 60 and 62. Accordingly, as shown at the right side of FIG. 2 each arm will nest securely between the upstanding sides 72 and 74 of the corresponding support element. It is also observed that the open space at the intermediate portion 55 will receive arms 60 or 62 at right angles generally as shown in FIGS. 3 and 4. The upstanding sides of the brackets 96 and 98 will continuously maintain the arms 60 and 62 in either the laterally projecting position illustrated at the right side of FIG. 2 or the essentially right angle orientation as illustrated in FIGS. 3 and 4. The thumb screw 92 or 94 will prevent vertical extension of the arm except when desired for movement into a selected position as shown in FIG. 5.
Both of the arms 60 and 62 have corresponding wood inserts 61 and 63 which have substantially the same cross section as the insert 51 (see FIG. 3). The length of the wood inserts 61 and 63 is selected to be substantially identical to the length of the arms 60 and 62.
Each of the inserts 51, 61 and 63 are replaceable within their corresponding channel elements. Referring particularly to FIG. 4, it is pointed out that cross channel 53 is provided with a plurality of elongated slots 84 at spaced locations along its entire length, only one slot being illustrated in FIG. 4. The elongated slots 84 permit wood screws (not shown) to threadedly engage and secure the insert 51 when the insert is nested within the channel 53. Arm 62, as shown in FIG. 4, is also provided with elongated slots 85 and 86 similarly adapted to receive wood screws (not shown) to secure insert 63 between the upper right sides 76 and 78 of the arm 62. While a specific illustration of the securement of the insert 61 to the arm 60 is not illustrated, it is understood that the insert 61 is similarly secured to the arm 60.
The advantage of the mentioned securement is that the inserts may be easily removed by simply removing the corresponding screws and lifting the insert from its corresponding channel member. Thus, damaged inserts can be simply and quickly replaced with little waste of material and time.
The mode of operation of the work platform 10 will now be described. For transport and storage, the platform 10 is preferably folded as illustrated in FIG. 1. In this folded configuration, the platform is essentially planar and because of its lightweight construction can be easily moved from place to place and stored with little difficulty. In order to properly use the platform, transverse stability is afforded when the support stand is rotated about the longitudinal axis of the neck 26 within the sleeve 28. Rotation is accommodated by loosening the set screw 30 and manually twisting the support stand 20 into position. While the support stand 20 is illustrated at an essentially right angle orientation with respect to cross piece 18, it should be appreciated that any reasonable orientation of the support stand 20 may be used as long as it gives the desired stability. On sloping or uneven terrain, the neck 26 may be extended from within the sleeve 28 to assure that at least three of the feet 22, 24, 38 and 40 solidly engage the ground.
The normal operational position of the work platform 10 is to place the arms 60 and 62 in outwardly projecting positions as shown at the right side of FIG. 2 or, alternatively, in the right angle positions as illustrated in FIG. 3. To position the arms in the described orientation from the folded position illustrated in FIG. 1, thumb screws 92 and 94 are loosened to permit extension of the arms as shown in FIG. 5 and, simultaneously, to permit rotation of the arms into either the illustrated right angle position (FIG. 3) or the coextensive position (the right hand side of FIG. 2). It is noted that the described structure permits rotation of the arms 60 and 62 through 360°, if desired. When the arm has been oriented according to the desired position, the shaft 66 is telescoped into the tube 48 and the thumb screw 94 tightened to hold the position of the arm 62. The bracket 98 including upstanding sides 72 and 74 will prevent inadvertent rotation about the axis of shaft 66 even if the thumb screw 94 should fail to hold the arm 62 in position.
The work platform may be used in a variety of ways to support a workpiece. For example, as shown in FIG. 2, a workpiece 100 may be placed upon the upper work surface of insert 51 and held tightly in place by first extending the arm 60 from within the tube 46, then rotating the arm 60 so as to be superimposed over the workpiece 100 and thereafter lowering the arm 60 into tight engagement with the workpiece 100. If desired, tightening of the thumb screw 92 will assist to hold the workpiece 100, the arm 60 and the work surface provided by insert 51 forming a clamp to hold the workpiece 100. As shown in FIG. 3, the workpiece may be placed upon the arms 60 and 62 located at essentially a right angle to thereby present a generally flat work surface defined by the wood inserts 61, 51 and 63. It has also been found desirable to use the work platform 10 in tandem with another similar work platform in the same general way in which saw horses have heretofore been used.
In the course of continued use of the work platform 10, it is likely that the wood inserts 51, 61 and 63 will become damaged as tools are used on the workpieces 100 and 102. As shown in FIG. 4, however, the damaged inserts 51, 61 and 63 can be easily replaced with corresponding inserts by simply removing the screws passing through slots 84-86, removing the old damaged inserts and replacing with substitute, undamaged wood inserts.
The invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive and the scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.
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An improved foldable work stand and platform having an upper work support surface with wooden inserts therein to protect saws and the like from being damaged by accidental contact with the metal structure of the platform. The foldable work platform also includes improved structure for elevating the working surface and an adjustable stabilizer leg to maintain the work surface generally horizontal on uneven terrain. Lateral extensions of the work surface provide versatility in the work surface configuration and are easily secured in a selected orientation.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
Prior art with which applicant is familiar is U.S. Pat. No. 3,983,936, and the patents cited therein. While U.S. Pat. No. 3,983,936 discloses a method of cutting submerged well equipment and retrieving it from a water covered area in one operation, such invention contemplates positioning the spear within the well equipment to be cut while such cutting operation is performed and prior to completion of the cut.
In some situations, it may be undesirable to position the spear or engaging tool within the submerged well equipment which is to be cut and retrieved before such cutting is completed. For example, in some circumstances it may be necessary to interrupt such operation and retrieve the spear to the surface of the water covered area due to weather conditions or other conditions. Also, it is desired to have a minimum amount of equipment within the tubular member and associated well equipment while it is being severed, so that if it is necessary to disengage from such tubular member and associated well equipment, such disengagement may be made rapidly, or in a manner so as to lessen the likelihood of sticking the well string within the tubular member and well equipment thereby necessitating further fishing or cutting operations.
An object of the present invention is to provide a method and apparatus for cutting and retrieving a tubular member and associated well equipment on the submerged floor of a water covered area wherein only the cutting tool is positioned in the well equipment while the cutting operation is being effected.
Yet a further object of the present invention is to provide a method and apparatus for cutting and retrieving well equipment from the submerged surface in a water covered area wherein a well string is lowered into the water covered area including a cutting tool at the lower end of the well string, a rotary swivel for resting on the well equipment while the cut is being performed, and a spear or engaging tool on the well tool in spaced relation above the swivel for subsequent positioning within the well equipment to retrieve it.
Yet a further object of the present invention is to provide a method and apparatus for cutting and retrieving well equipment from the submerged surface in a water covered area wherein a well string is lowered into the water covered area including a cutting tool at the lower end of the well string, a rotary swivel for resting on the well equipment while the cut is being performed, and a spear or engaging tool on the well tool in spaced relation above the swivel and wherein the swivel is constructed and arranged so that it may be collapsed to enable it to be lowered into the well equipment along with the spear thereabove after the cut has been performed whereby the spear may be engaged with the severed well equipment for retrieving it to the surface of the submerged water covered area along with the well string.
Other objects and advantages of the present invention will become more readily apparent from a consideration of the following description and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic, partial sectional view illustrating well equipment including a tubular member in a submerged surface of a water covered area and showing the present invention being lowered thereinto;
FIG. 2 is a view similar to FIG. 1 showing the present invention with the swivel seated on the upper end of the well equipment and with the cutter in position after cutting of the well equipment has been effected;
FIG. 3 is a view similar to FIG. 2 showing the relationship of the components of the swivel after it has been actuated to effect collapsing of a portion thereof to enable such swivel and the spear thereabove to be lowered into the severed well equipment for engagement and retrieval to the surface of the submerged area;
FIG. 4 is a view similar to FIGS. 1--3 and showing the spear engaged with the well equipment for retrieval thereof;
FIG. 5 is a view similar to FIG. 4 showing the spear within, but disengaged from the well equipment;
FIG. 6 is a sectional view partly in elevation showing a well string with a cutter, swivel and spear carried thereby;
FIG. 7 is an enlarged sectional view illustrating the details of a form of hydraulically actuated cutter which may be used with the present invention;
FIG. 8 is a quarter sectional view illustrating the details of the preferred form of swivel employed with the present invention and showing the position assumed by the support means to seat on the well equipment while the present invention is actuated to sever the well equipment;
FIG. 9 is a sectional view similar to FIG. 8 but showing the position of the support means when the well string is lowered while the support means is seated on the well equipment to effect deactivation or retraction of such support means;
FIG. 10 is a sectional view similar to FIG. 9 showing the support means in deactivated or retracted position so that the swivel and the spear thereabove may be lowered into the severed well equipment for engagement by such spear; and
FIG. 11 is a quarter sectional view illustrating a form of spear which may be employed with the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In FIG. 1 the submerged surface in a water covered area is referred to generally by the letter S. As the well bore B is drilled in the submerged surface S, a tubular casing illustrated at C and associated well equipment referred to generally by the letter E is shown as extending upwardly above the submerged surface S in the water covered area. After drilling operations have been completed, it is generally desirable to remove the portion of the tubular member C and well equipment E extending upwardly above the submerged surface S to inhibit any problems that might otherwise be associated with leaving such equipment projecting above the submerged surface S.
A well string designated generally by the letter W is lowered into the water covered area from a drilling vessel or platform and includes cutter means referred to generally by the numeral 15, a swivel referred to generally by the numeral 30 and a spear referred to generally by the numeral 40. It will be noted that, as shown in the drawings, the cutter means 15 is adjacent the lower end of the well string W, while the swivel 30 is spaced above the cutter means 15 and the spear 40 is positioned in spaced relation above the swivel 30.
In FIG. 1 the well string W is shown as being lowered into the well equipment E including the tubular member C while in FIG. 2 the well string W is shown in the position it will assume after the cut on the well equipment E has been completed and the well string lowered to actuate the swivel to enable the swivel 30 and spear 40 to be subsequently lowered into the well equipment E whereby the spear 40 may be engaged with the severed well equipment E for retrieval to the surface in the water covered area.
FIG. 3 shows the position of the well string W after the swivel 30 has been actuated to enable it to assume a position so that the well string W with the swivel 30 and the spear 40 may be moved into the well equipment E to assume the position illustrated in FIG. 4 of the drawings to engage the spear 40 with the severed well equipment.
FIG. 5 illustrates the position of the well string W and the spear 40 in relation to the well equipment E if, for any reason, it is desired to disengage the spear from the well equipment and retrieve the well string W to the surface of the water without retrieving the well equipment E.
FIGS. 6--11 illustrate further structural details of the cutter means 15, swivel 30 and spear 40 connected in the well string W to accomplish the objects of the present invention. The cutter means 15 as shown in FIG. 7 includes elongated hollow tubular body 16 having the bore 17 therethrough. The body 16 is provided with threaded ends 16a and 16b for engagement within the well string W. A plurality of circumferentially spaced, longitudinally extending slots 18 are formed in the body 16 as illustrated in the drawings. Pivotally mounted at 19 within the slots 18 is a cutter arm or body 19a which extends longitudinally of each slot 18 as shown and may be provided with any suitable cutting surface such as illustrated at 19b for engaging and cutting the tubular member C and well equipment E associated therewith. As shown, the cutter means 15 is of the hydraulically actuated type and to this end a longitudinally extending tubular member 20 is arranged in the bore 17 and supported therein by the spring 21 to accommodate movement of the tubular member 20 within the bore 17 relative to the body 16 of the cutter means 15.
Seals 20a and 20b sealably engage between the elongated tubular member 20 and the bore 17 as shown. The lower end of the tubular member 20 is provided with an orifice or restriction 21 so that discharge of fluid from the bore 17 into the hollow elongated tubular member 20 and through the orifice 21 in the lower end is retarded. Thus, when hydrostatic pressure is applied in the well string W above the cutter means 15, the orifice 21 restricts discharge of fluid from member thereby causing the tubular member 20 to move downwardly. The longitudinally extending member 20 includes gear teeth 22 which extend longitudinally on the outer periphery of the member 20 as shown to form a gear rack 22a. The end 19c of the pivotally mounted cutter blade 19a is provided with gear teeth 19d which mate with the gear rack 22a as shown. It can be appreciated that each cutter blade 19 is provided with such gear teeth 19, and a gear rack 22a is provided on the elongated member 20 adjacent each of the cutter blades 19a to engage therewith. In operation of the cutter means 15, the hydrostatic pressure in well string W is increased and this causes member 20 to move downwardly against the force of spring 21. Movement of rack 22a causes the cutter blades 19a to pivot outwardly and engage with the casing C below the surface S. Thereupon rotation of the well string W may be effected at the surface and such rotation continued while the hydrostatic pressure is maintained to continue to urge the cutter blades 19a outwardly to effect cutting of the tubular member C and associated well equipment E as illustrated at 25 in FIG. 2. When the cut is completed, the hydrostatic pressure in the well string W is relieved which relieves the pressure in the bore 17 and the spring 21 returns the tubular member 20 to the position illustrated in FIG. 7. As this occurs the pinion 19d and gear rack 22a cooperate to retract the cutter blades 19a to the position shown in FIG. 7 of the drawings.
The swivel 30 associated with the well string W to perform the method of the present invention is illustrated in FIGS. 8 thru 10 and is shown as including a tubular mandrel or body 31 having a longitudinal bore 32 therethrough. An outer housing 33 is rotatably and sealably carried on the mandrel 32 by the bearings 34 and the seals 35, respectively, whereby the mandrel 32 and well string W may be rotated relative to the housing 33. The seals 35 protect the bearings 34 in the subsea environment. The lower end of the outer housing 33 includes an annular, downwardly depending skirt 34a in which slots 34b are formed as shown. Such slots are circumferentially spaced and extend from a position beneath the lowermost seal 35 to the lower end of the outer housing 33 as shown in the drawings. Supports means 36 in the form of plate like members are pivotally mounted as shown at 37 in each of the slots 34b and are adapted to seat on the upper end 14 of the well equipment as illustrated in FIG. 2 of the drawings.
The support means 36 is maintained in a position for seating on the upper end of the well equipment W, such position being as illustrated in FIG. 8 of the drawings. The support means 36 is maintained in such position by the release means referred to generally at 38. Such release means is preferably in the form of a shear pin 38a which extends through the support means 36 within the slots 34b and into skirt 34a.
After the cutter means 15 has been actuated to perform the cut on the well equipment E as illustrated at 25 in FIG. 2, it is then desirable to lower the well string W so as to engage the spear 40 with the severed portion and retrieve it to the surface of the water along with the well string W. To accomplish this the well string W is lowered so as to set weight on the support means 36 of the swivel 30 in an amount sufficent to shear the pins 38a. When the pins 38a are sheared, the support means 36 are then ready to assume a configuration relative to the remainder of the swivel 30 as shown in FIGS. 2 and 10 of the drawings. The well string W is then elevated so the support means 36 can pivot downwardly to assume the relationship shown in FIGS. 3--5, and 10 of the drawings to enable the swivel 30 and the spear 40 thereabove to be telescoped within the well equipment E as shown in FIGS. 4 and 5 of the drawings.
The spear 40 includes the mandrel 41 having threads 42 and 43 for engagement within the well string W. An annular, outwardly tapered portion 41a is formed on mandrel 41 as shown, and longitudinally extending stops 48 extend outwardly from the surface 41a at circumferentially spaced points as shown.
An outer tubular member or housing 44 is slidably carried on the mandrel 41 as shown in the drawings. Such outer housing 44 includes longitudinally extending slots 45 with circumferentially extending slip segments 46 formed between the slots 45 as shown.
Additional longitudinal slots 47 are provided at circumferentially spaced positions on housing 44 as shown in the drawings to receive the stops 48 when it is desired to actuate the spear 40 to engage well equipment W.
When the mandrel 41 and the outer member 44 are in the position as illustrated with the stops 48 positioned in the slots 47, an upward force to cause upward movement of the well string W will urge the slip segments 46 to ride outwardly on the annular surface 41a of the mandrel 41 and thereby engage with the well equipment E immediately beneath the annular flange A formed internally thereof.
The upper end 49 of the stops 48 are tapered as shown and the spear 40 is initially positioned in the well string W so that the tapered upper end 49 of the stop 48 engage the lower tapered ends 46a of the slip segments 46 to inhibit outward movement thereof. However, after cutting of the well equipment E by the cutter means 15 as described, and after the swivel 30 and spear 40 have been lowered into the severed well equipment, the well string may be rotated to release the stops 48 from the ends 46a and align them with the slots 47 so that subsequent outward movement of the slip segments 46 may occur as described.
If, for any reason, it should be desired to disengage the spear 40 from the severed well equipment E, the well string W may be lowered and then rotated to disengage the stops 48 from slots 47, whereupon the slip segments may spring inwardly over the annular inwardly extending projection A as the well string W is pulled or retrieved to the earth's surface.
From the foregoing, it can be seen that the present invention provides a method and arrangement wherein only the cutter means on the well string W is positioned within the well equipment E and tubular member C as a cut is being performed. Thus, should some emergency arise requiring disengagement or discontinuing of such operations, the cutter blades 19a may be readily retracted and disengaged and the well string W moved out of the well equipment E to the surface. However, in the prior art where the spear 40 is within the well equipment E during the cutting operation, such spear may actuate improperly, or may inhibit release of the well string W from the well equipement E if, for some reason, it is desired to terminate or interrupt the cutting operations.
The foregoing disclosure and description of the invention are illustrative and explanatory thereof, and various changes in the size, shape, and materials as well as in the details of the illustrated construction may be made without departing from the spirit of the invention.
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A method and apparatus for cutting and recovering tubular and associated well equipment submerged in a water covered area including the steps of lowering a well string including a cutting tool, a swivel and a releasable spear in a water covered area to seat the swivel on the well equipment to thereby position the spear above the well equipment and the cutting tool within the equipment to be cut and pulled, actuating the cutting tool to sever the well equipment, lowering the well string and then raising it sufficiently to unseat the swivel from the tubular and associated well equipment, and then lowering it again to telescope the swivel and releasable spear within the severed well equipment, and actuating the releasable spear to engage the severed well equipment for retrieval by pulling the well string out of the water covered area.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates generally to improvements in the field of windrow elevators used in an asphalt paving machine to pick up, process, and provide a ready supply of asphalt-based material. More specifically, the present invention comprises an apparatus and a method, for fragmenting agglomerated pieces of rubberized asphalt material and re-mixing the fragmented pieces with smaller pieces of the same material, to achieve an acceptably homogeneous consistency in the material readied for immediate use by the asphalt paving machine.
[0003] 2. Description of the Prior Art
[0004] A material commonly known as Hot Mix Asphalt (“HMA”) is widely used in roadway construction and resurfacing. HMA is comprised of a mixture of asphalt oil binder, sand, small rocks, and other filler material, processed at a batch plant. Ideally, the batch plant is located close to the paving site, so the HMA will stay hot and workable until it is applied on the roadway. A short transportation distance also minimizes the phenomenon known as material segregation. Because HMA is composed of different sized aggregate and fill material, agitation and gravity act on these pieces of HMA differently. The larger, heavier pieces and the smaller, lighter pieces tend to separate and collect in like groups during transport. When the dump trailer deposits the HMA material on the roadway in a windrow, the smaller particles are concentrated in the central, elevated region of the windrow and the larger particles are concentrated in the lateral, lower regions of the windrow.
[0005] U.S. Pat. No. 6,481,922, issued to Boyd, provides a solution to the above-noted material segregation problem. The '922 Patent discloses an apparatus and a method for re-mixing the large particles with the small particles, so that a more uniform mixture of those particles is achieved before the HMA is applied onto the roadway. Through the use of a pair of lateral augers which continuously deliver the larger particles into a centrally positioned stream of the smaller particles, the HMA is re-mixed into a homogeneous mixture before being delivered into a collection hopper for subsequent application on the roadway.
[0006] However, as a roadway material, HMA is not without its faults. The asphalt oil binder used to coat and hold the aggregate particles together, plays a critical role in the performance and longevity of the roadway. The adhesive and agglomerating properties of the binder are affected by temperature, the amount and rate of road loading, and aging. Over a period of time, the surface of well-used roads, particularly in harsh environments, begins to crack and delaminate from lower support layers. To mitigate these effects, various additives have been proposed and tested with existing asphalt binders.
[0007] One of the most promising and successful additives used so far is rubber, recycled from used motor vehicle tires containing a high content of natural rubber. The tires are ground up into small particles known in the industry as “crumb rubber”. Pieces of the steel belts used in the manufacture of tires are removed from the ground up tires, before the crumb rubber is ready for further processing and incorporation into an asphalt based road material. The resultant product is variously known in the paving industry as Rubberized Asphalt, Rubberized Asphalt Concrete (“RAC”), and Asphalt-Rubber.
[0008] Two basic methods have been used to make the rubberized asphalt. The first method, known as the “wet process”, calls for the crumb rubber to be mixed with the binder (approximately 80% asphalt cement and 20% rubber) in a field blending unit. This first step occurs prior to the addition of the mixture to the other materials at a separate hot mix plant. In a second method, rubberized asphalt can be produced directly, using a terminal blended process where the crumb rubber is added at the refinery or at the asphalt cement terminal. The advantage of the latter method is that no specialized and costly rubberized blending plant is required, and the asphalt binder can be shipped to the hot mix plant just as a standard binder would be.
[0009] Irrespective of how it is manufactured, rubberized asphalt has been proven a superior roadway material over unmodified HMA in several significant areas. Rubberized asphalt is highly-skid-resistant, quieter than HMA or concrete, and resistant to rutting and cracking. In the process of making rubberized asphalt, used tires are consumed and utilized for a new purpose. A two-inch thick roadway resurfacing project can consume approximately 2000 waste tires per lane per mile. Thus, land-fill can be reduced and environmental concerns associated with the storage of flammable stores of waste tires are alleviated. Research has established that 4″ thick conventional HMA roadway can be replaced with 2″ thick rubberized asphalt, and achieve the same fatigue life. Rubberized asphalt provides excellent long-lasting, color contrast, for road striping and marking. Lastly, rubberized asphalt can generally be applied using conventional road-paving equipment and methods.
[0010] The last mentioned feature of rubberized asphalt has several exceptions, however. Rubberized asphalt is made using smaller and more uniform aggregate, typically on the order of ¼″ to ⅜″, or so, in diameter. This results in a material which is much less susceptible to the segregation problem caused by material transport, characteristic of HMA. But rubberized asphalt cools at a different rate than HMA, and it has a tendency to agglomerate in ways that HMA does not. Between the batch plant where the rubberized asphalt is manufactured and the roadway job site, cooling of the material occurs, especially in areas contingent and adjacent the sidewall and floor of the material hopper.
[0011] When rubberized asphalt has cooled a sufficient amount before it is even deposited into a windrow on the roadway, it may agglomerate into relatively large balls or sheets of material of irregular size and shape known as “clingers”. For example, a sheet of such agglomerated material may be 2″ to 3″ thick, 4″ to 5″ wide, and 12″ to 18″ long. These large pieces of agglomerated material are randomly dispersed through the windrow.
[0012] The present practice is to remove such agglomerated material manually from the windrow, before material pickup and application of the rubberized asphalt to the roadway occurs. This method is labor intensive, and also relies upon the workers finding and removing all of the offending clingers. If not removed, such large chunks of agglomerated material may jam in the paving machine or be deposited into the roadway and remain an unintegrated surface component.
SUMMARY OF THE INVENTION
[0013] The present invention comprises an apparatus and a method for fragmenting agglomerated pieces of rubberized asphalt material, and then re-mixing the smaller fragmented pieces with the smaller loose material prior to applying the re-mixture to a road surface. The agglomerated pieces are formed from smaller pieces of rubberized asphalt material which have cooled together to form the agglomerated pieces, during transport to the job site. A random mixture of agglomerated pieces and the rubberized asphalt material is delivered to the job site, forming a windrow along the middle of the roadway. A pickup machine passes over the windrow, and an elevator picks up the mixture. The elevator carries the mixture upwardly, and delivers it to the upper portion of a generally cylindrical housing mounted on the pickup machine.
[0014] In a first embodiment, an auger and tine assembly having a common drive shaft, is mounted for rotation within the housing. The assembly includes first and second auger sections, mounted along the drive shaft in spaced relation. A rotating tine section is mounted on the drive shaft between the auger sections. The auger sections have converging, opposite handedness, effective to transport the agglomerated pieces and the material inwardly toward the rotating tine section. A fixed tine section is mounted in the housing in interdigitized relation with the rotating tine section.
[0015] In a second embodiment, a rotating tine section extending the entire length of the drive shaft, is provided within the housing. A fixed tine section is also provided within the housing, having a length corresponding to that of the rotating tine section. As with the first embodiment, the fixed tine section is arranged in interdigitized relation with the tines of the rotating tine section.
[0016] In both embodiments, the agglomerated pieces and the material are deposited into a fragmenting and re-mixing zone adjacent and around the rotating and fixed tine sections. The spacing between adjacent fixed and rotating tines is such that a pre-determined maximum size is established for agglomerated pieces fragmented by the action of the tines. These smaller fragmented pieces are concurrently re-mixed with the other material resulting in rubberized asphalt having a size and composition appropriate to form a road surface.
[0017] The first embodiment of the invention can also be used advantageously with HMA paving material, to alleviate the material segregation. In other words, without making any modifications or changes to its structure or operation, the same apparatus which fragments and re-mixes rubberized asphalt material will also re-mix size and weight segregated HMA into a homogeneous material ready for instant use by a paving machine.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a perspective view, showing a road paving machine incorporating the apparatus for fragmenting and re-mixing agglomerated pieces of rubberized asphalt material of the present invention;
[0019] FIG. 2 is a fragmentary top plan view of the road paving machine, with portions of the cover and the housing broken away to show the windrow elevator, the auger sections, and the tine section;
[0020] FIG. 3 is a fragmentary cross-sectional view, taken through the longitudinal axis of the windrow elevator of FIG. 2 , showing the delivery of rubberized asphalt material into the auger and tine housing;
[0021] FIG. 4 is a fragmentary perspective view showing the upper end of the elevator and the auger and tine housing of the first embodiment;
[0022] FIG. 5 is a view as in FIG. 4 , but with a portion of the housing broken away to show the arrangement of the auger sections and the tine sections;
[0023] FIG. 6 is a side elevational view of the auger and tine housing, showing discharge of the fragmented and re-mixed rubberized asphalt material;
[0024] FIG. 7 is a fragmentary perspective view showing the upper end of the elevator and the tine housing of the second embodiment;
[0025] FIG. 8 is a view as in FIG. 7 , but with a portion of the housing broken away to show the tine section; and,
[0026] FIG. 9 is a front elevational view of the tine housing, showing discharge of the fragmented and re-mixed rubberized asphalt material.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0027] Turning now to FIG. 1 , the fragmenting and re-mixing apparatus 11 of the present invention is shown in combination with a windrow elevator 12 and a paving machine 13 . At the job site depicted in FIG. 1 , the paving machine 13 is re-paving a roadway surface 14 with a mat 15 of rubberized asphalt 16 .
[0028] At an off-site batch plant, the rubberized asphalt material 16 is manufactured from first combining a hot and liquid asphalt cement binder with particles of rubber. Generally, the amount of rubber in the mixture will vary from approximately 15% to 25%, or so, by weight. The rubber is preferably in the form of recycled “crumb rubber”, made from used automobile and small truck tires which have been shredded to a crumb-like size and consistency. At the plant, this crumb rubber has been heated to a sufficient amount that it physically swells, enabling it to combine and integrate with the asphalt cement. Next, this asphaltic combination is mixed with aggregate, such as crushed rock. The aggregate used in making rubberized asphalt is fairly small and uniform in size, ranging from ¼″ to ⅜″, or so, in diameter. This hot mixture is then loaded into a belly dump trailer, and the trip to the job site begins.
[0029] The best case scenario for transporting rubberized asphalt is a short trip during the hottest part of the day during the summer season. Deviations from those circumstances during transport will cause varying amounts of greater cooling to the rubberized asphalt mixture. The most critical areas for cooling tend to be around the floor and sidewalls of the trailer, where the mass of the metal plates and the trailer frame can absorb heat from the mixture. In contrast to HMA, rubberized asphalt cools and agglomerates more quickly. With more paving and re-paving jobs occurring during evening hours to avoid traffic delays, the problem with material agglomeration has become worse for rubberized asphalt jobs.
[0030] Upon arrival at the job site, the belly dump trailer deposits its load of rubberized asphalt material 16 in a windrow 17 . Under circumstances where the material had sufficiently cooled during transport, agglomerated pieces 18 in various shapes and sizes known as “clingers” have formed. As shown in FIG. 1 , these pieces may be globular or sheet-like in configuration. Reports indicate that the sheet pieces appear to peel off the floors and sidewalls of the trailer, and these pieces may be 2″ to 3 ” thick, 4″ to 5″ thick, and 12″ to 18″ in size. The agglomerated pieces are randomly dispersed throughout the windrow, with some pieces exposed and others located within the body of the windrow out of sight. Heretofore, these pieces have been manually removed from the windrow, by workers who pick through the windrow before the paving machine 13 reaches the freshly dumped rubberized asphalt material.
[0031] A paving machine 13 fitted with the fragmenting and re-mixing apparatus 11 of the present invention does not need additional workers to remove clingers or agglomerated pieces 18 from the windrow 17 . Instead, the apparatus 11 aboard the paving machine 13 is capable of processing the agglomerated pieces in such a way that it can be intermixed with the remainder of the material and incorporated directly into the mat 15 . To that end, as the paving machine 13 advances over the windrow 17 , the windrow elevator 12 picks up the rubberized asphalt material 16 including the agglomerated pieces 18 in the usual way and delivers it to an upper discharge end 19 of the windrow elevator 12 .
[0032] As shown in the various Figures, the apparatus 11 is located at the discharge end 19 , and comprises an auger and tine assembly 21 having a first helical auger section 22 and a second helical auger section 23 . First auger section 22 has a top portion 24 and an inner portion 26 . Second auger section 23 has a top portion 27 and an inner portion 28 opposing inner portion 26 . As shown most clearly in FIG. 5 , auger section 22 and auger section 23 are mounted in spaced relation over respective ends of a rotatable drive shaft 29 .
[0033] A rotating tine section 30 having a top portion 32 is mounted on drive shaft 29 between inner portions 26 and 28 . The rotating tine section 30 is comprised of a plurality of tines 31 , arranged in a plurality of rows, extending perpendicularly from drive shaft 29 . Each of the rotating tines comprises an inner shank portion and an enlarged outer head portion, especially adapted for fragmenting agglomerated pieces 18 . It should be noted that the first and second auger sections are of converging, opposite handedness, so as to advance rubberized asphalt material 16 and the agglomerated pieces 18 inwardly toward the rotating tine section 30 .
[0034] Apparatus 11 further comprises an auger and tine housing 33 having an upper portion with a material inlet 34 and a lower portion with a material discharge 36 . Housing 33 also includes a first endwall 37 and a second endwall 38 . Auger and tine assembly 21 is mounted for rotation within the lower portion of housing 33 between said first endwall 37 and second endwall 38 . A fixed tine section 39 is mounted in housing 33 in interdigitized relation with rotating tine section 30 . Tine section 39 is comprised of a plurality of fixed tines 41 , welded to a plate bolted to auger and tine housing 33 . Fixed tines 41 are arranged in a row, extending in perpendicular fashion from the axis of drive shaft 29 . Preferably, material discharge 36 is located just below tine section 39 .
[0035] The spacing between fixed tines 41 and an adjacent rotatable tine 31 is approximately 1″ to 1½″, or so, thereby establishing a maximum transverse dimension for agglomerated pieces as they are forced between the two structures. This dimension can be changed as the circumstances demand. For example, smaller fragmented pieces may be achieved by reducing the spacing between the rotating and stationary tines. This will provide the paving machine with an even more homogeneous mixture, as the fragmenting process will produce smaller pieces. The downside of such a modification, is that the material “throughput” of the apparatus 11 will be reduced. This will necessarily reduce the speed of the paving machine 13 .
[0036] Material inlet 34 in housing 33 allows rubberized asphalt 16 and agglomerated pieces 18 to be delivered into the top portions of the first and second auger sections and the rotating tine section. The remainder of auger and tine housing 33 substantially surrounds the first auger section 22 , the second auger section 23 , the rotating tine section 30 , and the fixed tine sections 39 . The first auger section and the second auger section acting in conjunction with the housing 33 , transport and direct asphalt 16 and agglomerated pieces 18 to the rotating tine section 30 . Housing 33 further defines a fragmenting and re-mixing zone 42 adjacent and around rotating and fixed tine sections 30 and 39 .
[0037] Drive means 43 , preferably a hydraulic motor, is provided for rotating drive shaft 29 and auger and tine assembly 21 at the desired speed. If more aggressive fragmenting and re-mixing is desired or necessary, the speed of drive means 43 may be increased. This might be appropriate, for example, where more than the usual number of agglomerated pieces 18 are found in a particular load. A hydraulic motor 44 is included on drive shaft 46 of windrow elevator 12 , to provide a continuous stream of rubberized asphalt material 16 and agglomerated pieces 18 into the material inlet 34 . In operation, agglomerated pieces and material entering the material inlet are advanced inwardly toward the center of housing 33 , and deposited onto the rotating tine section and the fixed tine section in the fragmenting and re-mixing zone 42 . In this manner, the agglomerated pieces are fragmented and re-mixed with the asphalt material before passing through the material discharge 36 .
[0038] The fragmented pieces 47 and the rubberized material 16 are deposited as a substantially homogeneous mixture into a hopper 48 , in readiness to be utilized by the paving machine 13 . The size and physical shape of the pieces 47 is such that when the mat 15 is laid by the paving machine 13 and subsequently compressed by a street roller, all of the rubberized asphalt forms a uniform and structurally integrated surface that is durable and long-lasting.
[0039] Apparatus 49 , comprising a second embodiment of the invention, is shown in FIGS. 7-9 . For the sake of clarity, the same element numbers will be used in describing this embodiment, where the structure and operation of those elements are identical to those in the first embodiment, set forth above. It should also be noted that this second embodiment is also an apparatus for fragmenting and re-mixing rubberized asphalt material containing agglomerated pieces, and may be used interchangeably in the same application as the apparatus of the first embodiment. Therefore, since the structure and operation of the upstream and downstream components, such as the windrow elevator, hopper, and paver devices have already been described, this discussion will not be repeated.
[0040] Apparatus 49 includes a rotating tine section 50 , mounted on a rotatable drive shaft 51 . Rotating tine section 50 comprises of a plurality of tines 31 , arranged in a plurality of rows, extending radially from drive shaft 51 . For ease of construction, tine section 50 may be welded to a pipe or tube (not shown) which fits over and is bolted to drive shaft 51 . Alternatively, the tines may be welded directly to shaft 51 . Tine section 50 also includes a top portion 52 , into which incoming rubberized asphalt 16 and agglomerated pieces 18 are deposited.
[0041] Apparatus 49 also includes a fixed tine section 53 . As is shown most clearly in FIG. 9 , fixed tine section 53 is substantially coextensive in length with rotating tine section 50 . Fixed tine section 53 is comprised of a plurality of tines 41 , arranged in a row and extending perpendicularly from drive shaft 51 . Each of the rotating and fixed tines comprises an inner shank portion and an enlarged outer head portion, especially adapted for fragmenting agglomerated pieces 18 . It should also be noted that the enlarged outer head portions of the rotating and fixed tines are arranged in opposing relation, to enhance the fragmentation and re-mixing process.
[0042] Apparatus 49 also includes a tine housing 54 , having an upper portion with a material inlet 56 and a lower portion with a material discharge 57 . Tine housing 54 further has a first endwall 58 and a second endwall 59 . Rotating tine section 50 is mounted for rotation within the lower portion of housing 54 , between the first and second endwalls. FIG. 9 shows that fixed tine section 53 is mounted in tine housing 54 , in interdigitized relation with rotating tine section 50 . The spacing between adjacent rotating and fixed tines is selected to ensure a maximum acceptable size for the fragmented pieces discharged from the apparatus 49 .
[0043] Tine housing 54 substantially surrounds rotating tine section 50 and fixed tine section 53 , but leaves the top portion 52 of the rotating tine section exposed to material inlet 56 . Rubberized asphalt and agglomerated pieces of asphalt are thereby delivered into the rotating tine section. Tine housing 54 further defines a fragmenting and re-mixing zone 61 adjacent and around the rotating tine section 50 and the fixed tine section 53 .
[0044] Drive means 43 is also provided, for rotating tine section 50 at an appropriate speed. Preferably, a hydraulic motor is used for drive means 43 , as the speed of the rotating tines can easily be changed by the operator independently either from the forward speed of the paving machine 13 or from the speed of the windrow elevator 12 .
[0045] In operation, rubberized asphalt material 16 and agglomerated pieces 18 entering the material inlet 56 are deposited onto the rotating tine section 50 and the fixed tine section 53 in the fragmenting and mixing zone 61 . The agglomerated pieces which are larger than the space between the rotating tines and the fixed tines are fragmented and re-mixed with the asphalt material 16 before the homogeneous mixture passes through the material discharge 57 . In all other respects, the operation and general function of the second embodiment, represented by the apparatus 49 is identical to that of the first embodiment, represented by the apparatus 11 .
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An apparatus and method for fragmenting and re-mixing agglomerated pieces of rubberized asphalt prior to applying same to a road surface. Agglomerated pieces and rubberized asphalt material are delivered to the upper portion of a housing. In a first embodiment, an auger and tine assembly having a common drive shaft, is mounted for rotation within the housing. The assembly includes first and second auger sections, mounted along the shaft in spaced relation and having converging, opposite handedness. A rotating tine section is positioned between the auger sections. A fixed tine section is mounted in the housing in interdigitized relation with the rotating tine section. In a second embodiment, the entire drive shaft includes a rotating tine section, and a corresponding interdigitized fixed tine section is provided within the housing. Passing through apertures defined by the fixed and rotating tine sections, agglomerated pieces are fragmented and re-mixed with the other material.
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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 generally to locks, and more specifically to a pointer padlock that provides a safety burglarproof effect.
2. Description of the Related Art
Conventional locks generally include a key controlled lock, which needs a correct key to unlock it, and a combination controlled lock, which needs a correct permutation of numbers or symbols to unlock it.
When a user would like to buy a lock, the burglarproof effect of the lock is the most important concern for the user. As far as the combination controlled lock is concerned, it can provide better burglarproof effect than the key controlled lock by means of rotating numbered wheels to show the correct permutation of numbers or symbols. However, the conventional combination controlled lock generally has three or four numbered wheels and therefore the permutation of numbers is finite and may be easily unscrambled by someone. If the number of the numbered wheels is increased, the permutation of numbers showed by the numbered wheels will be too complex to be remembered by the user and the structure of the combination controlled lock will be too complicated, limiting the outline design of the combination controlled lock.
SUMMARY OF THE INVENTION
The present invention has been accomplished in view of the above-noted circumstances. It is one objective of the present invention to provide a padlock, which has pointers to provide a safety burglarproof effect.
To achieve this objective of the present invention, the padlock comprises a housing, a shackle, a retaining device, and at least two pointers. The housing has an accommodation chamber, a first top hole in communication with the accommodation chamber, a second top hole in communication with the accommodation chamber, and a dial mounted on a top side thereof and provided with a plurality of figures. The shackle has a pivoting portion pivotally passing through the first top hole of the housing into the accommodation chamber of the housing and axially movable relative to the housing, and a locking end insertable into the second top hole of the housing. The retaining device is disposed in the accommodation chamber of the housing and has at least two driving wheels for controlling an axial movement of the pivoting portion of the shackle. The pointers are located above the dial of the housing and respectively driven by the driving wheels of the retaining device to point to one of the figures. When both of the pointers point to correct figures, the pivoting portion of the shackle is axially moveable relative to the housing under the control of the driving wheels of the retaining device, such that the locking end of the shackle is moveable away from the second top hole of the housing to unlock the padlock.
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 DRAWINGS
The present invention will become more fully understood from the detailed description given herein below 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 perspective view of a padlock according to a preferred embodiment of the present invention;
FIG. 2 is an exploded view of the padlock according to the preferred embodiment of the present invention;
FIG. 3 is a front view of the padlock according to the preferred embodiment of the present invention;
FIG. 4 is a rear view of the padlock according to the preferred embodiment of the present invention, in which the base is removed;
FIG. 5 is a sectional view taken along line 5 - 5 of FIG. 4 ;
FIG. 6 is a partial exploded view of the padlock according to the preferred embodiment of the present invention, showing the padlock is unlocked;
FIG. 7 is a partial exploded view of the padlock according to the preferred embodiment of the present invention, showing the padlock is locked;
FIG. 8 is a rear view of the padlock according to the preferred embodiment of the present invention, showing the tab is located at the second position;
FIG. 9 is a partial exploded view of the padlock according to the preferred embodiment of the present invention, showing the protrusion of the tab is engaged with the recess of the latch, and
FIG. 10 is a perspective view of the padlock according to the preferred embodiment of the present invention, showing a band is connected with the housing.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIGS. 1 to 3 , a padlock 10 in accordance with a preferred embodiment of the present invention comprises a housing 20 , a shackle 30 , a retaining device 40 , a first pointer 50 , a second pointer 52 , a third pointer 54 , and an adjusting member 60 .
The housing 20 includes a top lid 22 and a base 24 coupled to the top lid 22 so as to define an accommodation chamber 202 , a first top hole 204 in communication with the accommodation chamber 202 , and a second top hole 206 in communication with the accommodation chamber 202 . The housing 20 has a dial 26 mounted on a top side of the top lid 22 and provided with a plurality of figures 262 , which are embodied as Arabic numerals 1 to 12 in this embodiment, and a transparent cover 28 covered on the dial 26 .
The housing 30 has a pivoting portion 32 passing through the first top hole 204 of the housing 20 into the accommodation chamber 202 of the housing 20 and axially movable and pivotable relative to the housing 20 , a block portion 34 provided at a bottom end of the pivoting portion 32 , and a hook portion 36 integrally connected with the pivoting portion 32 and having a locking end 362 insertable into the second top hole 206 of the housing 20 .
The retaining device 40 includes a latch 41 , a block member 42 , three driving wheels 43 a - 43 c , a first transmission wheel 44 , a second transmission wheel 45 , a third transmission wheel 46 , three retaining wheels 47 , and an elastic member 48 .
The latch 41 is mounted in the accommodation chamber 202 of the housing 20 and movable relative to the housing 20 . The latch 41 is provided at a bottom thereof with three insertion portions 412 , each of which is formed as a trapezoid having two first beveled surfaces 414 , as shown in FIG. 2 . The latch 41 further includes an inclined groove 416 at a middle thereof with a top end defining with the pivoting portion 32 of the shackle 30 a distance that is longer than a distance defined between a bottom end of the inclined groove 416 and the pivoting portion 32 of the shackle 30 , as shown in FIG. 4 , and a recess 418 at a rear side thereof.
The block member 42 has a block end 424 and a connection end 422 inserted into the inclined groove 416 of the latch 41 and slidable between the two ends of the inclined groove 416 of the latch 41 , as shown in FIGS. 6 and 7 , such that the block end 424 can approach or leave the pivoting portion 32 of the shackle 30 .
The driving wheels 43 a - 43 c are rotatably mounted in the accommodation chamber 202 of the housing 20 and partially extend out of the housing 20 for user's operation. Each of the driving wheels 43 a - 43 c has twelve indentations 432 a - 432 c on the periphery thereof.
The first transmission wheel 44 has a first gear 441 engaged with the indentation 432 a of the driving wheel 43 a such that the first transmission wheel 44 can be driven by the driving wheel 43 a to rotate and a first shaft 443 extending from a center of the first gear 441 , as shown in FIG. 2 , and penetrating through the top lid 22 of the housing 20 and projecting out of the dial 26 of the housing 20 , as shown in FIG. 5 .
The second transmission wheel 45 has a second gear 452 engaged with the indentations 432 b of the driving wheel 43 b such that the second transmission wheel 45 can be driven by the driving wheel 43 b to rotate, and a second shaft 454 coaxially sleeved onto the first shaft 443 of the first transmission wheel 44 and penetrating through the top lid 22 of the housing 20 and projecting out of the dial 26 of the housing 20 . The second shaft 454 is shorter in length than the first shaft 443 such that a distal end of the first shaft 443 is protruded out of a distal end of the second shaft 454 , as shown in FIG. 5 .
The third transmission wheel 46 has a third gear 462 engaged with the indentation 432 c of the driving wheel 43 c such that the third transmission wheel 46 can be driven by the driving wheel 43 c to rotate, and a third shaft 464 coaxially sleeved onto the second shaft 454 of the second transmission wheel 45 and penetrating through the top lid 22 of the housing 20 and projecting out of the dial 26 of the housing 20 . The third shaft 464 is shorter in length than the second shaft 454 such that a distal end of the second shaft 454 is protruded out of a distal end of the third shaft 464 , as shown in FIG. 5 .
The retaining wheels 47 are respectively sleeved onto the first shaft 443 of the first transmission wheel 44 , the second shaft 454 of the second transmission wheel 45 , and the third shaft 464 of the third transmission wheel 46 so as to be respectively rotated with the first transmission wheel 45 , the second transmission wheel 46 , and the third transmission wheel 47 . Each retaining wheel 47 has a notch 472 with two second beveled surfaces 474 matched up with the first beveled surfaces 414 of the latch 41 .
The elastic member 48 is mounted in the accommodation chamber 202 of the housing 20 and has two ends respectively stopped against a periphery of the accommodation chamber 202 of the housing 20 and the latch 41 for providing an elastic force to push the latch 41 toward the retaining wheels 47 .
The first pointer 50 , the second pointer 52 , and the third pointer 54 are respectively connected to the first shaft 443 of the first transmission wheel 44 , the second shaft 454 of the second transmission wheel 45 , and the third shaft 464 of the third transmission wheel 46 and located above the dial 26 of the housing 20 , as shown in FIG. 5 , such that the first pointer 50 , the second pointer 52 , and the third pointer 54 can be respectively driven by the first transmission wheel 44 , the second transmission wheel 45 , and the third transmission wheel 46 to point to one of the figures 262 . When all of the first pointer 50 , the second pointer 52 , and the third pointer 54 point to predetermined correct figures 262 , the insertion portions 412 of the latch 41 are inserted into the notches 472 of the retaining wheels 47 , as shown in FIG. 6 , such that the connection end 422 of the block member 42 moves to the top end of the inclined groove 416 of the latch 41 and the block end 424 of the block member 30 leaves the block portion 34 of the shackle 30 , resulting in that the pivoting portion 32 of the shackle 30 can be axially moved and therefore the locking end 362 of the shackle 30 can be moved away from the second top hole 206 of the housing 20 to unlock the padlock 10 . On the contrary, when one of the first pointer 50 , the second pointer 52 , and the third pointer 54 points to an incorrect figure 262 , the insertion portions 412 of the latch 41 and the notches 472 of the retaining wheels 47 are staggered, as shown in FIG. 7 , such that the connection end 422 of the block member 42 moves to the bottom end of the inclined groove 416 of the latch 41 and the block end 424 of the block member 42 blocks the block portion 34 of the shackle 30 , resulting in that the pivoting portion 32 of the shackle 30 cannot be axially moved and therefore the locking end 362 of the shackle 30 cannot be moved away from the second top hole 206 of the housing 20 .
The adjusting member 60 is mounted in the accommodation chamber 202 of the housing 20 , including a tab 62 and a linking member 64 , as shown in FIG. 2 . The tab 62 has a protrusion 622 coupled to the linking member 64 and a bottom side exposed out of the base 24 of the housing 20 for enabling the tab 62 to be driven by an external force to make the adjusting member 60 move between a first position where the protrusion 622 of the tab 62 is disengaged from the recess 418 of the latch 41 , as shown in FIG. 6 , and therefore the latch 41 can be moved upwards, and a second position where the protrusion 622 of the tab 62 is engaged with the recess 418 of the latch 41 , as shown in FIG. 9 , and therefore the latch 41 cannot be moved upwards
When a user would like to unlock the padlock 10 and the code to unlock the padlock 10 is set to two o'clock and fifty minutes as an example, he/she can rotate the driving wheel 43 c to move the third pointer 54 to point to Arabic numeral 2 through the third transmission wheel 46 , and then rotates the driving wheel 43 b to move the second pointer 52 to point to Arabic numeral 10 through the second transmission wheel 45 , and then rotates the driving wheel 43 a to move the first pointer 50 to point to Arabic numeral 12, as shown in FIG. 3 . As a result, the insertion portions 412 of the latch 41 are inserted into the notches 472 of the retaining wheels 47 , as shown in FIG. 6 , and the connection end 422 of the block member 42 moves to the top end of the inclined groove 416 of the latch 41 such that the block end 424 of the block member 30 leaves the block portion 34 of the shackle 30 . Therefore, the user can pull upwards the hook portion 36 of the shackle 30 to enable the locking end 362 of the shackle 30 to leave the second top hole 206 of the housing 20 and enable the pivoting portion 32 of the shackle 30 to pivot relative the housing 20 , thereby unlocking the padlock 10 .
When the user would like to lock the padlock 10 , he/she can press the hook portion 36 of the shackle 30 to make the locking end 362 of the shackle 30 insert into the second top hole 206 of housing 20 , and then rotates the driving wheels 43 a - 43 c to drive the retaining wheels 47 to rotate. At this time, the second beveled surfaces 474 of the notches 472 of the retaining wheels 47 will push upwards the first beveled surfaces 414 of the insertion portions 412 of the latch 41 to force the insertion portions 412 of the latch 41 to leave the notches 472 of the retaining wheels 47 , as shown in FIG. 7 . Accordingly, the block member 42 will approach the block portion 34 of the shackle 30 such that the connection end 422 of the block member 42 moves to the bottom end of the inclined groove 416 of the latch 41 and the block end 424 of the block member 42 blocks the block portion 34 of the shackle 30 , resulting in that the pivoting portion 32 of the shackle 30 cannot be axially movable.
The code to unlock the padlock 10 can be changed according to the user's requirement. In the code changing processes, the user can rotate the driving wheels 43 a - 43 c to move the first pointer 50 , the second pointer 52 , and the third pointer 54 to point to the previously set correct figures 262 first for enabling the insertion portions 412 of the latch 41 to be inserted into the notches 472 of the retaining wheels 47 , and then forces the tab 62 to move to the second position where the protrusion 622 of the tab 62 is engaged with the recess 418 of the latch 41 , as shown in FIG. 8 and FIG. 9 , and then rotates the driving wheels 43 a - 43 c to drive the first transmission wheel 44 , the second transmission wheel 45 , and the third transmission wheel 46 to rotate. At this time, the retaining wheels 47 cannot force the latch 41 to move upwards due to the engagement of the protrusion 622 and the recess 418 and cannot be rotated with the first transmission wheel 44 , the second transmission wheel 45 , and the third transmission wheel 46 due to the engagement of the insertion portions 412 and the notches 472 . In this situation, when the driving wheels 43 a - 43 c are rotated, the first transmission wheel 44 , the second transmission wheel 45 , and the third transmission wheel 46 will run idly relative to the retaining wheels 47 . Therefore, as long as the user rotates the driving wheels 43 a - 43 c to move the first pointer 50 , the second pointer 52 , and the third pointer 54 to set a new code and then forces the tab 62 to move to the first position, the code changing process of the padlock 10 is completed.
As shown in FIG. 10 , the padlock 10 can include a band 70 with one end connected with a bottom of the housing 20 and the other end curvedly extending such that the padlock 10 can be worn on the user's wrist for convenience of use and decoration.
By means of the aforesaid design, the padlock is designed as a watch, i.e. the first pointer, the second pointer, and the third pointer are respectively regarded as a second hand, a minute hand, and an hour hand. Thus, the user has to rotate all of the pointers to point to the correct time for unlocking the padlock such that the padlock of the invention has a safety burglarproof effect and uncomplicated structure. Besides, the padlock of the invention can be made like an alarm clock or a bomb as long as the padlock can be unlocked by rotating the pointers. In addition, the padlock of the invention can be made with various kinds of design. For example, the number of the driving wheels, the transmission wheels, and the retaining wheels is not limited to the above-mentioned embodiment as long as the driving wheels, the transmission wheels, and the retaining wheels are equivalent in amount. Further, the figures are not limited to Arabic numerals but can be presented in English letters or other symbols.
The invention being thus described, it will be obvious that the same may 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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A padlock includes a housing, a shackle having a pivoting portion pivotally passing through a first top hole of the housing into an accommodation chamber of the housing and a locking end passing through a second top hole of the housing, a retaining device disposed in the accommodation chamber and having at least two driving wheels for controlling an axial movement of the pivoting portion of the shackle, and at least two pointers located above a dial of the housing and respectively driven by the driving wheels to point to one of figures of the dial. When both of the pointers point to correct figures, the pivoting portion of the shackle is axially moveable relative to the housing under the control of the driving wheels, such that locking end of the shackle is moveable away from the second top hole of the housing to unlock the padlock.
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BACKGROUND OF THE INVENTION
Spring loaded cam rise lift hinges have been employed in the past to lift a door as it is being opened and to generate a force tending to close the door when it is released. In these prior art hinges, the spring is positioned to be compressed when the strap portion of the hinge is cammed up by swinging movement of the door toward its open position. The compression of the spring presses the cam elements together and thereby tends to return the door to its closed position. However, in applications that involve relatively large doors, e.g. heavy walk-in refrigerator doors, the door closing force may not be large enough to completely close the door and latch it, particularly when the door has only been partially opened.
SUMMARY OF THE INVENTION
In the spring hinge of this invention, the door closing force is substantially increased by securing one end of a special torsion-compression spring to the strap portion of the hinge and by securing the other end of the spring to the butt portion of the hinge so that the spring will be simultaneously twisted as it is being compressed by swinging movement of the strap portion toward its open position. The twisting of the spring generates a torsion force which acts directly on the strap portion and adds to the effect of spring assisted gravity in returning the door to its closed position.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front elevational view of a walk-in refrigerator door swingably mounted on a frame and equipped with a pair of spring hinges of this invention.
FIG. 2 is an exploded front elevational view of one hinge.
FIG. 3 is a longitudinal sectional view of the hinge of FIG. 2 with the strap portion thereof in its closed position.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings, the preferred spring hinge of this invention includes a butt portion 10 which can be attached to a door frame 12 (FIG. 1) by machine screws 14 (FIG. 3) and a strap portion 16 which is swingably mounted on butt portion 10 and can be attached to a door 18 (FIG. 1) by machine screws 20 (FIG. 2). In this example, door 18 is the door of a walk-in refrigerator, but it will be obvious that the invention can also be applied to other doors.
As best shown in FIG. 3, butt portion 10 includes a flat plate 22 which has holes 24 therein to accept screws 14 and has a ledge 26 which projects outwardly from the bottom of plate 22 to support strap portion 16 and door 18. Curved bracing ribs 28 extend between the bottom of ledge 26 and lower side edges of plate 22 to help support the same. Plate 22, ledge 26, and ribs 28 are preferably made of suitable metal.
A downwardly tapering hole 30 is formed midway of the width of ledge 26 to receive the tapered enlargement 32 at the lower portion of an upstanding pin 34, there being a hexagonally shaped portion 36 immediately above tapered portion 32. The lower end of pin 34 is threaded at 38 to receive an acorn nut 40 which fastens pin 34 to ledge 26. The upper end of pin 34 is slotted at 42 and is threaded at 44 to receive the threaded, nut-like upper end 46 of a protective cap 48 and to receive a second acorn nut 50. Pin 34 and its enlarged portions 32 and 36 are preferably made of steel. An internal tooth lock washer 49 is used above nut 40.
Cooperating cylindrical cam elements 52 and 54 are fitted within the bore 56 of an enlarged portion 57 of strap 16 around pin 34. The outer cam element 52 is a hollow cylindrical sleeve which carries cam surface 58. The inner cam element 54 has a matching cam surface 60 on its upper edge and has a hexagonal recess 62 in its lower portion to receive the hexagonal portion 36 of pin 34, which passes through a central bore 64 in inner cam element 54. Hexagonal recess 62 and hexagonal portion 36 of pin 34 keep inner cam element 54 from rotating when strap portion 16 is pivoted about pin 34 to open the door. Outer cam element 52 pivots with strap portion 16 and causes cam surface 58 to rotate over cam surface 60.
Cam surfaces 58 and 60 are shaped to cause outer cam element 52 to rise as strap portion 16 is swung toward its open position, i.e. toward the open position of door 18, and to cause outer cam element 52 to move downwardly as strap portion 16 is swung toward its closed position.
Inwardly projecting internal shoulders 66 above the top of outer cam element 52 and shoulder 67 transfer this lifting effect to strap portion 16, which thereby rises when it is swung toward its open position and moves downwardly when it is swung toward its closed position.
Cam elements 52 and 54 are preferably made of a low friction material such as nylon or the like to reduce wear on the cam surfaces 58 and 60.
A coiled wire torsion-compression spring 68 is positioned to be compressed by the rising of strap portion 16 and arranged in a novel manner to be simultaneously twisted by the pivotal movement of strap portion 16. Spring 68 surrounds the upper portion of pin 34, with its lower portion within a bore 70 in strap portion 16. The end 72 of the wire forming spring 68 is bent to engage in a hole 74 in strap portion 16, and the upper end 76 of spring 68 is bent to engage the slot 42 in the upper portion of pin 34. A nylon shim 78 is seated in the slot 42 on top of upper wire end 76 and has ends which project from opposite sides of the slot, with the underside of top 46 of protective cap 48 engaging said projecting ends of the shim. A nylon spacer 80 is seated within the top of bore portion 70 around spring 68 and the bottom of cylinder 48. It rests on an internal shoulder 81
Since the bottom end 72 of spring 68 is secured to strap portion 16 at 74, and since the upper end 76 is secured in the slot 42 of pin 34, pivoting of strap portion 16 toward its open position will cause both endwise compression and twisting of spring 68 to occur simultaneously, the compression being caused by the camming up of strap portion 16, and the twisting being caused by the fact that hole 74 pivots with strap portion 16 while the slot 42 of pin 34 remains stationary. The compression of spring 68 generates a force which aids gravity in causing lowering movement of strap portion 16 toward its closed position when it is released. This is the door closing force that has been relied on in the past to tend to close the door when it is released. However, the door closing force due to spring compression alone may not be adequate to completely close and latch heavy walk-in refrigerator doors such as door 18, particularly when it has been only partially opened. This drawback is overcome in this invention by augmenting the door closing force due to the compression of spring 68 with an additional door closing force due to the twisting of spring 68. The door closing force due to the twisting of spring 68 acts directly on strap portion 16 at the margins of the hole 74 which receives the lower end 72 of spring 68. The torsional door closing force can be selected to be any desired value within design limits by selecting the appropriate torsional characteristics for spring 68. By this means, the combined door closing force can be raised to a level which is sufficient to close and latch heavy walk-in refrigerator doors even when they have only been partially opened.
Various changes and modifications may be made without departing from the spirit of the invention, and all of such changes are contemplated as may come within the scope of the claims.
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A cam rise hinge has a swingable strap portion which is cammed up relative to a stationary butt portion when a door on which the strap portion is mounted is swung towards its open position. A coiled wire torsion-compression spring is positioned and mounted so as to be compressed and simultaneously twisted when the strap portion is cammed up. This generates two different forces aiding each other and gravity in swinging the strap portion and door back toward closed position.
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This application is a continuation of application Ser. No. 768,237, filed 8/22/85 now abandoned.
FIELD OF THE INVENTION
This invention relates generally to gate latches, and specifically to a new and improved gravity-operated latch apparatus that includes a support member which ensures proper latching action of a bar with a keeper mechanism, particularly where the gate has sagged, or where any other condition has occurred that normally would produce improper alignment.
BACKGROUND OF THE INVENTION
Gravity operated gate latches are known. See, for example, U.S. Pat. No. 830,327, Johnston, issued Sept. 4, 1906, U.S. Pat. No. 890,660, Kent, issued June 16, 1908, and U.S. Pat. No. 1,821,847, Polaire, issued Sept. 1, 1931. These latch systems generally include a ring that is pivoted to frame on the gate post in a manner such that the ring can swing freely inward, but is restrained against outward movement. A latch bar on the gate forces the ring upward as the gate is closed, after which the ring drops down in front of the bar under the influence of gravity to trap the latch bar. A frame that pivotally mounts two rings can be used to enable the gate to swing open in the outward or the inward direction. In either case the latch is released by manually lifting a ring upward to disengage it from the latch bar.
Prior gate latches of the type described above are considered to have a number of shortcomings. For example, many of the prior systems are rather complicated structurally, and consequently would be expensive to manufacture and not cost-effective. Other systems, although simplified, have the disadvantage that should the gate sag so that the latch bar engages a lower point on the periphery of the keeper ring, the bar itself can lift the ring and cause the gate open if subjected to even a small open force due to wind or being bumped by an animal or the like. Of course, if gate sag is extensive (which often occurs with the passage of time) the bar may not engage the keeper ring at all, so that the latch system becomes useless.
The general object of the present invention is to provide a new and improved gravity-operated latch system of the type described.
A more specific object of the present invention is to provide a new and improved pivoted ring-type gate latch apparatus that includes a support that is located a predetermined distance below the pivot point of the ring to ensure operability of the latch, even where gate sag has occurred.
Another object of the present invention is to provide a new and improved gravity-operated latch system for gates and the like which is relatively inexpensive to manufacture, and is simple, reliable and fool-proof in operation.
SUMMARY OF THE INVENTION
These and other objects are attained in accordance with the concepts of the present invention through the provision of a latch system for swinging gates, or equivalent structures, comprising a frame adapted to be mounted on a gate post and including a pair of spaced members, a keeper ring pivotally mounted and carried between these members, and means for limiting outward swinging of the ring. A latch bar that is secured to the gate is arranged to engage the ring during closing movement and to lift it upward so that the bar can pass the ring and engage a stop. The ring automatically drops down in front of the bar, and a limiting means is operable to prevent outward swinging of the ring to latch the gate closed. In a preferred embodiment the latch bar has a vertical dimension that is not substantially less than the radius of the ring to provide an improved latching action, and a width that provides strength against bending as well as preventing any substantial amount of lateral play.
The latch system further includes a support means that is located below the pivot point of the ring a distance that preferably is substantially equal to the outer diameter of the ring. The support means has a horizontal portion directly below the ring, and an inclined portion that extends from the outer edge of the horizontal portion downwardly and outwardly. If the gate has sagged to any appreciable extent with the passage of time, the latch bar will engage the inclined portion and be ramped upward onto the horizontal portion where it will pass the ring and be trapped thereby. The vertical height of the bar is such that it is practically impossible for the latch to be inadvertently opened when the bar is resting on the horizontal portion of the support.
A locking feature also is provided to enable the latch system to be locked closed by a typical padlock.
An alternative embodiment of the present invention comprises a pair of keeper rings to enable the gate to be opened in either the inward or the outward direction. In this embodiment the support means has inclined ramp portions at the opposite ends of an elongated horizontal central portion.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention has other objects, features, advantages and uses which will become more clearly apparent in connection with the following detailed description of preferred embodiments, taken in conjunction with the appended drawings in which:
FIG. 1 is a front elevation of a gate having the latch system of the present invention;
FIG. 2 is an isometric view of a single action latch in accordance with the present invention;
FIG. 3 is an isometric view of a double action latch system of the present invention which permits the gate to be opened outward or inward; and
FIGS. 4A-4C are front views of the latch of FIG. 2 showing its operational sequence.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Referring initially to FIG. 1, a gate latch apparatus that is constructed in accordance with the principles and concepts of the present invention is shown generally at 10. A keeper system 11 is mounted in a secure manner to the outer face of the post 12, and cooperates with a latch bar 13 that is securely fastened to the gate 14. Of course the gate 14 is mounted for swinging movement on the opposite post 15 by a pair of hinges 16.
As shown in FIG. 2, a single action latch system 10 includes a pair of side members 17, 18 that are spaced apart to provide an elongated slot. The members can be separate bars as shown, or in the alterntaive can be a single bar bent into bights on its opposite ends. Tubular spacers 19, 19' are provided to fix the width of the slot to a precise distance, and a bolt 20 is used to secure the outer ends of the members 17, 18. Additional apertures are provided near the inner ends of the members 17, 18 for reception of one side of a U-bolt 21 that may be used to secure the assembly to a tubular metal fence post. In this case, a typical bracket 22 would be used having a concave rear recess 23 which fits against the outer periphery of the post. Additional tubular spacers 25 may be provided to mount the assembly as shown.
The spacer 19' has attached thereto a stop member 26 having a vertical face 27. Another set of apertures 28 is located inwardly of the outer ends of the members 17, 18, and receives the other side of the U-bolt 21 which passes through another tubular spacer 29. Nuts 30 are tightened onto the threaded ends of the U-bolt to rigidly secure the assembly to the post.
A latch ring 35 having a width slightly less than the length of the spacer 29 is pivotally mounted thereon. The length of the slot between the spacers 29 and 19' is substantially greater than its length between the spacer 19 and 29. Thus the ring 35 can pivot freely in the counter clockwise direction about the axis of the apertures 28, however the spacer 19 will engage the outer periphery of the ring at a point well above a horizontal line passing through the center of the ring to limit its pivotal rotation in the clockwise direction.
A support member 40 is secured to the frame assembly by suitable means such as a vertical bracket 39 that is welded at its upper and lower ends. The member 40 has an elongated horizontal portion 41 of substantially the same length as the distance between the spacers 29 and 19', and an inclined portion 42 that may have substantially the same length as the distance between the outer ends of the members 17, 18 and the spacer 29. The portion 42 is inclined downwardly and outwardly at a suitable angle such as about forth-five (45°) degrees. The support member 40 may be constructed out of angle iron having a vertical side 43 to produce increased rigidity.
The latch bar 13 (FIG. 4A) preferably is made of angle iron to provide a horizontal upper portion 44 and a vertical side portion 45, both of substantial width. The L-shape of the bar 13 provides increased strength to reduce the possibility of bending. The width of the upper portion 44 reduces play of the bar in the closed position, and the height prevents accidental opening as will be subsequently described.
It will be recognized that the outer spacer 19 engages the outer periphery of the ring 35 on a line that is well above a line passing through the center of the ring, and is parallel thereto. When the ring 35 is subjected to an opening force in the outward direction, the spacer 19 reacts to prevent clockwise swinging movement of the ring with a force that is directed through the center of the ring, and which is the resultant of a horizontal, inwardly directed force, and a vertical downwardly directed force. So long as the ring 35 is not subjected to an upward force which substantially exceeds the vertical component of the reaction force, the latch cannot open. Thus it is important for the latch bar 13 to have a substantial vertical height so that it will engage the outer periphery of the ring 35 at a line that is not any substantial distance below the horizontal diameter thereof. The width of the upper portion 44 of the latch bar 13 is only slightly less than the distance between the outer peripheral surface of the ring 35 at its center and the opposing face of the stop member 26. Thus arranged, there is very little play that is afforded between the latch bar 13 and the keeper assembly, and the height of the bar is such as to prevent inadvertent opening. The L-shape of the bar provides a structure which inhibits bending, all of which are highly desirable features in a rugged and foolproof gate latch assembly.
Another embodiment of the present invention is shown in FIG. 3, which illustrates a two-way latch assembly that permits a gate to open inward or outward. Since the embodiments are similar, the same reference numerals have been given to identical parts. In this embodiment, the side members 50, 51 are somewhat longer, and an inner bolt 52 and a spacer 53 are provided. The stop member of the previous embodiment is replaced by a tubular spacer 54 on which is pivotally mounted another latch ring 55. The support member 40' has an inwardly and downwardly inclined portion 56 at its inner side to provide an oppositely disposed ramp that is useful when the gate is being closed from its outer open position. The distance between the center lines of the spacers 19 and 53 is such that the upper horizontal portion of the latch bar 13 fits between the rings 35, 55 with very little play when the gate 14 is closed.
OPERATION
In operation, the keeper assembly 11 and support are mounted on the fence post 12 as shown, and the latch bar 13 is mounted on the gate 14 at the proper vertical height so that its lower edge just barely clears the upper surface of the horizontal portion 41 of the support 40 as the gate closes. As shown in FIG. 4A, normally the rings 35, 55 hang on the pivots with their adjacent outer peripheries being separated by a distance d, and their upper outer peripheries being engaged by the spacers 19 and 53. As the gate 14 is closed, the bar 13 forces the ring 55 to swing, as shown in FIG. 4B, clockwise so that the leading edge of the bar begins to engage the ring well below its center. At this point, the vertical component of the opening force lifts the ring 55 vertically upward to permit the bar 13 to pass to a location between the rings 35, 55, whereupon the lifted ring 55 falls downward and occupies its original position as shown in FIG. 4C. Since lateral movement of the bar 13, either forward or rearward, brings the limiting action of the spacers 19 and 53 into play, the gate 14 is securely latched.
To release the latching action of either embodiment of the present invention, it is only necessary for a person to use his or her finger to lift the ring member on the opening side to thereby free the latch bar 13.
Should the gate 14 sag with the passage of time, which almost always occurs irregardless of the construction thereof, the support member 40 ensures that the latch bar 13 always will be properly positioned, in the vertical sense, for proper latching action. The ramps 42, 56 aid the user in positioning the bar 13 on the horizontal portion 41 of the support.
The one-way embodiment 11 of the present invention operates in the same manner as the embodiment just described, except that the stop lug 26 limits rearward movement of the bar 13, rather than another ring.
The latch can be locked by inserting the shackle of a padlock through the apertures 60 and 61 in the bar 13 and support 40, respectively.
A number of modifications, and other uses, may be made to and of the present invention without departing from the inventive concepts embodied therein. For example, the support member 40 need not be physically attached to the keeper assembly 11 by a strap 39 as shown, provided care is exercised in attaching the support member to the post 12 a proper distance below the keeper assembly by a separate U-bolt assembly in the case of a circular post, or lag screws in the case of a square or rectangular wooden post. The latch bar 13 is shown as made out of angle iron, however the bar could be made out of square tubing. Where the latch bar 13 is attached to other types of gate constructions, the bar can be bent to an offset position prior to attachment, so as to be properly aligned. Of course it will be apparent that the mounting positions of the keeper assembly 11 and the latch bar 13 can be reversed. Where the keeper assembly 11 is attached to a wooden post as shown in FIG. 1, of course lag screws passing through the apertures 28 in the side members of the frame can be used.
Respecting uses of the present invention other than for latching gates, applicants believe that the invention could be used as a cabinet door latch that would be relatively child-proof. For this use a significant amount of play would be permitted for the latch bar 13, so that the door, which normally would be held totally closed by typical magnets or the like, could be opened a small amount before limiting takes place. An adult could then reach his or her finger in to lift the ring 35 and release the latch, however a small child would not normally have fingers sufficiently long to be able to reach the ring.
Since various changes or modifications may be made in the present invention without departing from the unique concepts involved, it is the aim of the appended claims to cover all such changes and modifications fully within the true spirit and scope of the present invention.
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In accordance with illustrative embodiments of the present invention, a gate latch apparatus includes a frame having spaced side members, a ring pivotally mounted between the side members, and means to limit outward swinging of the ring. A support rigidly secured with respect to the frame has a horizontal portion and an inclined portion to aid the user in positioning a latch bar on the horizontal portion where operation of the latch is assured. The bar causes the ring to swing inwardly during closure, and the ring drops downward upon passage of the bar to latch the gate closed. To release the latch, the ring is lifted to enable the bar to be removed from the support.
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You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND
1. Field of Invention
The disclosure herein relates in general to rolling cone earth boring bits and in particular to improving the performance of a roller cone bit.
2. Description of Prior Art
Drilling systems having earth boring drill bits are used in the oil and gas industry for creating wells drilled into hydrocarbon bearing substrata. Drilling systems typically comprise a drilling rig (not shown) used in conjunction with a rotating drill string wherein the drill bit is disposed on the terminal end of the drill string and used for boring through the subterranean formation.
Drill bits typically are chosen from one of two types, either drag bits or roller cone bits. Rotating the bit body with the cutting elements on the outer surface of the roller cone body crushes the rock and the cuttings may be washed away with drilling fluid. One example of a prior art roller cone bit 11 is provided in a side partial perspective view in FIG. 1 , the bit 11 having a body 13 with a threaded attachment 15 on the bit 11 upper end for connection to a drill string (not shown). The bit 11 further includes legs 18 extending downward from the bit body 13 . Each bit leg 18 is shown having a lubrication compensator 17 .
The bit body 13 is further illustrating having a nozzle 19 for directing pressurized drilling fluid from within the drill string to cool and clean bit 11 during drilling operation. A plurality of cutter cones 21 are rotatably secured to respective bit legs 18 . Typically, each bit 11 has three cutter cones 21 , and one of the three cutter cones is obscured from view in FIG. 1 .
Each cutter cone 21 has a shell surface including a gage surface 25 and a heel region indicated generally at 27 . Teeth 29 are formed in heel region 27 and form a heel row 28 of teeth. The heel teeth 29 depicted are of generally conventional design, each having leading and trailing flanks 31 , 32 that converge to a crest 33 . Each tooth 29 has an inner end (not shown) and an outer end 35 that joins to crest 33 .
Typically steel tooth bits are for penetration into relatively soft geological formations of the earth. The strength and fracture toughness of the steel teeth permits the use of relatively long teeth, which enables the aggressive gouging and scraping actions that are advantageous for rapid penetration of soft formations with low compressive strengths. However, geological formations often comprise streaks of hard, abrasive materials that a steel-tooth bit should penetrate economically without damage to the bit. Although steel teeth possess good strength, abrasion resistance is inadequate to permit continued rapid penetration of hard or abrasive streaks.
A layer of wear-resistant “hardfacing” material (not shown) may be applied on portions of roller cone bits 11 , including the body 13 , legs 18 , cutter cones 21 , and teeth 29 . Hardfacing typically consists of extremely hard particles, such as sintered, cast, or macrocrystalline tungsten carbide, dispersed in a steel matrix. Typical hardfacing deposits are welded over a steel tooth that has been machined similar to the desired final shape. Generally, the hardfacing materials do not have a tendency to heat crack during service which helps counteract the occurrence of frictional heat cracks associated with carbide inserts. The hardfacing resists wear better than the steel cone material, therefore the hardfacing on the surface of steel teeth makes the teeth more resistant to wear.
A front view of a prior art cutter cone 21 is illustrated in FIG. 2 . Shown formed on the cutter cone 21 is an inner row 36 having inner row teeth 37 extending radially inward from the heel 27 (see FIG. 1 ). The inner row teeth 37 have flanks and crests similar to the flanks 31 , 32 and crests 33 of the heel teeth 29 . An apex 38 is shown proximate to the cutter cone 21 center, the apex 38 having grooves radially extending from the apex 38 midpoint to its outer periphery. A layer of hardfacing 39 is shown having been applied to surfaces of the heel teeth 29 and the inner row teeth 37 . The span between oppositely facing leading 32 and trailing flanks 31 can be filled with hardfacing to form a disk shaped cutting row on the cutter cone 21 .
SUMMARY OF INVENTION
Disclosed herein is an earth boring drill bit having a body, a leg depending from the body, a bearing shaft extending radially inward from the leg, a cutting cone mounted on the bearing shaft, a cutting disk on the cutting cone, and compacts set flush within the cutting disk. The earth boring bit may include a cutting surface defined by a path on the cutting disk surface where the crests of the compacts are arranged. The cutting disk, in an example, has an upper surface, a lower surface, and an outer edge that extends between the upper and lower surfaces, and wherein the compacts are arranged so that their crests are aligned with the outer edge to thereby define a cutting surface along the outer edge and the crests of the compacts. The upper and lower surfaces may be angled towards one another proximate to the outer edge and wherein the compacts include profiled surfaces depending downward from the crests, so that when the compacts are disposed in the cutting disk, the profiled surfaces are coplanar with the upper and lower surfaces. The cutting disk can be coaxially disposed on the cutting cone. The compacts can be formed from cemented carbide.
Optionally, the earth boring bit can further include serrations provided on the cutting disk outer edge. In another alternative, the serrations are provided between adjacent compacts. Teeth may be included on the cutting cone having compacts flush within the teeth. Each compact may include a chisel shaped tip on an axis and a cylindrically shaped body about an axis that is angled with respect to the axis of the chisel wherein adjacent compacts are rotated so their respective bodies are spaced apart in the cutting disk. The ratio of compact material hardness to cutter material hardness can, in one example be about 1.2:1, about 1.8:1, about 2:1, about 3:1, or about 3.3:1.
Also disclosed herein is a method of forming an earth boring bit. In one example the method includes providing a bit that has a body, a leg depending from the body, a bearing shaft extending radially inward from the leg, a cutting cone mounted on the bearing shaft, a cutting surface on the cutting cone, and bores extending from the cutting surface into the cutting cone. The method of this example can further include providing compacts with an elongated body portion, a chisel shaped tip on an end of the body portion, and coupling each compact within one of the bores and arranging the compacts so that each tip is substantially flush with the cutting surface. Each compact of the method can be formed from cemented carbide. Coupling be applying a press fit between the compact and the bore or brazing the compacts in the bore. The tip and body of each compact may be canted with respect to one another and wherein adjacent bores in the cutting cone project along non-parallel paths so that the respective bodies of adjacent compacts are disposed in non-interfering positions.
The cutting cone of the method can further include teeth arranged on the cutting cone having bores formed into the teeth, and the method can further involve coupling compacts flush into the bores in the teeth. Counterbores can be provided in the cutting disk prior to creating bores therein where the counterbores are covered during a step of heat treating the bit. The compacts can have an optional diamond covering.
BRIEF DESCRIPTION OF DRAWINGS
Some of the features and benefits of the present invention having been stated, others will become apparent as the description proceeds when taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a side perspective view of a prior art roller cone bit.
FIG. 2 depicts a bottom view of a prior art milled steel tooth cutting cone.
FIG. 3 depicts in a perspective view an example of a compact for use in an earth boring bit.
FIG. 3A illustrates a side sectional view of an alternative compact for use in an earth boring bit.
FIG. 4 portrays an example of a cone of a roller cone having compacts flush within a disk row.
FIG. 5 illustrates in an enlarged side perspective view, a portion of the cone of FIG. 4 .
FIG. 6 depicts in side perspective view an example of a roller cone with flush compacts and serrations on a disk row.
FIG. 7 provides in a perspective view an example of a roller cone with compacts flush within cutting teeth.
FIG. 8 illustrates in perspective view an example of a step of forming a roller cone.
While the subject device and method will be described in connection with the preferred embodiments but not limited thereto. On the contrary, it is intended to cover all alternatives, modifications, and equivalents, as may be included within the spirit and scope of the present disclosure as defined by the appended claims.
DETAILED DESCRIPTION OF INVENTION
The method and system of the present disclosure will now be described more fully hereinafter with reference to the accompanying drawings in which embodiments are shown. The method and system of the present disclosure may be in many different forms and should not be construed as limited to the illustrated embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be through and complete, and will fully convey its scope to those skilled in the art. Like numbers refer to like elements throughout.
It is to be further understood that the scope of the present disclosure is not limited to the exact details of construction, operation, exact materials, or embodiments shown and described, as modifications and equivalents will be apparent to one skilled in the art. In the drawings and specification, there have been disclosed illustrative embodiments and, although specific terms are employed, they are used in a generic and descriptive sense only and not for the purpose of limitation. Accordingly, the improvements herein described are therefore to be limited only by the scope of the appended claims.
Shown in a side perspective view in FIG. 3 is an example of a compact 50 ; also alternatively referred to herein as an insert. In an example, the compact 50 is formed from cemented carbide. The compacts 50 may have a Rockwell “A” hardness ranging from about 83 up to about 95. The compact 50 of FIG. 3 is shown having a chisel-shaped tip 52 and a substantially cylindrical barrel 54 depending downward from the tip 52 . As shown, the tip 52 includes a recumbent crest 58 on its upper terminal edge with downwardly depending planar surfaces or flanks 56 , 57 formed along opposite lateral sides of the crest 58 terminating at the upper end of the barrel 54 . Flanks 56 , 57 incline at different angles relative to the axis of barrel 54 . Flanks 56 , 57 are on inner and outer sides of compact 50 , not leading and trailing sides. Crest 58 and flanks 56 , 67 may be substantially flat surfaces or they may be curved slightly.
In FIG. 3A , an alternative embodiment of a compact 50 A is shown in a side view. In this embodiment, the tip 52 A is canted with respect to the barrel 54 A. The compact 50 A is canted by setting the barrel 54 A around an axis A S and setting the tip 52 A around a corresponding axis A T ; wherein the axes A S and A T are at an angle with respect to each other. As will be described in more detail below, providing canted compacts 50 A can avoid interference between adjacently disposed compacts 50 A.
An example of a cutting cone 62 in accordance with the present disclosure is provided in perspective view in FIG. 4 . In this example, the cutting cone 62 includes an apex or nose 64 on its uppermost surface having cutting elements on its upper surface that coaxially circumscribe the axis A x of the cutting cone 62 . Also coaxial with the cone axis A x is an inner row or disk 66 shown on the cutting cone 62 that is generally smooth along its periphery. Included within the inner row 66 are compacts 50 ; their respective barrels 54 are directed radially inward towards the cone axis A x from the peripheral edge of the cutting cone 62 . The cutting cone 62 also includes an outer row 70 coaxial with the cone axis A x and disposed on a side of the inner row 66 opposite the apex 64 . The outer row 70 includes a series of teeth 72 arranged around the cutting cone 62 forming a cutting surface. An example of cutting cone 62 material includes steel having a Rockwell C hardness from about 40 to about 54.
FIG. 5 is an enlarged side perspective view of a portion of the disk or inner row 66 of FIG. 4 . The inner row 66 includes an inner surface 68 facing the apex 64 ( FIG. 4 ) and intersected by the cone axis A x . Inner surface 68 is a continuous conical surface, but it could be a substantially flat surface perpendicular to axis A x . The inner row 66 further includes an outer surface 69 forming an opposite side of the inner row 66 . Outer surface 69 is shown as a continuous conical surface at a greater angle relative to cone axis A x than inner surface 68 . In one embodiment, the outer surface 69 could be a substantially flat surface perpendicular to axis A x . The row circular ridge or peripheral edge 67 defines the row 66 periphery and connects between the inner and outer surfaces 68 , 69 on their respective terminal ends. In this view, the compacts 50 are shown flush-mounted within the inner row 66 so that the flanks 56 , 57 on each compact 50 coincide with the inner and outer surfaces 68 , 69 of the inner row 66 . This orients the flank 56 of the compact 50 substantially flush with the inner surface 68 of the inner row 66 and the flank 57 of each compact 50 coplanar and aligned with the outer surface 69 of the inner row 66 . Additionally, the crest 58 of each compact 50 is set so that it is substantially seamless with the inner row peripheral edge 67 . The peripheral edge 67 and compact crests 58 combine to form a disk-shaped cutting surface with a continuous circular periphery. If flanks 56 , 57 and crest 58 are substantially flat, they will not be quite flush with inner and outer surfaces 68 , 69 and peripheral edge 67 because these surfaces are curved in conical and circular shapes. Flanks 56 , 57 and crest 58 could be curved to be precisely flush, if desired. Optional hardfacing 78 is shown on the outer edge 67 and upper and lower surfaces 68 , 69 of the inner row 66 . The hardfacing 78 can be applied on all other surfaces of the cone 62 and may be flush with or project above the compacts 50 .
One of the advantages of the embodiment shown herein is the hardened composition of the compacts 50 resist wear longer than the typical ferrous materials used as a base material of the inner row 66 . Accordingly, the compacts 50 will experience less erosion during use than the inner row 66 and provide a cutting function for a longer period of time. Moreover, it is expected that the portion of the inner row 66 adjacent the trailing edge of each compact crest 58 will experience less erosion than the portion of the peripheral edge 67 proximate the compact leading edge. The presence of this portion of the peripheral edge at the trailing edge portion of each compact 50 supports the compacts 50 within the respective bores 65 formed within the inner row 66 . The compacts 50 may be coupled with the inner row 66 by a press or interference fit technique. Optionally, the compacts 50 may be brazed within the bores 65 . Hardfacing may be applied over the inner row 66 , outer edge 67 , upper surface 68 , and/or lower surface 69 .
In an optional method of forming the cutting cone 62 of FIG. 4 ; the bores 65 are not formed along a line normal with the circular peripheral edge 67 . Instead adjacent bores 65 may alternatingly be angled inward towards the apex 64 or outward toward the outer row 70 . Thus when the compacts 50 are set in the adjacent bores 65 the risk of interference within the body of the cutting cone 62 is eliminated. In one example of use, when the canted compacts 50 A of FIG. 3A are set in adjacent bores they may be rotated 180° with respect to one another. The respective angled barrels 54 A of adjacent compacts 50 A are offset in opposite directions along the axis A x and not in an interfering arrangement. The canted configuration allows the tip 52 A of each compact 50 A to be positioned flush with the outer periphery of the cutting disk 66 of the cutting cone 62 .
An alternate embodiment of the present device is illustrated in a side perspective view in FIG. 6 . In this embodiment, a cutting cone 62 A is shown having an inner row 66 A with bores formed therein that project radially towards the cone axis and having compacts 50 provided in the bores 65 . In this embodiment, serrations 74 are formed along the inner row 66 A peripheral edge 67 A and between adjacent compacts 50 . Removing material between adjacent compacts 50 can enhance boring operations by maximizing contact between the harder compacts 50 and the formation. The circumferential extent of each serration 74 is preferably less than the circumferential distance between adjacent compacts. Each crest of each compact 50 is thus flush with a portion of peripheral edge 67 A. Serrations 74 are illustrated as being curved, partially circular recesses,
Referring now to FIG. 7 , an alternative embodiment of a cutting cone 62 B is shown in a perspective view. The cutting cone 62 B of FIG. 7 includes an inner row 66 A with compacts 50 in bores 65 , and serrations 74 between the compacts 50 . The cutting cone 62 B farther includes an outer row 70 B of teeth 72 B, the teeth 72 B having bores 65 B formed therein. The bores 65 B, shown in dashed outline, extend towards the cone axis (not shown) from the crest of each tooth 72 B. Set within the bores 65 B, the crests of compacts 50 B are shown flush with the upper terminal portion or crest of each tooth 72 B. The inner and outer flanks of compacts 50 B are illustrated flush with the inner and outer sides of each tooth 72 B. The presence of the hard material compacts 50 B provides added wear resistance to an inner core of each tooth 72 B, thereby increasing their useful life.
FIG. 8 illustrates an example of an alternate method of forming the cutting cone 62 described herein. A counter bore 75 is shown formed in the periphery of an inner row of a cutting cone 62 . Counter bore 75 was formed during an intermediate stage of forming the cutting cone 62 and prior to heat treatment. Counter bore 75 has the same diameter as compact bore 65 (shown in dashed outline) but a smaller depth. The depth of counter bore 75 is approximately equal to the length of tip 52 ( FIG. 3 ) of compact 50 . During heat treatment and carburizing, at least the base of each counter bore 75 is covered by a plug or flat disk so that carburization does not precipitate proximate to where the bores 65 will be formed. After heat treatment, the plug is removed and the bore 65 is formed by drilling into the base of counter bore 75 for the length of barrel 54 ( FIG. 3 ). The total distance from the bottom of bore 65 to the peripheral edge 67 will equal the total height of compact 50 . The diameter of bore 65 will be the same as the diameter of counter bore 75 .
The scope of the present disclosure is not limited to roller cone bits with flush mounted compacts; but also includes earth boring bits having inserts flush with the bit cutting surface, where the hardness of the inserts exceeds the hardness of the cutting surface material. In an example, the ratio of insert hardness to cutting surface material hardness can range from about 1.2:1 to about 3.3:1. Specific hardness ratios include about 1.2:1, about 1.8:1, about 2:1, about 3:1, and about 3.3:1. These example ratios of hardness are also applicable to the respective material of the compacts 50 and cutting cones 62 .
The improvements described herein, therefore, are well adapted to carry out the objects and attain the ends and advantages mentioned, as well as others inherent therein. While presently preferred embodiments have been given for purposes of disclosure, numerous changes exist in the details of procedures for accomplishing the desired results. For example, embodiments exist wherein a row or rows on cutting cones 62 , 62 A, 62 B can include the compacts 50 of FIG. 3 and the compacts 50 A of FIG. 3A . Optionally, compacts 50 can be within one row on a cutting cone and compacts 50 A on another row of the same cutting cone. These and other similar modifications will readily suggest themselves to those skilled in the art, and are intended to be encompassed within the spirit of the present disclosure and the scope of the appended claims.
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An earth boring drill bit that includes a cutting cone with a cutting disk. Compacts are inserted within the disk having a chisel shaped end set flush with the cutting disk periphery. The compact crests and cutting disk periphery form a generally seamless cutting surface. The cutting cone can further include cutting teeth thereon also having flush mounted compacts. The compacts can be made from a material such as cemented carbide, hardfacing, tungsten, tungsten alloys, tungsten carbide and the cutter made from steel.
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BACKGROUND OF THE INVENTION
1. Field of Invention
This invention relates to the formation of holes of relatively large diameter in soils such as silty clays, which are of such a composition and density as to be susceptible to compaction or displacement by application of a high intensity ramming force in relatively small increments.
2. Description of the Prior Art
Large diameter shafts on the order of 2 ft. to 15 ft. or more in diameter are commonly formed in such soft soils by sinking an open ended cylindrical steel shell or casing. Earth is removed from within the causing by means of an auger type excavating device or a grab type (clam shell) excavator. Vertical ramming force, occasionally with the addition of rotational, oscillatory, or vibratory forces, is often necessary to force the casing down into the soil. The soil presses tightly against the outer surface of the casing due to soil displacement and compaction. This increases frictional forces acting on the outer surface of the casing and makes downward moving of the casing difficult.
Underreaming tools may be employed in an effort to overcome the severe frictional forces tending to resist downward movement of the casing. These tools remove soil from beneath the lower edge of the casing and so remove resistance of the soil against this lower edge. But unless the soil is virtually self-supporting, friction will again build up along the outer surface of the casing resisting its downward movement.
In self-supporting soil, such as very stiff clay, the casing may be unnecessary. However, because soil density varies greatly and is of indeterminate quality, the reliability of this method is suspect. Personnel are not permitted to enter an uncased hole due to the danger of partial collapse of the hole. The uncertain results of this method, together with the attendant expense of loss of construction time in the event of a partial collapse, must always be considered as a possibility.
Present methods described above require massive equipment. A disposal cycle auger-type excavator, i.e., one which is raised out of the hole periodically to spin-off excavated soil, requires from 20 H.P. to 30 H.P. per foot of hole diameter and is typically capable of excavating holes up to six feet in diameter to a maximum practical depth of about 100 ft. In easily augered self-supporting soil, production rates up to 20 ft./hour may be achieved. Where casing of the hole is required, as in unstable soil, equipment requirements are increased and production rate greatly reduced. The cost of disposal cycle auger-type excavator equipment ranges from $60,000 to $150,000 and up.
Grab type excavators with which a shield is invariably employed, require somewhat less horsepower but achieve lower production rates. Equipment cost, including shield placing equipment, is somewhat greater than disposal cycle auger-type excavators. While both types of equipment are capable of penetrating very dense soil strata including those containing some cobbles and boulders and even low strength rock, they are unsuited to placing large diameter holes through soft soil at great depth, say on the order of 100 ft. and over. This unsuitability stems from uneconomically high power requirement, and from the progressively greater time and cost required for soil removal, as hole depth increases.
With the aid of pre-drilling techniques, very heavy steel casings can be driven to great depths through soil. These techniques are used in the construction of oil well drilling platforms in deep water. Equipment for driving these tubular casings up to 42" in diameter to depths of 400 ft. weigh as much as 300 tons and cost on the order of $1,000,000 and up. Equipment for driving such casings to depths of 1,000 ft., which will be required in the near future, is not available commercially at this time.
SUMMARY OF THE INVENTION
An object of this invention is to provide a method and apparatus for forming large diameter holes in soil by compaction and/or displacement of the soil.
Another object is to provide a method and apparatus for forming such a hole without the necessity of removing the soil therefrom.
Another object is to provide apparatus for forming such a hole in soil which apparatus is much lighter and more economical than equipment that is presently available.
Another object is to provide a method and apparatus for forming such a hole, the walls of which are compacted by ramming and so are far more stable and less susceptible to collapse than the walls of a similar hole from which earth has been excavated by customary means.
A further object is to provide a method and apparatus for enlarging the diameter of an existing hole.
Another object is to provide a method and apparatus for forming a hole in the earth which employs means providing instantaneous engineering data on the actual in situ strength of soil strata traversed, which data may be used in calculating the load carrying capacity of bearing members placed within the hole so formed.
According to the present invention, a tool is provided consisting of two or more ram assemblies, stacked one above the other, each comprising ramming means which may be actuated by any conventional means. From the bottom to the top of the tool, the ram assemblies or the strokes of their respective ramming means are successively longer and the ramming means are actuated either simultaneously or sequentially, with or without rotation of the entire tool, to compress or displace the soil to form a hole of incrementally increasing size. To permit entry of the lowest ram assembly into the soil, the soil beneath it is removed, for example by preboring with an auger, or displaced, for example, by rotating or driving a tapered point beneath the ram assembly into the soil.
Cementitious fluid such as a slurry of portland cement and water may be injected into the soil below or adjacent to the ram assemblies to assist in maintaining sidewall stability of the hole as the tool is advanced. A shield slightly smaller than hole size may be introduced into the hole immediately above the uppermost ram assembly to prevent collapse of the hole sidewalls.
By way of example, one embodiment of tool comprises a point tapering up to a diameter of 12", a series of ten ram assemblies, each having ramming means comprising one or more cylinders actuated by hydraulic fluid at a pressure within the range of about 5,000 to 10,000 psi. The ram assemblies range successively upward in length from 12" to 48" in 4" increments, each with a ramming means stroke slightly longer than 4" so mounted as to displace slightly more than 2" of soil on opposite sides of the ram assembly, with the ramming means at its extended position. The end of each ramming means is 4" in depth and has an arcuate ramming surface so selected as to displace slightly more than 30° of arc. The uppermost ram assembly is followed by a shield of 50" inside diameter.
The hole is advanced by activating the ramming means and then rotating the entire tool, including the ram assemblies and shield, in five 30° indexed steps, and actuating the ramming means at each step. For reasons explained more fully hereinafter, it may be desirable in certain instances to repeat the indexed steps a second time, with the tool radially displaced with reference to the first set of indexed steps. Thereafter the tool is lowered 4" into the hole formed by the ramming action.
This sequence of operation is repeated until the hole has been advanced to full depth after which the ram assembly is retracted and withdrawn with the shield, or through it, if the shield is to remain in place.
In non-cohesive soil, e.g., sand, cementitious fluids or slurries, such as Portland cement and water, or a drilling fluid consisting of a suspension of bentonite in water may be injected through the ram assemblies to act as a soil binder, inhibiting collapse of the rammed soil. The suspension may be passed upwardly through the annulus between the shield and the rammed soil, where it may function as a lubricating fluid to ease rotation of the shield as it is advanced downward into the hole.
In accordance with another embodiment of the invention the ram assemblies are of the same length, with each next higher ramming means having a stroke 4" longer than that of the next lower ramming means.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view, with parts in section, of a tool of the present invention showing the arrangement of ram assemblies and shield;
FIG. 2 is a perspective view of ramming means in the form of one double acting ram of one of the ram assemblies illustrated in FIG. 1;
FIG. 3 is a diagram illustrating a typical sequence of operation of a single double acting ram of one of the ram assemblies illustrated in FIG. 1;
FIG. 4 is a sectional view of the ram assemblies of FIG. 1 and the hole formed by one operational cycle of the ram assemblies;
FIG. 5 is a fragmentary plan view illustrating an alternate embodiment of the present invention;
FIG. 6 is a fragmentary perspective view with parts in section, of a partially completed diaphragm wall and the employment of the tool of the present invention for constructing such a wall;
FIG. 7 is a fragmentary plan view of another alternate embodiment of ram assembly; and
FIG. 8 is a fragmentary elevation view of another alternate embodiment of tool in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
With reference to FIG. 1, it will be seen that the hole forming tool of the present invention, designated generally as 11, comprises a series of integrally connected, vertically disposed ram assemblies designated generally as 12, the lowermost of which is secured to lead point 13, which in the embodiment illustrated takes the form of an auger. The uppermost of ram assembly 12 is drivingly connected to shaft 14.
Hole forming tool 11 as illustrated in FIG. 1 is provided with an optional following shield 15, suitably connected for rotation with shaft 14, by braces 20 drivingly but releasably interconnecting shaft 14 with the inner surface of shield 15.
The hole forming tool is further provided with line 16 and pump 17 for removing drilling fluid and excavated soil from the situs, and line 27 for injecting drilling fluid or a soil stabilizing slurry of portland cement, which discharges through aperture 28 in lead point 13. In order to prevent drilling fluid or cementitious slurry discharged from aperture 28 from entering the interior of shield 15, the shield is provided with a fluid impervious diaphragm 18 disposed in sealing engagement with the shaft 14, and with the interior walls of shield 15 through peripheral seal 19.
Turning to FIG. 2, which illustrates in detail one of ram assemblies 12 shown in FIG. 1, it will be seen that the ram assembly comprises ramming means, which in the embodiment illustrated, takes the form of double acting hydraulic cylinder 21 whose piston rods 21a are in operative engagement with diametrically opposed ram shoes 22. The cylinder and ram shoes are so mounted that each ram shoe 22 moves outwardly a fixed and equal distance, so that the pressure of the surrounding soil, designated P s , on one ram shoe 22 is counterbalanced by a pressure of equal magnitude on the opposed ram shoe, thereby maintaining centering and alignment of the entire assembly.
The ram assembly further comprises enclosing ring 25 to prevent contamination of the operating mechanism by the surrounding soil.
Hydraulic fluid under pressure is supplied (from a source not illustrated) to double acting cylinder 21 through fluid pressure lines 23, one of which is provided with pressure gauge 24.
Another feature of the invention is the provision of ram shoe position indicators designated generally as 26 which electrically record, and transmit to the tool operator the distance ram shoes travel following pressurization of cylinder 21. In the embodiment illustrated the indicator takes the form of a resist wire 26a mounted on ram shoe 22, having one end permanently connected to lead 26b, and making sliding contact with wiper 26c connected to lead 26d. An ohmmeter (not shown) is connected to the distal ends of leads 26b, 26d, which provides a readout of the distance the ram shoe has moved, as a function of the resistance tapped between the leads.
Referring to FIG. 3, the operation of ram assembly 12 is as follows. With ram shoes 22 aligned with sectors a-a' as illustrated in the figure, hydraulic fluid under pressure (from a source not illustrated) is admitted through lines 23 (FIG. 2) actuating the pistons of the double acting cylinder, causing ram shoes 22 to move radially outwardly a distance S/2, thereby compacting soil segments a-a'. Ram shoes 22 are then retracted, for example by the use of return springs or the application of hydraulic pressure to the outbound surfaces of the pistons, and the tool is indexed through an angle of 30°, placing ram shoes 22 in registry with segments b-b'. Hydraulic fluid under pressure is again introduced into lines 23 (FIG. 2), causing the double acting cylinder and its associated piston rods to force ram shoe 22 outwardly a distance S/2, thereby compacting soil segments b-b'.
The cycle continues by the tool being serially indexed in 30° increments to compact soil segments c-c', d-d', e-e' and f-f'.
It will be noted that due to the geometry involved, small wedges of soil g (FIG. 3) will remain uncompressed after one complete cycle of indexing ram shoes 22. If desired or necessary, these segments can be compressed by running the tool through a second indexed cycle, radially offset from the first cycle. For example, a 15° offset for the second indexed cycle would place ram shoe 22 in a position where its actuation would compress a segment g.
Alternatively, the creation of wedges g can be avoided by incrementally indexing the tool through an arc of somewhat less than 30°. Thus, ram shoe 22 would be indexed from segment a to segment b in FIG. 3 through a suitable arc such that the left edge of ram shoe 22 will contact the outer periphery of the hole at or slightly to the left of the base of wedge g.
It will be appreciated that the avoidance of creating wedges g can also be effected by retaining the 30° indexing arc, while providing ram shoes 22 which are sufficiently over-sized to provide a slight overlap of contact area at the outer periphery of the hole.
Upon completion of the cycle or cycles by any of the procedures described above, the tool 11 may be lowered further into the excavation a distance h equal to the height of ram shoes 22 (see FIG. 2).
FIG. 4 shows the relative dimensioning of the ram assemblies, and how this dimensioning interacts to provide an incremental increase in the diameter of the excavation. The lowermost ram assembly with its ramming means in the retracted position has a diameter of d and an effective diameter with its ramming means in the extended position, of d+s. The next above ram assembly with its ramming means in the retracted position has a diameter d+s and an effective diameter of d+2s with its ramming means in the extended position. The next above ram assembly with its ramming means in the retracted position has a diameter of d+2s and an effective diameter of d+3s with its ramming means in the extended position. Finally, the uppermost ram assembly with its ramming means in the retracted position has a diameter of d+3s and an effective diameter of d+4s with its ramming means in the extended position.
It will be seen that as each of the ram assemblies is indexed through its 360° cycle, the entire tool can be lowered into the excavation a height h which is equal to the height of ram shoe 22.
Where it is desirable or necessary to employ a drilling fluid to act as a vehicle for removal of displaced soil, fluid is introduced through line 27 and discharged into the excavation through aperture 28 in lead point 13. The fluid may then be pumped out employing pump 17 and line 16.
In some instances it may be desirable to utilize the drilling fluid as a lubricating agent, particularly where following shield 15 is employed. In such circumstances, a valve (not illustrated) can be placed in line 16 and the discharge flow of drilling fluid through line 16 can thereby be partially or completely blocked, forcing the drilling fluid around the periphery of ram assemblies 12 and into the space between the excavation and the outer wall of following shield 15.
To assist in maintaining side wall stability of the ram in the soil, a soil stabilizing fluid such as a slurry of portland cement and water may be injected into the excavation. To this end, the slurry may be introduced into line 27 and discharged through aperture 28 in lead point 13.
In order to prevent drilling fluid and soil stabilizing fluid from passing upwardly through the interior of the following shield 15, there is provided liquid impermeable diaphragm 18 disposed in liquid sealing engagement with the shaft 14, and through seal 19, in liquid sealing engagement with the interior surface of following shield 15.
Following shield 15 may be dispensed with where the excavation is formed in soil which is securely stabilized by ramming action. Where soil conditions dictate the use of following shield 15, it is convenient to transmit torque to the shaft 14 from beyond the outer surface of the shield, for example, by applying a turning force to members 29. The force is transmitted to shaft 14 by braces 20. Rotation of shield 15 provides the additional advantage of lessening the tendency of the shield to bind in its frictional engagement with the surrounding soil. This facilitates the advancement of the shield into the soil as well as its later removal if required. To permit operation of the hole forming tool without the shield, it is necessary to provide suitable means (not illustrated) for releasably securing the shield to braces 20, or for releasably securing braces 20 to shaft 14.
After hole forming tool 11 has been advanced to full desired depth, ram assemblies 12, or at least the uppermost ram assembly, is fully retracted and the tool may be removed by application of upward hoisting force on the tool. A hardenable cementitious slurry such as mortar or concrete may be injected through line 27 and discharged through aperture 28 in lead point 13, as the tool is withdrawn, to form a structural bearing member. Shield 15, if used, may be left in place or withdrawn.
To start the excavation of a hole, tool 11 is advanced into a pilot hole having a diameter approximately equal to the retracted diameter d of the lowermost ram assembly. The pilot hole may be formed by conventional means such as a displacement screw on lead point 13, which is advanced into the soil by rotating shaft 14. In soft soil, the pilot hole may be formed simply by lowering tool 11 and permitting lead point 13 to sink into the soil under the weight of the tool. In hard soil, it may be necessary to inject drilling fluid under high pressure into line 27 and to remove the drilling fluid and displaced soil through line 16 and discharge pump 17.
Under circumstances where it is desirable to operate the tool without a lead point, it is necessary to separately predrill a hole at least equal in diameter to the retracted diameter of the lowermost ram assembly.
By way of example, and with reference to FIGS. 2, 3, cylinder 21 may be actuated by hydraulic fluid at pressures in the range of 5,000 to 10,000 psi. The working surface area of ram shoe 22 and its ratio with the surface area of the piston in the cylinder 21 may be selected so as to permit application of a ramming force against the soil on the order of 1,000 psi. Since the flow rate of the hydraulic fluid is relatively low, on the order of one-quarter to one-half gallon per minute per cylinder, overall horsepower requirements of the ram assemblies may be as low as two and one-half horsepower per foot of hole diameter.
The embodiment described above utilizes horizontally opposed ram wing means movable radially with respect to the shaft of the hole forming tool. The invention contemplates hole forming tools in which the movement of the ram wing means follows different paths with respect to the shaft of the tool, and one such arrangement is illustrated in FIG. 5. Here, the ramming means comprises ram shoe 30 which is pivotally mounted at 31 to shell 32. The free end of ram shoe 30 is connected to piston rod 33 which in turn is connected to hydraulic cylinder 34. The location of ram shoe 30 in its extended position is illustrated in phantom lines.
The invention may also be used to advantage in the formation of noncircular apertures. One such application is the construction of diaphragms of concrete within a soil body as illustrated in FIG. 6. Here the hole forming tool comprises shaft 35 upon which are mounted a series of vertically disposed, stepped ram assemblies 36 which, by incremental ramming action of ram shoes 37 enlarge a small slot shaped hole initiated by lead point 38. Drilling fluid may be pumped through shaft 35 and discharged from aperture 39 in lead point 38 to lubricate passage of the tool through the soil, and to aid in the compaction, displacement and/or removal of soil particles. Following shield 40 may be used to maintain stability of the side walls of the hole during its formation.
In operation, it may be convenient to first drive into the soil structure steel member 41 which serves as a reaction member against which ram assemblies 36 push during formation of the first concrete diaphragm panel 42. Once this first panel is formed and the concrete has hardened, the panel itself serves as a reaction member, during formation of the adjacent panel. The leading edge of each panel may be shaped, for example as illustrated at 43, to provide alignment means for the formation of succeeding concrete panels.
A further embodiment of the invention is illustrated in FIG. 7. Here the hole forming tool comprises shaft 44, and a ram assembly designated generally as 44a, having ramming means comprising a series of hydraulic cylinders 45 disposed radially and symmetrically with respect to shaft 44. Each hydraulic cylinder 45 is of the single acting variety, and through piston rod 46, actuates ram shoe 47.
The ram wing means thus described, consisting of six ram shoes, each actuated by its own hyraulic cylinder, permits simultaneous actuation of all cylinders 45. Since each cylinder is opposed by a separately actuated cylinder 180° out of phase with it, simultaneous operation of opposed cylinders provides a counter-balancing of identical forces in opposite directions, maintaining the centering and alignment of the hole forming tool.
The advantage of the arrangement illustrated in FIG. 7 is that the tool need be indexed less frequently to effect an enlargement of the entire periphery of the excavation. Thus, with hydraulic cylinders 45 actuated in the positions illustrated in FIG. 7, ram shoes 47 will compact soil segments a. By indexing the tool a first time, and actuating hydraulic cylinders 45, ram shoes 47 will compact soil segments b. By indexing the tool a second time and actuating hydraulic cylinders 45, ram shoes 47 will compact soil segment c. In this manner, the entire periphery of the aperture, consisting of soil segments a, b and c, is compacted with only two indexing steps of the hole forming tool. Further, it will be seen that sufficient overlap of ramming trajectory is provided so that substantially continuous soil compression is effected along the periphery of the hole.
In the various embodiments illustrated above, the ram assemblies and the retracted positions of the corresponding ramming means have been fashioned stepwise, while the length of movement of ram wing means from the retracted position to the extended position have been held constant. FIG. 8 illustrates an embodiment of the hole forming tool in which the reverse is true.
With reference to FIG. 8, it will be seen that the hole forming tool comprises shaft 48 upon which are mounted a series of ram assemblies 49 and lead point 50. It will be noted that the superposed ram assemblies are all of identical diameter. It will be noted however that the distance the ram shoes 51 move from a retracted to an extended position varies incrementally. Thus, the lowermost ram shoe 51 moves a distance s/2 from its retracted position to its extended position while the next above ram shoe 51 moves a distance of s. The uppermost ram shoe 51 moves a total distance of 4s from its retracted position to its extended position. In all other respects the operation of the ram assembly illustrated in FIG. 8 is substantially the same as that described in connection with the embodiment illustrated in FIGS. 1-4.
As previously indicated the method and apparatus of the present invention may also be used to enlarge an existing hole. Such an existing hole may be one which was drilled in a relatively small diameter to satisfy one purpose, and which now can serve a new function if enlarged.
In some situations it may be desirable to form a pilot hole for example of diameter d (FIG. 4), by conventional means, before employing the method and apparatus of the present invention. This has the effect of reducing the amount of soil compaction which must be accomplished by the method and means of the present invention. This could be advantageous when operating in soils which are difficult to compact.
If the existing hole has been filled with drilling mud to effect dimensional stability of the hole, it would be advantageous to retain lead point 13. If the existing hole is empty, and extends to the desired depth, the lead point can be dispensed with.
It will be appreciated that other embodiments, modifications, variations and applications of the invention will occur to those having ordinary skill in the art. For example, hole forming tools can be designed to form asymmetrical excavations as well as circular excavations. Further, the excavations need not be vertical as generally illustrated in the figures accompanying the application, but may be horizontal and at any angle between the horizontal and vertical.
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A hole is formed in soil by penetrating it with a tool comprising a shaft having a tapered point or auger of relatively small cross section attached to its lower end, and a series of outwardly pressing rams mounted on the shaft above the tapered point. The rams are effective successively to enlarge incrementally by outward compaction or displacement of the soil, the hole initially formed by the tapered point or auger. Full hole dimension above the tool is maintained by reason of the fact that the soil is incrementally compacted and compressed to resist collapse. If desired, the integrity of the hole may be preserved with the aid of a following shield, or the hole may be filled with soil stabilizing fluid such as drilling mud. After formation of the hole, the tool is withdrawn and the hole may be filled with concrete to form a load supporting column or it may be left as an open shaft.
The method and apparatus may also be used to enlarge the diameter of an existing hole.
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PRIORITY CLAIM
[0001] This application claims the benefit of priority under 35 U.S.C. §119(e) of U.S. Provisional Application No. 60/344,729 filed on Dec. 28, 2001, titled MOBILE TELESCOPING CAMERA MOUNT, the entirety of which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] This invention relates to a mobile telescoping camera mount that elevates a video camera above the height of its user, allowing the user to capture images from a higher vantage point. This mobile telescoping camera mount allows the user to manually aim the video camera. There are many possible applications for this invention, including sporting events, photojournalism, crowd control and the study of nature, to name only a few.
SUMMARY OF THE INVENTION
[0003] The preferred embodiment of the invention comprises a base frame which provides support, a extensible telescoping mast with camera mounts to elevate a video camera or a camera to a higher vantage point, an operator control assembly which allows the user to manually aim the video camera which is beyond his reach, and a display for the user to view the output from the video camera. Embodiments of the invention may additionally comprise a camera control module to remotely control the electronic functions of the camera (e.g. zoom) and an optional sunscreen to shield the display from direct sunlight.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] [0004]FIG. 1 is a perspective view of one embodiment of the telescoping camera mount,
[0005] [0005]FIG. 2 is a perspective view of the bottom portion of the mobile telescoping camera mount shown in FIG. 1,
[0006] [0006]FIG. 3 is a perspective view of the top end of the mast of the mobile telescoping camera mount of FIG. 1,
[0007] [0007]FIG. 4 is a perspective view of the operator control assembly of the mobile telescoping camera mount of FIG. 1,
[0008] [0008]FIG. 5 is a perspective view illustrating the interaction between the extensible telescoping mast and the operator control system,
[0009] [0009]FIG. 6 is a perspective view of the bottom end of the extensible telescoping mast,
[0010] [0010]FIG. 7 is an exploded perspective view of the components mounted at the bottom end of the extensible telescoping mast,
[0011] [0011]FIG. 8 is a perspective view illustrating the interaction between the tilt pulley and the bottom pulleys, and
[0012] [0012]FIG. 9 is a perspective view further illustrating the operation of the mobile telescoping camera mount of FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0013] Referring to FIGS. 1 and 2, a base frame ( 100 ) supports an extensible telescoping mast ( 200 ) having video camera mounts at the top, and the operator control assembly ( 300 ). The base frame ( 100 ) serves as a platform on which other subparts are mounted.
[0014] For mobility the base frame ( 100 ) is equipped with wheels ( 102 , 104 , 106 ). Optimally, two fixed wheels ( 102 , 104 ) are mounted at the opposite front corners of the base frame ( 100 ), while a pivoting wheel ( 106 ) is mounted in the center at the rear of the base frame ( 100 ). This setup (biplane style) maximizes the maneuverability of the base frame ( 100 ) with the least number of wheels. Alternatively, in other embodiments of the invention, wheels may be mounted at all four corners of the base frame, with the front set being pivoting and the rear set being fixed (shopping cart style) or vice versa. The latter two setups provide more stability when the base frame is in motion, e.g., when it is wheeled to and from its location of deployment.
[0015] For additional stability when deployed, the base frame is equipped with telescoping legs ( 108 , 110 , 112 ). Preferably, there are four telescoping legs with one mounted near each corner of the base frame. The telescoping leg at the front left corner of the base frame ( 100 ) is hidden from view in FIG. 2. Optimally, these telescoping legs are infinitely adjustable in length to allow the operator to deploy on irregular terrain to adjust the base to provide a level mount for the mast ( 100 ). Preferably, the legs are foldable, to ease transportation. In the preferred embodiment, all four telescoping legs swing out from folded positions along axes perpendicular to the ground. To maximize stability when deployed at least the front telescoping legs may be positioned such that they extend over the front wheels. Locking pins or the like fix the positions, while wing nuts or the like lock the lengths of the telescoping legs when deployed.
[0016] The extensible telescoping mast ( 200 ) is mounted vertically on the base frame ( 100 ), perpendicularly to the base frame ( 100 ) and to the ground. The end of the mast ( 200 ) attached to the base frame ( 100 ) is referred to as the bottom end, while the other end is referred to as the top end. The bottom end of the mast ( 200 ) is mounted to the base frame ( 100 ) in a manner which allows the mast to be rotated along its center axis. See infra regarding panning.
[0017] A cable winch ( 202 ) allows the user to extend or to collapse the extensible telescoping mast ( 200 ). Preferably the winch ( 202 ) has a locking mechanism that allows the user to select a height up to the maximum extended length of the mast ( 200 ). Extensible telescoping masts are well known in the prior art and a lengthy description is not required here.
[0018] The operator control assembly ( 300 ) is also mounted to the base frame ( 100 ), aft of the telescoping mast ( 200 ). It is described in further detail below in FIG. 4.
[0019] A display, preferably a lightweight LCD screen (not shown) is advantageously mounted on the base frame ( 100 ) to allow the user to view the output from the camera or cameras mounted on the camera mounts at the top end of the telescoping mast ( 200 ). Ideally the display is mounted just aft of the telescoping mast and forwards of the operator control assembly ( 300 ). Also ideally the display mount is adjustable height-wise to allow the most ergonomic viewing position while the user is articulating the operator control assembly.
[0020] An optional sunscreen, the size of which is customizable, may be mounted to the base frame at a height above that of the display, so that the image on the display is not washed out when viewed under sunny conditions. The sunscreen is preferably large enough so that multiple viewers may view the display together.
[0021] Camera mounts ( 204 , 206 ) are provided at the top end of the mast ( 200 ) as shown in FIG. 3. In the preferred embodiment, two L-shaped camera mounts ( 204 , 206 ) are attached to both ends of a top horizontal shaft ( 208 ) extending through the top end of the mast ( 200 ) along the mast's diameter. A pulley is mounted on the top horizontal shaft ( 208 ) next to each camera mount, with the top horizontal shaft ( 208 ) extending through the center of each pulley. The pulley thus mounted between the left camera mount ( 204 ) and the mast ( 200 ) is referred to as the left top pulley ( 210 ), while the pulley thus mounted between the right camera mount ( 206 ) and the mast ( 200 ) is referred to as the right top pulley ( 212 ). The top pulleys ( 210 , 212 ) are of the same size. Both camera mounts ( 204 , 206 ) and both top pulleys ( 210 , 212 ) are fixed in relation to each other and the top horizontal shaft ( 208 ), e.g., the camera mounts ( 204 , 206 ) and the top pulleys ( 210 , 212 ) do not rotate freely around the shaft. The top horizontal shaft ( 208 ) does rotate freely in relation to the top end of the telescoping mast ( 200 ). In the preferred embodiment both camera mounts ( 204 , 206 ) are tilted simultaneously.
[0022] The left and right top pulleys ( 210 , 212 ) are used to control the tilting of the camera mounts ( 204 , 206 ) in an upwards or downwards direction. See infra regarding tilting. Advantageously, each camera mount is sized such that the camera may be mounted with the camera's center of gravity at or just below the center of the top pulley attached to the camera mount. In the preferred embodiment two identical cameras can be mounted, one to keep track of the wide angle view and the other zoomed in on the center of the action. We can thus think of the cameras as sharing a common center of gravity. If the cameras' center of gravity is above the center of the top pulleys, the weight of the cameras tends to exaggerate any tilting motion of the camera mounts. Conversely, if the cameras' center of gravity is below the center of the top pulleys, the weight of the cameras tends to hinder any tilting motion of the camera mounts, exerting a force due to gravity to return the tilt angle of the cameras to a neutral position determined by the cameras' center of gravity. For precise control the latter is preferred. For cameras positioned to record activities at or near ground level, a center of gravity forwards (the direction the cameras are pointing) of the center of the top pulleys is desired. An arm extending backwards (not shown) may be mounted on either camera mount as a counter balance. To summarize the cameras on the preferred embodiment are mounted with their common center of gravity just forwards of and below the centers of the top pulleys.
[0023] The operator control assembly ( 300 ) best shown in FIG. 4 enables the user to remotely control the panning and the tilting of the camera mounts via handlebars ( 302 , 304 ) extending from this operator control assembly ( 300 ). There are two circular pulleys in the operator control assembly ( 300 ). The pan pulley ( 306 ) is mounted with its plane of rotation parallel to the base frame ( 100 ), and with its axis of rotation parallel to the axis of rotation of the telescoping mast ( 200 ). The tilt pulley ( 308 ) is formed by a left tilt pulley disk ( 310 ) and a right tilt pulley disk ( 312 ), both of which are mounted at right angles to the pan pulley ( 306 ). Thus the tilt pulley ( 308 ) is mounted with its plane of rotation perpendicular to the ground.
[0024] Handlebars ( 302 , 304 ) extending from the operator control assembly allow the user to rotate the pan pulley ( 306 ) and the tilt pulley ( 308 ), either individually or simultaneously. Thus control of the pan angle can be maintained while tilting the camera mounts, and likewise control of the tilt angle can be maintained while panning the camera mounts. This precise degree of control is a significant advantage of the preferred embodiments of the present invention. The user controls the rotation of the pan pulley ( 306 ) by turning the handlebars ( 302 , 304 ) in a motion similar to steering a motorcycle. The user controls the rotation of the tilt pulley ( 308 ) via pushing or pulling the handlebars ( 302 , 304 ), in a motion similar to rowing a boat.
[0025] A camera control module (not shown) is advantageously mounted on either handlebar of the operator control assembly ( 300 ). This camera control module is provided with buttons to remotely effectuate camera controls such as zoom, record start and stop, slow motion, etc.. As is well known in the art, this camera control module can be programmed with the camera maker” proprietary camera control codes, which is sent up to the camera via a signal cable (not shown).
[0026] The interaction between the extensible telescoping mast ( 200 ) and the operator control assembly ( 300 ) is best shown in FIG. 5. A concentric pulley ( 314 ) is fixed concentrically around the bottom end of the mast ( 200 ), and thus they share the same axis of rotation. The concentric pulley ( 314 ) rotates with the telescoping mast ( 200 ). In the preferred embodiment two cables ( 316 , 318 ) running between the pan pulley ( 306 ) and the concentric pulley ( 314 ) allow rotation of the pan pulley ( 306 ) to rotate the concentric pulley ( 314 ). The first cable ( 316 ) is attached such that when the pan pulley ( 306 ) is rotated clockwise (from a top view), the first cable ( 316 ) pulls the concentric pulley ( 314 ) to rotate clockwise too. Likewise, the second cable ( 318 ) is attached such that when the pan pulley ( 306 ) is rotated counter-clockwise (from a top view), the second cable ( 318 ) pulls the concentric pulley ( 314 ) to rotate counter-clockwise. Alternatively a belt wrapped around both pulleys, similar to tank treads, may be used to link the rotation of the two pulleys.
[0027] The sizes of the pan pulley ( 306 ) and the concentric pulley ( 314 ) may be customized to adjust the ratio of rotation. Currently the diameter of the pan pulley ( 306 ) is twice that of the concentric pulley ( 314 ), such that a 1:2 ratio of rotation is achieved, e.g., the user only needs to rotate the pan pulley (via the handlebars) 10 degrees to pan the camera mounts by 20 degrees. This reduces the range of motion of the user while still allowing him to precisely pan the camera mounts.
[0028] Referring to FIG. 6, a bracket ( 400 ) protruding forwards (from the user) is mounted on the bottom end of the mast ( 200 ). A bottom horizontal shaft ( 402 ) extends through this bracket ( 400 ) along an axis parallel to the diameter of the mast ( 200 ). Attached on either end of the bottom horizontal shaft ( 406 ) are the left take up reel ( 404 ) and the right take up reel ( 406 ), respectively. The left bottom pulley ( 408 ) is sandwiched between the left take up reel ( 404 ) and the bottom end of the mast ( 200 ), while the right bottom pulley ( 410 ) is sandwiched between the right take up reel ( 406 ) and the bottom end of the mast ( 200 ). The bottom pulleys ( 408 , 410 ) are of the same size. The bottom pulleys ( 408 , 410 ) are fixed in relation to each other and to the bottom horizontal shaft ( 402 ) such that they all rotate together. The take up reels ( 404 , 406 ) are free to rotate around the bottom horizontal shaft ( 402 ). A cable runs from each take up reel up to its corresponding top pulley at the top end of the mast. These two cables are the third cable ( 412 ) and the fourth cable ( 414 ). The third cable ( 412 ) runs from the left take up reel ( 404 ) up to the left top pulley, while the fourth cable ( 414 ) runs from the right take up reel ( 406 ) up to the right top pulley.
[0029] [0029]FIG. 7 shows a disassembled view of the components mounted on the bracket ( 400 ) at the bottom end of the mast. The bottom horizontal shaft ( 402 ), the bottom pulleys ( 408 , 410 ) and the take up reels ( 404 , 406 ) are all shown. In addition, two clutch caps ( 416 , 418 ) are shown. Each take up reel may be engaged to its neighboring bottom pulley by using the clutch cap to tighten the take up reel against its neighboring bottom pulley, so that the take up reel will rotate with its neighboring bottom pulley.
[0030] Referring to FIG. 8, the interaction between the tilt pulley ( 308 ) and the bottom pulleys ( 408 , 410 ) is as follows: The tilt pulley ( 308 ) in the operator control assembly ( 300 ) controls the rotation of the bottom horizontal shaft ( 402 ), on which the bottom pulleys ( 408 , 410 ) are mounted. A fifth cable ( 420 ), wrapped around the left tilt pulley disk ( 310 ) of the tilt pulley ( 308 ) in one direction, runs to the left bottom pulley ( 408 ), while a sixth cable ( 422 ), wrapped around the right tilt pulley disk ( 312 ) in the opposite direction, runs to the right bottom pulley ( 410 ). Both cables ( 420 , 422 ) run through a cable guide plate ( 424 ) mounted on the bottom end of the mast ( 200 ). Both cables ( 420 , 422 ) are shielded in flexible jackets running from the cable guide plate ( 424 ) to the operator control assembly ( 300 ). The cables ( 420 , 422 ) running from the tilt pulley ( 308 ) to the bottom pulleys ( 408 , 410 ) are set up so that any rotation of the tilt pulley ( 308 ) causes rotation of the bottom pulleys ( 408 , 410 ) and the bottom horizontal shaft ( 402 ) in the same direction. For users desiring inverted tilt control of the camera mounts, these two cables ( 420 , 422 ) may be routed through alternate cable guide holes in the cable guide plate ( 424 ) so that any rotation of the tilt pulley ( 308 ) causes rotation of the bottom pulleys ( 408 , 410 ) and the bottom horizontal shaft ( 402 ) in the opposite direction.
[0031] The sizes of the tilt pulley ( 308 ) and the bottom pulleys ( 408 , 410 ) may be customized to adjust the ratio of rotation. Currently the diameter of the tilt pulley ( 308 ) is twice that of the bottom pulleys ( 408 , 410 ) such that a 1:2 ratio of rotation is achieved. The rate of rotation between the tilt pulley and the bottom pulleys should be equal to the rate of rotation between the pan pulley and the concentric pulley, so that the rate of rotation for both panning and tilting the camera mounts are the same. This is the most intuitive setup. However, a user may individually adjust these two ratios if such need arises.
[0032] [0032]FIG. 9 illustrates the chain of interactions between the right tilt pulley disk ( 312 ), the right bottom pulley ( 410 ), the right take up reel ( 406 ), the right top pulley ( 212 ) and the right camera mount ( 206 ). As mentioned above under FIG. 8, rotation of the right tilt pulley disk ( 312 ) causes rotation of the right bottom pulley ( 410 ) according to a determined ratio of rotation. The right take up reel ( 406 ) may be engaged to the neighboring right bottom pulley ( 410 ) via a clutch mechanism as described under FIG. 7. Rotation of the right bottom pulley ( 410 ) causes the cable ( 422 ) from the right take up reel ( 406 ) to pull on the right top pulley ( 212 ), rotating the right top pulley ( 212 ) in the same direction as the right bottom pulley ( 410 ). The right camera mount ( 206 ) is attached to the right top pulley ( 212 ). Recall that the above description applies equally to the left tilt pulley disk and the bottom pulley, take up reel, top pulley and camera mount on the left side of the mast. Thus rotation of the tilt pulley, formed by the tilt pulley disks ( 310 , 312 ) controls the tilting of the camera mounts ( 204 , 206 ).
[0033] Schematically, a take up reel connects its corresponding top and bottom pulleys on the same side of the extensible telescoping mast. This serves three functions. Since the height of the mast is adjustable, each take up reel allows the cable running up to its corresponding top pulley to be adjustable. When the telescoping mast is fully collapsed, each take up reel may be fully disengaged from its corresponding bottom pulley to serve as a winch to collect the excess length in the cable running up to its corresponding top pulley. Lastly, the user may adjust the default tilt angle of the camera mounts via the clutch mechanisms between each take up reel and its neighboring bottom pulley.
[0034] The preferred embodiments of this invention provide several significant advantages First, the user can stay put while aiming the camera. Second, the ratios of rotation in both the pan and tilt directions of the camera mounts are customizable. Third, as mentioned, the default tilt angle of the camera mounts is adjustable. Fourth, opposed pulling cables control rotation of the camera mounts in both horizontal and vertical planes, allowing precise control.
[0035] It will be evident to those skilled in the art that the invention is not limited to the details of the foregoing illustrated embodiments and that the present invention may be embodied in other specific forms without departing from the spirit or essential attributed thereof. The foregoing description of the present embodiments is therefore to be considered in all respects as illustrative and not restrictive, with the scope of the invention being delineated by the appended claims and their equivalents.
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The preferred embodiment of the invention comprises a base frame which provides support, a extensible telescoping mast with camera mounts to elevate a video camera to a higher vantage point, an operator control assembly which allows the user to manually aim the video camera which is beyond his reach, and a display for the user to view the output from the video camera. This gives the operator an advantageous vantage point and field of view during sporting events, social functions, photojournalism, crowd control and the study of nature, to name only a few applications. Embodiments of the invention may additionally comprise a camera control module to remotely control the electronic functions of the camera (e.g. zoom) and an optional sunscreen to shield the display from direct sunlight.
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